Service Manual For B320

Service Manual
B320
Applicable type and model: B320

Contents
Foreword .......................................................................1
Overview ....................................................................1-1
Power system............................................................2-1
Power train system ...................................................3-1
Travel system ............................................................4-1
Work implement hydraulic system .........................5-1
Work implement system ..........................................6-1
Electrical system ......................................................7-1

Foreword
This manual is applied to help the maintenance staff keep the good maintenance quality and know the vehicle
well, and to indicate the correct maintenance methods and judgments for maintenance staff. Please make sure
that you know well about the contents and application methods of this manual, so that the manual can play an
effective role in your work.
This manual mainly contains the technical information of necessary operations in the maintenance shop.
To help you understand well, this manual is divided into several chapters by main components and each con-
tains several sections.
Structure and function

This section describes the structures and functions of various components. This will not only help you under-
stand the structure, but also service as a reference for troubleshooting.
Test and adjustment

This section describes the check and adjustment required before and after maintenance. This section also
contains the troubleshooting chart related to “diagnosis” and “cause”.
Disassembly and assembly

This section describes the procedures of removing, installing, disassembling and assembling each component
and the relevant operation precautions.
Maintenance standard
This section describes the judgment criteria used on checking the disassembled components.
Safety Precautions
Proper maintenance is quite important for the safe running of the vehicle.
In this manual, the maintenance and the service techniques from LiuGong are about the effective and safe
operation of the vehicle.
Special tools designed by LiuGong are required for part of the maintenance operations.
To prevent the workers from injury, the safety signs  and are used in this manual to indicate the
precautions for safety operation. Pay special attention to the precautions marked with this sign. In case of
dangerous conditions, take into account the safety first and then take necessary safety measures.
Foreword-2
Safety
General preventive measures:
Wrong operations are very dangerous. Before operating the machine, please read the operation manual in
great detail.
1. Before lubrication and repair, please read all the indications and patterns on the nameplate of the machine.
2. It is required to wear safety shoes and safety helmet during operation. Do not wear loose clothes or the
clothes short of buttons.
•Be sure to wear the safety glasses when knocking parts with a hammer.
•Be sure to wear the safety glasses when grinding parts with a grinder.
3. If needed, welding repair shall be done by a trained and experienced welder. Be sure to wear welding
gloves, apron, glasses, helmet and other proper clothes before welding.
4. When the operation is done by two or more workers, a consensus about the operation procedure shall be
achieved, and the partners shall be noticed before the operation is started. A repair sign shall be hung on
the mechanism controlled by the operator.
5. Keep all the tools in good condition and learn the correct method of application.
6. Select an area to store the tools and the parts and components removed, and always keep the tools and
components in the correct position. Make sure that the work area is clean and the floor is free of dust and
greasy dirt. Smoking is forbidden during working.
Preparations:
7. When filling the oil or performing any repair, park the machine at a solid and smooth place and fix the
wheels and the track to prevent the machine from rotating.
8. Before starting the work, place the shovel blade, ripper or other work implements on the ground. If it is
unavailable, insert the safety pin or underlay with wood block to prevent the work implement from falling.
Moreover, be sure to lock all the control levers and hang warning signs on them.
9. Before the disassembly, prop the big piece at the lower part of the machine with wood block, jack or
support.
10. Remove the mud or the greasy dirt on the ladder or at the place used to get on and off the machine. Get
on and off the machine with the handrail and ladder, and jumping up and down is forbidden. If the handrail
and the ladder are unavailable. The step on the safety standing area can be used.
Preventive measures during work:

11. When removing the oiler cover, oil drain plug or the hole plug used for measuring the hydraulic pressure,
release them slowly to avoid oil spray. Release the pressure in the piping before disconnecting or removing
the oil-water or gas piping.
12. When the engine is shut down, the oil and water in the engine are hot, so be careful to avoid scald.
13. The oil and water shall be cooled down before the management of oil and water.
14. Before the commencement, remove the wire, and the negative pole wire of the battery shall be removed
first.
Foreword-3
15. Lift the big component with the crane or the hoist. Check the wire rope, chain and hook for any damage.
The lifting device used commonly shall not be loaded fully.
16. The lifting device shall be set in the correct place. The crane shall be operated slowly to avoid colliding
other parts. Do not work with the hook lifting or the crane rising.
17. When removing the cover which has interior pressure or the spring pressure, the two bolts at the opposite
side shall not be removed. Release the pressure slowly and then loosen the bolt slowly to remove it.
18. When removing the components, be sure not to break or damage the wiring. Damaging the wiring may
cause fire.
19. When removing the piping, try to avoid the spill of the fuel or the engine oil. If fuel or engine oil drops on the
ground, clean it immediately. The fuel or engine oil dropped on the ground may make you slip or even
cause fire.
20. Generally, do not clean the parts with gasoline, especially for the electric parts.
21. Make sure that the parts are installed in the original position, and replace the damaged part with new one.
•During the installation of the hose and wire, make sure that they will not be damaged because of contact-
ing with other parts during the operation.
22. When installing the high-pressure hose, ensure that the hose is not twisted. The damaged hose is
dangerous. Be very careful when installing the high-pressure piping. Moreover, check whether the
fastenings are correct or not.
23. Assemble and install the parts according to the specified tightening torque. When installing the parts like
the shield, or the parts which revolve rapidly or shake intensively, check whether the installation is correct
or not in great detail.
24. When two holes are aligned, never put your finger into it, or your finger may be squeezed.
25. Before the hydraulic pressure test, check whether the test tools are installed correctly.
26. During the installation of the track of the track type machine, be careful that the track may separate
suddenly during the disassembly. So, anyone is forbidden to stand at any end of the track.
Foreword-4
To make the manual works effectively, the following safety and quality signs are marked in the
important parts.
Mark Item Remarks
Pay special attention to the safety during work
Safety
Pay special attention to the safety during work because of the high
interior pressure.
● Pay special attention to the technical requirements during work to

Notice
ensure that the standards are met.
Quality of component or the entire system
Mark Weight Pay special attention to the choice of the sling and the work
posture.
Tightening During the installation, pay special attention to the tightening

torque torque at this position.
Coating During installation, use adhesive to coat at this position.
Oil, water Position filled with oil or water. Volume
Discharge Position discharging the oil, total oil discharged

Foreword-5
The standard procedures of disassembling or assembling the various components of the vehi-
cle are shown in the figure.
A series of procedures and statements used during the disassembly and assembly are shown in
the following network diagram.
5
1 3 C
A B
6
Component
Network 4 D
diagram
E
2
F Component
The series of procedures are shown in the upper left of the block diagram with Arabic numbers.
For example:
The procedure of removing the component D from the gp is A→B→D. For another example, the
procedure of removing the component E is A→E. F gp is a disassembled component which is
stated separately. The procedure of installation is the same as that of disassembly.
As shown below, the special fault symptom will be stated in the designated "diagnosis" item.
"Fault cause" is marked.
Problem 1: Traction declines or the running speed is low
Causes
Oil leakage of
Air enters the
Diagnosis torque
hydraulic pump
converter
The indication of the torque converter oil
Troubles
pressure gage is lower than the normal
hooting ○ ○ ○
condition
chart
(Normal oil pressure: 0.3-0.48MPa)
The indication of the transmission oil
pressure gage is lower than the normal
○
condition.
(Normal oil pressure: 2.0-2.3MPa)
○
Foreword-6
Standard It is the standard design size and the finish size of the new component.
size:
It is the limiting size under which the component can still be used (When in use, the component
Repair
changes its size due to the wear and deformation.). If the component exceeds the repair limit, it
limit:
must be repaired or replaced.
It is the clearance between two new components after installation,indicating the range between
Standard
the minimum and maximum clearances. Generally, after the component is repaired, it must be
clearance:
adjusted to be within the clearance.
It is the maximum allowable clearance between components. (When in use, the clearance may
Clearance
become larger due to wear). When the clearance exceeds the limit, the component must be
limit:
repaired or replaced with a new one.
Maintenan This is the serial number of the items shown in the figure. For the purpose of convenient confir-
ce mation, the same serial number is used at the left side.
standard:
Unit: mm
Counter
No. Check items Judgment standards
measure
Serial number Standard size Repair limit
1
Unit: mm
Check Counter
No. Judgment standards
items measure
Serial Standard Tolerance Standard Clearance
10 number size Shaft Hole clearance limit
1 Overview
Exterior drawing of the machine ..................................... 1-2

Cab interior drawing ......................................................... 1-3
Technical specification table ........................................... 1-4
List of parts quality (kg) ................................................. 1-7
List of water and oil refilling (L)....................................... 1-9
Each filling or discharging port..................................... 1-10
Exterior dimensional drawing of the machine ............. 1-11
1-2
Exterior drawing of the machine
Exterior drawing of the machine
3 2 1
LIUG
ONG
L IU GONG
5
¹¤
Áø
B320
13
6
7 8
9 12
10
11
LGB32001001
1. Blade lifting oil cylinder 8. Track roller

2. Exhaust cartridge 9. Push rod
3. Cab 10. Oil cylinder
4. Working oil tank 11. Blade angle
5. Track 12. Shovel blade
6. Track frame 13. Blade
7. Carrier roller
1-3
Cab interior drawing
Cab interior drawing

1. Steering lever
2. Fuel control lever
3. Shift lever
4. Safety rod (for transmission lever)
5. Brake pedal
4
1
6. Reducer pedal
LIU GONG
Áø
ï͞
7. Brake lock bar
A A
6
2
8. Blade control lever
9. Safety switch (for shovel blade control lever)
10. Ripper control lever 3
11. Voltmeter 5
12. Oil pressure gauge LGB32001002
13. Torque converter oil temperature gauge

14. Engine water temperature gauge
15. Service hour meter 9 10
16. Start switch
17. Light switch
7
LGB32001003
13
12 14
L IU GONG
Áø
ï͞
11 15
A A
16
17
LGB32001004
1-4
Technical specification table

Dozer type Straight tilt blade Semi-U shovel U shovel
Operation quality 38000 38500 38985
Minimum turning radius (mm) 3800 3870 3910
Gradeability (degree) 30
Stability (front, rear, left and right)

35
(degree)
Gear 1 0 ~ 3.7
Forward Gear 2 0 ~ 6.8
Gear 3 0 ~ 11.8
Speed
(km/h)
Gear 1 0 ~ 4.5
Performance parameters
Backward Gear 2 0 ~ 8.2
Gear 3 0 ~ 13.7
Overall Vehicle length 8995 9065 9125
Overall vehicle width 4130 4030 4030
Overall vehicle height 3590 3590 3590
Track gauge (mm) 2140
Ground contact length of track 3150
Track shoe width 560610660
Average Bulldozer 0.107 0.099 0.092

ground
pressure
(MPa) Track shoe width 560 610 660
Minimum ground clearance 500

1-5
Chongqing Cummins Chongqing Cummins

Engine model
NTA855-C360-S10 NTAA855-C360-S20
Turbo charger, water-
Turbo charger, water-cooling, direct
Mode cooling, direct injection,
injection, vertical 4-stroke
vertical 4-stroke
Number of cylinders- inner
6-140×152 6-140×152
diameter X stroke (mm)
Total air displacement
14 14
(L)
Rated power
257(345)/2000 257(345)/2000
[kW(PS)/r/min]
Maximum torque
1509/1400 1509/1400
[N·m/r/min]
Engine
Maximum idle
2250 2250
(r/min)
Min. idle
575 ~ 650 575 ~ 650
(r/min)
Fuel consumption rate
217 217
[g/kW·h]
Starter motor 24V 24V
Alternator output quantity 35 35
Battery 12V,6-QW-120T×2
Torque converter 3-element, single stage, single phase

Power transmission unit
Planetary gear, manual control hydraulic gearshift, forced

Power shift transmission
lubrication, forward gear 3, reverse gear 3
Braking device Wet-type, belt-type, direct clutch and hydraulic power
Central drive Spiral bevel gear, splash lubrication
Wet-type, multi-disc, spring press, hydraulic disengagement,

Steering clutch
constant engagement
Final drive Spur gear, 2 -stage reduction, splash lubrication

1-6
Suspension mode Semi-rigid, walking beam

Running gear
Track roller (unit) (one side) 2
Thrust wheel (unit) (one side) 7
Crawler Combined type, single shoe, 41 knot (one side), pitch: 228.6
Hydraulic system of working device
Maximum pressure MPa 20
Oil Mode Gear type

pum
p Flow rate L/min (engine 2,
230
000 r/min)
Control valve Pilot type
Cylinder Double-acting piston type
Hydraulic oil tank Plate welding type
Type of bulldozing plate support Brace type tilting cylinder on the right
Maximum lifting height 1380

Char
acter Maximum cutting depth mm 560
istic
Work implement
dime
nsion Maximum tilting height 1000
s
Cutting angle ° 55
Phys Dozer form Straight tilt blade Semi-U shovel U shovel

ical
dime Width 4130 4030 4030
nsion mm
s Height 1590 1720 1720
Cab General cab or anti-tilting cab

1-7
List of parts quality (kg)

Engine transfer case and torque converter gp 2880
• Transfer case 324
• Torque converter as 221
• Engine (wet weight) 1800
Radiator gp 547
• Radiator 307
Transmission and control valve as 882
Transmission as 709
Steering clutch (each) 155
Steering brake as (each) 55
• Horizontal axis 31
• Spiral bevel gear 31
Final drive cover (single side) 184
Gear hub and gear ring as (single side) 300
The first gear and second gear as (single side) 77
Sprocket block as (single side) 286
Half shaft (single side) 143
Main frame 2854

• Rear axle housing 1750
Track as (standard type 560mm, single side) 2240
• Track shoe (standard type 560mm, each) 24.8
A frame as (single side) 3627
• Idler as (each) 450
• Track roller as (one at double sides) 140
• Track roller as (one at single side) 130
• Carrier roller as (each) 65
• Tensioner as (each) 285
• Trolley frame (each) 1330
Bottom guard 524
Rear bottom guard 172
Walking beam as 339
Seats
1-8
Working pump lines 312

• Hydraulic oil tank 164
• Working pump 50
Shovel blade lift cylinder (each) 184
Blade tilting cylinder 209
Ripper lift cylinder (each) 198
Ripper angle adjusting cylinder (each) 243
Straight dozer as 4520

• Straight dozer welded parts 2148
• Push rod (each) 656
Steering pump 25
Variant pump 10
Hood as 1577
Fuel tank as (fully filled) 690

• Fuel tank gp 202
Plate control as 1409
• Wing plate as 968
• Floor plate as 346
1-9
List of water and oil refilling (L)
List of water and oil refilling (L)

Part Use level (L) Varieties
Engine cooling water 121 Coolant
Fuel tank 600 0# fuel or -30# light fuel
Engine sump 47 SAE10W-30CF
Torque converter, transmission,

185 SAE10W-30CD
steering case
Final transmission (each side) 55 SAE10W-30CD
Hydraulic oil tank 220 HM46
Idler
0.39 ~ 0.45 SAE85W-140
(one)
Track roller
0.39 ~ 0.45 SAE85W-140
(one)
Carrier roller
0.63 ~ 0.72 SAE85W-140
(one)
The numbers in the () are the capacities of oil and water replacement.
1-10
Each filling or discharging port
Each filling or discharging port

Cooling water filler Cooling water drain port
Oil cooler drain port

Engine oil drain port
Torque converter drain port
Oil filler
Steering case drain port
Final transmission case filler
Hydraulic oil tank discharge
L IU GONG
Final transmission case drain port
Hydraulic oil tank filler
Fuel tank drain port Steering case drain port Fuel tank filler
LGB32001005
1-11
Exterior dimensional drawing of the machine

Bulldozer with the 1-tooth ripper straight-tilt shovel
LGB32001006
Bulldozer with the 3-tooth ripper sanitation shovel
LGB32001007
1-12
2 Power system
1 Structure and function................................................................ 2-3

1.1 Engine related component.............................................................2-3
1.2 Exterior drawing of the engine .......................................................2-4
1.3. Main performance parameters of engine......................................2-5
1.4 Engine characteristic curve............................................................2-6
1.5 Working principle of fuel system ....................................................2-7
1.6 Working principle of fuel system lubrication...................................2-8
1.7 Turbocharger .................................................................................2-9
1.8 Intake and exhaust system ..........................................................2-11
1.9 Radiator as NTA855C360S10 .....................................................2-13
1.10 Radiator as NTAA855C360S20.................................................2-14
1.11 P.T.O. device (transfer case).....................................................2-16
1.12 Engine control system ...............................................................2-17
1.13 Fuel tank as ...............................................................................2-19
2 Inspection and adjustment ..................................................... 2-20
2.1 Standard value during inspection and adjustment.......................2-20
2.2 Tool needed during inspection and adjustment ...........................2-20
2.3 Intake and exhaust system ..........................................................2-21
2.4 Lubrication system.......................................................................2-22
2.5 Fuel system .................................................................................2-23
2.6 Cooling system ............................................................................2-24
3 Disassembly and assembly .................................................... 2-26
3.1 Removal of starter components...................................................2-26
3.2 Assembly of the starter components ...........................................2-26
3.3 Removal of alternator components..............................................2-26
3.4 Assembly of alternator components ............................................2-27
3.5 Removal of engine cooler components .......................................2-28
3.6 Assembly of engine oil cooler components .................................2-29
3.7 Removal of torque converter oil cooler components ...................2-31
3.8 Assembly of the torque converter oil cooler components ............2-32
3.9 Removal of engine oil pump components....................................2-33
3.10 Assembly of engine oil pump components ................................2-34
2-2
3.11 Removal of the PT fuel pump components ............................... 2-34

