Unsafe use of this machine may cause serious

injury or death. Operators and maintenance

personnel must read this manual before operating or
maintaining this machine. This manual should be
kept near the machine for reference and periodically
reviewed by all personnel who will come into contact
with it.
 FOREWORD
The SD22、SD22E 、SD22S and SD22Dis bulldozers of 162 KW (220
HP) with hydraulic transmission.
This manual described procedures for structure, performance，
operating a machine, maintenance, troubleshooting transport and
storage. It will help the operator or anyone realize peak
performance through effective, economical and safe machine
operation and maintenance.
Please read this manual carefully before operating a machine.
When proper operation is completed, you may operate it.
The operation, maintenance and trouble shooting of engine with
the exception of mentioned in this manual, please see “OPERATION AND
MAINTENANCE MANUAL OF ENGINE. ”
Operation, inspection and maintenance should be carefully
carried out and the safety must be given the first priority. Safety
precautions are indicated with marks and technical precautions
with ★ marks in this manual. The safety information contained in
this manual is intended only to supplement safety codes, insurance
requirements, local laws, rules and regulations.
Some photographs and illustration pictures are different from
your machine as technical improvement is continuously reflected on
it. Revision to up-to-date manual’s content is performed in later
editions.
 SAFETY HINTS ★
1.Before application of machine read the Operation and
Maintenance Manual carefully. Operate the machine in
correspondence with requirement of instruction.
2.The operator must be trained. Do not drive when tired or after
drinking. Prohibit non-operator from driving.
3.If the nature of work requires safety, wear well-fitting
helmet, safety shoes and working clothes or other protection.
4.Learn about the safety devices on your own machine and about
how to use them.
5.Learn the relevant traffic regulations and how to use the fire
extinguisher.
6.When refilling fuel or performing any maintenance, never smoke
in work place and separate from any fire source.
7.Learn geological structure, environment condition and
facilities in space and under ground before operating.
8.Before starting always clean out parts or tools laying around
in the vicinity of machine or on the floor of the operator’s
compartment.
9.Before operating the machine check that everything is in
proper state.
10.Do not operate the machine from any other position. Sit in the
operator’s seat while operating. Do not allow unauthorized
persons in to the operator’s compartment.
11.Confirm that the machine is functioning normally after
starting or running. Operate the machine in suitable travel
speeds.
12.If these tests reveal anything wrong, however slight it may
be, contact the man in charge of the machine and operate the
machine only after obtaining his permission.
13.When running the engine in a poor ventilated area, there is
a danger of gas poisoning, so adopt measures to ensure a good
supply of fresh air.
14.When getting on or off the machine, use the handrail and step
 provided. Do not jump or down from the machine.
15.When operating at night, be sure to arrange an adequate
lighting system.
16.When operating on slopes, in snow and in forest areas, where
existed fallen trees, logs piles of leaves or after, be
particularly careful as machine may be tripping by slipping.
17.After stopping the machine, put the blade on the ground and
put all the lock levers in the LOCK position.
18.For sake of safety yourself and machine no allow it to operate
in spite fault or overload.
19.Operating in special conditions please see“Precautions of
operation in special environment.”
★ 20.The type of lubricant and water used depends on the ambient
temperature. Select according to the table “FUEL, COOLANT
AND LUBRICANTS”.
★ 21.Never use any antifreeze made from methyl alcohol or ethyl
alcohol which may be a cause of engine trouble. Take care for
fire as antifreeze is inflammable.
★ 22.Use city water for cooling system as possibility. Do not use
dirty water as cooling water.
★ 23.Never replenish any leakage proof solvent into cooling water.
★ 24.Clean and replace element of various filters, according to
the maintenance table.
★ 25.Occasionally check the level of coolant, fuel, lubricants and
hydraulic oil and replenish as require.
★ 26.When starting engine, do not leave key in start for more than
20 seconds.

If engine will not start, repeat the starting procedure after

about 2 minutes.
BREAKING IN YOUR NEW MACHINE
Each machine is carefully adjusted and tested before shipment.
However, a new machine requires careful operation during the first
100 hours to break in the various parts.
If a machine is subjected to unreasonably hard use at the initial
operation stage, the using life of machine will be shorted. A new
machine must be operated with care, particularly with regard to the
following items.
1. Before starting get ready for machine all over.
2. After starting, let the engine idle for 5 minutes to allow
proper engine warm-up prior to actual operation.
3. Avoid operation with heavy loads or at high speeds.
4. Sudden starting or acceleration, unnecessarily abrupt
braking and sharp turning should be avoided.
5. Occasionally observe and adjust machine, keep it in normal
operation.
6. After 250 hours of operation, the machine should be
maintained as the following contents and 250 hours service
table.
★ The first 250 hours maintenance table.
★ Hours of operation are indicated by the service meter.
★ When replacing oil filter elements(cartridges), check their
interiors for dirt and dust. If heavily collected, check for
possible cause before starting operation.
 CONTENTS
Ⅰ.Main technical performance and specification…………1～8

Ⅱ.General locations and controls …………………………9～24

Ⅲ.Safety regulations………………………………………25～28

Ⅳ.Notice for disassembly ………………………………29～30

Ⅴ.Structure and principle of bulldozer……………………31～94

Ⅵ.Maintenance ………………………………………… 95～109

Ⅶ.Method of adjusting parts ……………………………111～116

Ⅷ.Trouble shooting guide ………………………………117～120

Ⅸ.Overhaul criterion for major parts……………………121～151

SD22 bulldozer lubricant chart …………………………152～155

Fuel, Coolant and Lubricants ……………………………156～157

 Ⅰ. MAIN TECHNICAL PERFORMANCE
AND SPECIFICATION
1.1 General locations (Fig.1-1)

Fig.1-1

1.Blade 2.Frame 3.Tilt cylinder 4.Idler 5.Track frame

6.Track roller 7.Carrier roller 8.Track 9.Cab
10.Exhaust pipe 11.Lift cylinder

1
1.2 Main specifications
1.2.1 Engine
Model: CUMMINS NT855-C280(BCⅢ)
Type: In line, cooling water, four stroke, direction injection,
turbocharged diesel engine.
Rated speed: 1800rpm
Rated power: 162kw(220HP)/1800rpm
Number of cylinder-bore×stroke: 6—139.7mmX152.4mm
Displacement: 14.01L
Lowest fuel consumption: ≤205g/kw.h (153g/ps.h)
1.2.2 Travel speed (km/h)
1st 2nd 3rd
Forward 0-3.6 0-6.5 0-11.2
Reverse 0-4.3 0-7.7 0-13.2
1.2.3 Curve of towing performance
Traction and Travel speed
Traction×1000Kg

Travel speed

Fig1-2
1.2.4 Power train feature
1. Torque converter: 3-element single-stage single-phase
2. Transmission: Planetary gear, multiple disc clutch, hydraulically
actuated, forced lubrication
3. Main drive: Spire taper gear, one stage reduction, splash lubrication
2
 4. Steering clutch: Wet, multiple discs, spring–loaded, hydraulic-ally
separated, hand and hydraulic operated
5. Steering brake: Wet, float, engage directly, hydraulic boost
6. Final drive: Two-stage spur gear reduction, splash lubrication
1.2.5 Undercarriage system
Type: Splayed beam vibration type, suspended structure of equalizer.
Carrier rollers: 2/each side
Track rollers: SD22: 6/each side (four, single side; two, double side)
SD22E,SD22D: 7/each side (four, single side; three, double side)
SD22S: 8/each side (five, single side; three, double side)
Type of track: SD22: Assembled type, single grouser (38/each side)
SD22E,SD22D: Assembled type, single grouser (41/each side)
SD22S: Assembled type, round triangle grouser
(45/each side)
Width of track shoes: SD22, SD22E: 560 mm (straight tilt dozer,
angle dozer)
610mm(U type dozer)
SD22S: 910 mm
SD22D: 610mm
Pitch: 216 mm
1.2.6 Power takes off shaft
Position：Middle of steering case rear
Rotating speed：1800rpm
Rotating direction：Clockwise (See from driving side)

3
1.2.7 Working equipment
Model SD22 SD22E
Parameter Half Straight Angle SD22S SD22D
U-dozer
U-dozer tilt dozer dozer
Blade width (mm) 3725 3725 4365 3800 4365 4365
Blade height (mm) 1374 1315 1055 1343 1248 1248
Max cutting depth
538 540 535 540 550 550
(mm)
Max lift height
1210 1210 1290 1210 1330 1420
(mm)
Max tilt (mm) >735 >735 >500 >755 >500 >800
Max turning angle
/ / 25 / / /
（°）
Cutting angle（°） 55 55 55 55 55 55
Weight（kg） 3750 3630 3850 4196 3478 2900

1.2.8 Ripper
Type: parallelogram, may be adjusted, disassembled
Number of shanks: 3 shanks
Distance of shanks: 1000mm (3 shanks)
2000mm (3 shanks)
Max ripper digging depth: 665 mm
Max lift height: 555 mm
Weight: 2900 kg
1.2.9 Hydraulic system (working equipment)
Max oil pressure: 14Mpa(140kg/cm2)
Oil pump type: gear oil pump
Displacement: 262L/min (engine rotational speed 1800rpm)
Control valve type: Spool type
Work cylinder bore × number: Φ120mm x 2(double acting)
Tilt cylinder bore × number: Φ200mm x 1
Ripper cylinder bore × number:Φ150mm x 1
Ripper relief valve pressure: 16Mpa(160kg/cm2)

4
1.2.10 Overall dimensions
SD22、SD22E（angle） （See fig1-3）

Fig.1-3

5
 Model
Parameter (mm) SD22 SD22E SD22S SD22D

L 5750 6000 6060 6150

W 3725 3725 4365 4365

Cab is not equipped with 3395 3395 3435 /

H
Cab is equipped with
3402 3402 3402 /
23Y-56B-00000
L1 3725 3725 3850 3806

L2 2730 3050 3480 3050

L3 1155 1405 1595 1405

W1 560 560 910 660

W2 2000 2000 2250 2000

W3 2620 2620 3160 2660

H1 2610 2610 2645 2610

H2 470 470 805 470

H3 540 540 550 550

H4 1210 1416 1330 1420

H5 735 735 500 800

H6 72 72 123 72

When H is bigger than 3395, it means the distance from the top of cab to the ground.
For SD22D, H means the height from air cleaner cap to the ground.

6
1.2.11 Other parameter
SD22、SD22E
Model
Half SD22S SD22D
Straight Angle U type
U type
Parameter tilt dozer dozer blade
blade
Min. ground clearance
405 405 405 405 513 405
（mm）
19800 19800 19800 19800
Operating Tractor 22250 /
(21000) (21000) (21000) (21000)
weight
23450 23450 23670 24020
(Kg) Bulldozer 25700 28000
(24600) (24600) (24800) (25200)
0.065 0.065 0.065 0.059
Ground Tractor 0.034 /
(0.061) (0.061) (0.061) (0.061)
pressure
0.077 0.077 0.077 0.078
(Mpa) Bulldozer 0.041 0.070
(0.072) (0.072) (0.072) (0.073)
Min. turning radius 3300 3300 3300 3300
3800 4100
(mm) (4000) (4000) (4000) (4000)
Grade ability (°) 30 30 30 30 30 30
Track gauge (mm) 2000 2000 2000 2000 2250 2000
Single blade capacity
7 6.4 4.7 7.5 6.8 6.8
（m3）
Productivity（m3/h） 345 330 245 365 345 345

Note：Operating weight and ground pressure does not include cab and weight
of ripper.
Productivity is the theory value that when the distance is 40 meters.
The value in bracket is the parameter value of SD22E.

7
1.2.12 Transmission principle chart（Fig.1-4）

Fig.1-4
1.Engine 2.Torque converter 3.Universal joint 4.Transmission case
5.Centre drive 6.Steering clutch 7.Steering brake 8.Final drive
9.Undercarriage system 10.Transfer case

8
 Ⅱ.GENERAL LOCATIONS AND CONTROLS
2.1 Control devices and instrument name
Location and name of devices is in bulldozer. (See Fig.2-1 and 2-2)

Fig.2-1

Fig.2-2

9
2.2 Control and instrument
2.2.1 Function of all control devices (see Fig.2-3)

Fig.2-3
2.2.1.1 Fuel control lever①((Fig.2-4)
This lever is used to control the engine speed and output power.
Low idling position
High speed position

Fig.2-4 Fig.2-5 Fig.2-6

2.2.1.2 Gear shift lever②(Fig.2-5)
Three-speed forward and three-speed reverse travel can easily be selected
by simply shifting the gear shift lever to any desired position.(F-Forward、
R-Reverse、N-Neutral)
2.2.1.3 Steering lever③(Fig.2-6)
To turn the machine gently to one direction, pull the steering lever on
the same side halfway. When the steering lever is further pulled all the way
out, the machine will make a sharp pivot turn.

10
 Lock

Free

Fig.2-7 Fig. 2-8 Fig.2-9

2.2.1.4 Brake pedal④(Fig.2-7)
When both brake pedals are depressed simultaneously by stepping on the
center area, both right and left brakes are actuated. If the steering lever
is pulled out half-way and the brake pedal on the same side as the lever is
depressed at the same time, the machine will make a pivot turn.
Do not place your foot on pedals unnecessarily.
2.2.1.5 Deceleration pedal⑤(Fig.2-8)
This pedal is used to decelerate engine speed.
When arrive at the top of a slope or when dumping earth from a cliff,
the machine will increase its speed with the sudden loss of load. Slow the
machine by depressing the deceleration pedal.
2.2.1.6 Brake lock lever⑥(Fig.2-9)
This device is used to lock the brake pedal when parking. When the pedals
are depressed and the lock lever is placed in LOCK, the brake is locked.
To release brakes, depress the brake pedals and set the lever in FREE.
Whenever machine is parked, lock brake pedals without fail.

Free

Free
Lock
Lock

Fig.2-10 Fig.2-11 Fig.2-12

Lift
Tilt R.H

Falling
Tilt L.H
Fig.2-13 Fig.2-14 Fig.2-15

11
2.2.1.7 Gear shift lever⑦ (Fig.2-10)
When the machine is stopped, the device is used to lock the gearshift lever.
When the machine is stopped for a while, be sure to set the gearshift
lever in neutral and set the safety lever to LOCK.
2.2.1.8 Blade control lock button (Fig.2-11) ○ 8
Press on the button, blade control lever is locked; Pull out the button,
the blade control lever is in state.
When parking or servicing the machine, be sure to lower the blade and
set the safety lock in LOCK position.
2.2.1.9 Blade control lever⑨(Fig.2-12)
The control lever is usually in HOLD position ○ 2 , pull the lever to
position①, the blade is lifted (fig2-13); push it to position③, the blade
is dropped; go on pushing it to ④,the blade is in FLOAT position .
When the lever is in position④, it does not spring back to HOLD position.
Move it back to the HOLD position by hand.
When the straight dozer is controlled, the lever is moved to position ,
the blade is tilt right; the lever is moved to position , the blade can be
tilted at a tilt left. (Fig 2-14)
by position of ① to ③.
★ and are possible only with tilt dozer.
★ Lever should be returned quickly to HOLD position at the end of tilt
cylinder stroke.
★ Do not operate tilting when blade is at top or bottom position.
2.2.1.10 Ripper control lever⑩(Fig.2-15)
The lever is usually in HOLD position ○ 2 .Move the lever to position
①,ripper is lifted(Fig.2-16); Move it to position ③,ripper is dropped.

Lift

Free

Lock

Drop

Fig.2-13 Fig.2-14
2.2.1.11 Ripper control lock button ⑾(Fig.2-17)
Press the button, can be lifted and dropped.

12
 When parking or servicing the machine, be sure to lower the ripper and
set safety lock in lock position.
2.2.2 Combined instrument and main function（Fig.2-18）

Fig 2-18
2.2.2.1 Function of combined instrument
The combined instrument consists of oil pressure gauge of engine,
water temperature gauge, oil temperature gauge, voltage gauge, time
meter and alarm unit etc. Alarm unit consists of alarm of engine low oil
pressure, alarm of high water and oil temperature, alarm of alternator trouble,
indication of neutral signal and indication of
preheat signal.
2.2.2.2 Oil pressure gauge（Fig.2-19）
Limit of oil pressure gauge is 0 bar～10 bar
（about 0 MPa～1 MPa），work range of engine is 1
bar～10bar. When oil pressure is low, alarm light
flashes. When cold starting pressure is sometimes
low, should preheat first until the point is in
normal work range.
Fig.2-19
2.2.2.3 Voltage gauge (See Fig.2-20)
Before the engine running, if the voltage is higher than 24V, the voltage
is normal. If it is lower than 24V,the voltage is low. At the time it is
possible too different to start the machine. If the engine cannot be started,
should replenish for the battery.

13
 When the machine normal working, the green light flashes, the voltage
is about 28V. If the voltage is low or high, should find out the cause and
operate after troubleshooting.

Fig.2-20 Fig.2-21
2.2.2.4 Water temperature gauge (See Fig.2-21)
It indicates the water temperature of engine. When the machine normal
working, the green light flashes. When the water temperature is high, the
red light flashes. At the time, should reduce the engine speed until the
instrument indication returns to normal range and stop the machine to check
water level as needed.
2.2.2.5 Oil temperature gauge (See Fig.2-22)

Fig.2-22 Fig.2-23
It indicates oil temperature of torque converter. The machine normal
working range is 50—120 ℃. When the machine working, if oil temperature
is high, alarm light flashes. At the time, should reduce the working load

14
until instrument indication returns to normal range.
2.2.2.6 Time meter (See Fig.2-23)
It records the running time of engine, which as the basis of periodical
maintenance and trouble time.
2.2.3.Other devices
2.2.3.1. Starting switch (Fig.2-24)

Fig.2-24 Fig.2-25
OFF Key insertion withdrawal position. None of electrical circuits
activate.
ON Charging and lamp circuits activate. Keep key at ON position after
starting
START At this key position, the starting motor will crank the engine,
release key immediately after starting. The key will return
automatically to the ON position.
2.2.3.2 Horn switch (Fig.2-25)
When this switch is pressed, the horn will sound.
2.2.3.3 Fuse box（Fig 2-26）
The fuse protect the electrical devices and wiring from burning out. If
any fuse is rusted or coated with white powder, replace it.
★ Place a fuse with another of the same capacity.
Before replacing a fuse, be sure to turn off the starting switch.

15
Fuse arrangement and circuit capacity:

Fig.2-26

16
2.2.3.4 Operator’s seat adjustment (Fig.2-27)
Forward and backward adjustment:
The control lever“1” is lifted, the seat can
be adjusted forwards or backward in the desired
position, then release the lever.
Height adjustment:
To raise and lower the seat by moving lever
“2” to left or right.
Tilting adjustment:
Lever “ 4 ” is lifted, set seat in desired
position, then release lever. Fig.2-27
Hard and soft seat adjustment:
To harden seat, turn lever“3”clockwise. To soften seat turn it counter
clockwise. You can obtain the best condition as operator’s weight.
2.2.3.5 Door lock（Fig.2-28）
When the door is opened, the lock can lock the door is in opening position.
1. When the door presses the door lock
(1), the door is locked in opening position.
2. When press the button (2) on the door
lock, the door lock is released and the
door is closed. Fig.2-28
2.3 Operation rules Fig.2-28
The correctly skilled operation not only raises productivity and economy,
but also is important factor for person and machine safety. Operation rules
must be strictly followed.
2.3.1 Operation of engine
1.Before starting the engine:
①Should be checked daily (check item, refer to periodic maintenance
table)
②Check that if brake pedal is locked.
③Check that if gearshift lever is in neutral position or locked.
④Check that if the control lever is locked after putting the blade on
the ground.
⑤Check that if the fuel control lever is moved into engine with the
17
throttle smallest open position.
⑥If the fuel cut-off valve is closed, please open it.
2.Starting:
⑦Turn the starting switch key to START position to start the engine.
When starting, the engine runs by starting motor. Check the engine oil
pressure indication lamp to see if the lubricant oil has pressure.
⑧After starting, return the key to ON position. The key should be stopped
at START position no more than 30 seconds.
If the engine is not started, repeat the starting procedure after an
interval of about 2 minutes
3.Starting on special conditions:
①When magnet valve occurs troubles:
After opening the magnet valve to start. If stop the engine, must close
the valve.
②Starting after closing the starting switch:
During the engine running, if the starting switch is closed by mistaken,
should start it again after stopping the engine.
4.Check after starting:
After starting the engine, do not operate the machine at once, should
carry out the following procedures.
①Run the engine at low idling speed and make sure the engine oil pressure
gauge shows green range.
②Pull the fuel control lever backward to run the engine at midrange speed
for about 5 minutes no load.
③Run the engine with load after the engine water temperature gauge
indicator moves into green range.
④After warm-up run, check all gauges and indicator for normality.
⑤Check for color of exhaust, noise and vibration.
⑥ Check for any leakage of oil, fuel or water. The procedures ○ 1 -○3 are
called “warm up run”. The engine is cooler, if the engine oil pressure
indicator moves into outside the green range after starting, the warm up run
should be continued after the indicator moves into the green range.
When the engine runs idling for more than 20 minutes, the engine should
be run with load. Do not run the engine at idling for a long time, otherwise

18
it causes the fire is not well, cylinder and chamber with carbon piling up.
Result in moving parts wear abruptly and it also result in leak out from the
bottom of the turbine.
5.Stopping the engine
⑦After running the engine at low idling speed for 5 minutes, return the
key of starting switch to OFF position, the engine will stop.
⑧After working finished daily, the fuel check valve must be shut off.
2.3.2 Operating of bulldozer
1. Starting
①After starting the engine, increase the engine speed by pulling the
fuel control lever backward.
②Unlock the blade control lever. Raise the blade 400 to 500 mm from the
ground.
③Unlock the ripper control lever. Rise ripper to the highest position.
④Step on the middle position of brake pedals. Place the brake lock lever
in FREE position and then release the brake pedals.
⑤Push gearshift lock lever to FREE position.
⑥Push gearshift lock lever to the desired position make bulldozer start.
When a machine is traveling, step on the deceleration pedal to increase
the engine speed so the machine can start off without jerking
When traveling on a slope, run the engine at full-throttle and shift
gearshift lever into 1st with brake pedals depressed. At this time the machine
has started slowly by releasing brake pedals slowly.
Even when you start the engine without setting gearshift lever in neutral,
the machine will not start by safety valve functions. In such case, you should
put the gearshift lever in neutral, and then put it in desired position and
machine begins travel.
2. Gear shifting
Put the gearshift lever into desired position and make the machine to
shift gears.
There is no need to stop the machine to shift gears
3. Shifting of forward and reverse:
First step on the decelerating pedals, after decelerating to shift gears
to prevent from damaging the machine.

19
 4. Turning
A machine traveling to one direction, pull the steering lever on the same
side halfway. This disengages the steering clutch and allows the
machine to start turn slowly.
When the steering lever is further pulled all the way out and the brake pedal
on the same side is depressed, the machine will turn a sharp pivot.
5. Turning while descending a slope
When descending a slope that the machine will go down of its own weight or
when going down a slope with a scraper, you should care the machine
Will turn to the opposite side to that of the pulled lever.
Avoid as much as possible turning the machine on slope because the machine
can tend to slip sideways. Particularly care be taken on soft or clay land.
Do not make a sharp pivot turn at high speed.
6. When turning the machine to the left (right) on a slope slowly
Turn the machine to the left (right) slowly while pulling the steering lever
on the halfway. (Direction of machine turning are opposite while the machine
descending by its own weight.
7. Turn the machine to the left (right) at the original port.
When pulling the steering lever to the left (right) all the way, the machine
will make a pivot turn.
8. Stopping machine
①Lower the engine speed by pushing fuel control lever forward.
②Push gearshift lever in NEUTRAL position.
③Step brake pedal on the middle the left (right) brake pedals and lock
brakes with brake lock lever after braking.
④Lock gearshift lever with lock lever.
⑤Put the blade and ripper on the horizontal ground.
⑥Lock the blade and ripper control lever with lock lever.
⑦Stopping the engine to be carried out according to rules of the engine
9. Blade operation
Position of control lever
①Raise ②Hold Blade is stopped and held in this position.
③Lower ④Float
Blade can be freely raised and lowered at this time, the control lever

20
 can not be moved.
A. Right tilt
Blade right side down and left side up can be tilted.
B. Left tilt
Blade left side down and right side up can be tilted.
Blade can be tilted at any position 1 --○
○ 3.
Lever should be returned quickly to HOLD position, at the end of tilt
cylinder stroke.
Do not operate lever when blade is at top or bottom position.
10. Ripper operation
Position of control lever
○1 Raise ○ 3 Lower
11. Precautions for traveling or working
○1 When torque converter oil temperature gauge indicator exceeds green

range while operating reduce load and wait for lowering of temperature.
○2 If the fuel level is too low on sloped areas, the engine may draw air

due to slopped grade or machine vibration and as a result braking force

may decrease. Exercise special care about the remaining amount of the fuel
in the fuel tank.
○3 While descending at a slope, place gearshift lever in the lowest
position and put the fuel control lever in the lowest speed position and
put to get braking effect of the torque converter by the difference of speed
between the engine and machine .
At the time, if the engine will over run step the brake pedal slowly to decrease
the engine speed prohibit to brake the machine).
If the engine will over run, it often causes an accident.
12. Precautions for working in water
○1 Before beginning work, securely tighten each drain plug.

○2 Do not operate machine in such a depth that carrier rollers are submerged.

It is necessary to expose the whole carrier rollers on the water surface.

Further be careful so that the cooling fan will not come in contact with
the water.
○3 When the machine stopping during operation or finished working, remove

mud from each part and check the engine oil pan, torque converter case,

21
transmission case steering case, hydraulic system etc. for:
a. Oil leakage
b. Oil level
c. Check for if any water is mixed into oil. If necessary, drain off water.
Pay particular attention to the level of the final drive case.
2.3.3. Cold weather operation
1. Preparation for temperature
If the temperature is low, it easily causes starting the engine
difficultly and freezing cooling water etc., it should take the following
measures:
1 Replace lubrication of all devices with specified lower viscosity
○
lubrication oil.
2 Fuel: light oil whose flow point is lower than atmospheric temperature
○
5℃ should be used.
3 Mix antifreeze into water.
○
Cautions for using antifreeze:
a. Clean water (city water) shall be used as mixing water.
b. Check the radiator, pump and water tank, whether have water leakage
or not.
c. Cooling water must be drained thoroughly, wash the interior and remove
the water scale before filling with antifreeze.
2. If there is no antifreeze in cold weather, the following precautions
should be taken:
1 Caution for running the engine
○
Thermostat valve open temperature is specified 77℃,as a general rule,
in cold weather, when running the engine, the water is cool, water inside
radiator is still, this maybe frozen. In this case, the thermostat must
be removed. During working, usually pay attention to the water temperature
indicator shows green range.
2 Cautions for stopping the engine
○
After working completed daily, drain the cooling water to prevent from
freezing and the following precautions must be taken:
a. Open the water drain valves on the machine body and oil cooler. (Do
not throw away the drained water).
b. Remove corrosion remover tin to prevent from freezing. Pack with cloth
22
and pay attention to warm so as to use again.
When remove the corrosion remover tin, be sure to lock the valve that
the corrosion remover tin entrance exit.
The corrosion remover device is used for preventing the engine cooling
system from rusting. So it must be fit when using again.
c. In order to prevent from freezing, drained the water with resist
corrosion. Do not throw it away. You should store it away to use next again.
If throw away the cooling water or all of water is exchanged for new
water by mistaken. Corrosion remover of this device is also exchanged for
new. At the same time add three bottles of DCA-4L into cooling system.
DCA-4L corrosion remover is made overseas. If you cannot get it, you
may add 30-50ml potassium bichromates of 10 percent in 1liter water. At
this time, should measure the PH value of cooling water. The PH valve is
recommended is 8.5 by CUMMINS.
Potassium bichromate has poison. Do not touch it with your skin when
using it.
d. When the temperature drops, the ability of battery can reduce and make
capacity of battery reduce. The capacity should be kept over 75% and keep
insulate and warm. If the level is low, should replenish distilled water
before working the next morning to prevent the liquid from freezing at
night.
The following table is the relation between specific gravity and rate
of charge:
Temperature of Liquid
20℃ 0℃ -10℃ -20℃
Rate of charge

100% 1.28 1.29 1.30 1.31

90% 1.26 1.27 1.28 1.29

80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
2.3.4 Long-term storage
1. Before parking:
1 After washing and drying every parts of machine, shall be place in
○
a dry building. If in out of room, lay wooden plates on the ground,
23
park the machine on the plate and cover it with the sheet.
2 Fill up oil and grease in all parts and replace lubricant.
○
3 Apply a thin coat of grease to metal surface (hydraulic piston rod
○
and front idler adjusting rod).
4 As to battery, remove the minus terminals and cover them or remove
○
them from the machine and store separately.
○5 When the atmospheric temperature is drop below o℃，pour antifreeze

into cooling water according to “the operation in cold weather”.

○6 Each controlling lever shall set to neutral and locked by the safety

lever and the brake pedal shall not be locked.

2. During parking
Operate the engine and move the machine to a short distance once
a month to prevent from corroding.
When operate the work equipment, remove grease on the hydraulic
cylinder piston rods.
When the rust preventive operation is made in door, open the windows
and doors to prevent the gas poisoning.
3. After parking
After parking (when it is kept without cover or the rust preventive
operation once a month is not made), you shall practice following
procedure before operation.
○1 Remove the drain plugs on the oil pan and other cases and drain the

mixed water.
○2 Remove the rocker housing cover and lubricate sufficiently valves

and rocker arms and inspect valve operation condition.

○3 Remove the flange on the turbocharger oil inlet, fill with

0.5-1liter the engine oil, and leave the flange lightly loosened. Then
rotate the engine by the starting motor to check pressure. Then tighten
the flange and start the engine.
○4 After starting the engine operate it until it is warmed up

completely.