3.12 Assembly of the PT fuel pump components.............................. 2-34
3.13 Removal of the water pump components.................................. 2-35
3.14 Assembly of the water pump components ................................ 2-37
3.15 Removal of the turbocharger components ................................ 2-38
3.16 Assembly of the turbocharger components............................... 2-39
3.17 Dis assembly of radiator protector ............................................ 2-40
3.18 Assembly of the radiator protector ............................................ 2-46
3.19 320 Removal of the radiator at the second stage ..................... 2-52
3.20 320 Assembly of the radiator at the second stage .................... 2-56
3.21 Disassembly of fuel tank gp ...................................................... 2-60
3.22 Assembly of fuel tank gp ........................................................... 2-61
3.23 Removal of the transfer case .................................................... 2-63
3.24 Assembly of P.T.O (Power Takeoff).......................................... 2-65
3.25 Disassembly of the power takeoff ............................................. 2-68
3.26 Assembly of the power takeoff .................................................. 2-71
3.27 Disassembly of engine components ......................................... 2-74
3.28 Assembly of engine components .............................................. 2-79
3.29 Removal of the parts related to the vehicle body from the engine 
component ........................................................................................ 2-84
3.30 Removal of floor frame.............................................................. 2-87
3.31 Installation of floor plate ............................................................ 2-93
2-3
1 Structure and function
1.1 Engine related component

1.1 Engine related component
3 4 1 3
LGB32002001
1. Cooling system 1. Cooling system

2. Air intake and exhaust 2. Air intake and exhaust
3. Engine 3. Engine
4. Power takeoff 4. Power takeoff
2-4
1.2 Exterior drawing of the engine
1.2 Exterior drawing of the engine
NTAA855C360S20 NTA855C360S10
10
9 11
7 8
LGB32002002
1. Air filter
5 6 2. Turbocharger
3. Muffler
4. Anti-corrosive pot
5. Alternator
6. Fuel filter
7. Start motor
8. Oil filter
9. Shock absorber
10. PT pump
11. Bypass filter (only used for NTA855C360S10)
LGB32002003
2-5
1.3. Main performance parameters of engine
1.3. Main performance parameters of engine

NTA855C360S10
Engine model
NTAA855C360S20
Number of cylinders – cylinder bore × stroke 6—140×152
Total air displacement (t) 14.01(t)
Ignition order 1—5—3—6—2—4
Total length (mm) 1691 (flywheel housing ~ front end of the fan)
Dimension Total width (mm) 1116 (rear bracket ~ rear bracket)

2741.9 (exhaust pipe ~ oil sump tank
Total height (mm)
discharging valve)
Net weight (kg) 1270
Rated speed (rpm) 2000
Rated power (kw) 257(345PS)
Performance Maximum torque (N·m/rpm) 1509/1400
Maximum speed without load (rpm) 2250
Minimum speed without load (rpm) 575~ 650
Minimum fuel consumption rate (g/kw.h) <217
Alternator for charging Silicon rectification alternator 24V 35A
Start mode Start motor 24V 11kw
Battery 12V, 6-QW-120T×2
Lubricant capacity (L) 45
Cooling water volume (L) 79
2-6
1.4 Engine characteristic curve
1.4 Engine characteristic curve
Torque
Power
Fuel consumption rate

2-7
1.5 Working principle of fuel system
1.5 Working principle of fuel system
Fuel transfer lines

Air transfer lines
LGB32002004
1. Injector 3. Fuel pump 5. Fuel tank

2. Intake pipe 4. Fuel filter 6. Check valve
When the engine works, the crankshaft revolves. The this moment. When the diesel engine speed
fuel pump (24) revolves driven by the transmission of increases, the idle passage is closed and the fuel is
the gear. (Both of them have the same speed) The output from the main passage. It is completed by VS
main shaft (24) drives the gear pump (9), speed gov- speed governor during work.
ernor fly hammer (2) and the tachometer shaft to
The fuel from various injectors is injected to the cylin-
work.
der combustion chamber after passing through the
The fuel output from the fuel tank (5) enters the fuel orifice. For the measurement and the injecting pro-
pump (3) after passing through the filter (4). cess, please refer to the "Injector" description. The
action of the injector plunger is finished by the diesel
Then the fuel is filtered by the strainer (19) after
engine crankshaft transmission gear cam shaft, cam
passing through the gear pump (9), then the fuel
roller, push rod tappet, bucket lever, and other truss-
enters the accelerator shaft (18) after passing
ing.
through the speed governor. At idle, the fuel enters
the accelerator shaft after flowing through the idle After the injection is finished, the plunger will stop for
port on the speed governor socket, and then passes a while. At this moment, a part of the fuel (about
through the shutoff valve (4) to the injector (1). 80%) goes back to the fuel tank and cools down the
injector meanwhile. As the fuel supply depends on
As the fuel enters the accelerator shaft through main
the fuel supply pressure and the fuel injection time.
passage and idle passage, so when the diesel
So, the fuel system takes the abbreviation of Pres-
engine runs at idle, the main passage is closed, and
sure and Time as the PT fuel system.
the fuel can only be output from the idle passage at
2-8
1.6 Working principle of fuel system lubrication
1.6 Working principle of fuel system lubrication
High pressure lines
Drain lines
LGB320042004
1. Oil sump tank 8. Engine oil filter safety 15. Bucket lever
2. Engine oil pump 9. Cam shaft 17. Bucket lever
3. Bypass valve 10. Main lubricant passage 18. Valves
4. Bypass filter 11. Gear 19. Turbocharger
5. Regulating valve 12. Crankshaft A. Cooling water is output from the water pump
6. Oil cooler 13. Piston cooling nozzle B. Water discharge (to water manifold)
7. Oil filter 14. Piston
The forced lubrication method is taken, and the pressure is generated by the engine oil pump driven by the
engine crankshaft gear.
The lubrication system mainly comprises of engine oil pump (2), regulating valve (5), oil cooler (6), oil filter (7),
dipstick, etc.
2-9
1.7 Turbocharger
1.7 Turbocharger
The type of the turbocharger is T - 46
1. Heat shield
2. Seal ring
3. Exhaust outlet
4. Turbine wheel and shaft
5. Turbine housing
6. Exhaust inlet
7. Engine oil outlet
8. Air to the engine
9. Air compressor housing
10.Bearing insert
11.Seal ring
12.Oil seal sleeve
13.Air compressor impeller
14.Air inlet
15.Oil seal plate
16.O-ring
LGB32002006
17.Bearing housing
18.Engine oil outlet
19.Turbocharger bearing
20.Thermal insulation material
Injector (part No. 3013725)
1. Nozzle head
2. Nozzle head cap nut
3. Ball check valve
4. Snap ring
5. Strainer
6. Orifice plug
7. Gasket
8. Plunger pipe
9. Injector spring
10.Push rod
11.Injector body
12.O-ring
13.Threaded pin
14.Plunger
LGB32002007 15.Plunger
2-10
1.7 Turbocharger
The injector body (11) contains the plunger spring (9), enters the measuring orifice directly from the ball
adjustable orifice (6), orifice gasket (7), fuel strainer check valve). When the fuel is not injected, it flows
(5) and strainer snap ring (4), and an O-ring (12), out from the oil return measuring orifice of the plunger
which seals the cylinder head and forms the fuel inlet circular groove. At this moment, the plunger drops on
passage and return passage, is equipped in the exte- the base surface of the nozzle head. The nozzle
rior. The fuel can flow to the plunger sleeve (15) after head, injector body and the plunger sleeve are fas-
passing through the adjustable orifice (6), and reach tened together by the nozzle head cap nut (2).
the passage between the nozzle head and the
plunger sleeve after flowing through the ball check Fuel pump (part No. 3262175)
valve, and then flow upward to the measuring orifice. PT (G) VS type fuel pump mainly comprises of gear
The fuel enters the nozzle head (1) after passing pump, standard speed governor, throttle valve and a
through the measuring orifice at this position. (In the VS variable speed governor.
plunger sleeve which supplies fuel directly, the fuel
PT (G) VS (variable speed) type fuel pump and fuel flow direction
LGB32002008
1. Drive gear and shaft 9. Gear pump 17.Idle spring plunger

2. VS speed governor fly hammer 10.Pulse eliminator 18.Accelerator shaft
3. Fuel flowing to the nozzle 11.Fuel from the filter 19.Filter strainer
4. Shutoff valve 12.Pressure adjuster valve 20.Speed governor plunger
5. VS Speed governor plunger 13.Idle adjusting screw 21.Torque spring
6. VS Idle spring 14.Spring spacer bush 22.Speed governor fly hammer
7. VS High speed spring 15.High speed spring 23.Speed governor auxiliary plunger
8. VS Accelerator shaft 16.Idle spring 24.Main shaft
2-11
1.8 Intake and exhaust system

Structure & function
Intake and exhaust system comprises of exhaust pipe
1 2 (1) air pre-filter

(2) muffler
3 4
(3) air filter
(4) indicator
(5) fastenings, etc.
Intake system
Air enters from the air pre-filter (2), and after passing
through the vortex revolving path, the large dust parti-
LGB32002009 cles are discharged from the surrounding of the air filter
(2) bottom. Then the air primarily filtered enters the air
filter (4) from the bottom center of the air filter (2) for
further filtering. Pushed by the turbocharger, the fresh
air filtered by the air filter (4) is inhaled and pressur-
ized, then it enters the intake manifold and cylinder
where it is atomized together with the fuel. Then the air
and the fuel burn together to push the engine crank-
shaft to revolve, and then the power is output.
Exhaust system
The exhaust gas formed by the combustion in the
engine cylinder enters the muffler (3) after passing
through the turbocharger (pushing the turbocharger to
revolve), then enters the atmosphere through the
exhaust pipe (1).
LGB32002010
2-12
Air filter
Inner filter element Outer filter element
The air filter, which comprises of cyclone pipe strainer
and paper filter element filter, is dry two stage type.
The filtration efficiency of the air filter can reach 99.8%.
During the cleaning of the filter element, only the exte-
rior filter element can be cleaned.
Inner filter element part No.: 6127 - 81 - 7412
Outer filter element part No. 6128 - 81 - 7320
LGB32002011
2-13
1.9 Radiator as NTA855C360S10
1.9 Radiator as NTA855C360S10
LGB32002012
1. Upper chamber 5. Hose 9. Core

2. Upper hose 6. Fan wheel 10.Mounting bracket
3. Guard 7. Lower hose 11.LLower connecting hose of upper
4. Upper connecting hose of upper cham-8. Seal plate chamber and lower hose
ber and lower hose
The radiator comprises of the upper chamber (1), copper band and copper pipe. It has two forms: cop-
upper hose (2), guard (3), lower hose (7), seal plate per pipe and band type and copper pipe fin type.
(8), core (9), mounting bracket (10), several connect-
When the temperature of the coolant decreases,
ing hose, etc.
engine water pump will send it back into engine. A
After the coolant flows through thermostat of the pressure valve is installed in the upper chamber (1), it
engine, it flows to the water chamber (1) through maintains the pressure in the tank under 0.075MPa,
upper hose (2), and separate the air from coolant, thus to increase the boiling point of the coolant to pre-
then flow through core (9) to lower hose (7). At this vent air bubbles into the coolant.
time, engine temperature can lower to 85-95 °C, and
it is the ideal working temperature of the engine.
The core (9) of CLGB320 radiator is composed by
2-14
1.10 Radiator as NTAA855C360S20
10
LGB32002013
1. Baffle
2. Air cooler outlet
3. Upper hose
4. Upper chamber
5. Hose
6. Lower hose
7. Air cooler inlet
8. Hose
9. Chassis hydraulic oil cooler
10.Fan cage
11.Engine water radiator
12.Connecting hose of the upper chamber and the lower hose
13.Work implement oil cooler
14.Air cooler
LGB32002014
2-15
Structure & function gearbox, torque converter and steering case from
the outlet of the chassis oil cooler (10) making the
The two stage radiator as comprises of upper cham-
torque converter oil temperature less than 120°C.
ber (3), upper hose (2), lower hose (5), baffle (9),
chassis oil cooler (10), fan cage (11), engine water Work implement oil cooler: a part of the work imple-
radiator (12), work implement oil cooler (13), air ment hydraulic system oil flows through the work
cooler (14), several connecting piping, etc. implement oil cooler (13) element from its inlet. The
outside cold air flows through the element exterior
The chassis oil cooler (10), engine water radiator
to take the oil heat away and make the oil tempera-
(12), work implement oil cooler (13) and the air
ture reduced, then the air flows back to the hydraulic
cooler (14) of the two stage radiator as are made of
oil tank from the outlet of the work implement oil
aluminium alloy.
cooler (13) making the hydraulic oil tank tempera-
Engine water radiator: when the engine coolant ture less than 80°C.
circulation temperature is <82°C, the coolant dissi-
Air cooler: after the pressurization of the air by the
pates the heat by the small circulation in the interior
turbocharger, the air temperature increases rapidly
of the engine; when the coolant temperature is
with high temperature. The air flows into the air
≥82°C, the engine thermostat is opened, and a part
cooler (14) from its inlet (7) and then passes
of the coolant enters the upper chamber (3) from the
through the element of the air cooler (14). The out-
engine upper hose (2), and then flows into the lower
side cold air flows through the exterior of the ele-
hose (5) through the engine water radiator (12) ele-
ment to take away the air heat in the air cooler (14)
ment. The exterior cold air flows through the outside
making its temperature reduced and less than 80°C,
of the element to remove the coolant heat, and then
then the air flows into the engine intake manifold
the coolant temperature is reduced. After that the air
and cylinder from the air cooler outlet (1)
flows into the engine through the lower hose (5),
then the big circulation heat dissipation of the
engine water radiator (12) is finished; When the
coolant temperature reaches 92°C, the thermostat
will close the small circulation passage, and all the
coolant will flow through the big circulation to dissi-
pate heat.
After passing through the engine thermostat, the
water coolant reaches the upper chamber (3)
through the upper hose (2), and separates the air
from the coolant, then flows into the lower hose (5)
after passing through the engine water radiator (12).
At this time, engine temperature can lower to 85-95
°C, and it is the ideal working temperature of the
engine.
When the temperature of the coolant decreases,
engine water pump will send it back into engine. A
pressure valve is installed in the upper chamber (3),
it maintains the pressure in the tank under
0.075MPa, thus to increase the boiling point of the
coolant to prevent air bubbles into the coolant.
Chassis oil cooler: torque converter oil flows into
the chassis oil cooler (10) element from its inlet. The
exterior cold air flows through the exterior of the ele-
ment to take the oil heat away and make the oil tem-
perature reduced, and then the air flows back to the
2-16
1.11 P.T.O. device (transfer case)
1.11 P.T.O. device (transfer case)
LGB32002015
1. Gear 5. Lubrication piping 9. Flywheel gear

2. Gear shift pump drive shaft 6. Flywheel 10.Steering pump gear
3. Fan pump drive shaft 7. Lubrication piping
4. Working pump drive shaft 8. Housing
Structure & function gear (3). The steering pump gear (1) transfers the
power to the steering pump to make it work normally
The transfer case comprises of steering pump gear
by driving the steering pump. The gear (4) transfers
(1), gear shift pump driver shaft (2), flywheel gear (3),
the power to the gear shift pump drive shaft (2), fan
gear (4), fan pump drive shaft (5), working pump drive
pump driver shaft (5) and the working pump drive
shaft (6), lubrication piping (7), housing (8), flywheel
shaft (6) to drive the gear shift pump, fan pump and
(9), etc.
working pump and make them operate normally.
The transfer case transfers the most of the engine
The lubrication piping (7) is fixed on the relevant posi-
power to the final drive through the flywheel and
tions of the housing (8) for the purpose of transferring
torque converter to drive the track operate normally,
the lubricant to the transfer case points which need
and the rest power is used to drive the gear (1) and
lubrication.
the gear (4) through the flywheel (9) and the flywheel
2-17
1.12 Engine control system
1.12 Engine control system When the bulldozer drives to the top of the slope or
push earth downward from cliffs, the driving speed
Fuel control lever is mounted in the left control box,. will increase abruptly due to the loss of the load,
Reduction pedal is mounted in front of the right foot. step down reduction pedal to reduce engine speed.
When the reduction pedal is stepped down, shock The three-dimensional and two-dimensional sche-
absorber A works to prevent fuel control lever from matic diagrams of the engine control system are
moving. shown as below.
Reduction pedal
LGB32002016
2-18
1.12 Engine control system
Idle speed High speed
5
1
LGB32002017
1. Accelerator control lever 3. Bucket lever 5. High speed adjusting screw

2. Idle adjusting screw 4. Rod
2-19
1.13 Fuel tank as
1.13 Fuel tank as

LGB32002018

1. Fuel tank 3. Return pipe 5. Water drain valve
2. Oil filler 4. Suction pipe
Structure & function

Fuel tank (1) is installed at the left side of the vehicle
body. Fuel tank (1) fill fuel through strainer. Remove
cap (2), the screen and dipstick can been seen.
Fuel enters into fuel pump filter from the fuel tank (1)
through diesel pipe (4) then it will return to fuel tank
through diesel pipe (3).
A fuel stop valve and water drain valve is installed at
the bottom of the fuel tank(1).
2-20
2 Inspection and adjustment
2.1 Standard value during inspection and adjustment