24
 Ⅲ. SAFETY REGULATIONS
Operators must master the knowledge of construction, performance
operation and maintenance of bulldozers. The safety codes for operation
should be strictly followed. Always concentrate when operating a machine.
Do not allow unauthorized persons to operate a machine.
3.1 Preparations before starting
1. Put on working clothes.
2. Check the level of the fuel, lubricant and cooling water. If necessary,
should add oil etc.
3. Check leakages from hydraulic system and fuel tank.
4. Check that if bolt is tightened.
5. Check that if control lever is in neutral.
6. When replenish all kinds of oils, do not smoke or near flame. Then check
if each oil caps or plugs are firmly tightened.
7. Clean the cab fully, do not put anything that hinder one’s work in it.
8. The bulldozer must not be started if faults are found.
3.2 After starting the engine
1. Confirm that all gauges indicators are within the normal range.
2. Check that if all control lever, pedal is flexible and if stroke accord
with the prescription.
3. Check that if the blade operates normally.
4. Check that if the transmission controls normally.
5. Check that if the left and right steering is normally.
6. Check that if the steering brake is normally.
7. Check that if color of exhaust smoke is normally.
8. Check that if the safety devices are reliability.
9. Check that if all parts of machine has abnormal sound and vibration
10. Check that if the battery discharge is enough.
3.3 No-road travel
1. When machine traveling, should raise the blade 40-50cm from the ground.
2. Before starting and turning, should sound the horn and give the signal.
3. Do not start brake and turn suddenly. Do not snake and coast.
4. When passing through a narrow place, should have instructor and signal
outside the machine.
5. Check the load ability of bridge before crossing, when operating on bridge,
drives at as low a speed as possible.
6. When operating in water or in muddy areas, first check the bed soil
condition and the depth and flow speed of water.
25
7. When crossing through the railway, be careful of the other cars, drives
at as low a speed as possible.
8. Avoid traveling over obstacles. If the machine has to travel crossing over
large rocks, fallen trees, should travel at low speed. Never move over
obstacles at an angle. Never disengage on end clutch to travel over
obstacles.
9. When operating at night and in fog, be sure to arrange an adequate lighting
system.
10. When operating in snow and rain, should caution for change of ground
condition.
11.When driving on a slope, pay attention to the following points:
○1 Should travel along direct line at a low speed. Never drive horizontally

or turn across the slope.

○2 Do not change gears on the slope.

○3 Do not drive over the obstacles on a slope.

○4 Do not pass through fallen trees or log, pile of leaves of branches to

avoid occurring accident.

○5 If the engine stalls on a slope, first use the brake to stop the machine

and let the blade contact the ground and lock brake,then return the gearshift
lever to NEUTRAL before starting the engine again.
○6 Do not drive down on a slope with its own weight and inertia.

○7 If the engine cannot be controlled, should use the brake or let the blade

drops to the ground to the desired cutting position for decelerating of

machine.
○8 When the machine slipping down with its own weight, the function of steering

brake lever is the opposite of driving with normality.

○9 Never use the brake to stop the machine on slope suddenly. Lowing the blade

to stop if necessary.
12. Never allow other person than the operator to ride on the machine during
operation.
3.4 Working regulations
1. Examine the work site before operating to avoid accidents.
2. The operator must concentrate when operate a machine. Observe all the
gauges, exhaust gas color and show if the machine is normality according
to sound, vibration or response of the control lever. If any abnormity
occurs, park the machine immediately in a safe place to find out the cause.
3. Do not operate the machine standing up to prevent from knocking and
damaging.
4. When operating in fallen tree, jungle, we must remove them on the engine

26
 to prevent from damaging the engine and occurring a fire.
5. To extend the life of using the machine, should avoid working excess load.
6. When dumping soil the speed of machine is getting quickly because of
reducing of load. So, when operating in a cliff or shoulder, must pay
attention to this especially, to avoid the machine turnover.
7. When traveling and working, pay attention to keep away from wiring, cable
and careful for electric shock.
8. When operating in the building pushed down or cliff, always notice fallen
stone and collapse.
9. Be sure to arrange an adequate lighting system at night operation.
10. If the machine needs to be towed, do not allow unauthorized persons around
the wire rope.
3.5 Parking and maintenance
1. Put the machine on a safe, stable ground. If parking the machine on a slope,
be sure to make the machine facing down and lock the brake pedal (should
first depress the brake pedal and lock the brakes with brake lock lever.
When locking brakes, be sure to keep the engine running otherwise that
is dangerous.) If the slope is large, should make a blade shovel soil to
prevent the machine body from slipping down.
2. After the machine has been stopped, should put all control levers at
neutral position.
3. Check for the leakage of oil and water and check tightness of bolts and
nuts, and retighten if required.
3.6 Cautions for maintenance
1. Do not work under the blade without reliable protection. Do not maintain
while the machine traveling.

Lower the blade to the ground before maintenance. If the blade is

lifted to carry out maintenance, should first pad the blade with stable
subjects.
2. Maintenance should always be carried out after stopping the engine
generally.
If maintenance is carried out with the engine running, there must be two
men prevent:
One sits in the cab to operate, and the other performs maintenance.
When the rotating parts of the engine are carried out maintenance. Should
first stop the engine running.
3. Working under the undercarriage, hang a caution sign in the cab and all
around. This will prevent anyone from starting or moving the machine by
27
 mistake.
4. When putting the blade to the ground and raising the front of a machine
to carry out maintenance, each control lever must be locked. Then the track
must be securely supported with hard things.
5. Flames should never be used instead of lamps.
6. Do not make any fire or flame near to battery.

Never use battery plug to contact metal for checking battery charge.
7. When feeding or draining the oil and maintenance, release the pressure
first.
8. When checking, do not make tools or other things drop inside of the machine.
9. Do not remove the machine cap while the water temperature is high to prevent
the hot water from spurting out.
10.All kinds of oils should accord with the stipulation of this manual.
11. Never use unsuitable spare parts.

28
 Ⅳ.NOTICE FOR DISASSEMBLY AND ASSEMBLY
4.1 Disassembly
1. Before the any parts of machine are removed, always read carefully the
MANUAL. It is an important that grasp the structures and applications of
all kinds of parts.
2. When disassembly, should pay attention to the direction and position of
each part, mark them with ink if necessary. At the same time maintain
disassembled parts in good order to make sure to assemble correctly.
3. Always use the special tool prescribed in rules of operation. If have no
special tool, the similar tools can be used. If common tools make any parts
damage, the special tools must be used.
4. The parts with or fitting closely should be installed in original position.
If these parts has been found loosing. Must examine their wearing
condition.
5. Thoroughly clean disassembled parts and put them together in regular order
to make sure take precautions to prevent from dust. There are two
detergents: One is used for remove the dirty, the other is used for cleaning
out.
Filter, magnetic plug and vent hood are especially needed cleaning parts.
4.2 Assembly
1. Before all parts are assembled should be cleanly, the parts that are
replaced coating rust preventative, should be cleaned.
2. Use press-fitting tools to assemble bearings,bushings and oil seals.
3. Spring washer, flat washer, tongue shape washer and cotter pin are
important parts. When assembly, should especially pay attention to this.
When install the bolts and nuts, always examine if tightening method is
proper.
4. Use torque wrench in which designated limit. For fixing cover or many
similar bolts (such as valve body etc.), be sure to tighten bolts evenly.
5. Fitting marks are not distinguishing mark that match parts. They are used
for making parts align as correctly as possible.
4.3 Disassembly and assembly of bearings
1. When replace bearings, after all assembled works have been finished,
remove the package of bearings.
29
2. Be sure to use the gasoline as detergents of bearings. If there is
compression air, also clean with the kerosene and the diesel and then blow
out the dust with compression air.
3. When assembly the bearings, be sure to make bearings near to location steps
or bearing seat to reduce the over clearance of two ends.
4.4 Disassembly and assembly of the oil seal
1. Be careful to install the oil seal with its lips of oil and gear oil facing
inside and lips of grease facing outside.
2. Should make the oil seal near to location step or the oil seal seat.
3. Before install the oil seal, make sure that coat the lips with lithium
grease to prevent the oil seal from scratching.
4. When installing the oil seal, should make a wire tube to slip into the
housing (see fig 4-1A). If there is no such a wire tube, may use a piece
of copper instead of it. (See fig4-1B)
5. Must use a proper tool to press the oil seal into the housing. (See fig4-1C).
Make the pressure apply to the oil seal end is evenly. The diameter of
the tool is smaller 0.5-1mm than the hole of the housing. The free end
should have the shape apply to hammering.

Fig.4-1 The oil seal assembly method

30
Ⅴ.STRUCTURE AND PRINCIPLE OF BULLDOZER
5.1 Engine
5.1.1 Engine overall structure (See Fig.5-1, 5-2)

1. Alternator
2. Air cleaner
3. Fuel filter
4. Bypass filter

5. Muffler
6. Preservative agent can
7. Turbocharger
8. Oil cooler
9. Starting motor
10. Oil strainer
11. Damper

Fig.5-1

31
Fig.5-2

32
5.1.2 Engine main specifications
1. Main specifications
Engine model NT855-C280(BCⅢ)
No. of cylinder- bore × stroke（mm） 6-139.7×152.4
Displacement (l) 14.01
Firing order 1-5-3-6-2-4
1691(Flywheel housing～
Overall length（mm）
front end of fan)
Dime
Overall width（mm） 1116(Rear bracket～Rear bracket)
nsion
2741.9(Exhaust pipe～
Overall height（mm）
Air drain valve of oil pan)
Net weight（kg） 1750
Rated speed（rpm） 1800

Perfo Rated horsepower（k w） 162(220PS)

rman Max. torque（N·m/rpm） 1030/1250
ce The highest speed without load（rpm） 1900~2000
The lowest speed without load（rpm） 550~600
Min. fuel consumption ratio（g/ k w·h） ≤228
Alternator for charge Silicon commutate alternator 35A
Starting method Starting motor 24 v 11 k w
Battery 24 v 195 A. h×2
Volume of lubricant（L） 45
Volume of cooling water（L） 79
2. Distribution phasigram (See fig 5-3)

Fig.5-3
33
3.Performance curve (See Fig.5-4)
Flywheel horsepower：162kw(220ps)/1800rpm
Max. torque：1030N·m/1250rpm
Min. fuel consumption：<205g/kw·h

Output Torsion
Output power

Fuel wastage

Engine rotate speed

Fig.5-4

34
 Inside Filter Outside Filter
5.1.3 Introduction engine systems
1. Air intake and exhaust system
The system consists of air cleaner, turbocharger,
muffler, exhausting pipe.
1 Air cleaner (See Fig.5-5)
○
Air cleaner is dry type, two stages cleaner
and it consists of revolving pipe strainer and
paper strainer, the straining effectiveness reaches to Fig.5-5
99.8%. When cleaning the cartridge, only outside cartridge needs cleaning and inside
cartridge is not allowed cleaning.
Inside cartridge part No.: 6127-81-7412；Outside cartridge part No.: 6128-81-7320
○2 Turbocharger

Model: T-46 (See Fig.5-6)

1.Isolating heat plate
2.Seal ring
3.Exhaust outlet
4.Turbo wheel and shaft
5.Turbine housing
6.Exhaust inlet
7.Oil outlet
8.To the air of engine
9.Air compressor case
10.Bearing spacer
11.Seal ring
12.Oil seal sleeve
13.Air compressor wheel
14.Air inlet
15.Oil seal plate
Fig.5-6 16.O ring
17.Bearing case
18.Oil outlet
19.Turbocharger bearing
20.Isolating material

35
2. Fuel system
1.Oil injector (Part No. 3013725) (See Fig.5-7)
Injector
2.Injector cap
3.Check ball valve
4.Snap ring
5.Strainer screen
6.Plug
7.Seal shim
8.Plunger pipe
9.Injector spring
10.Lever
11.Injector body
12.O ring
13.Thread pin Fig.5-7
14.Plunger
15.Plunger sleeve
The injector body (11) is equipped with plunger spring (9), adjustable hole (6), seal
shim (7), fuel strainer screen (5), ring (4) and ring (12). The injector body is sealed with
cylinder head together to compose fuel intake and return line. Fuel passes through
adjustable hole (6) to flow into plunger sleeve (15) and passes check ball valve (3) to the
oil line of injector and plunger sleeve and then to measurement hole. The fuel is measured
into injector (1). When the fuel is not injected, the fuel passes through measurement hole
and ring and flows out from fuel return hole. At this time the plunger falls on the injector
surface. Injector, fuel injector body and plunger sleeve are tightened together by the
injector cap (2).
2 Fuel pump (Part No. 3262175)(See Fig.5-8)
○
The fuel pump of model PT (G) VS consists of gear pump, standard regulator and one VS
regulator.

36
 Fig.5-8 Model PT (G) VS fuel pump and fuel flowing direction
1.Driving gear and shaft 2.Vs regulator flying hammer
3. Fuel to injector 4.Cut-off valve
5.VS regulator plunger 6.VS idling spring
7.VS speed spring 8.VS throttle shaft
9.Gear pump 10.Pulse reducer
11.Fuel from filter 12.Pressure regulator valve
13.Idling adjusting screw 14.Spring sleeve
1. High speed spring 16.Idling spring
17.Idling spring plunger 18.Throttle shaft
19.Filter screen 20. Regulator plunger
21.Torque spring 22. Regulator spring
23. Regulator auxiliary plunger 24. Main shaft
○
3 Work principle for fuel system (See Fig.5-8 and 5-9)

When the engine running, the crankshaft turns. Fuel pump main shaft (24)
turns by the means of gear drive. The main shaft (24) drives gear pump (9),
regulator fly hammer (2) and rotational speed meter shaft to work.
(See Fig.5-8)

37
 Fig.5-9
1. Injector 2. Air intake tube
3. Fuel pump 4. Fuel filter
5. Fuel tank 6. Check valve
Diesel oil is exported from fuel tank (5) is filtered by fuel filtered
(4) into fuel pump (3) (See fig 5-9).
The oil passes through gear pump (9) and is filtered by filter screen
(19) and through regulator into throttle shaft (18). When idling running,
the fuel passes through idling port on regulator sleeve into throttle shaft
and enters into injector (1) from fuel pump cut-off valve (4) (See fig 5-9).
Because fuel enters throttle shaft through main oil line and idling oil line,
when diesel engine idling running, the main oil line is shut off. At this
time, only idling oil line transmits oil. When the engine high speed running,
the idling oil line is shut off and main oil line transmits oil. These works
are finished by means of VS regulator.
38
 Fuel flows into injector passes measurement hole to cylinder chamber.
Measure and injection process, please see “instruction of injector”. The
injector plunger operation is finished by means of camshaft, cam roller, frame
and rocker. After finishing the injection, the plunger has stopped operating
for sometime. At this time, a port of fuel (about 50%) passes through the
injector to return the fuel tank and cool the injector. Because the supply
oil capacity depends on supply oil pressure and oil injection time, the fuel
system is PT fuel system.
3. Lubricating system (See Fig.5-10)
It adopts forced lubricating method. Pressure produced from engine
crankshaft gear drives oil pump. Lubricating system consists of oil pump (2),
regulating valve (5), oil cooler (6), oil cooler (7) and gauge.