Notice: Park and stop the vehicle on a flat ground before inspections or adjustments, make sure the safety
bar is locked. When many staffs are involved in the operation, keep frequent communication of the
working progress and keep irrelevant staffs away from the area. Be very careful with rotary parts
and high temperature parts.
2.1 Standard value during inspection and adjustment
Reference
Item No. Item Item Remarks
value
High idle adjustment revolving
1 (rpm) 650
speed
High idle adjustment revolving
2 (rpm) 2150
speed
3 Torque converter rotation number (rpm) 1540±50
Low idle
Above 0.1
Engine oil adjustment timing
4 (MPa) Oil temperature: above 50±5
pressure High idle
0.45±0.1
adjustment timing
5 Coolant temperature (℃) 87±15
Deflection when pressed by finger

6 Tension of engine drive belt (mm) About 10
with the force about 60N
2.2 Tool needed during inspection and adjustment

Measurement and
Item No. Measurement· check item Remarks
check tools
1 Engine speed Tachometer Digital
3 Engine oil pressure Hydraulic tester ─
Water temperature· oil Measured temperature 0~200°C

4 Thermistor tool kit
temperature exhaust temperature (Exhaust temperature) 0~1000°C
12 Oil is mixed with water

Diesel engine oil
Oil is mixed with fuel insoluble in detector
13
benzene
2-21

Inspection for clogged air filter element
1. Inspection of dust indicator
Check the dust indicator (1) for any action (if
any, the red mark will be appear)
• As the filter element is blocked, the inhalation
resistance will increase, and when the inhala-
1
tion negative pressure reaches 7.5kPa, the
dust indicator will act to show red color
LGB32002019
2. Inspection of filter element

When the dust indicator acts (red mark), or the
exhaust gas is very dark, the wing nut (2) must
be unscrewed to remove the cover (3), and
take out the filter element directly to check it.
• Clean the filter interior as well when checking,
2
3 cleaning or replacing the filter element. But
generally, do not remove the interior filter ele-
ment unless the interior filter element have to
be replaced. So as to prevent the dust from fall-
ing into the engine.
The wing nut must be fast tightened.
LGB32002020 Press the button to restore the dust indicator to
previous state before action.
2-22
2.4 Lubrication system
2.4 Lubrication system

Inspection of lubricant
1
• Measure with the oil quantity indicator (1)
• When the engine stops, the oil quantity must be
between the mark H and L.
• The oil level inspection at engine stop must be
performed before engine start.
LGB32002021
Inspection of oil pollution and deterioration

• Detect the variable which does not dissolve the
benzene in the oil with the diesel engine oil detec-
tor.
Inspection of fuel mixed in engine oil
• When engine oil is mixed with a large quantity of
fuel, it can be detected by smelling, the decrease
of the viscosity and the obvious increment of oil
quantity.
• If the oil detector of the diesel engine is used,
heat the oil to the standard temperature, and then
observe whether it burns or not to judge it.
Inspection of the water mixed in the oil
2
• When engine oil is mixed with a large amount of
water, it can be detected by observing whether
the oil is white or not and by the decrease of the
cooling water.
• Remove oil filler cap (2), check for water drops.
• When the engine is running, apply the oil on the
oil level indicator, and then drop the oil on the
exhaust manifold to see whether there are any
water drops burst.
• When the oil detector is used for engine, drip a
couple of oil on the plate to check if there is any
bubbles.
LGB32002022
• Water tolerance in oil: 0.2%
2-23
2.5 Fuel system
Inspection of metal power mixed in engine oil

• When replacing oil filter element or oil, check if
there is any metal power mixed in the oil to judge
if there is any wear.
LGB32002023
2.5 Fuel system

Inspection of fuel
Inspection of fuel level
• Check with the fuel quantity indicator after remov-
ing the fuel filler cap of the fuel tank.
• After inspection, refill the fuel tank to full level.
Otherwise, if any clearance exists in the fuel tank,
when the temperature drops during night, the
moisture may separate from the air and enter into
the fuel which will accelerate the damage of the
engine.
• Inspection of dust and water mixed in the fuel
Release the water drain valve (2) at the lower part
of the fuel tank slowly to check for dust or water.
LGB32002024
1 Blocking inspection of fuel tank vent

• Negative pressure may for if the vent on the refill-
ing cap is clogged, it may cause insufficient fuel
supply.
LGB32002025
2-24
2.6 Cooling system
2.6 Cooling system

Inspection of cooling water quantity
• Open the radiator cover (1) to check whether the
cooling water level reaches the upper part of the
upper groove.
1
Notice: The cover can only be opened when the
engine is cooled down. Otherwise you may
be scalded!
• If the cooling water is found less, be sure to check
the leakage part of the cooling water piping.
• If the engine oil is found increased or the cooling
water is mixed with fuel, check the interior leakage
part of the engine.
LGB32002026
Measurement of water temperature

1. Remove the water thermometer in the radiator inlet
pipe (2) and then take the plug out (PT1/8).
2. Install the adapter A used for the thermometer
2
sensor and the sensor on the position where the
water thermometer is removed.
3. Connect the sensor and the thermistor
thermometer to test the water temperature.
• When the water temperature is overheated, be sure
to check the cooling water quantity, the wear and
extension of the fan belt, the wear of the radiator
element, the blocking caused by dust, etc.
LGB32002027 • When the water temperature is low, be sure to
check the thermostat.
1 Inspection of fan belt tension
• As the tensioning pulley is attached, so it is not nec-
essary to adjust, but only check the wear of the V
belt and the pulley.
• Press the part between the alternator pulley and
the attachment pulley by finger with about 60N
force. The deflection at this moment may be the
inspection standard for the alternator tension.
LGB32002028
2-25
2.6 Cooling system
Inspection and adjustment of the tension of alter-

Alternator
nator drive belt
1
• To adjust the tension of the engine drive belt,
release the bolt (1) fixing the engine and the cap-
tive bolt at the lower part of the engine, and then
Auxiliary drive remove the engine.
belt pulley • Standard deflection of the engine drive belt: about
10mm
10mm • Check the damage of each pulley, V groove, and V
belt. Pay special attention that do not contact the V
belt and the V groove bottom.
• If the adjustment size has been used up or worn
because of the tight belt, the belt must be replaced.
LGB32002029
• When replacing the V belt, adjust it again after run-
ning it for about 1 hour.
Tension pulley
Water pump
belt pulley
1
10mm
Auxiliary drive
belt pulley
LGB32002030
2-26
3 Disassembly and assembly
3.1 Removal of starter components

3.1 Removal of starter components
1. Remove the side cover at the right side of the
engine.
2
2. Separate the wirings (1) and (2).
3. Separate the earthing cable (3) from the engine.
4. Remove the starter component (4).
3
1
4
LGB32002031
3.2 Assembly of the starter components

1. Put the gasket first and then install the starter component (4).
2. Connect the earthing cable (3) to the engine.
3. Match the wirings (2) and (1).
4. Install the engine right side cover.
3.3 Removal of alternator components

1. Separate the alternator wiring (1)
4
2. Remove the V belt tension adjusting bolt (2).
Loosen the alternator mounting bolt, then put the
alternator (3) down sideway and outward, and
then remove the V belt (3) on the alternator
pulley.
1
3. Remove the mounting bolt, and remove the
3 alternator component (4).
2 LGB32002032
2-27
3.4 Assembly of alternator components
3.4 Assembly of alternator components

1. Install the bolt meter to adjust the bolt, and tense the alternator component (4) temporarily.
2. First put the V belt (3) into the alternator pulley, and then adjust the tension with the following methods.
1) Put a iron bar between the alternator and the timing gear box, support the alternator upward, and then
tense the V belt at this moment.
2) Press the middle part between the alternator and the aux pulley with about 60N force, and tighten the
adjusting bolt (2) normally when the settlement is 5~15mm.
3. Match wiring (1) on the joint
POS+ terminal Red (thick)
R terminal Red and green (thin)
D+ terminal Red and white (thin)
E Terminal Black (thick)
2-28
3.5 Removal of engine cooler components
3.5 Removal of engine cooler components

1. Drain the water
2. Turbocharger
induction pipe
Bulldozer
3. Water pipes
4. Engine oil cooler

component
1. Water discharge
Remove the cover (1), unscrew the cooler drain
switch (2) to discharge the cooling water.
• If the anti-freeze agent is filled, please be sure to
recycle it and discharging the anti-freeze agent at
will is forbidden.
1
LGB32002033
2. Turbocharger induction pipe

Remove the turbocharger induction pipe (3)
• Crankcase with clamp.
3
LGB32002034
2-29
3.6 Assembly of engine oil cooler components
3. Engine oil cooler components

1) Separate water pipe (4)
1) Remove the oil cooler mounting bolt (5)
7 installed on the side of the engine.
2) Lift the oil cooler component (6), release the
5 mounting bolt (7) of the carrier to remove the
carrier.
Oil cooler component weight: 75Kg
4 6
LGB32002035

2. Water pipes
Engine 1. Engine oil cooler

3. Turbocharger induction pipe
cylinder gp component
4. Supply water
1. Engine oil cooler components

1) Lift the engine oil cooler component (6), and
put the packing cushion on the engine to
make certain its position.
7
2) Tighten the oil cooler mounting bolt (5), and
tighten the carrier mounting bolt (7).
5
3) Install the retainer to connect to the water
pipe (4)
4 6
LGB32002036
2-30
2. Turbocharger oil inlet pipe

Install the turbocharger oil inlet pipe (3)
3
LGB32002037
3. Water supply
1) Screw the drain plug.
2) Supply water through the water filler (7) to the
specified level.
8 Be sure to start the engine timely to check the
cooling water circulation state to confirm the
water level.
LGB32002038
2-31
3.7 Removal of torque converter oil cooler components
3.7 Removal of torque converter oil cooler components

1. Remove the cover (1), unscrew the cooler drain
plug (2) and the oil cooler drain plug to discharge
the cooling water.
• If the anti-freeze agent is filled, the cooling water
must be collected and not be discharged at will.
2. Remove the right side hood (2) on the engine.
LGB32002039
3. Remove the inlet and outlet water pipes (3) and

(4) connecting with the engine.
5 4. Remove the hydraulic pipes (5) and (6).
5. Lift the torque converter oil cooler component (7),
remove the mounting bolt on the rack first, and
then lift it for disassembly.
7 Torque converter oil cooler component

weight: 30Kg
LGB32002040
3 4
LGB32002041
2-32
3.8 Assembly of the torque converter oil cooler components
3.8 Assembly of the torque converter oil cooler components

1. Lift the torque converter oil cooler component (7),
3 and then tighten the mounting bolt toward the oil
cooler.
2. Connect the water pipes (3) and (4) after
installing the packing cushion.
5
3. Connect the oil cooler hydraulic pipes (5) and (6)
4 after installing the O-ring.
4. Install the engine right side cover.
5. Unscrew the drain plug and supply water through
the water filler (8) to the specified level.
• Be sure to start the engine timely to check the
cooling water circulation state so as to confirm
6 LGB32002042 the water level.
LGB32002043
2-33
3.9 Removal of engine oil pump components
3.9 Removal of engine oil pump components

1. Take out the cover (1) to remove the drain plug
(2), unscrew the drain plug (3), and extract the
engine oil for about 20Kg.
2. Remove the engine left side cover.
LGB32002044
LGB32002045
3. Remove the filler tube (4).

4. Remove the pump outlet tube (5) and the pump
5 4 inlet tube (6).
5. Remove the engine oil pump component (7).
6
LGB32002046
2-34
3.10 Assembly of engine oil pump components
3.10 Assembly of engine oil pump components

1. Assemble the oil component (7) after installing
the packing cushion.
5 4 2. Install the pump inlet tube (6) and assemble the
pump outlet tube (5).
3. Assemble the oil filler after installing the packing
cushion.
Notice: Hose shall not be twisted and interfered

as well.
7
4. Assemble the engine left side cover.
5. Screw the drain plug (2) and the drain plug (3),
and supply oil through the oil filler (4) to the
6
specified level.
LGB32002046
• Be sure to start the engine timely to check the oil
circulation state in the passage so as to confirm
the oil level again.
3.11 Removal of the PT fuel pump components

4 1. Remove the engine left side cover.
5 2. Remove the carrier (1)
7 3 3. Separate the fuel inlet hose (2)
4. Separate the fuel control lever (3)
6 5. Separate the oil cut-off valve wiring (4)
6. Separate the tube (5) of the oil pump and the
outlet tube (6) of the oil pump.
7. Remove the PT fuel pump component (7).
1
2
LGB32002047
3.12 Assembly of the PT fuel pump components

1. Assemble the PT fuel component (7) after installing the packing cushion.
2. Connect the tubes (6) and (5).
3. Match and connect the shutoff valve wiring (4).
4. Connect the fuel control lever (3).
Be sure to make the split pin bent when using it.
5. Connect the fuel inlet hose (2).
6. Assemble the engine left side cover.
2-35
3.13 Removal of the water pump components

1. Drain the
water
4. Anti-etcher
2. Engine right 5. Water pump 7. Water pump

Bulldozer side cover induction pipe component
6. Bypass pipe
3. V-belt
1. Water discharge
Remove the cover (1) and unscrew the radiator
drain plug (2) to discharge the cooling water.
recycle it and discharging the anti-freeze agent at
will is forbidden.
1
2. Engine right side cover.
2
Remove the engine right side cover.
LGB32002048
2-36
3. V-belt
4
Unscrew the tension adjusting bolt (3), and put
the tension pulley (4) down sideway and out-
ward, and then remove the V-belt (5).
3 LGB32002049
6 10 4. Anti-etcher
11
1) Separate the water pump induction pipe and the
hose (6) at the middle of the radiator.
2) First take out the outlet and inlet hose, and then
13 remove the anti-etcher (7).
7
5. Water pump induction pipe
Separate the clamp (8) first and then remove the
12 induction pipe (9) to place them around tempo-
rarily.
14 LGB32002051
6. Bypass pipe
8 1) Release the clamp (10), and move the hose (11)
upward.
2) Take out the thin plate (12), and remove the
piping (13).
7. Water pump components
Remove the water pump components.
Install all the 7 bolts.
LGB32002052
2-37
3.14 Assembly of the water pump components
3.14 Assembly of the water pump components

5. V-belt
2. Bypass pipe
1. Water pump 3. Water pump 6. Engine right

Bulldozer
component induction pipe side cover
4. Anti-etcher
7. Supply
water
6 10 1. Water pump components

11
Assemble the water pump component (14) after
installing the packing cushion.
Install all the 7 bolts.
13
2. Bypass pipe
7
1) Install the O-ring rear bypass pipe (13), and
assemble the thin plate (12).
12
2) Move the hose (11) back to the original position,
and tighten the clamp (10).
9
14 LGB32002051
2-38
3.15 Removal of the turbocharger components
3. Water pump induction pipe

8 Assemble the pipe (9) and tighten the clamp (8)
after installing the packing cushion.
4. Anti-etcher
1) Assemble the anti-etcher (7) and connect the
water in take hose.
2) Connect the hose (6).
5. V-belt
Hang the V-belt (5) and eject the engine (4) to
stretch the belt, and tighten the adjusting bolt (3).
6. Engine right side cover.
LGB32002052
Assemble the side cover.
7. Water supply
specified level.
15
circulation water cooling state so as to confirm
the water level.
LGB32002053
3.15 Removal of the turbocharger components

1 1. Loosen the clamp (1)
Remove the intake connector (2).
2. Remove the air pre-filter (3) and (4).
3. Loosen the air filter hose clamp (5), intake hose
2 clamp (6) and strap (7), remove the bolt (8) and
move the air filter component (9) backward.
4. Separate the turbine oil return tube (10) from the
turbocharger, and loosen the clamp.
5. Remove the turbine oil inlet tube (11).
6. Remove the turbocharger component (12).
10 LGB32002054
6 11
2-39
3.16 Assembly of the turbocharger components
3.16 Assembly of the turbocharger components

5 1. Assemble after installing the seal ring and the
packing cushion on the turbocharger component
(12).
2. Install the oil inlet tube (11) of the turbocharger.
4
As the elbow is thin, the torque wrench shall be
12 used during work.
9 3. Connect the turbine oil return tube and then
tighten the clamp.
7
4. Align the air filter component outlet with the
turbine, fix the position, install the bolt (8), and
then tighten the strap (7) and the clamp.
8 LGB32002055
5. Assemble the air pre-filters (3) and (4).

6. After installing the packing cushion, assemble
the intake connector (2) dust exhauster clamp
3
(5), and then tighten the hose clamp (1).
LGB32002056
2-40
3.17 Dis assembly of radiator protector

1. Drain the water
5. Cooler outlet pipe
2. Bottom guard
plate (front) 6. Wiring unit
Bulldozer
3. Top cover
7. Cap
8. Road cover 11. Hood
9. Working device
cylinder hose
10. Fan belt
4. Engine left &

right side covers
1. Water discharge
Remove the cover (1), unscrew the drain plug (2)
to discharge the cooling water.
2 recycle it and discharging the anti-freeze agent at
will is forbidden.
1
LGB32002057
2-41
2. Lift piping
3
Remove the 4 lift hoses (3) on the upper part of
the top cover and the 2 hoses (4) at the lower
part.
4
LGB32002058
3. Lift cylinder
9 8 5 Raise the lift cylinder with the special sling, and

then remove the lift cylinder (5) and the lift cylin-
der fork (6).
• The lift cylinder fork can be pulled out after being
revolved for 25°.
7 6
L IU GONG
LGB32002059
4 Upper hood
1) Remove the right and left side hoods (7) of the
9
engine.
2) Remove the upper cover (8) of the water tank.
3) Lift and remove the upper hood (9) with the
special sling.
LGB32002060
2-42
10
5. Front grill
1) Remove the front hood grill (10).
2) Remove the front hood counterweight (11).
11
LGB32002061
6. Oil cooler piping

14
1) Remove the oil inlet and outlet hose (12) and
(13) of the pilot cooler lines.
2) Remove the oil cooler (14).
12 13 LGB32002062
16 7. Inlet and outlet tube of the radiator.

1) Remove the water intake hose (15), breather
17 hose (16), loosen the hose clamp, and remove
the filling hose (17).
2) Separate the water intake hose (18).
15
18 LGB32002063
2-43
8. Fan belt
Adjust the tension pulley (19) to the inside with
the iron bar to remove the fan belt (20).
20
19
LGB32002064
9. Front hood
Lift the front hood (21) with the special sling, and
them remove the front hood and the main frame
binder bolt (22).
21
22
LGB32002065
Hood weight: 1600Kg
LGB32002066
2-44
10. Radiator
1) Remove the radiator fixing carrier (23) (4 in total).
2) Remove the radiator and the fixing bolt (24) of
the front hood.
3) Remove the bolt fixing the fan shield (27) and the
radiator.
23
LGB32002067
24
25
27
LGB32002068 LGB32002069
4) Remove the radiator (26) with special lifting ring

and sling.
26
Radiator weight: 200Kg
LGB32002070
2-45
11. Fan shield

1) Remove the fan shield (27) with special lifting
ring and sling.
2) Remove the fan protective steel mesh (28).
28
LGB32002071
3) Remove the fan fastening bushing (29) and the

fan shaft (30).
29
LGB32002072
30
LGB32002073
2-46
3.18 Assembly of the radiator protector

2. Connection wiring
4. Bottom guard
plate (front)
3. Cooler outlet pipe
5. Fan belt
6. Working device
Body frame
cylinder hose
1. Hood
7. Road pipe
9. Top cover
8. Cap
10. Engine left &

right side
covers
11. Supply water
1. Fan shield
1) Use the socket to install the fan shaft (30) and
fan shaft bushing (29) on the shield with M12
30
bolt.
 Bolt tightening torque: 120±10Nm
LGB32002074
2-47
2) Use 18 socket to install the fan protective steel

mesh (28), on the fan shield with M12 bolt.
27
LGB32002075
3) Lift the fan shield (27) into the front hood (21)
with special lifting ring and sling.
29
LGB32002076
2. Radiator
1) Lift the radiator (26) into the front hood with
27 special lifting ring and sling, and fix the radiator
and the front hood with bolt (25) and then tighten
them with the support plate 5 and the bracket 6.
LGB32002077
2-48
25
2) Lift the radiator into the front hood with special
lifting ring and sling, and pre-tighten the radiator
and the front hood with bolt (25) and then tighten
them with the support plate (24) and the bracket.
26
LGB32002078
24
LGB32002079
3. Radiator hood as
Lift the front hood with special sling and install it
on the main frame, and then fasten it with bolt
22 (22).
LGB32002080
2-49
4. Fan belt
Install the fan belt (20), and adjust the tension
pulley (19) inward to adjust the tightness degree
of the fan belt.
Notice: Measure whether the flatness between

the plane of the engine pulley and that of
20 the fan pulley is ≦ 3mm.
19
LGB32002081
5. Inlet and outlet tube of the radiator

16
1) Assemble the water intake hose (15), breather
17 hose (16), loosen the hose clamp, and assemble
the filling hose (17).
2) Assemble the water intake hose (18)
8
15
18 LGB32002082
6. Work implement pilot oil cooler

14
Install the oil cooler 8 and the oil cooler piping 9
12 13 LGB32002083
2-50
7. Front grill
1) Assemble the front hood grill (10).
10
2) Assemble the front hood counterweight (11).
11 LGB32002084
8. Upper hood
1) Lift and assemble the upper hood (9) with the
special sling.
2) Assemble the upper cover (8) of the water tank.
3) Assemble the right and left side hoods (7) of the
engine.
9
LGB32002085
9. Lift cylinder
9 8 5
1) Assemble the lift cylinder fork (6).
2) Raise the lift cylinder with the special sling, and
then assemble the lift cylinder (5) and insert the
lift cylinder fork rotationally
L IU G ONG
7
LGB32002086
2-51
10. Lift piping

3
Assemble the 4 lift hoses (3) on the upper part of
the upper hood and the 2 hoses (4) at the lower
part.
4
LGB32002087
11. Water supply

specified level.
31
the water level.
LGB32002088
2-52
3.19 320 Removal of the radiator at the second stage

1. Water discharge, lift piping, lift cylinder, engine
1 upper hood, water tank top cover and side cover,
front grill, front hood
For removal, please refer to CLGB320I Removal
of radiator (the water drain valve (1) position is
different).
LGB32002089
2. Intercooler pipe
3
2 Remove the vent intercooler pipes (2) and (3).
LGB32002090
3. Radiator lines
1) Remove the water intake hose (4), breather hose
6
5 (5), loosen the hose clamp, and remove the filling
hose (6). Remove the oil inlet hose (7) of the
torque converter.
2) Separate the water intake hose (18).
LGB32002091
2-53
LGB32002092
17
3) Disassemble the fan motor oil return hose (15),
16 15
pilot radiator oil inlet hose (16). Disassemble
the fan motor leakage hose (17), hydraulic oil
cooler tube (18), and the torque converter oil
cooler tube (19).
18
19 LGB32002093
26 4. Fan motor lines

Disassemble the fan motor oil return hose (15),
oil inlet tube (20). Disassemble the fan motor
leakage hose (17).
17
15
20 LGB32002094
2-54
5. Front hood
1) Remove the surrounding baffle (21)
2) Remove the front cover (22).
21 3) Unscrew the middle beam bolt (23).
27
4) Unscrew the radiator mounting base bolt (24),
and then remove the front hood and the fixing
bolt (25) of the main frame. Remove the harness
22
25 (26) at the front end, and lift and move away the
front hood (27) with the special sling.
24
LGB32002095
6. Beam
28 Remove the middle beam (28)
27
LGB32002096
7. Fan bracket
Remove the fan shield bolt (29) and take the fan
bracket as (30) out.
30
29 LGB32002097
2-55
8. Radiator
32 33
Remove the bolt (31) fixing the radiator and bot-
tom plate and the bolt (32) fixing the radiator and
the front hood, lift the radiator (33) with the spe-
cial sling.
31 LGB32002098
2-56
3.20 320 Assembly of the radiator at the second stage

1. Radiator bulk base
Install and fix the radiator bottom plate (34), and
tighten the bolt (24) at both side a little.
34
24
LGB32002099
2. Radiator
32 33
Lift the radiator (33) into the front hood with spe-
cial sling, and assemble the bolt (32) (M16) and
the lock bolt (31) (M18) with the socket.
31 LGB32002100
3. Fan motor
1) Fix the fan motor (35) on the fan shield with the
37 bolt (36) (M14).
36 35  Bolt tightening torque: 195±15Nm
2) Install the fan (37) on the fan shield
LGB32002101
2-57
3) Fix the fan shield as (30) on the radiator with

the bolt (29) (M14).
30
29
LGB32002102
4. Middle beam
28
Pre-tighten the beam (28) with bolt (27).
27
LGB32002103
5. Front hood
1) Lift the front hood (27) on the main frame with
special sling, and tighten the front hood and the
fixing bolt (25) of the main frame.
21
2) Tighten the middle beam bolt (23).
27
3) Tighten the radiator mounting base bolt (24).
4) Assemble the front cover (22), the surrounding
22
25
baffle (21), and the front end harness (26).
24
LGB32002104
2-58
26
6. Fan motor lines
1) Assemble the fan motor oil return hose (15), oil
inlet tube (20). Assemble the fan motor leakage
hose (17).
17
15
20 LGB32002105
17
2) Assemble the fan motor oil return hose (15), pilot
16 15
radiator oil inlet hose (16). Assemble the fan
motor leakage hose (17), hydraulic oil cooler
tube (18), and the torque converter oil cooler
tube (19).
18
19 LGB32002106
7. Radiator piping
1) Assemble the water intake hose (4), breather
6
5 hose (5). Assemble the filling hose (6) and
tighten the hose clamp. Assemble the oil inlet
hose (7) of the torque converter.
LGB32002107
2-59
2) Assemble the water inlet hose (8)
8
LGB32002108
8. Intercooler pipe
3
2 Remove the breather intercooler pipes (2) and
(3).
Water discharge, lift piping, lift cylinder, engine
top cover, water tank top cover and side cover,
front protective grid, front hood. For removal,
please refer to CLGB320I Radiator Removal (the
water drain valve (1) position is different).
LGB32002109
9. Water supply
1) Screw tight the drain plug.
specified level.
Be sure to start the engine timely to check the
38
the water level.
LGB32002110
2-60
3.21 Disassembly of fuel tank gp
3.21 Disassembly of fuel tank gp

1. Remove the 4 bolts (1) at this position with the
2 5mm inner hexagon spanner, and separate the
filler tube (2).
LGB32002111
2. Close the fuel feeding switch (3), and

4
disassemble the hose (4) between the oil filter
and the oil inlet of the diesel engine.
LGB32002112
3. Disassemble the hose (5) between the tank and

the diesel engine oil return port.
5 6
4. Remove four fuel tank mounting bolts( 6).
LGB32002113
2-61
3.22 Assembly of fuel tank gp
5. Remove the fuel tank gp (7)
Fuel tank gp dry weight: 255Kg
LGB32002114

1. Lift and fix the fuel tank gp (7).
7
LGB32002115
2-62
2. Tighten the 4 bolts (6) installing the fuel tank.

6 5 Install bolt and apply adhesives (LT-2) on it.
3. Disassemble the hose (5) between the tank and
the diesel engine oil return port.
LGB32002116
4. Connect the hose (4) between the oil filter and

4
the oil inlet of the diesel engine. Unscrew the fuel
feeding switch (3)
LGB32002117
5. Tighten the 4 bolts (1) at this position with the

5mm inner hexagon spanner, and fix filler tube
(2) and the fuel tank.
1
LGB32002118
2-63
3.23 Removal of the transfer case

1
Drain
3 4
TY3208 Variable pump Variable pump
bulldozer pipe line assembly
2 5 6 8
The floor Working implement Working implement Power take off
frame assembly pump assembly pump assembly
assembly assembly assembly
7
Lubrication pipe
1. Oil drain
Loosen refilling cap to discharge the pressure

inside the oil tank. Tighten the drain plug (1) to
discharge the oil.
1
Work oil tank capacity approaches 180kg.

2. The floor frame gp
See " Removal of floor frame gp"
LGB32002119
3. Gear shift pump line

2 4 3
Remove the pump outlet tube (2), and inlet tube
(3).
4. Gear shift pump gp
Remove gear shift pump gp (4)
LGB32002120
2-64
6 8
5. Work implement line
1) Separate the pilot oil pump inlet pipe (5) (the
hose connecting with the work tank can be
removed), and the outlet hose (6).
5 7 LGB32002121
6. Working implement pump gp

9
1) Remove the two mounting bolts from the lower
working implement pump gp, then tie up tightly
with nylon sling.
2) Remove the two upper mounting bolts to remove
working implement pump gp (9).
Work implement pump gp: 40kg
LGB32002122
12 7. Fan motor lines pump as

11
Remove the fan motor lines pump as (oil inlet
tube (10), oil outlet tube (11)), and the pump (12).
CLGB320 I machine does not have this pump,
and for the CLGB320 II machine, this pump shall
be removed when the work pump is removed.
LGB32002123
10
2-65
3.24 Assembly of P.T.O (Power Takeoff)
8. Lubrication pipe
14 13
Remove power takeoff lubrication pipe (13).
9. Power takeoff gp
1) Install the lifting bolt ① (M12, screw pitch: 1.75)
15 on the power takeoff and lift it.
Power takeoff gp: 80kg

2) Remove mounting bolt (14), then remove power
takeoff gp (15).
LGB32002124

2
Lubrication
pipe
4 7
Working implement The floor
1 assembly pump Pipeline
assembly frame
assembly
Power take
Flywheel off Unit
cover 5 6
Variable pump Variable pump
assembly pipe line
8
supply FUEL
1. Power takeoff
14 13
Lift lubrication pipe with the lifting bolt ① (M12,
screw pitch: 1.75) after the lubrication pipe is
installed with O-ring, and assemble the power
takeoff component (15).
15
2. Lubrication pipe
Connect power takeoff lubrication pipe (13).
LGB32002125
2-66
12 11 3. Fan motor lines pump as

Remove the fan motor lines pump as (oil inlet
tube (10), oil outlet tube (11)), and the pump (12).
CLGB320 I machine does not have this pump,
and for the CLGB320 II machine, this pump shall
be removed when the work pump is removed.
LGB32002126
10
4. Work implement pump gp

9
1) Install O-ring to the side of power takeoff;
2) First tie up the work implement pump gp (9) with
the nylon sling firmly, and then lift the component
to the power takeoff box for assembly.
LGB32002127
6 8
5. Work implement pump pipeline
1) After installing the O-ring, connect oil inlet tube
(5) and oil outlet pipe (6) to the main pump of the
work implements.
2) After installing the O-ring, connect the oil inlet
tube (7) and the oil outlet hose (8) to the work
implement pilot pump.
• O-ring is installed in the circular groove indeed.
5 7 LGB32002128
2-67
6. Gear shift pump gp

2 4 3
First install the O-ring to the side of power take-
off, install gear shift pump gp (4).
7. Gear shift pump pipeline
After installing O-ring, install outlet pipe (3) and
inlet pipe (2) to gear pump.
See the "Assembly of the floor frame gp" section
LGB32002129
9. Oil supply
16 1) Screw the drain plug.
2) Fill working oil to specified level through refilling
port (16).
Work oil tank: approximately 70kg.

• Start engine immediately to circulate the fuel
and reconfirm the fuel level;
LGB32002130
2-68
3.25 Disassembly of the power takeoff

Drive gear gp of Bearing
working device pump bushing

Cap Case as Drive shaft gear gp
of gear shift pump
Power take
off assembly

Drive gear gp of
output device
Cap Sealing Nut

sleeve
1 1. Cover
2
1) Put the power takeoff on the platform and then fix
them.
2) Remove cover (2)
LGB32002131
2. Case gp
Remove the mounting bolt (3) to separate the
case cover (4) and the housing (5).
5 3
LGB32002132
2-69
3. Cover
1) Overturn the case gp upside down, and put them
on the platform and then fix them.
2) Remove cover (6)
4. Connecting sleeve
Take the connecting sleeve (7) out.
7 6 LGB32002133
5. Nut
Remove the nut (8) with wrench.
LGB32002134
6. Work implement pump drive gear gp

11
Beat the work implement pump drive gear gp (9)
from inside to outside with a copper hammer to
remove it.
7. Gear shift pump drive gear gp
10
9
Beat the gear shift pump drive gear gp (10) from
inside to outside with a copper hammer to
remove it.
LGB32002135
2-70
8. Drive gear gp of power takeoff

Press the power takeoff drive gear gp with the
press machine to remove it.
11 9. Bearing bushing
12
Remove the bearing bushing (12)
LGB32002136
13-49
2-71
3.26 Assembly of the power takeoff

Bearing Gear gp of working
device pump
bushing

off device box
Power take
Drive shaft gear gp

Case as Cap
of gear shift pump

Drive gear gp
of output device
Sealing
Nut Cap
sleeve
1. Bearing bushing
12
Install the O-ring and install the bearing support
(12) to the housing (5).
LGB32002137
19 20 16 2. Power takeoff drive gear gp

15 18
1) Press the steering shaft into the bearing (15) with
the pushing tool (inner diameter 80mm).
2) First install the key (16) on the steering shaft, and
then press into the gear (17) with the pushing
tool (inner diameter 70mm).
3) Press the bearing (18) into the tank (5) with the
pushing tool ② (Ф150).
4) Press the exterior race (19) into the tank (4) with
pushing tool (Ф125), and then install the snap
ring (20).
17
14 LGB32002138
2-72
5) Press the bearing with the pushing tool, and then

press the power takeoff drive gear gp (11).
11
3. Gear shift pump drive gear gp
1) Press the upper and lower bearings (22) on the
24 gear (21) with the pushing tool (inner diameter
21
45mm).
23 2) Beat into the gear shift pump drive gear (10) with
22
the copper hammer
LGB32002139
8
4. Work implement pump drive gear gp
1) Press the upper and lower bearings (24) on the
gear (23) with the pushing tool (inner diameter
60mm).
2) Beat into the work implement pump drive gear gp
(9) with the copper hammer.
5. Nut
Install the division plate, lock plate, and tighten
the nut (8) with the wrench.
• Lock plate is bend indeed.
LGB32002140
2 6. Connecting sleeve
Press the oil seal on the connecting sleeve (7),
and then assemble the tank shell after the O-ring
is assembled.
7. Cover
Assemble the cover (6) after the packing cushion
is installed.
7 LGB32002141
6
2-73
8. Case gp
1) After overturning the case gp (5) upside down,
put them on the platform ① (about 150mm high)
and then fix them.
2) After the packing cushion is installed, cover the
upper tank (4) and then tighten the mounting bolt
(3).
Apply the liquid seal (LG-1) on both
sides of the packing cushion
4
9. Cover
Install the cover (2) after the installation of the
5 3 packing cushion.
LGB32002142
Apply the liquid seal (LG-1) on both sides of
the packing cushion
2-74
3.27 Disassembly of engine components