Fig.5-10
1. Oil pan 2. Oil pump
3. Pass by valve 4. Pass by strainer
5. Adjusting valve 6. Oil cooler
39
7. Oil strainer 8. Oil strainer safety valve
1. Cam shaft 10. Main lubricating oil line
11. Gear 12. Crankshaft
13. Piston cooling injector 14. Piston
15. Lever 16. Injector
17. Lever 18. Valve
19. Turbocharger
A. Cooling water inters from water pump
B. Drain water (To water manifold)
4. Cooling system (See Fig.5-11)
Cooling method of water, Water cycle is produced from centrifugal water
pump. The power is transferred by crankshaft through belt drive. In order
to reduce the temperature, heat of water in radiator (9) is exhausted by fan
(8) into the air.

Fig.5-11
1. Corrosion protection water filter 2. Thermostat
3. Water manifold 4. Piston
5. Cylinder bushing 6. Oil cooler
7. Water pump 8. Fan
9. Radiator
40
 A. Inter oil from oil pump.
B. To main oil line of engine.
C. To hydraulic system for undercarriage.
D. From hydraulic system for undercarriage.
5.1.4 Power take-off
1. Flywheel housing assembly (See Fig.5-12)

Fig.5-12
1. Flywheel housing 2. Idler 3. Bearing 4.Transfer case driving gear (Z=56)
5. Bearing 6. Cover
Main function is to finish power take off.
2. Transfer case (See Fig.5-13)

Fig.5-13

41
1. Flywheel housing 2. Transfer case body
3. Driven gear 4. Transfer case cover
5. Main shaft 6. Driving gear
7. Cover 8. Driven gear
9. Lubricating tube 10. Distributor
Transfer case is installed on the top of flywheel housing. The gear on
flywheel housing drives the main shaft (5) and driving gear turns to make
driven gear (3)、(8) revolute. Remove the under cover (7) and install work
pump. Driven gear (3) drives gearshift oil pump. Install steering oil pump
on the front of flywheel housing. The lubricating oil of transfer case gear
and bearing is from oil cooler return hose and distributed by distributor
to enter all positions through lubricating tube (9).
5.1.5 Radiator assembly (See Fig.5-14)
The radiator consists of upper tank (1), radiator (12), lower tank (10)
and related attachments. Cooling water passes through the thermostat to the
upper tank (1), remove the air in water, it then flows through radiator core
(12) into the lower tank (10).
When cooling water passes
through radiator core (12), the
water is cooled with action of
fan behind the radiator. After
the water temperature is dropped,
the cooling water is drained by
water pump through the lower
tank into engine cylinder body.
The system is closed system. The
operation pressure of pressure
valve fitted to the upper tank is
below 0.075Mpa. Thus raise the
vapor temperature of cooling
water, reduce the loss of water
and raise the efficiency of
scattering heat. The power of
fan (13) is transferred by fan
pulley on the front of the engine
by V-belt. Cooling effect is
improved by providing forced wind. Fig.5-14

42
 1. Upper tank 7.Shaft
2. Hose 8.Case
3. Inlet tube 9.Outlet tube
4. Guard of fan 10.Lower tank
5. Hose of adding water 11.Guard
6. Pulley 12.Radiator core
13.Fan
5.1.6.Fuel tank and piping (See Fig.5-15)

Fig.5-15
The fuel tank is installed on the rear of machine body. The fuel tank
fills oil by filling oil screen. The fuel flows into the injection pump fuel
filter from fuel tank. There is a fuel stop valve and oil drain valve on the
back of fuel tank.

43
5.1.7.Engine control (See Fig.5-16)
Stop Idling High speed

Fig.5-16
1. Fuel control lever
2. Idling adjusting screw
3. Lever
4. Lever
5. High speed adjusting screw

44
5.2 Torque converter (See Fig.5-17)
It adopts three elements, 1 stage and 1 phase torque converter

Fig.5-17
1. Driving gear 2.Driving housing 3.Turbine 4.Torque converter housing
5.Pump 6.Driving gear 7.Stator shaft 8.Cover 9.Coupling 10.Turbine output
shaft 11.Stator shaft hub 12.Stator 13.Pump case 14.Driving gear
15.Strainer 16.Oil outlet 17.Turbine hub 18.Plate 19.Pilot
Pump (5), turbine (3) and stator (12) are filled with working oil. When

45
the pump wheel (5) turns, the pump wheel can make oil shock into impeller
to make turbine revolute. Oil flows from the turbine into the stator and flows
from stator into pump wheel inlet. Thus, the cycle of oil is finished.
Stator may change turning movement of liquid to make the turbine torque
enlarge. The turbine torque depends on working condition. So, when the load
is increased, the turbine can get the larger resistance to drop automatically
the speed.
Power input line is: Driving gear (1) →Driving housing (2) →Pump (5)
Power output line is: Turbine (3) → Turbine hub (17) → Turbine output shaft
(10)
5.3 Universal joint (See Fig.5-18)
The function is to finish the power transfer between torque converter
and transmission case.

Fig.5-18
1. Spider assembly
2. Plate
3. Bolt
4. Bolt

46
5.4 Transmission case (Fig.5-19)
The function of transmission case is:
1. Realize the forward and reverse movement of machine.
2. It may obtain different output drive ratio (include parking).
The machine adopts planet gear, multi-disc clutch structure. It is controlled
by controlling valve, and depends on hydraulic force to obtain forward and
reverse three speeds.
No.1 clutch is for forward; No. 2 is for reverse; No. 3 is for 3rd speed;
No. 4 is for 2nd speed; No. 5 is for 1st speed.

Fig.5-19
47
1. Transmission case housing 2.No.1 clutch cylinder body
3.No.1 clutch piston 4.Washer 5.Disc 6.Plate 7.No. 1,2 and 3 planet
gear shaft 8.No. 2 clutch piston 9.No. 2 clutch cylinder body
10.No. 3 and 4 clutch cylinder body 11. No.3 clutch piston
12.No.4 clutch piston 13. Plate 14. No. 4 planet gear shaft
15.No. 5 clutch outside drum 16. No. 5 clutch cylinder body
17.Check valve ball 18. Rear case body 19. Case
20.Output shaft sleeve 21.Input shaft 22. Bearing cage 23. Cover
24.Bearing cover 25.Bearing plate 26. No. 5 clutch piston
27.No.5 clutch inside drum 28.No. 4 planet spring 29.Disc spring
30.No. 4 planet carrier 31.No. 3 planet spring
32.No.2 planet spring 33.No.1 planet spring 34. No.1,2 and 3 planet carrier
35.Bolt 36.No.2 planet gear shaft 37.Bearing cage 38.Bearing cage
39.Plate 40.Coupler
Direction of Clutch to be
Gear shift
movement engaged
The first clutch is forward 1st No.1, No.5
The second clutch is reverse Forward 2nd No.1, No.4
The third clutch is 3rd speed 3rd No.1, No.3
The forth clutch is 2nd speed 1st No.2, No.5
The fifth clutch is 1st speed Reverse 2nd No.2, No.4
3rd No.2, No.3

1. Principle of planetary gear mechanism and clutch mechanism

(1) Principle of planetary gear work
(Fig.5-20)
The planetary gear mechanism consists
of sun gear (A), planetary gear (B), ring
gear (C) and carrier (D). The planetary
gear (B) is installed on the carrier (D).
At the same time, it is engaged with sun Clutch
gear (A) and ring gear (C).

A. Sun gear B. Planetary gear

C. Ring gear D. Carrier

Fig.5-20
48
 If ring gear is fixed, the torque is transmitted from sun gear (A) to
planetary gear (B). The planetary gear (B) rotates by itself at the same time
rotates around sun gear (A). Rotation direction of the planetary gear shaft
is opposite from sun gear (A). (See Fig.5-21).
If carrier (D) is fixed, the torque is transmitted from sun gear (A) to
planetary gear (B), and is transmitted from planetary gear (B) to ring gear
(C) to make ring gear (C) rotate. Rotation direction of ring gear (C) is
opposite from sun gear (A). (See Fig.5-22).

Fig.5-21 Fig.5-22
The above principles are structure principle of No. 1,3,4 planetary gear
mechanism. The sun gear is active in No. 1 planetary gear mechanism. The
carrier (D) is active in No.3 and 4 planetary gear mechanisms.
A group of planetary gear (E) is increased only (See Fig.5-23) to obtain the
opposite output rotation direction as the above. This transferring method
A→B→E→C is structure principle No. 2 planetary gear mechanism.
(2) Clutch mechanism (See Fig.5-24)
No.5 clutch of transmission case is closed clutch.

49
 Fig.5-23 Fig.5-24
A. Sun gear B. E planetary gear C. Ring gear D. Carrier
Method of fixing of each planet gear as fig 5-25, it is realized by clutch.
Engagement of clutch is realized by pressure oil from controlling valve pushes
piston (3). (See Fig.5-26)

Fig.5-25 Fig.5-26
Disengagement of clutch is realized by back spring (33) pushes piston
(3) to original position after pressure oil is cut off. (See fig 5-27). The
function of disc spring (42) is to improve operating speed of piston (3) and
improve the disengaging effect of disks.
Fig.5-28 is structure diagram of No.5 clutch. When the clutch disengages,
oil in the cylinder body (16) by the action of centrifugal force, disks cannot
disengage quickly only by disc spring (29). This can make the clutch is in

50
half disengage. This will cause difficulty for next gearshift. In order to
remove this thing, the ball back valve (17) is installed.

Fig.5-27 Fig.5-28
When No. 5 clutch engages (See fig 5-29), pressure oil from controlling
valve enters into oil cavity and pushes piston (26), at the same time, the
oil pushes check valve ball (17) to plug the hole of valve. The clutch is
engaged quickly.
When the pressure oil from controlling valve is cut off, by the action
of centrifugal force, ball (17) can move to the direction of arrow in Fig.
5-30. At this time, the hole of valve cage is opened and the oil is drained
off.

Fig.5-29 Fig.5-30
1. Power transferring route
(1) Forward, 1st speed (See Fig.5-31)

51
 At the time, No. 1 and No.5 clutch engage at the same time.
Power transferring route is: A→B→(34) →J→O→P→Q (At this time, J、
N、H、K、L and No.5 clutches is connected together).
(2) Forward, 2nd speed (See Fig.5-32)
At the time, No. 1 and No.4 clutch engage at the same time.
Power transferring route is: A→B→(34) →J→(30)→L→K→O→P→Q

Fig.5-31

Fig.5-32
rd
(3) Forward, 3 speed (See Fig.5-33)
At the time, No. 1 and No.3 clutch engage at the same time.
Power transferring route is: A→B→(34) →J→I→H→O→P→Q
52
 Fig.5-33
st
(4) Reverse, 1 speed (See Fig.5-34)
At the time, No. 2 and No.5 clutch engage at the same time.
Power transferring route is: D→E→(34) →F→(34)→I→J→O→P→Q

Fig.5-34
nd rd
(5) Reverse, 2 and 3 speed (Omitting)
No.2 and No.4 clutch engage at the same time to get the 2nd speed reverse.
No.2 and No.3 clutch engage at the same time to get the 3rd speed reverse.

53
5.5 Main drive (See fig5-35)
The function of main drive:
1. Change the direction of power transfer (change the vertical direction to
the horizontal direction).
2. The first deceleration, increase torque, main drive, steering clutch and
steering brake are installed in steering case.

Fig.5-35
1. Outside drum 2.Plate 3.Outside disk 4.Inside plate 5.Inside drum
6.Hub 7.Bearing cage 8.Big bevel gear 9.Bevel gear shaft 10.Adjusting pad
11.Big spring 12.Small spring 13.Bolt
Main drive consists of big bevel gear (8), bevel gear shaft (9), bearing
cage (7) and bearing. Adjust adjusting pad (10) and the pad between pinion
gear assembly of transmission case and housing to make two bevel gears to
engage correctly.
Adjust adjusting the nut (9) and the pad between bevel pinion and housing
to allow a double of bevel gear to engage correctly.
The standard gap between two spiral bevel gears is 0.25~0.33 mm. The mark
engaged along the direction of the teeth length should more than a half of
the teeth length, and the direction of teeth length near to the small end.
The height is in a half of the teeth height. (See Fig.5-36)

54
 Fig.5-36
If the engage is not normal, should adjust according to the below table.
Contact position
on the driven gear surface
Forward
Direction of
Method of adjusting
gear movement
Make driven gear
close to driving
gear. If the gear gap
is too small, should
move the driving gear
outside.
Make driven gear
leave driving gear.
If the gear gap is too
large, should move
the driving gear
inside.
Make driving gear
close to driven gear.
If the gear gap is too
small, should move
the driven gear
outside.
Make driving gear
leave driven gear. If
the gear gap is too
large, should move
the driven gear
inside.
55
 Make driven gear
leave driving gear.
If the gear gap is too
large, should move
the driving gear
inside.
Make driven gear
close to driving
gear. If the gear gap
is too small, should
move the driving gear
outside.
Reverse
Make driving gear
close to driven gear.
If the gear gap is too
small, should move
the driven gear
outside.
Make driving gear
leave driven gear.
If the gear gap is too
large, should move
the driven gear
inside.

5.6 Steering clutch (See Fig.5-37)

Steering clutch is mounted on the cavity of left and right steering case.
The function is to turn on or off the power from center drive to finial to
change the direction of traveling. The structure consists of inside drum,
plate, inside and outside disk and spring.
The machine adopts the structure of wet, multi-disc, pressed spring,
separate hydraulically type. By the action of disc spring, inside and outside
disk are engaged. The power from bevel gear shaft passes through hub (6)
→inside drum (5)→inside disc (4)→outside disc (3) →outside drum (1) to
transfer to driving plate of finial drive.
When pressure oil from steering controlling valve enters the hub (6) (See
fig 5-37), pushes piston (10), bolt and plate (2) to make it move to the

56
direction of arrow. Allow inside disc (4) and the power transfer is cut off.
When oil pressure is cut off, the above parts can move as figure shown
direction by the pressure of spring and allow inside disk (4) and outside
disk to engage to realize the power transfer. (See Fig.5-38)

Fig.5-37 Fig.5-38
5.7 Steering brake (See Fig.5-39)
The machine adopts the brake of wet, band, hydraulic boost.

Fig.5-39

57
1. Lever 2.Lever 3.Spring seat 4.Spring 5.Spool 6.Bushing 7.Valve body
8.Piston 9.Lever 10.Stud 11.Lever 12.Adjusting bolt 13.End 14.Lever
15.Brake band 16.Lining band
The main function is to make finial drive gear stop drive by holding to
the outside drum of steering clutch to allow the machine to turn or park.
1. Principle of operating
If the outside drum of steering clutch rotates forward (See Fig.5-40A),
when the brake force is a little applied on brake pedal, the clearance between
brake band and outside drum is reduced until some positions contact. As the
action of friction, the brake band top contacts the end (13) to make pin A
into groove of lever (11). If the brake force is applied again, lever (14),
pin B and lever (11) will move as the direction of arrow. The operation of
holding to outside drum is realized at this time.
If the outside drum of clutch rotates reverse (See Fig.5-40B), lever (14),
pin B, lever (11) can move as figure shown direction to realize the operating
of holding to outside drum. But, at this time rotating point enters into point
C.
Both brake effects are same.

Fig.5-40

58
 2. Principle of boost valve function (Fig.5-40)
Usage of boost valve can greatly reduce operating force of operator. When
brakes, lever (1) pushes spool (5) to make the clearance between spool (5)
and piston (8) disappears. Push piston (8) and drive lever (9) to realize
the brake by the action of oil pressure from pump. Because of movement of
piston (8), the clearance between spool (5) and piston (8) will appear again.
In order to assure continuous operating, the brake pedal must be operated
continuously.
5.8 Finial drive (See Fig.5-41 and 5-42)
The machine adopts two stages spur gear reduction mechanism. Function
of finial drive is that increases output torque through two stages reduction.
The power is transmitted to traveling mechanism by sprocket.

Fig.5-41 Finial drive mechanism of model SD22S

1. Driving plate 10. Nut

59
2. Bearing cage 11. Bracket
3. One stage driving gear 12. Cover
4. One stage driven gear 13. Float seal
5. Two stages driving gear 14.Seal cover
6. Two stages driven gear 15.Float seal
7. Hub 16.Seal cover
8. Teeth 17.Case
9. Sprocket 18.Shaft

Fig.5-42 Finial drive mechanism of model SD22、SD22E、SD22D

1. Driving plate 11. Bracket
2. Bearing cage 12. Cover

60
3. One stage driving gear 13. Float seal
4. One stage driven gear 14.Seal cover
5. Two stages driving gear 15.Float seal
6. Two stages driven gear 16.Seal cover
7. Hub 17.Case
8. Teeth 18.Guard
9. Sprocket 19.Shaft
10. Nut
5.9 Control of power train
1. Gearshift control (See fig.5-43)

Fig.5-43
1. Gearshift lever
2. Gearshift lock lever
3. Gearshift valve

61
 2. Steering control (See Fig.5-44)

Fig.5-44
1. Brake pedal
2. Brake lock lever
3. Steering control lever
4. Steering valve
5. Brake valve

62
5.10 Travel system (See Fig.5-45 and 5-46)
The system consists of track frame (7), drive gear (3), idler (1), track
roller (4) (5), carrier roller, track and recoil mechanism of track. It can
realize traveling movement of bulldozer.

Fig.5-45 Travel mechanism of model SD22

1. Idler
2. Carrier roller
3. Sprocket
4. Track roller S (single side, 4 /each side)
5. Track roller D (double side, 2 /each side)
6. Guard
7. Track frame

63
 Fig.5-46 Travel mechanism of model SD22S

1. Idler
2. Carrier roller
3. Sprocket
4. Track roller S (single side, 5 /each side)
5. Track roller D (double side, 3 /each side)
6. Guard
7. Track frame
Travel system of model SD22D is the same as travel system of model SD22E.
Its travel system is more one double track roller than travel system of model
SD22 and its arranging order (from left to right) is ：
S、D、S、D、S、D、S.

64
1. Recoil mechanism of track (See Fig.5-47)

Fig.5-47
1. Bracket 10. Nut
2. Shaft 11. Cover
3. Cylinder 12.Bushing
4. Piston 13.Oil seal
5. Cover 14.Ring
6. Front seat of spring 15. Oil seal
7. Large recoil spring 16.Injector
8. Small recoil spring 17.Plug
9. Rear seat of spring

65
2. Idler (See fig 5-48)
Idler acts for pilot link and track.

Fig.5-48
1. Idler
2. Bushing
3. Shaft
4. Pilot plate
5. Float seal
6. Pilot

66
 3. Track roller (See Fig.5-49)
It supports the weight of bulldozer to prevent the track from leaving
the orbit. Track roller is divided into single and double side structure.
Track roller structure of double side as figure shown.

Fig.5-49

1. Track roller
2. Bushing
3. Cover
4. Float seal
5. Shaft

67
 4. Carrier roller (See Fig.5-50)
It supports the top of track to prevent the track from sagging, reducing
shock in traveling and sliding to side.

Fig.5-50
1. Bracket
2. Shaft
3. Float seal
4. Carrier roller
5. Cover
6. Nut
7. Float seal seat
8. Float seal seat

68
 5. Track
The function of track is to support the weight of bulldozer to assure
the attaching ability of bulldozer and make it has enough driving force.
Fig.5-51 is track assembly of model SD22、SD22E and SD22D bulldozer.
Fig.5-52 is track assembly of model SD22S.

Fig.5-51 Track assembly of model SD22、SD22E and SD22D

1. Dust ring 6. Master sleeve

2. Pin 7. Sleeve
3. Seal ring 8. Track shoe
4. Master pin 9. Bolt
5. Link 10.Nut

69
 Fig.5-52 Track assembly of model SD22S

1. Dust seal 6. Master sleeve

2. Pin 7.Bushing
3. Master pin seal 8.Track shoe
4. Master pin 9.Bolt
5. Link 10.Nut

70
6. Equalizer (See Fig.5-53)
It connects frame to undercarriage and acts for cushion.

Fig.5-53
1. Equalizer 2.Shaft 3.Sleeve 4.Sleeve

71
 5.11 Hydraulic system
The system consists of work equipment hydraulic system and gearshift and
steering hydraulic system.
1. Work equipment hydraulic system
Fig.5-54 to 5-57 shows hydraulic principle and diagram of model SD22、
SD22E、SD22S and SD22D bulldozer.

Fig.5-54 Hydraulic principle diagram of model

SD22、SD22E、SD22S and SD22D bulldozer
L: Lower R: Lift F: Float L.T: Left tilt R.T: Right tilt

72
Fig.5-55 Hydraulic system diagram of model SD22、SD22E AND SD22D

73
Fig.5-56 Hydraulic principle diagram of model SD22S bulldozer
L: Lower R: Lift L.T: Left tilt R.T: Right tilt

74
 Fig.5-57 Hydraulic system diagram of model SD22S bulldozer
1. Cylinder for blade 15. Replenish oil valve
2. Cylinder for tilt 16. Replenish oil valve
3. Quick drop valve 17. Relief valve
4. Oil pump for work equipment 18.Oil filter
75
 5. Steering oil pump
6. Screen
7. Filter
8. Strainer
9. Overload valve
10. Replenish oil valve
11. Replenish oil valve
12. Change direction valve
13. Change direction valve
14. Change direction valve
○
1 Gear pump (See Fig.5-58)
1. Driving gear 2.Front pump cover
5.Rear pump cover 6.Gasket
19.Rotary servo valve
20.Rotary servo valve
21.Rotary servo valve
22.Steering brake valve
23.Cylinder for ripper
24.Check valve for inlet
25.Check flow valve for inlet
26.Check valve for inlet
27.Steering case
28.Oil tank for work equipment
Inhale
Fig.5-58
3.Bushing 4.Pump body
7.Ring 8.Ring 9.Driven gear
76
 ○
2 Hydraulic system principle for work equipment (Fig.5-59)

Fig.5-59
The principle is that the gear pump sucks working oil out of oil tank
(28). And pump it into valve (12) (13) and (14). The oil passes through change
direction valve to filter (18) to return oil tank (28) without controlling
all work equipments. If the filter is clogged at this time, the oil can push
check valve of filter to return to the oil tank. If the valve (14) or (13)
is operated, the blade cylinder is controlled, the blade can realize the raise,
lower, hold and float; the tilt cylinder is controlled, the blade can realize
tilt left, tilt right and hold. If the valve (12) is operated, the ripper
cylinder is controlled, the ripper can realize the raise, lower and hold.

77
Valve (24) (25) (26) is installed on the front of changing direction valve
to remove the all shocks when each work mechanism changes direction.
The flow valve (25) (See Fig.5-60) is installed to make tilt cylinder gets
ideal movement speed.

Fig.5-60
The overload valve (9) is installed to avoid the high pressure with the
bigger load when loosening the soil.
During the working, if the load is large, system pressure is more than
14Mpa. At this time, the relief valve (17) (See Fig.5-61) is turned on. The
oil passes through relief valve to return to the oil tank.

Fig.5-61
78
 When the direction of external force is the same as the direction of
movement of cylinder piston, there is vacuum in the cylinder. So, replenish
oil valve (10) (11) (15) and (16) is installed. (See Fig.5-57). Structure
of replenish oil valve to see Fig.5-62 and Fig.5-63.

Fig.5-62 Fig.5-63
The above valves are all in the oil tank for work equipment.
In order to prevent dust from polluting the oil, the oil tank for work
equipment is closed structure. (Fig.5-64)

Fig.5-64
A. Inlet
B. To the cylinder bottom for blade (Lower)
C. To the cylinder head for ripper
D. To the cylinder bottom for ripper
E. To the cylinder head for tilt (Tilt right)
F. To the cylinder bottom for tilt (Tilt left)
G. To the cylinder head for blade (Raise)
H. Pump oil suction
79
 ○
3 Rotary servo valve (See Fig.5-65)

In order to convenience controlling change direction valve, the rotary

servo valve is installed.

Fig.5-65

1.Sleeve 2.Oil seal 3.Oil seal 4.Pin 5.Spring 6.Lever 7.Rotor

8.Piston 9.Pin 10.Spring 11.Lever
The oil of rotary servo valve is from steering pump and return to the
steering case. (See Fig.5-66)

1.Sleeve
6.Lever
7.Valve core
8.Piston
12.Cylinder
13.Linkage
Fig.5-66

80
 Operating output end of rotary servo valve is connected to change
direction valve rod for work equipment by linkage. It is used for controlling
the change direction valve. There is a location mechanism on the float
position.

Fig.5-67 Fig.5-68
Control lever (6) to make valve core (7) turn clockwise angle (See Fig.
5-67). At this time, the passage of A and C is on, the pressure oil enters
to the bottom of cylinder (12) and pushes the piston (8) and sleeve (1) to
turn a angle clockwise and the linkage (13) can make change direction valve
rod to move some distance. Because of turning of sleeve (1), the passage of
A and C is off, piston (8) to stop the movement at once. Go on controlling
(6) to keep the continuous movement.
Control lever (6) to make valve core (7) turn counterclockwise angle (See
Fig.5-68). At this time, the passage of B and C is on, the pressure oil enters
to the other end of cylinder and pushes the piston (8) and pulls sleeve (1)
to turn a angle counterclockwise and the linkage (13) can make change
direction valve rod to move some distance. Because of turning of sleeve (1),
the passage of Band C is off, piston (8) to stop the movement at once. Go
on controlling (6) to keep the continuous movement.
Fig.5-66 is neutral position, at this time the passage of A, C and B,
C is off, the cylinder piston doesn’t operate and sleeve doesn’t turn.
81
 1.Transmission and steering hydraulic system
About hydraulic principle diagram of transmission and steering system
to see Fig.5-69 and structure diagram to see Fig.5-70

Fig.5-69 Hydraulic principle diagram for transmission and steering system

82
Fig 5-70 Structure diagram for transmission and steering system

83
①Transmission circuit
About the principle of transmission circuit system to see Fig.5-71

No.5 clutch
No.4 clutch
No.3 clutch

0.45MPa

No.2 clutch
No.1 clutch

Fig.5-71
84
 About the structure diagram for transmission circuit system to see
Fig.5-72.

85
 Fig.5-72

The transmission pump is gear pump (See Fig.5-73) is connected to transfer

case and transmits the mechanism energy into hydraulic energy. The oil sucks
from the steering case is filtered by means of strainer (12). (See Fig.5-72).
The drained oil is filtered by filter (14) and enters regulating pressure
valve (15). The oil after regulating pressure enters into the relief valve
(5) of converter (Setting pressure is 0.87Mpa) and then the oil return to
the steering case. The pressure oil through relief valve enters into converter
(9) and the oil with enough pressure by back pressure valve (6) of converter.
The oil through back pressure valve is cooled by cooler and then flows
into lubricating valve (11). By the action of back pressure of lubricating
valve, the transfer case is lubricated and then the oil flows to converter
case. The oil from lubricating valve to lubricate the transmission case and
then the oil flows into steering case. The dump pump (2) can make the oil
in the converter case return continuously to the steering case.

Oil inlet
ports

Oil
outlet

Fig.5-73
1. Driving gear 4. Rear pump cover
2. Front pump cover 5. Driven
3. Pump body

86
 Strainer structure (See Fig.5-74)
Filter structure (See Fig.5-75)

Fig.5-74 Fig.5-75

Fig.5-76
Valves 15-20 are installed on transmission case. (See Fig.5-76)
Valve (15) is regulating pressure valve. Regulating pressure is 2.5Mpa.
After reaching this pressure, the regulating pressure valve is opened and
feeds oil to the converter.
Valve (16) is quick rotary valve. The valve and valve (15) can make all
87
clutches operating engage smoothly and disengage completely.
When the gearshift is operated, the system pressure changes according to the
curve in the fig 5-77. When operating, the pressure drops quickly and the
clutch can disengage completely. And then the pressure rises gradually to
make the clutch engage smoothly, so as to avoid shock and also improve the
life of power transmission system.
Valve (17) is relief valve. Outlet pressure is 1.25Mpa.
Valve (19) is start relief valve. The function of the valve is: First
put the gear lever in neutral position, then shift gears in regular order,
at this time the machine will start.
Valve (19) is speed valve. It is used for controlling clutches of
transmission case to get different speed.
Valve (20) is directional valve. It is used for controlling the first
and the second clutch to make the machine travel forward or reverse. The oil
of valves (15)-- (20) all return to steering case.

Pressure raising time

Pressure

Change gear Joining Time

Fig.5-77

88
 5.12 Work equipment
The work equipment consists of blade and ripper to finish all works of
bulldozer.
1. SD22S blade
The blade has only straight dozer type. (See fig 5-78). The frame is
box-type structure. It has excellent tensile strength, tensile stability and
high rigidity. The front end is connected to blade via cross connection and
the rear end is fixed on bracket (8) of track frame.
The frame and blade swing around the axle center and the blade is lifted and
lowered by the action of the blade cylinder.
The cutting angle of blade may be changed by means of changing the length
of adjusting bolt (5). The blade is also tilted to the left or to the right
by the action of tilt cylinder (6). The cutting edge can be used with turning
aside while it is used for sometime.

89
 Fig.5-78
1.Blade 2.Cutting edge 3.End bit 4.Frame 5.Adjusting screw
6.Tilt cylinder 7.Arm 8.Bracket
2. SD22, SD22E and SD22D bulldozer
There are three kinds of blades: Straight tilt dozer, angle dozer and
U-type dozer.
○1 Straight tilt dozer and U type dozer

Straight tilt dozer structure (See Fig.5-79)

U-type dozer structure is the same as straight tilt dozer structure, but
blade shape is a little difference.