1. Oil drain
Loosen refilling cap to discharge the pres-

sure inside the fuel tank
Unscrew the drain plug (1).
1
Discharge the oil in the hydraulic oil tank.
Hydraulic oil tank capacity: approximately

180kg
LGB32002143
3
2. Right and left side hoods (2) of the engine.
Remove the right and left side hoods of the
engine.
3. Hood counterweight (13)
See " Removal of hood"
2
4. The floor frame assembly
G ONG See " Removal of floor frame gp"
LGB32002144
4
5. Lower guard
Support the lower guard (4) with the crane ① ,
etc. so as to remove it.
Lower guard: 160kg
LGB32002145
2-75
6. Torque converter oil cooler piping separates the

9 5 6
water inlet and outlet pipe (5) and (6) of the
7 8 torque converter.
7. Starter wiring
Separate the starter wiring (7), (8) and (9).
LGB32002146
8. Power takeoff line

11 12
1) Separate hose (10).
2) Loosen the bolt (11) and remove the pipe (12).
10
LGB32002147
14
9. Work oil pump lines
16
13 15 LGB32002148
2-76
10. Oil inlet lines of the gear shift valve

17 18 19
Separate the gear shift valve inlet hose (17) at
the filter side.
11. Gear shift pump pipe line
1) Remove the pump inlet hose (18)
2) Separate the outlet hose (19) at the filter side.
LGB32002149
12. Hydraulic torque converter breather hose

Remove hydraulic torque converter breather
hose (20).
20
13. Torque converter oil temperature gauge wiring
21
Separate the torque converter oil temperature
harness (21).
LGB32002150
14. Torque converter regulating valve line

25 23
1) Separate the outlet hose (22) of the torque
converter regulating valve.
26
2) Disconnect the hose (23) of the torque converter
pressure measurement piping from the safety
valve.
15. Hydraulic torque converter safety valve pipeline
1 Separate the inlet hose (24) and the outlet hose
(25) of the torque converter safety valve.
2) Disconnect the steering brake overflow hose (26)
at the valve side.
24 22
LGB32002151
2-77
16. Universal joint gp

27
Remove universal joint gp (27).
LGB32002152
17. Steering pump piping fuel hose

1) Remove the steering pump inlet hose (28)
2) Separate the steering pump outlet hose (29).
28 29 LGB32002153
3) Separate the fuel filter inlet hose (30) and the oil
30 injection return hose (31).
31
LGB32002154
2-78
18. Engine components

1) Remove engine mounting bolts (32) and (33).
32 33
LGB32002155
2) Install lifting tools in the three lifting rings on the

engine component (34), lift the engine and
remove;
34
Engine component: 2200kg
• Sort the washers (front and rear, left and right)
and store in sets
LGB32002156
2-79
3.28 Assembly of engine components

1. Engine components
1) First install washers on left, right, left and right
34 mounting positions, then lift the engine
component (34) install to vehicle frame, tighten
mounting bolts.
• Standard thickness of the gasket: about 2mm
Front and rear mounting bolt: about 760±85Nm
each
LGB32002157
35
2) Centering tool (35) is installed on both the torque
converter and the gearbox coupling for
measuring the center deviation and the plane
deviation to confirm whether they are within the
standard value. When they are not within the
standard value, unscrew the mounting bolt and
increase or reduce the gasket to adjust.
• Standard: both the centering deviation and the
plane deviation are 0.5mm (based on the reading
of the dial indicator)
LGB32002158
3) Lock the mounting nut after tightening it

• Front mounting bolt (33) are locked by steel wire
32 33 indeed.
• Lock plate of the rear mounting bolt (32) is bend
indeed.
LGB32002159
2-80
2. Fuel hose, steering pump piping

30
1) Connect the oil injection return hose (31), fuel
filter, and the inlet hose (30).
31
LGB32002160
2) Connect pipe (28) to steering pump after

installing the O-ring.
3) Connect the tube (29) between the steering
pump and the filter after the O-ring is installed.
28 29 LGB32002161
3. Universal joint gp
31
Install universal joint gp (31)
• Fill grease (G2-L1) after installation.
LGB32002162
2-81
4. Hydraulic torque converter safety valve

25 24 23 1) After the O-ring is installed, connect both the
outlet hose (25), inlet hose (24) to the safety
26 valve.
2) Connect the steering brake overflow hose (26) to
the valve.
5. Hydraulic torque converter regulating valve line
1) Connect the hose (22) to the hydraulic torque
converter adjusting valve.
2) Connect the hose (23) of the hydraulic torque
converter pressure measurement piping from the
safety valve.
22
LGB32002163
6. Hydraulic torque converter oil temperature gauge

wiring.
21 Connect the torque converter oil temperature
20 harness (21).
7. Hydraulic torque converter breather hose
Connect hydraulic torque converter breather
hose (20)
LGB32002160
8. Gear shift pump line

17 18 19
1) Connect the gear shift pump outlet hose (17) to
the filter after the O-ring is installed.
• O-ring is really installed in the groove indeed.
2) Connect the pump inlet tube (18) between the
pump and the filter after the O-ring is installed.
Connect the gear shift valve inlet tube (19) to the
filter after the O-ring is installed.
LGB32002165
2-82
14 10. Work oil pump lines

16
1) After the O-ring is installed, connect oil inlet tube
(13) and oil outlet hose (14) to the main pump of
the work implements.
2) After the O-ring is installed, connect the oil inlet
tube (15) and the oil outlet hose (16) to the work
implement pilot pump.
O-ring is installed in the circular groove indeed.
13 15 LGB32002166
11. Power takeoff lines

12 11
1) Install the tube (11) and bolt (12) after the O-ring
is installed.
2) Connect the hose (10).
10
LGB32002167
12. Starter wiring

7 8 9 5 6 Connect the starter wiring (10), (9) and (8).
13. Torque converter oil cooler piping
Connect the water inlet and outlet pipe (7) and
(6) of the torque converter.
LGB32002168
2-83
14. Lower guard

Support the west guard (4) with the crane ① to
assemble.
See the "Assembly of the floor frame gp" section
4
LGB32002169
16. Hood (13)

3
See the " Assembly of hood" section
17. Right and left side hoods of the engine
Assemble the right and left side hoods (2) of the
engine.
2
G ONG
LGB32002170
18. Oil supply

36 1) Supply the specified work oil through the oil filler
(36) to the specified level.
Work oil tank: 230 L

• Start engine immediately to check the circulation
of the work oil and to reconfirm the oil quantity
level;
LGB32002171
2-84
3.29 Removal of the parts related to the vehicle body from the engine component
3.29 Removal of the parts related to the vehicle body from the
engine component
1. Steering pump
1) Remove the steering pump oil suction pipe (1),
and the oil outlet pipe (2).
2) Remove steering pump (3).
3
2
LGB32002172
2. Gear shift pump

Remove gear shift pump (4).
LGB32002173
2-85
3. Work pump
5
Remove work pump (5).
LGB32002174
8 7 4. Fan motor lines pump as

Remove the fan motor lines (oil inlet tube (6), oil
outlet tube (7)), and the pump (8). CLGB320 I
machine does not have this pump. For CLGB320
II,
II This pump shall be removed when the work
pump is removed.
6 LGB32002175
5. Power takeoff gp
10
1) Remove the lubrication pipe (9).
2) After lifting the lubrication pipe, install two lifting
9 bolts (M12, screw pitch: 1.75), and then remove
the mounting bolt and the power takeoff (10).
LGB32002176
2-86
6. Hydraulic torque converter gp

1) Remove the drain plug (11) to discharge the
engine oil in the torque converter.
11 LGB32002177
2) Lift the lifting ring with the steel wire, remove the
mounting bolt. After tightening with the drawing
bolt, pull out the torque converter component
(12) outward.
12
LGB32002178
2-87
3.30 Removal of floor frame

1. Remove the cover 1 from the floor frame of the
2 machine;
2. Loosen the 8 bolts 2 fixing the instrument cover,
remove the instrument cover 3, and then
disassemble the connectors of the harnesses to
remove the instrument cover as;
LGB32002179
5
LGB32002180
3. Loosen the 4 bolts 4 fixing the evaporator to

remove the evaporator 5;
4
LGB32002181
2-88
4. Remove the multi-way valve cover, loosen the 8

hoses connecting the blade control valve and
ripper control valve with the multi-way valve,
loosen the 2 hoses connecting the blade control
valve and ripper control valve with the oil return
᧝࡬䰶фཐ䐥
Control valve and
multi-way valve flange block, and then shield the disassembled
䰶䘔᧛䖥㇗
connection hose
connectors;
LGB32002182
5. Separate the unload valve oil inlet hose 6 and the

7 radiator hose 7, and shield the disassembled
connector;
LGB32002183
9 6. Loosen the fixing bolt 8 of battery box cover to

remove the battery box cover 9;
LGB32002184
2-89
7. Disassemble the battery cable (+) 10 and then

10 draw out the battery cable (+) to avoid damage of
the cable when lifting the floor plate;
LGB32002185
13 8. Loosen the fixing bolt 11 of the plate-lh and plate-

rh, remove the left and right lamp cover 12,
loosen the fixing bolt 1 of the pedal-lh and pedal-
14 rh and then remove the pedal-lh and the pedal-rh
14;
11 12 LGB32002186
9. Loosen the fixing bolt 15 of the portal frame, and

then remove the portal frame 16;
16 15
LGB32002187
2-90
10. Remove the fixing pin 16 of the brake link fork

and the cotter pin 17, and then separate the
brake link;
16,17 LGB32002188
11. Remove the pin 18 and the cotter pin 19

connecting the brake lock horizontal bar, and
then separate the brake lock link and the
horizontal bar;
18,19 LGB32002189
12. Remove the pin 20 and the cotter pin 21

connecting the steering flexible shaft and the
steering valve, and then separate the steering
flexible shaft;
20,21 LGB32002190
2-91
13. Remove the slotted nut 22 and the cotter pin 23

connecting the forward and backward link and
the bucket lever, and then separate the forward
and backward link;
22,23
LGB32002191
14. Loosen the nut connecting the flexible shaft and

the bracket, and remove the pin 24 and the cotter
pin 25 connecting the flexible shaft and the
bucket lever, and then separate the flexible shaft;
24,25 LGB32002192
15. At last, remove the 4 brackets connecting the

floor and the wing panel, loosen the 4 bolts 26
connecting the front left bracket and the wing
panel, and then separate the bracket;
26
ᐜࢃ᭥ᓝ
Front bracket-lh
LGB32002193
2-92
16. Loosen the 4 bolts 26 connecting the front right

bracket and the wing panel, and then separate
the bracket;
26
Front
਩ࢃ᭥ᓝ
bracket-rh
LGB32002194
Rear
bracket-lh
Rear
bracket-rh
LGB32002195
17. Loosen the 4 bolts 26 connecting the front left

bracket and the wing panel, and then separate
the bracket;
Rear bracket
bolt-lh
26
LGB32002196
2-93
3.31 Installation of floor plate
18. After all the 4 brackets are separated, the entire

floor plate can be lifted.
Rear bracket
bolt-rh
26
LGB32002197

1. Align the 4 bracket holes of the floor plate with
the wing panel holes respectively, and the
positions of the 4 brackets are shown in the
figure. Tighten the bolt 1 with the wrench 21 or
the socket, and the specified torque of the bolt is
195±15Nm;
Front bracket-lh
1
LGB32002198
Front bracket-lh LGB32002199

2-94
2. Align the brake link fork hole with the hole of the
bucket lever and put the pin 2 through the hole,
and then fix the pin 2 with the cotter pin 3;
Rear
bracket-lh
Rear
bracket-rh
LGB32002200
2,3 LGB32002201
3. Align the brake lock horizontal bar with the link

hole and put the pin 4 through the hole, and then
fix the pin 4 with the cotter pin 5;
4,5 LGB32002202
2-95
4. Align the brake flexible fork with the hole of the

steering valve bucket lever and put the pin 6
through the hole, and then fix the pin 6 with the
cotter pin 7;
6,7 LGB32002203
5. Align the forward and backward link with the hole

of the bucket lever, and install the slotted nut 8,
and then lock the slotted nut 8 with the cotter pin
9;
8,9
LGB32002204
6. Align the fork at the variable speed flexible shaft

end with the bucket lever hole and put the pin 10
through the hole, fix the pin 10 with the cotter pin
11, and then fix the variable speed flexible shaft
on the bracket and lock the nut;
10,11 LGB32002205
2-96
7. Lift the portal frame 12, align the portal frame

hole with the plate-lh and plate-rh, and fix with
the bolt 13. The bolt torque is 305±25Nm;
12
13
LGB32002206
15 8. Lift the pedal-lh and the pedal-rh 14, align the

step hole with the plate-lh and the plate-rh holes,
and fix them with the bolt 15, the bolt torque is
14 120±10Nm; install the lamp cover 16 of the plate-
rl and the plate-rh, and fasten it with the bolt 17,
the bolt torque is 120±10Nm;
16 17 LGB32002207
9. Connect the joint of the battery harness (+) 18

18 with the battery, tighten the small fixing bolt, and
fix the rubber jacket;
LGB32002208
2-97
19 10. Align the bolt holes of the battery cover 19 with

the bracket holes, and fix the cover with the bolt
20;
20
LGB32002202
11. Tighten the oil inlet hose 21 of the unload valve

22 and the radiator hose 22 with the corresponding
connectors;
21
LGB32002210
12. Connect the blade control valve and the ripper

control valve hoses connecting the multi-way
valve with the corresponding connectors, and
tighten the hose connectors; please refer to the
assembly of the blade control valve and the
ripper control valve for the specific methods;
LGB32002211
2-98
13. Install the evaporator 23, and fasten it with the

25 bolt 24, the bolt torque is 120±10Nm; after the
installation of the evaporator is finished, install
the cover as 25, and connect the console wiring,
electric lock cable, etc. completely, at last, fix the
cover with the bolt 26;
26
23
LGB32002212
24
LGB32002213
14. Finally, install the floor plate cover 27, and fix it
with the bolt 28, and the bolt torque is
120±10Nm;
27
28 LGB32002214
3 Power train system

1.1 Introduction ...................................................................................3-4
1.2 Hydraulic torque converter.............................................................3-6
1.3 Transmission ...............................................................................3-10
1.4 Planetary gear mechanism .........................................................3-12
1.5 Power transferring line ................................................................3-18
1.6 Chassis hydraulic system ...........................................................3-22
1.7 Hydraulic torque converter lines ..................................................3-23
1.8 Gearbox control valve..................................................................3-24
1.9 Safety valve .................................................................................3-28
1.10 Pressure reducing valve ............................................................3-30
1.11 Hydraulic torque shift control system.........................................3-32
1.12 Steering hydraulic control ..........................................................3-34
1.13 Cross shaft and steering clutch .................................................3-43
1.14 Steering brake ...........................................................................3-46
1.15 Final drive ..................................................................................3-50
1.16 Operation of power train system................................................3-51
2. Inspection and adjustment.................................................... 3-53
2.1 Overview......................................................................................3-53
2.2 Oil pressure and oil temperature measuring tools .......................3-55
2.3 Measurement skills of oil pressure and oil temperature ..............3-55
3. Removal and installation ........................................................ 3-64
3.1 Removal of the torque converter as.............................................3-64
3.2 Installation of the torque converter as.........................................3-65
3.3 Disassembly of torque converter as............................................3-66
3.4 Assembly of torque converter as .................................................3-71
3.5 Removal of the torque converter relief valve as ..........................3-78
3.6 Assembly of torque converter relief valve as ...............................3-78
3.7 Disassembly of torque converter relief valve as ..........................3-79
3.8 Assembly of torque converter relief valve as ...............................3-79
3.9 Disassembly of torque converter safety valve .............................3-79
3.10 Assembly of torque converter safety valve ................................3-80
3-2
3.11 Disassembly of gearbox............................................................ 3-80