Fig.5-79

90
 1.Blade 2.Cutting edge 3.End bit 4.Frame 5.Adjusting screw
6.Tilt cylinder 7.Arm 8.Bracket
②Angle dozer
Angle dozer structure as shown Fig.5-80

Fig.5-80
1. Pin 9. Cutting edge
2. Seat 10. Pin
3. Arch support 11. Pin
4. Lower support 12. Bolt
5. Upper support 13. Nut
6. Screw 14. Pin
7. End bit 15. Pin

91
 8. Blade 16. Pin

Blade (8) is articulated to arch support (3) by upper support (5) and
lower support (4). The arch support (3) is articulated to the seat (2) fixed
on track frame. The blade cylinder can make arch support swing with
centering round seat (2).
Draw out the pin (1), lower support (4) is installed on different seat of
arch support. Thus, the blade has three different positions and it can turn
25° to the left and the right.
③Ripper (See Fig.5-81)
Ripper can be used with straight dozer and angle dozer.

Fig.5-81
1. Bracket 2.Connection rod 3.Connection frame 4.Pin 5.Pin 6.Pin
7.Pin 8.Bar 9.Tooth 10.Tooth tip 11.Guard 12.Pin 13.Pin
The ripper is a four-bar linkage. Bracket (1), link (3), Connection frame
(4) and bar (8) are articulating type, and position of four articulating
points is a top point of parallelogram. So, no matter how the ripper cylinder
operates, while the teeth tip cut the soil to get best cutting angle.
There are holes of two groups on the bar (8). They have two installing
positions. When teeth tip (10) is used for some time, it may be installed

92
with turning around 180°to extend the using life.
For the hard soil, the middle or two sides teeth should be used.

5.13 Electrical system (See Fig.5-82)

The electrical system is used to start the diesel engine and illumination.
It consists of starting motor, silicon commutating alternator, magnetic
switch, regulator and two12V batteries.
A few points:
1. The advance magnetic force switch and voltage relay are adopted to protect
the starting motor and switch.
2. The commutating alternator of silicon is adopted and equipped with
integrated circuit regulator.
3. When the starting switch is in OFF position, the battery relay can shut
off the supply automatically to prevent from leaking electricity.
4. When connecting the element of electrical appliance, make sure that the
color, specification and position of wire and do not mistake.
5. Should use the same volume battery while change it. If use the battery
of small volume, when starting, it can be damaged by excess load.
6. Continuous starting time no more than 10 seconds each time. The interval
between twice starts is 2 minutes.
7. Lamp switch position:

OFF

8．Starting switch position:

Starting switch
B BR R1 R2 C ACC
Heating ○ ○ ○ ○
OFF ○
ON1 ○ ○ ○
ON2 ○ ○ ○ ○ ○
93
Fig.5-82

94
 Ⅵ. MAINTENANCE
Good maintenance is an assurance of assuring safety, supply good
performance, extend the using life of machine. So, must follow the methods.
Maintenance for engine should refer to OPERATION AND MAINTENANCE MANUAL
OF ENGINE.
6.1 Periodic service table
250
Every Every Every Every Every
Time Before hours
250 500 1000 2000 4000
starting after
Item starting
hours hours hours hours hours

Check for oil and water

○
leak
Check for all bolts and
○
nuts
Check for electric
wiring, connector, short ○
circuit
Check for coolant or
○
addition
Check for fuel level ○
Check for engine oil pan
○
oil
Check for steering case
○
level and replenish
Drain water in fuel tank
○
and sediment
Check for oil level of
final drive case and ○
replenish
Check for oil level of
○
hydraulic tank
Replenish grease on fan
○
pulley (1 point)
Replenish grease on
○
tension pulley (1 point)
Replenish grease on
tension pulley bracket (1 ○
point)
Replenish grease on tilt
arm (straight tilt dozer
○
1 point; angle dozer 2
points)

95
Replenish grease on cylinder
○
seat (2 points)
Replenish grease on cylinder
○
support (4 points)

Replenish grease on tilt

○
cylinder ball joint (1 point)

Replenish grease on tilt arm

ball joint (straight dozer, 1 ○
point)

Replenish grease on arm ball

○
joint (straight dozer, 2 points)

Replenish grease on tilt arm

ball joint (straight dozer, 4 ○
points)
Replenish grease on ripper
○
nipples (18 points)

Replace oil of engine oil pan ○ ○

Check for the level of battery ○

Clean and replace crankshaft
○
breather
Check and adjust the tension of
○
alternator belt
Replace steering case (include
converter and transmission ○
case) filter cartridge
Check and tighten bolts of track
○
shoe
Replace fuel filter ○ ○

Replace oil strainer and filter ○ ○

Replace corrosion remover
○
container
Clean steering case breather ○
Clean final drive case breather
○
(2 points)
Replenish grease on the bearing
○
liner seat (2 points)

96
Replenish grease on universal
○
joint (8 points)
Replenish grease on idler
○
tension lever (2 points)
Check and clean radiator fin ○

Replace oil of steering case

(include converter and ○ ○
transmission case)
Clean transmission and steering
○ ○
strainer
Clean converter filter ○ ○
Replace oil in hydraulic tank
○ ○
and filter cartridge
Replace oil in final drive case ○ ○
Check for lubricating oil of
track roller, carrier roller and ○
idler
Replenish grease on equalizer
○
shaft (1 point)
Replenish grease on throttle
○
pedal shaft (2 points)
Replenish grease on gearshift
○
lever shaft (3 points)
Replenish grease on brake
○
pedal shaft (6 points)
Replenish grease on fuel
○
control lever shaft (3 points)
Replenish grease on blade
○
control lever shaft (3 points)
Check for alternator and starter ○

Check for damper ○

Check for adjusting screw of

○ ○
injector
Tighten mounting screw of
○ ○
injector

97
Check and adjust engine
○ ○
valve clearance

Tighten air intake and exhaust

○
manifold

Clean, check and adjust

○
injector

Clean turbocharger impeller

Check and adjust clearance

○
between turbocharger rotor

Check and adjust PT pump ○

Replace PT pump strainer

○
screen and magnet

Check and adjust clearance

○
between crankshaft ends

Check for water pump ○

Nonscheduled service item:

Twice every year (spring, autumn)
Change cooling water
or every 1000 hours

Check, clean and change air cleaner Nonscheduled

Check and adjust track tension At any time

98
 6.2 Check before starting
1. Examine the connector of pressure hoses, hydraulic cylinder, floating
seals, radiator fin and water pipe connecter with special attention.
If any leakage is evident, check for the cause and repair.
2. Check tightness of bolts and nets, and retighten if required.
Particular check mounting of air cleaner, muffler, track roller
supports, track and work equipment.
3. Check for broken electric wiring, short circuits and terminals. If
necessary, repair.
4. Add cooling water take place after stopping engine, first feeding
water is filled up to overflow pipe lever. Then start engine and run
idle it for five minutes. If level low, add water to the height shown
in Fig.6-1 and 6-2 is the position of adding water port.

Fig.6-1 Fig.6-2
If more water than normal, it is necessary to fill up to the specified
level. Examine and repair it in time.
5. Pull out fuel dipstick and check oil level. If oil level is low, should
refill the fuel tank. Should check usually breather hole to prevent
form clogging.(See Fig.6-3)

Fig.6-3 Fig.6-4
6. Check oil level in the engine oil pan
When the engine stopped, check the oil level with dipstick G.
(See Fig.6-4).
99
 When the engine runs idle, should first check the engine oil pressure
gauge, water temperature gauge shows normally, then pull out the dipstick
G, check the level.
If necessary adding oil, open the
filter F and add oil.
7. Check oil level of steering case
Remove the right armrest of operator
seat. Pull out dipstick and check oil level
of steering case. If necessary, add oil to
specified level.
8. Drain dirty and water (See Fig.6-5) Fig.6-5
Open the rear cover, loosen the cock at the bottom of fuel tank and
drain dirty and water.
9. Check if all control levers and pedals are normal.
10.If air cleaner element is clogged, dust indicator lights. Should
remove the element and clean. After fitting the cleaning element,
start the engine and the indicator should not light.
6.3 In initial 250 hours serve
The following services should be carried out besides according to
the section of 6.2 about service before starting:
1. Replace fuel filter
2. Replace oil strainer and fuel filter
3. Replace oil of steering case (Include transmission case and
converter) (according to the demand in table)
4. Change oil in hydraulic tank.
5. Change filter element
6. Change oil in final drive case.
7. Clean transmission steering element.
8. Tighten mounting screw for injector.
9. Check and adjust valve clearance for engine.
About details for the above, please see 250 hours service.

100
 6.4 Every 250 hours service
The following services should be carried out besides according to
the section of 6.2 about service specified.
1. Check oil level of final drive case (See Fig.6-6)
Place the machine on level ground. Screw out
bolt. If the oil level does not reach the edge of
filler F, should replenish specified oil.
2. Check the oil level of the hydraulic tank and
supply oil. (See Fig.6-7)
Place the machine on level ground, stop the engine
for 5 minutes. Check if oil level is in red range
from oil filler (G). If oil quantity is not enough Fig.6-6
and remove tank cover F, fill specified oil at filler.

Fig.6-7
3. Grease on fan pulley (1 point).
4. Grease on tension pulley and bracket (2 points)
5. Grease on tilt arm ball joint (See Fig.6-8) (1 point)

Fig.6-8
6. Grease on cylinder seat (SD22S)(See Fig.6-9) 1 point

101
 Fig.6-9
7. Grease on cylinder support (See Fig.6-10) 4 points

Fig.6-10
8. Grease on tilt cylinder ball joint (See Fig.6-11) 1 point.
9. Grease on blade cylinder joint (See fig.6-12) 2 points.

Fig.6-11 Fig.6-12
10.Grease on arm ball joint (See Fig.6-13) 2 points
11.Grease on tilt arm ball joint (See Fig.6-14) 4 points

102
 Fig.6-13 Fig.6-14
12.Grease on all lubricators of ripper.
○1 Upper linkage (8 points)

○2 Cylinder piston rod top (2 points)

○3 Lower connecting frame pin (4 points)

○4 Lower connecting frame shaft (4 points)

13.Change oil of engine oil pan

(See Fig.6-15)
Remove the plate under the body and
release the drain plug to drain. After
changing strainer and filter, full up
specified oil from filler F.
General, change the strainer once every
six months whatever working hours.
14. Check the level of battery Fig.6-15
If the level of battery is not in the height specified (Over 10～12 mm
above the plate) ， should replenish distilled water. If battery
electrolyte is reduced as loss, should replenish thin sulphuric-acid
of same consistency.
Note: Don’ t use metal funnel.
When check the metal level, should clean the breather of battery
15. Clean and replace crankcase breather
① Remove the crankcase breather and disassemble.
② Clean all metal and rubber pieces with detergent and then blow
up completely with compressed air.
③ Check if gasket breaks and wears, if necessary, should replace.
④ Reassemble the cleaned and new parts on the engine.
16.Check and adjust alternator belt
Press down 10mm with the force of 60 N according to the direction
of arrow in Fig.6-16. When the belt is lengthened and can’t be adjusted,
should replace it. The two belts should be replaced at the same time.

103
 After fitting new belt, should run for one hour, then check and
adjust.
Note:
V belt must not contact the bottom of V Electromotor
groove.
17.Replace the filter cartridge of steering
case (include converter and transmission
case)
○1 Remove left guard cover.

○2 Remove bolt, cover plate, and take out

cartridge and clean the inner of case body.

○3 After replacing cartridge and
lubricating oil, start the engine and
release the drain cock. When oil spills
over, tighten it up. Fig.6-16
18.Check and tighten mounting bolt of track shoe.
Tighten torque: (700～820Nm)
19.Replace fuel filter
○1 Remove fuel filter cartridge and throw away.

○2 Fill new filter with clear fuel.

○3 Install filter and tighten until gasket touches filter cover. Then

retighten a half to 3/4 turn.

20. Replace strainer and filter.
○1 Remove oil strainer and throw away.

○2 Fill new cartridge with lubricant.

○3 Install new cartridge to filter head and tighten until gasket touched

filter head, then retighten a half to 3/4 turn.

6.5 Every 500 hours service
Maintenance for the section of 6.2, 6.3 and 6.4 should be carried
out at the same time.
1. Replace corrosion remover container
○1 Close down two valves on corrosion remover container.

○2 Turn cartridge to the left.

○3 Lubricating oil the seal surface and replace with a new element.

○4 When installing, retighten 1/2—3/4 turn after seal surface touches

the cover.
○5 Open valves after changing.

2. Clean out breather of steering case

3. Clean out breather of final drive, 2 points.
4. Grease undercarriage
104
 Stop the machine on a flat ground. Loosen plug, if lubricating
oil does not ooze out from thread, add new oil and then tighten plug.
Lubricating points:
idler, carrier roller, and track roller (Fig.6-17～Fig.6-19)

Fig.6-17 Fig.6-18 Fig.6-19

6.6 Every 1000 hours service
Maintenance for the section of 6.2, 6.3, 6.4 and 6.5 should be carried
out at the same time.
1. Grease on half bearing liner, 2 points (See Fig.6-20).
2. Grease on universal joint (8 points)
3. Grease idler tension lever, 2 points (See Fig.6-21).
4. Check and clean radiator fin.
Mud, dust on the radiator fin shall be clean off by compressed air
or water. Check if rubber hose is cracked or fragile. If it does, should
troubleshooting in time.
5. Change oil of steering case (including transmission case and
converter).
○1 Loosen the drain plug, drain oil and retighten. (See Fig.6-22)

○2 Remove left floor, bolt 1 and cover 2, and take out steering clutch

filter and magnet 4. (Fig.6-23)

○3 Remove bolt and cover, take out converter filter.

○4 Clean out the inner of each case body.

After finishing the above, assemble it as original.

○5 Fill oil from filler F according to the specified oil classification

in the table about water and oil. (See Fig.6-24)

105
 Fig.6-20 Fig.6-21

Fig.6-22 Fig.6-23

Fig.6-24 Fig.6-25

Fig.6-26 Fig.6-27

106
 6. Replace hydraulic oil and cartridge.
○1 Remove drain plug 1, release drain valve 2. After draining oil
retighten. (See Fig.6-25)
○2 Remove bolt and cover, take out cartridge to clean or change.

(See Fig.6-26)
○3 Fill specified oil capacity from F (see Fig.6-27)

Fig.6-28 Fig.6-29
7. Replace final case oil, 2 points.
○1 Remove drain plug, after draining oil, retighten. (Fig.6-28)

○2 Remove drain plug, fill oil to specified oil amount. (Fig.6-29)

6.7 Every 2000 hours service

Maintenance for the section of 6.2, 6.3, 6.4, 6.5 and 6.6 should be
carried out at the same time.
1. Grease on equalizer bar shaft. (1 point)
2. Grease on decelerator pedal shaft (1 point)
(See Fig.6-30)
3. Check and adjust screw of injector.
4. Tighten mounting screw of injector.
5. Check and adjust valve clearance of engine.

6.8 Every 4000 hours service Fig.6-30

Maintenance for the section of 6.2, 6.3, 6.4, 6.5, 6.6 and 6.7 should
be carried out at the same time.
1. Tighten air intake and exhaust pipe.
2. Clean up, check and adjust injector.
3. Clean the turbocharger impeller.
4. Check and adjust the play of the turbocharger rotor.
5. Check and adjust PT pump.
6. Replace filter screen of PT pump and magnet.
7. Check and adjust end clearance of crankshaft.
8. Check water pump
The above services should be carried out as specified in OPERATION
AND MAINTENANCE MANUAL OF ENGINE.
6.9 Nonscheduled service item
107
 1. Change cooling water
Change one time every year spring or autumn with antifreeze, change
one time every 1000 hours without antifreeze.
Method of replacing:
①Stop the engine, close the doors (2 points) of corrosion resister
and open the cover of water tank.
○2 Open the drain valve (radiator, rear of engine, oil cooler, 4
points) to drain water.
○3 After draining water, clean with detergent.
○4 Drain out detergent.
○5 Fill up clear water from filler.
○6 Run the engine at idle speed, open drain water cock to drain water,
then close drain water cock and refill water. (See the section of 6.2)
○7 Replace corrosion resistor cartridge. (See the section of 6.5)
2. Check, clean and replace air cleaner element
○1 Check
When air cleaner alarm lamp flashes, should clean air cleaner element.
When cleaning, should stop the engine.
○2 Clean or replace outer filter element
a. Remove nut and outer filter element (See Fig.6-31 and 6-33)
b. Clean the inner of air cleaner body.
c. Clean and check filter element. When once clean the outer filter
element, remove one code on the inner element tag. (See Fig.6-32).
Assemble the washed outer filter element.
Cards of
Marked plate word codes

Fig.6-31 Fig.6-32
Caution：
a. When the outer filter element has been cleaned for six
times or used for one year, should be replaced. At the same
time the inner filter element should be replaced.
b. When washer or nut is damaged, should be replaced.
(See Fig.6-33)
c. Check for tightness of fixing nut, if it is loose, should
tighten.
108
 Fig.6-33 Fig.6-34
○
3 Replace inner filter element (see Fig.6-33)
a. First remove outer filter element, then remove inner filter element.
b. Cover the air inlet.
c. Clean the inner of air cleaner body. Remove the cover of air inlet.
d. Install a new inner element to the connector and tighten it with nut.
e. Install the outer element.
Notes: Do not try to use again after cleaning inner element.
○4 Clean outer filter element

a. Using compressed air (See Fig.6-34)

Direct blow element inside with dry compressed air (less than 0.7MPa)
from inside along its wrinkle, then direct blow again from outside along
its wrinkle, and again from inside. Finally check if it is clearly.
b. Using water
Wash element with city water (less than 0.3MPa) according to above
mentioned method. After drying, check.
c. Using detergent
In order to remove dirt oil on element, may put element into warm
water mixed detergent, then wash with clear water, then dry it and check.
Notes:
a. Repeat blow from inside to outside with dry compressed air (less than
0.7MPa) to dry quickly, do not heat to dry.
b. May use heat water (about 40℃) instead of soap water.
c. After cleaning and drying, use light dropping into outer
element to check, if there is a small hole or it is thin,
replace outer element. (See Fig.6-35)
d. Remove dirt and stores it in dry place.
e. When clean the outer element, do not use other objects
knock it.
f. Do not use improperly outer element.
3. Inspect and adjust track tension. (According to Ⅶ) Fig.6-35
109
 Ⅶ. METHOD OF ADJUSTING PARTS
7.1 Adjustment of steering brake pedal (see Fig.7-1)
Measure when the engine running at low idle speed. Standard
stroke of brake pedal is 120 ±10mm. Stroke difference of left and
right brake pedal is within 10mm and brake force is less than 150N.
Method of adjusting:
1. Remove cover plate1.
2. Tighten adjusting bolt 2 to make brake band hold to braking
drum.
3. Loosen the adjusting bolt 1(1/6) turns to make the standard
clearance is 0.3mm. When using, because of wear of brake band to
make brake stroke become large. When the stroke is over 200 mm,
may fail to brake. So, must inspect usually and adjust according
to the above method.

Fig.7-1
7.2 Adjustment of idler position (Fig.7-2)
Because idler moves on track frame can lead to wear of
connecting parts. If the clearance of positions is large can make
idler swing and track get out of orbit. So, should adjust usually
according to the following methods.
111
 Clearance A
Fig.7-2
1. Adjust to the left and right
When machine travels 1～2 m, if the clearance of left and right
side (4 points) A＞4mm, should adjust.
Method of adjusting:
Loosen off bolt 1 three turns and remove shim a to make the
clearance A=0.5mm, then tighten the bolt.
Thickness of shim: 0.5mm and 1mm.
May choose as necessary.
2. Adjust up and down
When the clearance (B+C)≥5mm, should adjust.
Method of adjusting:
Loosen off bolt 5, remove shim, then insert it into b to make
(B+C)=2mm.
Normality: C=0
For example:
When B=5mm, amount of adjusting is 5-2=3mm
Caution:
Before and after adjusting, the amount between B and C
doesn’t change. Otherwise, it can cause support force of rubber
springs doesn’t even. Thickness of shim: 1mm and 2mm. After
adjusting, tighten bolt 5.
Tighten torque of bolt 1 and 5 is: 0.5～0.62KNm

112
7.3 Adjustment of fan belt (See Fig.7-3)
Because of equipping with tensioner, in the course of use
needn’t adjust usually.
If the belt is damaged, should
replace, A=113±5mm
The two belts should be replaced
at the same time.

Fig.7-3
7.4 Adjustment of blade tilt angle (See Fig.7-4)
Change the blade tilt angle by adjusting the length of left
diagonal brace.
Method of adjusting:
Draw out lever 1 to make support rotate and may change the
length. When the length extending, the blade raises left and drops
right. When the length shortening, the blade raises right and
drops left.

Fig.7-4 Fig.7-5
7.5 Adjustment of axial clearance on blade ball joint. (See
Fig.7-5)
Straight tilt blade 7 points ball joints. Its axial clearance
should be set to less than 1 mm.
Method of adjusting:
Tighten bolt 2 without shim and measure clearance valve of
A. Chose thickness of shim according to (A+1) mm. Release bolt
2, insert shim and tighten bolt 1.
7.6 Adjustment of track tension (See Fig.7-6)
Measure clearance C as shown Fig.7-6, C =20～30mm. It should
be tightly on rock region and should be loosely on clay region.
113
 When examining, should put the machine on a flat ground.
Measure the size with ruler on track teeth between carrier roller
and idler. There are fitting 1 and plug 2 on the spring box. (See
Fig.7-7). If need tension, grease with grease gun from fitting
1. If need loosely, tighten plug 2 one rotation and oil can flow
out.

Idler Carrier roller

Fig.7-6 Fig.7-7
7.7 Adjustment of angle blade angle (See Fig.7-8)
When adjusting, should raise blade to 300 ～ 400mm from the
ground. Changing the position of pin that connect support and
frame to adjust the level angle to get 25°steering angle. Method
of adjusting tilt is the same as adjusting tilt blade.

Fig.7-8 Fig.7-9

114
7.8 Adjustment of the clearance between center pin of angle blade
(See Fig.7-8)
The clearance between center pin of angle dozer and bow-frame
as shown figure. The standard clearance is 15mm. After installing
blade or using for sometime, if the clearance becomes small,
should adjust the length of lever and its clearance is 15mm.
7.9 Adjustment of ripper depth (See Fig.7-9)
Using two holes on shank to adjust the ripper depth. General
the lower hole is used and it needs increasing the depth of ripper,
the upper hole is used. Align the pin (1) with iron stick and knock
with a hammer, then pull out the pin (2) to change the position
of installing hole. (Up or down)
7.10 Change after wearing tooth tip of ripper
After wearing tooth tip, when changing beat pin with hammer.
Replacement should be carried out according to different wear
degree of three teeth tips to extend its life.
7.11 Assembly of straight dozer (See Fig.7-10)
When assemble the straight dozer of bulldozer, should pay
attention to the connecting method of lever (6) and blade (1).
Lever (6) and blade (1) is connected by inserting connecting block
(2) into trunnion of lever and two pin shaft (4) and (5). The
specification of two pin shafts is same. There are two holes of
pin (vertical and horizontal) on the connecting block. The size
of two holes is same. The either may be chosen as vertical or
horizontal hole. When assembling, first should pad under middle
point of the four supporting rods acts for horizontal strength.
The min. clearance from the front of flange to the rear of blade
is 35±10mm, then install pin shaft.
Correct and incorrect assembly method as shown the following
diagram:

115
 Correct assembly incorrect assembly

Fig.7-10
1.Blade 2.Connecting block 3.Lock 4.Pin 5.Shaft 6.Lever

116
 Ⅷ.TROUBLE SHOOTING GUIDE
In the following table, it does not mean cause of all troubles, but it is a
great help to troubleshooting.
No. Trouble symptom Cause Troubleshooting guide
. Release the terminal
Rotating speed of
. Check and repair
engine is definite, . Wiring is defective
1 damaged wiring
swing of current . Tension of belt is defective
. Adjust the tension of
meter is big.
belt
Rotating speed of
. Current meter is defective . Replace current meter
engine is raised,
2 . Wiring is defective . Check and repair
current meter doesn’t
. Alternator is defective . Replace
swing
. Wiring is defective . Check and repair
Starting switch is on, . Starting switch is defective . Repair switch
3 starting motor will not . Battery is not fully charged . Charge battery
rotate . Battery switch is defective . Repair switch
. Hydraulic lock . Reverse vehicle
Starting motor runs at . Wiring is defective . Check and repair
4
low speed only . Battery is not fully charged . Charge
When starting the
engine, the starting
. Wiring is defective. . Check and repair
5 motor gear is relieved
. Battery is not fully charged . Charge
of mesh (issue
abnormal noise)
When the engine stops
running, the point . Oil pressure meter is . Replace Oil pressure
6
doesn’t return to left defective meter
red range
. Amount of oil isn’t enough
. Replenish oil to
. Tighten of oil tube and joint
Swing of oil pressure specified oil amount
is defective or oil leakage
7 meter is big, the point . Check and repair
because of damaging
is in the left red range . Replace Oil pressure
. Oil pressure meter is
meter
defective
The point of oil . Viscosity of oil is high . Use the specified oil
8 pressure meter points . Oil pressure meter is . Replace Oil pressure
to the right red range defective meter

117
 .Check and refill
. Coolant is insufficient or cooling water.
leakage. . Adjust tension.
Steam spurts out from . Fan belt is loose. . Replace cooling water
9
the upper of radiator. . Coolant is dirty. and clean the inner of
. Radiator fins is clogged. cooling system.
. Thermostat is defective. . Clean or repair.
. Replace thermostat.
The point of water . Thermostat is defective
temperature meter . Seal of thermostat is
10 . Replace thermostat
points to the right red defective
range . Seal of radiator is loose
. Water temperature meter is
defective
The point of water . Replace water
. Contact of plug is defective
temperature meter temperature meter
11 . Thermostat is defective
points to the left red . Check and repair
. When it is cold, the contact
range . Repair thermostat
of cold wind and engine is
much
. Fuel is insufficient . Refill fuel
. Air is into fuel system . Repair mixed air
Starting motor is
. Injection pump or nozzle is . Replace injection
12 started, the engine is
defective pump or nozzle
not started
. Revolving speed of starting . Refer to electrical
motor is low system
. Adjust oil capacity to
. Oil level of oil pan is high
The engine emits specified amount
. Fuel is defective
13 while or blue exhaust . Replace with specified
. Oil leaks out of turbocharger
gas fuel
piping
. Check and repair
The engine emits black
14 . Air cleaner is clogged . Clean or replace
exhaust smoke
. Intake side of fuel piping
15 Engine hunting . Repair
leakage
. Change with specified
Engine creates . Use of improper fuel
fuel
16 knocking (In burning . Overheat
. See item 10
or mechanism) . Internal breakage of muffler
. Replace muffler

118
 . Loose fan belt
.The engine water
temperature is high . Replace belt
. See the engine units
Torque converter . Oil cooler is clogged
17 . Clean or replace
overheats . Restricted flow of
. Replace gear pump
lubricating oil due to worn . Check and repair
gear pump
. Inner leakage is big

.Oil pressure of torque

converter and transmission
case is not raised
. Oil leakage due to damaged . Check and repair
Machine will not start piping, loose piping joints . Check and replace
18 by engaging the shift .Wore out gear pump or . Supply oil to specified
lever scuffing amount
.Oil of transmission case is . Clean
insufficient
.Oil strainer element is
clogged

Machine moves
. System leakage
straight when steering . Check and repair
19 . Steering clutch brake
clutch lever on either . Adjust
(applied side) fails
side is pulled
. Out of adjustment of
. Adjust
clearance
Steering clutch lever is . Repair
20 . Defective control valve
not flexible (heavy) . Supply oil to specified
movement amount
. Insufficient oil
Machine will not stop
21 when brake pedals are . Defective brake . Adjust
stepped on
Track runs to either
22 . Loose track tension . Adjust tension
side
Abnormal wear occurs
23 . Improper track tension . Adjust tension
on sprocket

119
 Blade rises too slowly
. Supply oil to specified
or it does not rise . In sufficient hydraulic oil
amount
24 (Blade rolls over . Oil pump does not supply
. Check, repair or
slowly when its fully oil
replace
working begins again)

. Insufficient oil mount . Supply oil to specified

Ripper rises, force is . Defective adjusting valve, amount
25 too small or moves gear pump, piston seal, . Repair
slowly control valve
. Piping is clogged

Supporting force of
. Piping leakage
cylinder is not enough . Tighten piping
26 . Defective cylinder piston
or ripper drops . Repair
seal
automatically

120
Ⅸ.OVERHAUL CRITERION FOR MAJOR PARTS
9.1 Torque converter

Fig.9-1

121
 Unit: mm
Reference Standard
No. Check item Repair limit Measures
size clearance
Outside diameter
1 78 77.75
for guide neck
Outside diameter of
2 seal contact surface 105 104.9
for coupling

Inside diameter of Chrome

3 seal ring contact 135 135.3
surface for gear plating or

Inside diameter of replace

seal ring contact
4 60 60.1
surface for stator
shaft
Width：4.0 Width：3.5
Stator shaft seal
5 Thickness： Thickness：
ring
5.2 4.9
Width：2.5 Width：2.0
Turbine shaft seal
6 Thickness： Thickness：
ring
2.5 2.2
Clearance between 0.16～ Replace
7 scavenging pump 0.50
and driving gear 0.43

Axial clearance for

8 0.13 0.25
scavenging pump

Radial clearance for

9 0.15 0.30
scavenging pump

10 Tighten torque 55±5N.m

11 Tighten torque 70±5N.m

12 Tighten torque 115±10N.m

Adjust
13 Tighten torque 12±1N.m

14 Tighten torque 115±10N.m

15 Tighten torque 58±2N.m

122
9.2 Relief valve and regulator valve

Fig.9-2
Unit: mm
Standard Repair
No. Check item Reference size Measures
Clearance limit
Clearance
between valve 0.05～
1 0.20
body and sliding 0.091
valve