3.12 Installation of gearbox ............................................................... 3-83
3.13 Disassembly of the gearbox as ................................................. 3-83
3.14 Assembly of the gearbox as...................................................... 3-99
3.15 Disassembly of gear shift valve............................................... 3-119
3.16 Installation of gear shift valve.................................................. 3-119
3.17 Disassembly of gearbox control valve..................................... 3-120
3.18 Installation of gearbox control valve........................................ 3-121
3.19 Disassembly of gearbox control valve..................................... 3-121
3.20 Installation of gearbox control valve........................................ 3-122
3.21 Removal of transmission lubrication valve assembly.............. 3-122
3.22 Installation of gearbox lubrication valve as ............................. 3-122
3.23 Disassembly of gearbox lubrication valve as .......................... 3-122
3.24 Installation of gearbox lubrication valve as ............................. 3-123
3.25 Disassembly of cross shaft and bevel gear............................. 3-123
3.26 Assembly of cross shaft and bevel gear ................................. 3-126
3.27 Removal of steering clutch...................................................... 3-133
3.28 Installation of steering clutch................................................... 3-135
3.29 Disassembly of steering clutch as........................................... 3-136
3.30 Assembly of steering clutch as................................................ 3-137
3.31 Removal of brake assistor....................................................... 3-138
3.32 Installation of brake assistor.................................................... 3-141
3.33 Removal of steering valve and brake valve ............................ 3-141
3.34 Installation of steering valve and brake valve ......................... 3-142
3.35 Disassembly of steering valve as............................................ 3-142
3.36 Installation of steering valve as ............................................... 3-144
3.37 Removal of gear shift pump as ............................................... 3-144
3.38 Assemblyof gear shift pump as ............................................... 3-145
3.39 Removal of steering pump as ................................................. 3-146
3.40 Assembly of steering pump as ................................................ 3-147
3.41 Disassembly of level I pinion as .............................................. 3-147
3.42 Assembly of level I pinion as................................................... 3-149
3.43 Disassembly of final drive ....................................................... 3-152
3.44 Assembly of final drive ............................................................ 3-157
3.45 Disassembly of steering clutch as........................................... 3-163
4. Service standard ..................................................................... 3-165
3-3
4.1.Hydraulic torque converter.........................................................3-165

4.2 Gearbox ....................................................................................3-169
4.3 Cross shaft and steering part.....................................................3-174
4.4 Final drive ..................................................................................3-184
3-4
1.1 Introduction

1.1 Introduction
1 2 3 4 5 6
LGB32003001
The power generated by the diesel engine is trans- bevel pinion (a) assembled on the horizontal axis.
ferred to the impeller cover of the torque converter (1)
The steering clutch (5) assembled on both ends of
through engine impeller.
the horizontal axis is used to disconnect or connect
The impeller cover revolves together with the impel- the power from the horizontal axis to the final reducer
ler, and the engine makes the turbine revolve with the to complete the steering operation. Steering opera-
work liquid flow and drive the turbine shaft to revolve. tion valve is installed on the steering clutch, and
The power transferred to the turbine shaft is trans- operate this valve during steering to disconnect the
ferred to the input shaft of the gearbox (3) through clutch at the side which needs to steer. The steering
the universal joint (2). force magnitude depends on the brake force magni-
tude of the steering controller installed on the sur-
The gearbox control valve (4) is installed in the gear-
rounding of the steering clutch brake drum.
box, which can be used to operate the clutch in the
gearbox to select the optional power drive line (gear) The power from the steering clutch is transferred to
according to the change of the load. Then, the power the final reducer flange, and decelerate successively
is transferred to the bevel pinion at the rear end of the after passing through the two stages straight scales,
gearbox. and then the power is transferred to the chain wheel
(6) finally.
After being transferred backward through the engine
→ torque converter → gearbox power train system, The chain wheel revolves to drive the track of the
the power is transformed as the driving force in the travel device and then drive the vehicle to travel.
left and right directions by the bevel pinion and the
3-5
1.1 Introduction
10
9
1 2 3 4 5 6 7 8
NO.1 NO.2 NO.3 NO.4 NO.5
LGB32003002
1. Engine 5. Transmission 9. Chain wheel

2. Output force device 6. Intermediate shaft 10. Track
3. Hydraulic torque converter 7. Steering clutch
4. Universal joint 8. Final drive flange
Speed gear and the drive line
Forward/Reverse Speed gear Fastened clutch
1 NO.1NO.5
Forward 2 NO.1NO.4
3 NO.1NO.3
1 NO.2NO.5
Reverse 2 NO.2NO.4
3 NO.2NO.3
3-6
1.2 Hydraulic torque converter
31
1
30
2 29
28
3
27
4
26
5
25
6
24
7
23
22
10
21
11
20
12 13 14 15 16 17 18 19
LGB32003003
3-7
32
36
Oil࠰⋯ਙ
outlet
Oil
䘑⋯ਙ inlet
33 34 35
LGB32003004
1. Drive housing 13. Screw-plug 25. Cover

2. Drive gear 14. Drive gear 26. Guide wheel shaft
3. Bolt 15. Nut 27. Bearing
4. Split ring 16. Oil drain plug 28. Gear
5. Bearing 17 Oil filter 29. Impeller
6. Guide apparatus 18. Screw 30. Bolt
7. Bolt 19. Cover 31. Turbine assembly
8. Hub 20. Single-row radial ball bearing 32. Safety valve as
9. Bolt 21. Plate 33. Cover
10. Guide wheel 22. Seal socket 34. Scavenge pump gp
11. Guide wheel hub 23. Turbine shaft 35. Cover
12. Housing 24. Oil seal 36. Pressure regulating valve
CLGB320 bulldozer is equipped with the single stage, single phase torque converter with 3 components. With
the change of the vehicle load, the torque generated by the engine is changed through the liquid, then the
transmission is lubricated. The main components of the torque converter are: impeller (33) which converts the
mechanical energy of the engine power into the kinetic energy of the liquid, the turbine (35) which converts the
kinetic energy of the liquid into the mechanical energy again, and the guide wheel (10) which guides the flow of
the oil.
The drive gear (2) meshed with the interior gear of the flywheel revolves with the revolving of the engine, and
drive the housing (1) and the impeller (33) to revolve taking the bearing as the supporting point.
The impeller, turbine and the guide wheel are filled with the work oil. When the impeller starts to revolve, the oil
in the impeller will flow into the turbine outward spirally along the vane of the impeller under the action of the
centrifugal force.
3-8
The work oil flowing into the turbine rushes at the vane in the turbine to change the oil direction, and then
rushes at the guide wheel (10).
When the work oil flows past the vane, the turbine will revolve under the action of the reactive force to make
the turbine shaft (27) transfer the power.
The work oil from the turbine after passing the central part of the turbine flows past the guide wheel to make
the oil direction changed, and then circulate to the central part of the impeller.
As described above, the work oil flows past the impeller → turbine → guide wheel →impeller, and the power is
transferred to the turbine from the impeller continuously to make the universal joint revolve.
As the guide wheel of the TY320B bulldozer is fixed on the guide wheel shaft with spline, it cannot revolve.
• This is a hydraulic torque converter formed by a impeller, a turbine and a fixed guide wheel, which can also
be called as "3 components, single stage, single phase” hydraulic torque converter.
Hydraulic torque converter safety valve To avoid high hydraulic pressure entering the torque
converter, the pressure adjustment safety valve of the
gearbox control valve makes the work oil flow out with
the pressure setting value of 2±0.2MPa, and then
adjust the pressure as 0.87MPa.
To the lubrication safety valve
㠩
⏜
The pressure oil from the gearbox control valve flows
1
2
┇ past the oil port A and then the oil-way of the torque
⭞
converter housing to the oil pump side. The oil port A is
To the flow oil pump side
㠩 ᆿ
From gearbox control valve
⍷
㠠 ‫ޞ‬ filled with work oil, while the hydraulic pressure applied
਎ 䰶
ੇ 䙕 to the impeller is 0.7±0.01MPa, the pressure oil will
⋯
⌫
㇧ compress the spring (1) then push the slide valve (2)
᧝
‫ם‬ ࡬ upward. Then, the pressure oil will flows to the safety
䰶 valve circuit used for lubrication of the gearbox through
the oil port B.
LGB320030 • The opening pressure of the valve is 0.87MPa
Hydraulic torque converter pressure regulating To keep the oil pressure in the torque converter always
valve below 0.45±0.05MPa, it needs to protect the torque
converter and make it work effectively, so the torque
converter pressure adjustment valve is installed in the
circuit at the outlet.
The pressure oil from the hydraulic torque converter
fills the oil port C after passing through the passage of
the torque converter housing.
To oil cooler
㠩
Automatic torque converter turbine
3 ⋯
If the oil pressure in the oil port C rises to
Oil temperature device port
߭
⋯ 4 㠠
⑟
ಞ 0.45±0.05MPa, the pressure oil will compress the
਎
ಞ
⸟
spring, and push the slide valve (4) upward, and then
᧛
ਙ
ಞ flows to the oil cooler circuit through the oil port D.
⏗
䖤 • Setting value of pressure:
60L/min0.25±0.1MPa
LGB32003006 100L/min0.35±0.05MPa
200L/min0.45±0.05MPa
3-9
Dump pump 14. Driven gear

20. Cover
21. Driven gear
22. Pump housing
23
23. Drive gear
The oil leaked from the junction surface of the impeller,
turbine, and the guide wheel, and the lubrication oil of
the P.T.O device after lubricating the sliding compo-
nent will flow back to the interior of the hydraulic torque
converter housing.
22
The left oil in the torque converter housing flows past
the oil filter (17), and then is transferred to the oil return
14
circuit in the steering case with the scavenge pump
(39) driven by the gear (32) which is assembled in the
21
back of the torque converter oil pump.
20
LGB32003007
3-10
1.3 Transmission
1.3 Transmission
The TY320B bulldozer comprises of planetary gear mechanism and the disc clutch. The planetary gear is a
gearbox with "3 forward gears and 3 backward gears”.
The disc clutches of the 5 planetary gear mechanisms are controlled by the control valve, and the 2 clutches
are fixed with hydraulic pressure so as to select a turning direction and a speed.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
43
42
C G J M 16
F
41
17
L
40
B I K
A H
39
D
38
37 18
N
19
36 E O
35
34
20
33
21
32 31 30 29 28 27 26 25 24 23 22
LGB32003008
3-11
1.3 Transmission
1. Pin 16. Housing 31. Plate

2. The 1st clutch piston 17. Shaft 32. Oil cylinder body
3. Spring washer 18. Screw cap 33. Bolt
4. The 2nd clutch piston 19. Bearing 34. Planet carrier
5. Shaft 20. Cover 35. Transmission body
6. The 3rd clutch piston 21. Bearing bushing 36. Gasket
7. Snap ring 22. Bearing 37. Coupling knot
8. The 4th clutch piston 23. Shaft 38. Support plate
9. Gear 24. Spring 39. Bolt
10. Exterior drum 25. Plate 40. Shaft
11. Butterfly spring 26. The 4th carrier 41. Cage
12. The 5th housing 27. Oil cylinder body 42. Bearing seat
13. Steel ball 28. Bolt 43. Plate
14. Back cover 29. Bushing
15. Piston 30. Oil cylinder body
A The 1st sun gear (Number of teeth 35) ·The first clutch
B The 1st planetary gear (Number of teeth 24) · Drive plate number 5
C The 1st gear ring (Number of teeth 81) · Driven plate number 4
D the 2nd sun gear (Number of teeth 21) · The second clutch
E The 2nd planetary pinion (Number of teeth 23) · Drive plate number 3
F The 2nd planetary pinion (Number of teeth 24) · Driven plate number 4
G the 2nd gear ring (Number of teeth 81) · The second clutch
H the 3rd sun gear (Number of teeth 33) · Drive plate number 2
L the 3rd planetary gear (Number of teeth 24) · Driven plate number 3
J the 3rd gear ring (Number of teeth 81) · The fourth clutch
K the 4th sun gear (Number of teeth 42) · Drive plate number 1
L the 4th planetary gear (Number of teeth 19) · Driven plate number 2
M the 4th gear ring (Number of teeth 81) · The fifth clutch
N Last level drive gear of the gearbox (Number of teeth 29) · Drive plate number 4
O Last level passive gear of the gearbox (Number of teeth 24) · Driven plate number 5
The five driving plates of the 1st clutch, in which the
P Bevel pinion (number of teeth 21) Note plate at the piston side has the different thickness
comparing with others.
3-12
1.4 Planetary gear mechanism

Planetary gear train (Structural example)
C B The planetary gear train consists of the sun gear A, the
A D
planetary pinion B, the ring gear C and the planetary
carrier D.
The planetary pinion, supported by the planetary car-
rier, meshes with the sun gear and the ring gear.
LGB32003009
A. Sun gear B. Planetary gear C. Gear ring D. Planet carrier
When the ring gear is fixed

The power of the sun gear A will be passed to the plan-
A
B etary pinion B.
The planetary pinion meshes with the ring gear C.
Since the ring gear is fixed, the planetary pinion rotates
C
D around the ring gear.
At the moment, the power transmitted by the sun gear
A will be exported by the planetary carrier D. The plan-
etary pinion B rotates in the same direction as that of
the sun gear A.
LGB32003010
3-13
When the planetary carrier is fixed

The power of the sun gear A will be passed to the plan-
etary pinion B.
Since the planetary carrier D is fixed, the planetary pin-
ion meshing with the sun gear rotates at its original
position.
The ring gear C meshing with the planetary pinion
rotates in the direction opposite to that of the sun gear.
In this way, the power of the sun gear can be passed to
the ring gear.
LGB32003011
Change of direction of rotation

Install a planetary pinion E between the planetary pin-
E ion B and the ring gear C in the above figure to enable
the sun gear to rotate.
Since the ring gear is fixed and the planetary pinion E
cannot turn on its axis, the planetary pinion will revolve
around the ring gear.
In this way, the power of the sun gear will be passed to
the planetary carrier. Since there is a pair of additional
gears, the planetary carrier will rotate in the direction
opposite to that of the sun gear.
LGB32003012
3-14
Rotary clutch
15 44 43 12 9 The #5 clutch of the CLGB320 gearbox is different from
the #1 rotary clutch, the #2 rotary clutch, the #3 rotary
clutch or the #4 rotary clutch.
Under the effect of the pressure oil, the piston (15)
compresses the friction plate (44) and the steel disc
(43) to connect the clutch wheel (12) with the wheel (9)
through the friction between the friction plate and the
steel disc, so that the power will be exported to the out-
put shaft.
Such rotary clutch can be used to transmit a larger
torque, so it is usually applied to the clutch of the 1st
gear.
LGB32003013
Fixed gear ring

16 45 46 47 48
The clutch consists of the housing (16), the ring gear
15
(C), the piston (15), the steel disc (45), the friction plate
(46), the return spring (47) and the pin (48).
The inner teeth of the friction plate (46) meshes with
the outer teeth of the ring gear (C) and both the piston
(15) and the steel disc (45) are fixed to the housing
(16) through the pin (48), so the piston (15) and the
steel disc (45) cannot rotate all the time.
C
LGB32003014
3-15
Clutch engaged (fixed)

The pressure oil from the control valve passes through
16 15 45 46 47 48 the oil port of the housing (16) to the back of the piston
(15) and pushes the piston to move towards right to
compress the steel disc (45) and the friction plate (46)
together. Since the steel disc (45) cannot rotate, the
ring gear (C) meshing with the friction plate (46) is fixed
and cannot rotate, either.
LGB32003015
Disengagement (release) of clutch

After the pressure oil is cut off by the control valve,
16 15 45 46 47 48 under the effect of the return spring (47), the piston
(15) will be pushed back to its original position, so that
the steel disc (45) and the friction plate (46) can be
released and the ring gear (C) can rotate freely.
The spring washers are installed between the steel
disc and the steel disc as well as the steel disc and the
housing at the position of the pin (48). When releasing
the clutch, the spring washers can not only allow the
C
piston to return back quickly, but also allow the inner
disc to disengage the friction plate smoothly to avoid
halfway disengagement.
LGB32003016
3-16
#5 clutch (Ball check valve)

The # 5 clutch of the CLGB320 gearbox is the rotary
13 15
clutch, i.e., released clutch. Due to the oil in the back of
the housing (50), under the effect of centrifugal force,
the piston (15) cannot be pushed back to its original
position at once just by the force of the disc spring (49).
As a result, the clutch is engaged halfway.
49
Therefore, although the shift lever is in the "N" position,
50 actually, the clutch is still engaged, and this can affect
the next shifting action.
To avoid this state, the ball check valve (13) is
mounted on the rotary clutch.
LGB32003017
Engagement of clutch (fixed)

The pressure oil from the control valve passes through
the hole of the housing (50) to reach the back of the
15 piston (15). At the moment, under the effect of the
13 pressure oil, the ball check valve (13) can be clogged
so that the piston (15) will be pushed towards the right
to compress the friction plate and the steel disc. As a
result, the clutch will be engaged to start to transmit the
power.
50
LGB32003018
3-17
Disengagement (release) of clutch

After the pressure oil is cut off by the control valve, a
centrifugal force will be generated due to the rotation of
15 the ball check valve (13). Under the effect of the centrif-
13 ugal force, the ball check valve can be opened. As a
result, the oil in the back of the piston (15) will be dis-
charged through the gap of the ball check valve. With-
out the effect of the centrifugal force, the piston can
restore to its original position smoothly, resulting in
power cut-off.
50
LGB32003019
3-18
1.5 Power transferring line

Forward 1st speed
LGB32003020
Fasten the 1st clutch and the 5th clutch, fix the 1st grated with the 2nd and 3rd planetary carrier) rotates,
gear ring, and then connect the 5th gear (integrated so the 3rd, 4th sun gear, the 5th clutch, the 4th plane-
with the 4th planetary carrier) and the output shaft tary carrier and the 3rd gear ring will rotate entirely to
directly. make the output shaft (23) rotate toward the direction
same as the 1st sun gear to output power.
Power then can be transferred from the 1st sun gear
to the 1st planetary gear B. It is the last level drive gear O of the gearbox on the
output shaft through which the power is transferred to
As the 1st gear ring is fixed, the 1st planetary gear
the last level driven gear P, and then to the pinion Q
revolves around the 1st sun gear while rotating, at
to form output power, but the rotation direction is
this moment, the 1st planetary carrier (34) (integrated
opposite to that during input.
with the 2nd and 3rd planetary carrier) rotates toward
the direction same as the 1st sun gear to transfer
power. As the 5th clutch is fastened, the exterior
drum (10) of the 5th clutch, the 5th gear (9), the 4th
planetary carrier (26) and the 3rd gear ring J are inte-
grated.
Under this condition, the 1st planetary carrier (inte-
3-19
Forward 2nd speed
LGB32003021
Fasten the 1st clutch and the 4th clutch, fix the 1st
gear ring and connect the 4th gear
Power is then can be transferred from the 1st sun
gear to the 1st planetary gear B.
power.
The 4th gear ring M is also fixed. The rotation force of
the 1st planetary carrier makes the 4th planetary gear
L rotate along the interior teeth of the 4th gear ring
while revolving around the 4th sun gear through the
4th sun gear K (integrated with the 3rd sun gear H),
then the power is transferred to the output shaft (23).
3-20
Forward 3rd speed
LGB32003022
Fasten the 1st clutch and the 3rd clutch, fix the 1st
gear ring and connect the 3rd gear.
After the power is transferred from the first sun gear A
to the first planetary gear B
power.
As the 3rd gear ring J is fixed, so when the 1st plane-
tary carrier rotates, the 3rd planetary gear I rotates
along the 3rd gear ring while revolving around the 3rd
sun gear. At this moment, the 1st planetary carrier
rotates forcing the 3rd sun gear to rotate and then the
power is output to the output shaft (23).
3-21
Backward 1st speed
LGB32003023
Fasten the 2nd clutch and the 5th clutch, fix the 2nd In this way, the power in the reverse direction can be
gear ring, and then connect the 5th gear (integrated transferred. The power transfer route of the following
with the 4th planetary carrier) and the output shaft 1st speed, 2nd speed and 3rd speed is the same as
directly. that of the above-mentioned forward 1st speed, for-
ward 2nd speed and forward 3rd speed.
After the power is transferred from the 2nd sun gear
D to the 2nd planetary gear E (first group) (back-
ward), then it is transferred to the 2nd planetary gear
F (second group). As the 2nd gear ring is fixed, the
2nd planetary gear meshed with the 2nd gear ring,
and the 2nd planetary gear meshed with the 2nd sun
gear cannot rotate only, it is that the 2nd planetary
gear rotates along the 2nd gear ring while revolving
around the 2nd sun gear.
At this moment, the rotation force of the 2nd sun gear
drives the 2nd planetary carrier (integrated with the
1st and 3rd planetary carrier) to rotate, however as
the 2nd planetary gear used for reversing is in
between, the rotation direction of the 2nd planetary
carrier is different with that of the forward 1st speed
but opposite to that of the 2nd sun gear.
3-22
1.6 Chassis hydraulic system
1.6 Chassis hydraulic system
2 3 4
7
8
9
LGB32003024
LGB32003025 LGB32003026
1. Oil cooler 4. Transmission control valve 7. Safety valve

2. Transfer case and torque converter 5. Steering valve as 8. Secondary filter
3. Gear shift pump 6. Coarse filter 9. Steering pump
Chassis hydraulic system mainly includes steering brake lines, lubrication lines and shift lines. Main compo-
nents include cooler (1), gear shift pump (3), gearbox control valve (4), steering pump (9), primary filter (6),
secondary filter (8), steering valve as (5), safety valve (7), etc.
3-23
1.7 Hydraulic torque converter lines
1.7 Hydraulic torque converter lines
9
2
7
Part A amplification
6
1
3
5,12
10
LGB32003027
1. Oil cooler 4. Transmission control valve 7. Safety valve

2. Transfer case and torque converter 5. Steering valve as 8. Secondary filter
3. Gear shift pump 6. Coarse filter 9. Steering pump
Main components of torque converter lines system The oil flow passing through this valve is introduced
are primary filter (1), gear shift pump (2), secondary into the circulation system of torque converter. The oil
filter (3), gearbox control valve (4), torque converter is then introduced into the torque converter counter-
relief valve (5), torque converter (6), torque converter balance valve (7) from the torque converter.
counterbalance valve (7), oil cooler (8), gearbox lubri-
The pressure of counterbalance valve is set as
cation valve (9) and torque converter scavenge pump
0.45±0.05MPa, and the internal pressure of torque
(10).
converter is maintained at this oil valve. The oil with a
The oil in steering case is pumped to the gear shift pressure of 0.45±0.05MPa provided by the counter-
pump (2) by the primary filter (1), and supplied to the balance valve, after being cooled by oil cooler (8), is
gearbox control valve (4) through secondary filter (3). introduced into the torque converter lubrication valve
The shift valve is divided into pressure regulator and (9). The lubrication valve, with a set pressure of
torque converter relief valve. The pressure of oil flow 0.15MPa, supplies oil to all lubrication components of
is reduced to 2MPA by the pressure regulator, and the gearbox. The released oil from the valve flows
then the oil flow is supplied to the torque converter back to the steering case. The oil flow applied to lubri-
relief valve (5). cate torque converter (6) or exuding from each
shrinkable surface of torque converter flows back to
The pressure of torque converter relief valve is set at
the steering case through scavenge pump (10).
0.7±0.01MPa, and this relief valve controls the pres-
sure of oil which is transferred to the torque converter.
3-24
1.8 Gearbox control valve

2 3 4 5 6 7 8 9 1. Block cover
1
2. Pressure regulator spring (small)
3. Spring holder
10
4. Pressure regulating socket spring
11 5. Pressure regulator spring
6. Pressure regulating valve
7. Piston valve (A)
12 8. Pressure regulating valve
13 9. Piston valve
14 10.Cover
20
11. Limiter
15
19 12. Piston valve spring
13.Quick return valve
14.Quick return valve spring
18
15.Piston
17 16
16.Pressure reducing valve
To A To B LGB32003028
17.Pressure reducing valve spring
18. Limiter
21 22 23 24 19.Control valve body (A)
20. Limiter
21. Limiter
25 26 27 22.Safety valve spring
23.Steering control sliding valve
24.Control valve body (B)
25.Safety valve
26.Piston
27.Cover
28.Speed valve slide valve
1 To 1st speed clutch (NO.5)
2 To 2nd speed clutches (No.4)
3 To 3rd speed clutch (NO.3)
4 To forward clutch (No.1)
From A From B
28 5 To reverse clutch (NO.2)
LGB32003029
3-25
Rise of hydraulic pressure
Pressure regulating time
Set pressure value 2MPa
Pressure
δMPaε
Gear shift lever (engaged) Time

LGB32003030
What is shown in the above figure is the relationship

between pressure rise of pressure regulator and time
lapse.
Regulating relief valve
2 5
From oil pump 12 The regulating relief valve consists of pressure regula-
tor (6), pistons (7) and (9), piston spring (12), pressure
regulating socket (8), valve springs (2) and (5) and
socket spring (4), and it can realize the pressure regu-
lating function and the relief function of main oil way
with quick-return valve (13).
4 6 8 To quick-return valve 7 9
LGB32003031
3-26
Operate the speed valve (28) and steering slide valve

From oil pump
(23), open the oil way coming from the free pump, the
h
a oil pump can fill the clearance of the clutch piston with
oil, and at the same time, the hydraulic pressure
increases.
6 8 7 9
To quick-return valve
LGB32003032
The pressure oil coming from oil pump flows to the gap
From oil pump between two pistons (7) and (8) through the small hole
a of the pressure regulator (6), pull the pressure regu-
lator to the left to open the oil port between the pres-
a sure regulator and pressure regulating socket (8).
6 8 7 9
To quick-return valve
LGB32003033
On the other hand, the pressure oil from the small hole
From oil pump b of quick-return valve (13) pushes the quick-return
valve to the left, that is to close counterbalance relief oil
port c of pressure regulating socket.
The pressure oil passing through the center oil port of
quick-return valve, after flowing by the small hole d can
become the back pressure of the pressure regulating
socket.
c
b
d
13
LGB32003034
3-27
b
LGB32003035
As the pressure in the circuit rises, the oil pressure in

To hydraulic From oil
torque converter pump the pressure regulating socket rises, when the pres-
sure regulating socket moves to the left, then the oil
port h of pressure regulator will be closed if the pres-
sure regulating socket reaches it, therefore, the pres-
sure regulating can also moves to the left, and the
hydraulic pressure can rise accordingly until the limiter
(1) on the left blocks the pressure regulating socket.
The pressure oil from the oil pump, after passing pres-
sure regulator and pressure regulating socket, flows to
the torque converter from the oil port to increase the
1
pressure in the circuit.
To quick-return valve The pressure is set to 2MPa at this time.
LGB32003036
3-28
1.9 Safety valve
1.9 Safety valve

Safety valve (25) is installed in the middle of oil way from the speed valve (28) to directional control valve (23).
The function of safety valve is: when the gear shift lever is turn into speed gear, even if the engine is started,
the vehicle cannot be started.
If the vehicle is required to be started, turn the gear shift lever to neutrality, and then operate the vehicle in
order to reach the purpose.
When the gear shift lever is turned into neutrality,
The pressure oil coming from the pressure reducing
To the steering control valve 25 valve (16), through the speed valve and small hole e,
f push the safety valve to the left so as to connect the
circuit from pressure reducing valve to the speed valve
e and to the directional control valve.
From A From B
LGB32003037
When the gear shift lever is turned to any gear

The pressure oil from the pressure reducing valve
flows to the directional control valve through speed
To the steering control valve f valve.
26
When the speed valve has been moved at any gear,
e the oil on the right of safety valve can be released into
the housing through the small hole e, but the oil pass-
ing through the small hole f of safety valve push the
piston (26) to the right, so even if the direction of safety
Discharge
valve is not changed, the circuit to the directional con-

trol valve can be connected.
28
LGB32003038
3-29
1.9 Safety valve
Engage the gear shift lever to a gear position

When starting the engine, the gear shift lever is
engaged, the circuit from pressure reducing valve to
small hole e is disconnected, so under such condition,
To the steering control valve f
even if the engine is started, the pressure oil cannot
push the safety valve to the left, the circuit from pres-
e sure reducing valve to the directional control valve is
still disconnected, so the vehicle cannot be started.
If the vehicle is required to be started, operate the
valve (turn it to the neutrality) firstly in accordance with
the description in item A, and then engage the shift
gear lever to the required gear.
LGB32003039
3-30
1.10 Pressure reducing valve

Pressure reducing valve (16) is installed in the oil way
9
from pressure regulator (6) to speed valve (28), and its
function is to reduce the hydraulic pressure added by
1st gear clutch to 1.25MPa. All pressure in the circuit is
set to 2MPa by pressure regulator, only when the pres-
sure of 1st gear clutch circuit is 1.25MPa, the circuit
can be closed.
The pressure of circuit of 1st gear clutch increases
constantly, and the pressure oil passing through the
small hole g on the pressure reducing valve can push
16 15 the piston (15) to the right so as to move the pressure
reducing valve to the left.
To A To B LGB32003040
If the pressure of 1st gear clutch increases further, the

9
pressure reducing valve can move to the left com-
pletely, close the oil port of the circuit from the pump to
1st gear, so the oil pressure of 1st gear clutch can be
maintained at 1.25MPa.
At neutrality, the engine can move together, so the
pressure generated by the oil pump can operate on 1st
gear clutch.
.This mechanism can shorten the time to fill the oil into
the cylinder fully at the time of starting.
LGB32003041
When the gear shift lever is changed into the 1st

forward gear clutch, it only requires that the oil to cylin-
der F supplied by the oil pump can reach the aim.
While shift gears of F1 and F2, because the cylinder F
is full, the oil pump 2 is only required to change supply
oil to gear-2 cylinder. Therefore, the pressure regulat-
ing function can be finished in short period of time.
Hydraulic pressure shall be always added on the 1st
gear clutch, the reasons include: for the position of 1st
gear clutch, its distance to the control valve is too far,
the length of oil-way from valve to the cylinder is the
longest, so it requires too much time to fill the oil-way
with oil, therefore, the oil-way must be filled with oil in
LGB32003042 advance to shorten the time of pressure regulation.
3-31
Relief valve used for lubrication
1 2 3 4
From the oil cooler
B 7
To steering case 10
B
9
5
8 Lubrication
6 Lubrication Profile B-B

Profile A-A
A
LGB32003043
1. Valve body 5. Lubrication valve 9. Socket

2. Cover 6. Cover 10. Packing piece
3. Valve tube 7. O-ring
4. Valve spring 8. Socket
3-32
1.11 Hydraulic torque shift control system
8 9
#3 Clutch
(3rd)
#1 Clutch #2 Clutch #4 Clutch #5 Clutch

(forward) (reverse) (2nd)
(1st)
7
5
11 C
10
4 D
13
B
12
Water
From the steering

circulation system 16
14
18
21 17
3
From the steering

circulation system
2
20 15
A
19
To steering
circulation system
22
LGB32003044
3-33
4
A
Setting pressure 2MPa
From steering control valve
6 Setting pressure
1.25MPa
1 2 3
7
# 5 clutch (1st speed)
# 4 Clutch (2nd speed)
# 3 Clutch (3th speed)
9
F
8 B
R #2 Clutch (reverse)
#1 Clutch (forward)12 11
21
D
C
Setting pressure
13 0.45MPa
From the steering 10
circulation system
Setting pressure
3 0.87MPa
M Opening pressure
0.124MPa
Setting pressure 14 18
A 0.124MPa
To steering
circulation system 16
15
FAL045 2 17
19
93 liter/min
2030 rpm
Setting pressure
1
0.13MPa
20 20
22 22
LGB32003045
1. Strainer 12.Counterbalance valve A. Plug (PT1/8) used to gearbox

2. Gear shift pump 13.Oil cooler clutch pressure
3. Oil filter 14.Transmission lubrication valve B. Plug (PT1/8) used for pressure
4. Pressure regulating valve 15.Transmission lubrication reduction
5. Rapid return valve 16.P.T.O lubrication C. Plug (PT1/8) used for backpres-
6. Pressure reducing valve 17.Hydraulic torque converter housing sure
7. Speed valve 18.Scavenge pump D. Oil temp gauge
8. Direction valve 19.Brake lubrication valve
9. Safety valve 20.Brake lubrication
10.Relief valve of hydraulic torque converter 21.Servo valve
11.Hydraulic torque converter 22.Steering case
3-34
1.12 Steering hydraulic control

Steering control valve
1
B B
A A
16 Profile B-B
1 2 3 4 5 6 7 8 9 10 11
2 26
25
2
24
23
22 21 20 19 18 17 16 15 14 13 12
Profile A-A
LGB32003046
1. Valve body 10. Return spring 19. Return spring

2. Rod 11. Plug 20. Guiding device
3. Shaft 12. Plug 21. Adjusting bolt
4. Spring 13. Return spring 22. Rod
5. Stopper 14. Piston 23. Stopper
6. Regulating spring 15. Brake valve 24. Return spring
7. Stopper 16. Valve body 25. Stopper
8. Steering valve 17. Shaft 26. Space washer
9. Piston 18. Regulating spring
3-35
Function
To the torque converter circulatory system Bleeder
1. When the steering valve and brake valve are in the
1 27 neutral position:
The oil from the steering pump enter the port A and D
of main pressure reducing valve (27) and steering con-
trol valve.
Because the circulation system to the steering clutch
From steering pump To the braking air valve
and brake booster is closed, only the oil pressure in the

circulation system rises. Because of this result, the
main pressure reducing valve (27) is open, and the oil
flows to the circulation system of torque converter.
To steering clutch If the steering lever on the driver's seat is not operated,
the oil shall be released continually to make the clutch
To the brake pressure booster LGB32003047
actuate and release the brake. The oil pressure in the
circulation system is 2.2MPa.
2. When the oil pressure in the steering valve begins
to rise:
While pulling the steering linkage, the rod (22) pushes
22 3 4 6 8 9 the shaft (3) in the arrow direction →, so as to com-
From the pump press the spring. The counter-acting force of the com-
a
pressed spring (6) shall push and press the steering
valve (8) in the arrow direction →, so as to close the
circulation between port B and G. At the meantime, if
the passage between port A and B shall be open, and
G then the oil can flows to the steering clutch.
B If the circulation system from the pump and clutch is
To steering clutch fully filled with oil, the oil pressure will rise again.
LGB32003048
The oil entering port C through the small port "a"
pushes the piston (9), and the counter-acting force will
push back the steering valve (8) in the arrow direction
←, and then compresses the spring (6) and close the
passage between port A and B.
22 3 4 6 8 9 In this state, the oil pressure in circulation system from
a
From the pump
port B to clutch and the installation load of spring (6)
keep the oil pressure in constant balance. While the
steering linkage is pulled further, the installation load of
the spring (6) will increase gradually, so as to increase
C
the oil pressure in circulation system from port B.
Therefore, the clutch starts the actuating function of
some parts.
B
To steering clutch
LGB32003049
3-36
3. While the oil pressure of steering valve increase to

the greatest level:
While the steering linkage is pulled in accordance with
22 3 4 5 6 From the the description in section 2, the stopper (7) contacts
pump a 8
steering valve (8), and spring (6) reaches the lowest
installation height. Under such condition, the shaft (3)
starts to push the steering valve (8) through spring (4),
so the required force to operate the steering valve
increases.
While the steering linkage is pulled further, the shaft (3)
G
compresses the spring (4), so as to increase the instal-
7
lation load and the oil pressure in circulation system
B
To steering case from the rear part of port B.
LGB32003050
If the installation load of spring (4) reaches the maxi-
mum, the oil pressure in the circulation system reaches
1.6MPa, the regulation of steering valve stops and the
clutch is released.
3 4 5 To pump
8
B
To steering clutch
LGB320030051
3-37
4. When the oil pressure of the brake valve begins to

rise:

From the steering valve Pull the steering linkage in accordance with the
description of section 3, and regulate the bolt (21) to
E b D
move the shaft (17) in the arrow direction →, and then
push the brake valve (15). The circuit between port E
and H is closed, and the circuit between port D and E is
open, so the oil flow to the brake booster. In the other
direction, the oil entering port F by passing through
small port "b" push the piston (14). The counter-acting

force will push back the brake valve (15) in the arrow
H
F direction to compress the spring (18) and close the
21 17 To the brake 15
pressure booster passage between ports D and E. Under such condition,
LGB32003052
the oil pressure in circulation system from port E to
booster will be in balance with the installation load of
spring (18), so as to maintain the oil pressure on a con-
stant level.
In such condition, when the steering linkage is pulled
further, the installation load of spring (18) increases,
the oil pressure on the rear part of port E begins to
increase and the brake begins to actuate.