Free length
Relief pressure 137.7 134.2
2 Replace
valve spring Installation 579N
Load 635N

Free length
Regulator valve 126.6 120
3
spring Installation
load 209N 140N

123
9.3 Transmission case

Fig.9-3

124
 Unit：mm
Standard Repair
No. Check item Reference size Measures
clearance limit

Backlash between
1 No.1,3,4 sun gear 0.14～0.37
and planetary gear
Backlash between
2 No.2 sun gear and 0.13～0.43
planetary gear
Backlash between
3 gear ring and 0.13～0.48
planetary gear

Backlash of output
4 0.20～0.51
gear

Thickness of No.1～
5 5.4 4.6
4 clutch driven disc

Thickness of No.1～
6 7.0 6.2
4 clutch driving disc Replace
Thickness of No.5
7 5.4 4.6
clutch driven disc
Thickness of No.5
8 5.0 4.2
clutch driving disc
Free length 66 64.1
9 No.1 clutch spring Installation
133N 106N
load

Free length 45.7 44.8

10 No.2 clutch spring
Installation
96N 77N
load

Free length 45.7 44.5

11 No.3, 4 clutch spring
Installation
126N 101N
load

125
9.4 Transmission valve

Fig.9-4
126
 Unit: mm
Standard Repair
No. Check item Reference size Measures
clearance limit
Clearance between
0.035 ～
1 regulating pressure 0.064
0.058
valve and valve body
Clearance between
0.035 ～
2 relief valve and 0.064
0.058
servo valve
Clearance between
0.020 ～
3 relief valve and 0.054
0.048
piston
Clearance between
0.035 ～
4 quick rotary valve 0.062
0.056
and valve body
Clearance between
0.035 ～
5 pressure reducing 0.064
0.058
valve and valve body
Clearance between
0.020 ～
6 pressure reducing 0.054
0.048
valve and piston
Clearance between
0.035 ～
7 change directional 0.064
0.058
valve and valve body
Clearance between
0.035 ～
8 relief valve and 0.064
0.058
valve body Replace
Clearance between
0.020 ～
9 relief valve and 0.054
0.048
piston
Clearance between
0.035 ～
10 speed valve and 0.064
0.058
valve body
Free length 53 51.2
Regulating pressure
11 Installation
valve spring 86.5N 77.9N
load
Free length 38.5 37.3
Regulating pressure
12 Installation
valve spring (large) 217N 195N
load
Free length 43.8 42.6
Regulating pressure
13 Installation
valve spring (small) 403N 363N
load
Free length 52 50.7
Pressure-reducing
14 Installation
valve spring 219N 197N
load
Free length 79 75.8
15 Relief valve spring Installation
14.1N 13.4N
load

127
9.5 Center drive

Fig.9-5

128
 Unit: mm
Reference Standard
No. Check item Repair limit Measures
size clearance

0.1(Measure
Bevel gear back
1 after mounting
run-out Repair or
the shaft)
replace
Bevel gear 0.25 ～
2 0.75
backlash 0.33

Rotating torque:20-30N.m
Preloading of taper
3 (Based on small bevel gear to measure on Adjust
bearing
the end)

Fitting of bevel
4 0～0.042 0.1
gear bolt

Inside diameter of
seal ring contact
5 145 145.3
surface of bearing Replace
cage

Seal ring width 4.5 4.0

6
Seal groove width 4.5 5.0

150～
Taper spline press
7 300KN
force
(15～30T)

After pressing the

8 6±0.5
center drive shaft

700±
9 Tighten torque Adjust
50N.m

End run-out of
10 0.03
connecting plate

Radial run-out of
11 0.08
connecting plate

129
9.6 Steering clutch

Fig.9-6

130
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Thickness of
2.9 2.0
driving disc
1
Strain of driving
＜0.20 0.3
disc
Thickness of driven
4.7 3.7
disc
2
Strain of driven disc ＜0.20 0.3

General assembling
3 thickness of driving 50.3 46
and driven disc
Backlash between 0.3 ～
4 driving disc and 1.0
inside hub 0.4

Backlash between 0.3 ～

5 driving disc and 1.0
outside hub 0.4

Inside diameter of
6 inside hub and seal 245 245.3
ring contact

Seal ring width 4.9

7
Seal groove width 5

Free length 145.15 141

Spring (large)
Installation
2420N 2291N
load
8
Free length 137.83 146.5
Spring (small)
Installation
1380N 1320N
load

Diameter of outside
9 425 420
hub

131
9.7 Brake

Fig.9-7
Unit：mm
Reference Standard Repair
No. Check item Measures
size clearance limit
Brake lining
1 and brake band 14 9.5
thickness
Thickness of
2 9.5 5
brake lining
Free length 78.3 82 Replace
3 Spring Installation
load 200N 160N
Free length 42.4 43.3
4 Spring Installation
load 45.4N 36N

132
9.8 Steering control valve

Fig.9-8

133
 Unit: mm
Check
No. Criteria Measures
item
Clearance Reference Tolerance Standard Repair Replace
between size clearance limit
1 valve Shaft Hole
body and -0.035 +0.013 0.035～
valve core 26 0.08
-0.045 0 0.058
Clearance
between -0.030 +0.015 0.030～
2 10 0.08
valve core -0.040 0 0.055
and piston

Clearance
between -0.035 +0.013 0.035～
3 valve rod 26 0.08
and valve -0.045 0 0.058
body

Clearance
between
brake -0.030 +0.018 0.030～
4 16 0.08
valve and -0.035 0 0.053
valve
body
Clearance
between -0.030 +0.015 0.030～
5 brake 9 0.08
valve and -0.040 0 0.055
piston
Clearance
between
+0.023 +0.170 0.068～
6 control 22 0.2
+0.002 +0.086 0.168
lever and
sleeve

Clearance
between
+0.019 +0.156 0.067～
7 control 18 0.2
lever and +0.001 +0.086 0.155
sleeve
Reference size Repair limit
Return Free Installation Installation Free
8 spring for Load
length length load length
shaft
36 27.2 6.02kg 35.3 5.7kg

134
 Steering
9 valve 62 15.8 3.5kg 60.9 3.2kg
spring

Steering
valve
10 91.6 25 4.53kg 90.6 4.3kg
return
spring
Steering
11 valve 55 20.5 3.61kg 54 3.3kg
spring

Brake
12 regulating 28.5 25.5 3.0kg 28 2.8kg
spring

Brake
Valve
13 50.5 14 2.36kg 49.5 2.2kg
Return
spring
Brake
Valve
14 90 27 4.48kg 88.5 4.15kg
Return
spring

Operating
stroke for
15 13.7 Adjust
brake
valve

135
9.9 Final drive

Fig.9-10

136
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Clearance between half 0.036～

1 0.5
shaft and bearing liner 0.106
Replace
Clearance between 0.12～ sleeve
2 outer liner for half shaft 0.5
and sleeve 0.270

The first gear mesh 0.40～

3 1.5
backlash 0.623
Replace
The second gear mesh 0.48～
4 1.5
backlash 0.85

5 Pressing force 300～400KN(30～40 吨)

After pressing drive

6 2～3.5
plate

7 Tighten torque for nut 700±50Nm

8 Pressing force 50～160KN(5～16 吨)

After pressing sprocket

9 39～41
hub

10 Pressing force 500～600KN(50～60 吨)

Adjust
After pressing sprocket
11 39～41
hub

12 Pressing force 120～460KN(12～46 吨)

Half shaft end surface

13 599.9(SD22S 为 724.5)
and steering case

14 Tighten torque for nut 1050±150Nm

Tighten torque for

15 1050±150Nm
sprocket nut

16 Tighten torque for nut 950～1150Nm

137
 9.10 Undercarriage
1.Track frame

Fig.9-11
Unit：mm
Reference Standard Repair
No Check item Measures
size clearance limit
Deformation
7/300
On track frame
Deforming
1 for track Twist 3/300
frame Repair or
Opening replace
5
outside on idler

Clearance between half shaft 0.036～

2 0.5
and bearing liner 0.106

3 Tighten torque 760±85N.m

Adjust
4 Tighten torque 825±225N.m

138
2.Tensioner for track

Fig 9-12
Unit: mm
Standard Repair
No. Check item Reference size Measures
clearance limit
Free length
Recoil spring 817
Installation 154000N
(large) 171300N
load
1
Free length
Recoil spring 530
Installation 29000N
(small) 32500N Replace
load
Clearance
between 0.101 ～
2 0.5
cylinder and 0.226
bushing
Tension bar
3 150KN(15T)
pressing force
Clearance Adjust
between
4 10
control seat
and nut

139
3.Idler

Fig.9-13

140
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

1 Idler outside diameter 774 760

Idler tread outside

2 730 715
diameter
Repair or
3 Idler drum width 105 89 replace

4 Idler tread width 49.5 51.5

5 General width 204 194

6 Width of shaft flange 20 19.5

Clearance between 0.270～

7 shaft and double 1.5
sleeve 0.390

Interference between -0.03～

8 -0.35
idler and sleeve
-0.144
Replace
End play for idler 0.27～
9 1.5
shaft
0.39
Clearance between
10 sliding plate and 2
bracket

Clearance between
11 0.5～1.0 3
side plate and bracket

12 Tighten torque 210±5N.m Adjust

141
4.Single and double flange track roller

Fig 9-14

142
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Outside diameter for

1 257 247
track roller

Outside diameter for

2 249 239
track roller

3 Tread diameter 222 198

4 General width 251.2

Tread width (single Repair or

5 55.6 66.6 replace
flange)

Tread width (double

6 51.6 68.6
flange)

Flange width (single

7 21 6
flange)

Flange width
8 21 6
(double flange)

Flange width
9 21 6
(double flange)

10 Shaft flange width 20 18.5

Clearance between
11 0.31～0.39 1.0
shaft and sleeve

Interference between Replace

-0.013～
12 sleeve and track -0.35
roller -0.121

End play for track

13 0.40～0.80 1.5
roller shaft

143
5.Carrier roller

Fig.9-15
Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Outside diameter
1 217 207
for carrier roller

Outside diameter
2 185 166
for tread
Repair
3 Flange width 19 10

4 Tread width 57 66

End play for

Adjust or
5 carrier roller 0.10～0.13 0.2
replace
shaft

6 Tighten torque 560±60N.m

Adjust
7 Tighten torque 210±50N.m

144
6.Track

Fig.9-16

145
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit
Assembling
1 Link 216.25 219.25 turn over or
replace

Grouser 72 25
2
height 123(SD22S) 101 Repair or
replace
3 Link height 129 117

Bushing
4 74.3 70.8
diameter
Clearance
5 between pin 0.230～0.830
and bushing
Clearance
between
6 0.430～1.030
main pin and
bushing
Interference
between
7 0.230～0.344 0.22
bushing and
link Replace

Interference
8 between pin 0.023～0.185 0.203
and link

Interference
between
9 0.138～0.230 0.138
main pin and
link

Single flange:
Clearance of
0～1.1
10 link contact 8
surface Double flange:
0～2.2

Tighten
11 760±60N.m 0.5～1.0 3 Adjust
torque

146
9.11 Straight tilt dozer
1. Blade

Fig.9-17

147
 Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit
Clearance
1 between seat and 0.5～0.15 10
ball joint
Clearance
between pin and
2 0.3～0.8 3
blade bracket
joint
Clearance
3 between pin and 0.3～0.8 3
joint
Clearance
4 between joint and 0.3～1.1 6
blade bracket
Clearance
5 between pin and 0.5～1.0 2
bracket
Clearance
6 between pin and 0.6～1.0 2
stud
Replace
Clearance
7 between ball joint 0.2～0.6 1
and seat
Clearance
8 between cover 0.1～-0.4
and ball seat
Clearance
9 between ball joint 0.2～0.6 1
and seat
Clearance
0.046 ～
10 between cover
and ball seat 0.206
Clearance
11 between pin and 0.4～0.8 2
seat
Clearance
12 between bracket 0.3～0.7 1
and pin

148
2.End bit and cutting edge

Fig.9-18

Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Height of
1 254 213
cutting edge

Height of end
2 292 211
bit (outside)
Replace
Height of end
3 254 211
bit (inside)

Width of end
4 435 360
bit

5 Tighten torque 540±80N.m Adjust

149
 9.12 Cylinder bracket
1. Cylinder bracket for SD22、SD22E、SD22D

Fig.9-19(A)
2. Cylinder bracket for SD22S

Fig.9-19(B)
Unit: mm
Reference Standard Repair
No. Check item Measures
size clearance limit

Clearance between
1 0.072～0.180 0.5
shaft and bushing
Clearance between
2 0.060～0.152 0.5 Replace
shaft and bushing
Clearance between
3 0～0.074 0.5
shaft and bushing

150
 9.13 Ripper

Fig.9-20
Unit: mm
Reference Standard
No. Check item Repair limit Measures
size clearance

Clearance between 0.230～

1 1.5
pin and bushing 0.476

Clearance between
2 hole of teeth frame 1.4～2.6 10
and pin

Clearance between
3 pin and hole of 3.7～6.5 15 Replace
teeth bar

4 Wear of teeth tip 335 225

5 Wear of teeth sleeve 75 55

6 Tighten torque 2250±250N.m

151
 Table: FUEL, COOLANT AND LUBRICANTS
Part
Ambient temperature and suitable oil Capacity
-15 -10 -5 0 5 10 15 20 25 30 35 40 45℃ (L)

No.-10 ～ -35light
Engine diesel
450
fuel tank
No.0 light diesel

SAE10W-30
Engine oil
45
pan
※ SAE15W-40

Torque
converter
SAE10W-30

Transmission
Case ※ SAE15W-40 122

Steering case
SAE30

SAE10W-30
Hydraulic
110
tank ※ SAE15W-40

82
SAE30 ( SD22 、
Final drive SD22E、
case SD22D )
※ SAE40 101
( SD22S )
Track roller 0.28～ 0.32

Carrier roller SAE140 0.47～ 0.53

Idler 0.28～ 0.53

Other
Suitable
lubricating No.2 and No.3 lithium (soap) grease capacity
parts

Soft water＋ antifreeze

Engine
79
coolant
Soft water

152
CAUTION:
1.Brand of lubricating oil is CD grade. If the CC grade is

used, the time of replace oil should be carried out as

specified half of time.

2.When the ambient temperature is below -20℃, the oil of the

engine oil pan should be changed to SAE5W-20 .

3.When filling oil, first should draw out strainer screen from

filler and wash it with cleanly diesel and put it into the

filler, then fill oil. Should use the oil of sediment

completely.

4.Capacity of oil, grease and fuel must accord with the demand,

don’t fill overfull or too less.

5.The appliance of filling oil and water must cleanly, and put

them into sealing box or case after using.

6.When draining oil, the oil must be preheated to 30～40℃.

7. SAE is international standard oil number.

153