From the steering valve

E b
D

H F
18 15 14
To the brake pressure booster

LGB32003053
3-38
5. When the oil pressure of the brake valve rises to

the maximum level:
Pull the steering linkage to the end of its stroke, so the
23 25 3
From the
pump B shaft (3) will move in the arrow direction → until it con-
A tacts the stoppers (23) and (25). The steering valve (8)
does not move further. The regulating bolt (20) moves
the shaft (17) in the arrow direction and pushes the
brake valve (15). Even the shaft (3) reaches the end of
B
the stroke, and shaft (17) still does not reach the end of
D
E the stroke, the oil entering port F will push piston (14)
To steering clutch
through the small hole "b" of brake valve (15). The
21 17 18 b 15 14 counter-acting force will push back the stopper valve
To the brake pressure booster (15) in the arrow direction to compress the spring (18)
LGB32003054
and close the circuit between port D and E. Under such
condition, the oil pressure in circulation system from
port E to booster will keep balance with the tension of
the spring (18), reach the maximum installation load
and keep the oil pressure on a constant level, and the
From the steering valve operation of brake ends here.
E b
Under such condition, the oil pressure in the rear part
of port E is 1.69MPa.
H
To the brake
17 18 pressure booster15 14
LGB32003055
6. When the steering and brake valve are in the

neutral position:
While releasing the steering rod, the tension of each
3 From the pump 8 spring returns the shaft (3), shaft (17), brake valve (15)
A
and steering valve (8) in the arrow direction ←.
Then, the steering valve (8) closes the passage
between port A and B, and opens the passage
G between port B and G, so the oil in the steering circula-
D To the steering box tion system will be released to the steering case
From the steering clutch through port G. The brake valve (15) closes the pas-
H sage between port D and E and opens the passage
From re booste
pres steering
To th
box
between port E and H, so the oil in the brake booster

su
the b
e
17 E 15
will be released to the steering case through port H.
rake
LGB32003056
r
3-39
Steering control hydraulic piping system
1
Z
A 3
B 6
C
D 2
Z-direction
LGB32003057
1. Magnetic strainer (primary filter) Overview

2. Steering pump (FAR100)
3. Steering oil filter The oil in the steering case can flow to the gear steer-
4. Steering relief valve ing pump (2) through the magnetic filter (1), and this
5. Control valve pump transfer the oil to the steering control valve,
A. Right clutch pressure measurement port (PT1/8) brake booster and relief valve (4) through oil filter (3).
B. Left clutch pressure measuring point(PT1/8)
C. Right pressure measurement port of brake assistor (PT1/8) The oil flows to the torque converter from the steering
D. Right pressure measurement port of brake assistor (PT1/8) relief valve (setting pressure 2.2MPa).
When the corresponding steering linkage is pulled to
the “1st level”, the oil flows from steering control valve
(5) to each steering clutch which loosened the steer-
ing control valve. When the steering linkage is pulled
to the “2nd level”, the oil flows to the corresponding
brake booster and operates the steering brake.
No matter the steering is operating or not, when the
brake is stepped, the steering brake can be actuated
by the oil transferred to the brake booster.
3-40
Steering mechanism hydraulic control
5 5
5a 5a
To the torque converter

circulation system
5b 5b
7 7
8
3
9
A
2
1 6 6
To the gear shift

circulation system
LGB32003058
3-41
Steering hydraulic circulation system
5a 5b
Off On On Off
5a
Off On 5b On Off
8
Setting
pressure 4 D E
2.2MPa
To the torque
converter
circulation system
To the servo valve
7 7
Opening pressure
0.121MPa
3
2 B
FAR100
172.5 liter/min
Engine speed at 2000rpm
To the gear shift
1 circulation system 6
6
LGB32003059
1. Coarse filter 5a.Steering valve A. Steering pressure regulating and mea-

2. Steering pump 5b.Brake valve suring point
3. Secondary filter 6. Steering clutch B. Left clutch pressure measuring point
4. Steering relief valve 7. Brake booster C. Right clutch pressure measuring point
5. Steering brake control valve 8. Steering case D. Left clutch pressure measuring point
E. Right clutch pressure measuring point
3-42
Brake lubrication
Forced brake lubrication circuit
From oil cooler
To the brake lubrication From the servo valve
From oil cooler

To steering case
3 4 5 6 7
LGB32003060
1. Check valve gp 4. Tripping ball 7. O-ring

2. Oil separator module 5. Spring
3. Pipe 6. Flange
3-43
1.13 Cross shaft and steering clutch
1 2 3 4 5 6 7 8 9 10
13 12 11
LGB32003061
1. External drum (brake drum) 6. Piston 11. Big spring

2. Cover 7. Hub 12. Small spring
3. Inner disc (11 pieces on 1 side) 8. Bearing seat 13. Bushing
4. Friction plate (12 pieces on 1 side) 9. Horizontal axis
5. Internal drum (clutch drum) 10. Spiral bevel gear (49 teeth)
3-44
Overview
1. Cross shaft
Cross shaft installation device can transfer the power
from engine → torque converter (or main clutch) →
gearbox, engage the cross shaft with the cone pinion
on the rear of gearbox output shaft and the spiral
bevel gear (10), and make it transfer and reduce the
speed on the left and right direction.
On the small bevel gear and spiral bevel gear, use
spiral bevel gear, and on the cross shaft (9), insert the
regulating gasket in the steering case through bear-
ing support (8), so as to assemble the cone roller
bearing. On cross shaft and bearing support, the oil
port used by the steering clutch operation is cut.
Adopts splash lubrication manner.
For the regulation of the backlash and tooth contact
of bevel gear and spiral bevel gear, add or reduce the
gasket on the mounting surface of bevel gear bearing
pedestal on the gearbox side to regulate them on the
front and back direction, add and reduce the gasket
on the left and right of the cross shaft bearing mount-
ing surface to regulate them in the left and right direc-
tion, refer to the item "Installation of cross shaft and
spiral bevel gear" in section 23 for more details.
2. Steering clutch
In order to change the driving direction of vehicle,
install steering clutch on the left and right ends of
cross shaft, so as to connect and disconnect the
power from the cross shaft to the gearing to change
the driving direction of the vehicle.
What TY320B bulldozer used is wet-type, multi-disc,
and spring pressuring type steering clutch.
The formation of steering clutch includes: on the hub
(7) fixed on the cross shaft (9) with cone bearing, the
inner drum (5) fixed with bolt, outer drum (1) fixed on
the flange on the final driving first pinion, the inner
disc (3) engaged with the inner drum, fiction blade (4)
engaged with the outer disc, pressure plate (2) press-
ing the inner disc and friction plate, piston, clutch
springs (12) and (13), and piston and pressure plate
fixed by bolts.
The pressure plate of steering clutch is the driving
side and friction plate is the driven side.
3-45
Left steering clutch (engaged)

Under the pressure of small spring (24), and large
26 17 18 19
spring (25), the clutch presses the inner disc (18), fric-
tion plate (17) and inner drum (19) by the pressure
plate (26), and transfer the power from the inner drum
to the outer drum.
24
25 LGB32003062
Left steering clutch (disconnected)

When pulling the steering rod, the pressure oil coming
17 21 14
18 from the steering control valve flows to the right side of
piston (21) by passing through the bearing support (14)
and hub (4), pushes the piston to the left, compresses
the small spring (24) and big spring (25), pushes the
pressure plate (26) to left, and then releases the inner
disc (18) and friction plate (17), so as to disconnect the
power transfer to the final drive.
When releasing the steering rod, the oil drainage loop
of the steering control valve is open, and the big and
small springs can push the piston back to the original
position to make the posit the clutch on [connection]
position. If the left steering clutch is cut, the power can
25 24 4 LGB32003063 be transferred by the right steering clutch so the vehi-
cle swerves to the left.
3-46
1.14 Steering brake
1.14 Steering brake
13 12 11 10 9 8 7 6 5 4 3 2 1
14
23
15 22
16 21
17 20
19
18
LGB32003064
1. Brake cover 9. End cover 17. Linkage

2. Bucket lever 10. Screw 18. Trail cover
3. Rod 11. Return spring 19. Brake liner band
4. Spring 12. Cap 20. Brake band
5. Shaft 13. Adjusting bolt 21. Spring
6. Valve body 14. Bracket 22. Shaft bushing
7. Piston 15. Rod 23. Spring seat
8. Rod 16. Agglutination
3-47
1.14 Steering brake
LGB32003065
The steering brake is an oil-bath, bracket type and brake, once the middle of the overlapping part of left
contraction band type brake, and it can crimple the and right brake pedal is stepped and locked by the
external periphery of the brake drum. brake lock, so it can maintain the braking state of the
pedal.
Each steering brake has two functions: one is the
function of steering brake, so it can link to the steer-
ing rod; the other one is to carry out pedal brake for
the vehicle during the driving.
The steering brake can also be used as parking
3-48
1.14 Steering brake
Operation of hydraulic brake booster

1. The brake pedal is not stepped and the steering rod
Steering pump
Torque converter
is not pulled (the brake is not operated).
25
For the oil flow from the steering pump, one stream
flows to port A through the steering brake valve, and
the other stream flows to the port B directly without
B passing through any steering valve.
A If the steering rod is not pulled and the valve (25) does
not move, the oil fluid cannot flow to port B but only
flow to port B. Then the oil fluid of port B flows to port C
by passing through the small hole. But if the brake
pedal is not stepped, the oil on port C and port D is
connected. At this time, the pressure of oil flowing to
the brake system increases, when the oil pressure
D C LGB32003066 exceeds the setting pressure of the pressure reducing
valve, the oil will flow to the torque converter system by
passing the pressure reducing valve, and the pressure
of steering brake system can be maintained at 2.2MPa.
2. When pulling the steering rod (operate the brake).
8 Brake valve Steering pump Open the brake valve (25), and the pressure oil flows to
7
port A, so the oil from port A presses the piston (7) to
the left. Rod (8) moves, and pushes the brake to make
the brake bands hold tightly. The pressure on this point
is 1.67MPa.
LGB32003067
3. When the brake pedal is stepped (operate the

brake).
When the brake pedal is stepped slightly, the lever (2)
pushes the shaft (5) to the left, and at this time port C
and port D are connected. The oil from the pump flows
to ports C and D by passing through port B and small
hole (a).
LGB32003068
3-49
1.14 Steering brake
When the pressure of port D increases, the oil pressure

B 5 2
Brake valve Steering pump pushes the piston (7) to the left, and connects port D
and port A. The oil fluid will be released to steering
case from port A. In order to make piston moves con-
tinuously, the brake pedal must be stepped continu-
ously and the above mentioned process must be
repeated.
A D C LGB32003069
B
Steering Shaft (5) is pushed to the left further, and the oil of port
pump 5 2
Brake valve
B and port D is connected. The oil flow to port D
increases, and it quickens the movement of piston (7).
7
When the piston (7) pushes the rod (8) continuously,
the brake band shrinks and the brake works.
Under such condition, the hydraulic pressure increases
in two levels. Firstly, the oil flow pushes the piston (7)
slightly so there is a buffer when the brake is stepped,
and when the oil flows on port D and port B are con-
nected, large quantity of hydraulic oil pushes the pis-
7
ton. Therefore the sharp operation of brake can be
avoided.
4. When the brake pedal is stepped to the end (the
A D C LGB32003070
brake is operated).
When the brake pedal reaches the end of its stroke, the
oil flows on port D and port A keeps on shutoff condi-
tion, and the oil pressure increases further. When the
hydraulic pressure reaches 2.2MPa, the main pressure
reducing valve works, and the oil fluid flows to the
torque converter.
3-50
1.15 Final drive
1.15 Final drive

5 4 3 2 1
6
7
8
9
10
11
12
13
14 15 16 17 18 19 LGB32003071
1. Flange 8. Gear hub 15. Floating oil seal

2. Bearing seat 9. Sprocket hub 16. Cap
3. Pinion (12 teeth) 10. Nut 17. Guard plate
4. Gear (45 teeth) 11. Floating oil seal 18. Outer housing
5. Pinion (12 teeth) 12. Bracket 19. Half shaft
6. Gear (55 teeth) 13. Cap
7. Tooth pieces 14. Cap
Power transmission
• Shaft outer drum → flange (1) → pinion (3) → gear (4) → pinion (5) → gear (6) → gear hub (7) → chain
wheel hub (9) → tooth pieces (8) → track
3-51
1.16 Operation of power train system

Shift control
LGB32003072
1. Gear lever 2. Shift lock rod 3. Shift valve

3-52
Steering brake operation
2
1
LGB32003073
1. Brake pedal 3. Steering control rod 5. Brake valve

2. Brake lock rod 4. Steering valve
3-53
2. Inspection and adjustment
2.1 Overview

2.1 Overview
The introduction of test and adjustment methods here is to find out the obstruction and repaired condition of
power train system. In addition, if oil pressure circuit needs to be measured, please use oil pressure measuring
tool.
In any case, the vehicle must be subject to "Check by Eye" at first, then "Check after Start", and test by “Mea-
suring Instruments” at last.
Check by eye
1. Check of oil level and oil temperature
(1) Gearbox
(2) Steering case
(3) Final drive
2. Check of oil leakage and damage
Check exposed oil line systems, joints and exposed lines for oil leakage and damage.
3. Confirmation of adjusted value
(1) Check the gearbox, gearbox control linkage device, and steering and brake control linkage device for
damage or poor adjustment.
(2) Check the track for proper tension.
4. Confirmation of oil pollution, blocked mesh, inclusions, etc.
Please refer to the following items to check the gearbox and steering oil filter element and oil filter for inclu-
sions.
a. If iron power or copper power is attached, this is as a result of obstruction in gearbox.
b. If coppery metal power is mixed, this is as a result of obstruction in steering clutch.
c. If there are lustrous metal sheets in the filter or element, this is as a result of damage to steering pump.
d. If there is aluminum power in the filter or element, this is as a result of obstruction in torque converter.
e. If there are rubber pieces in the filter or element, this is as a result of damage to seal ring or hose.
If there are metal or rubber pieces, clean all parts of the hydraulic system and repair damaged parts.
Check after start
Start the engine, and try to set the shift control lever to each position of gearbox; at the moment, each position
shall correspond correctly. Drive at full speed level in every direction, and confirm whether the fuel speed level
is normal.
3-54
2.1 Overview
2.2 List of oil pressure measurement items

Set oil pressure (MPa)
Oil
Size of
temperatur Low-speed
Measurement measurin Engine all
Category e during of engine Remarks
items g plug speed Rpm
measuring Rpm
gauge
°C Revolve
Revolve
2150
600
Hydraulic
torque
0.7~0.9
converter relief
pressure (inlet) Place the shift lever
Hydraulic PT1/8 on the neutral
70~80
torque position
converter 0.3~0.5 0.2~0.3
Hydraulic regulator
pressure pressure
of Place the shift lever
hydraulic Transmission
1.9~2.5 1.7~2.2 on the neutral
torque clutch pressure
position
converter
It is unnecessary to
measure normally,
PT1/8 45~-55 and insert the
Gearbox
connector for
lubrication relief 0.15
measurement into
pressure
the oil line for
measurement in
case of fault.
Pull left steering
lever to measure the
oil pressure when
the left clutch is
Steering clutch disengaged, and pull
1.4~1.9 1.4~1.9
Steering pressure right steering lever to
hydraulic PT1/8 45~-55 measure the oil
pressure pressure when the
right clutch is
disengaged.
Brake relief
1.6~2.0 1.6~2.0
pressure
3-55
2.2 Oil pressure and oil temperature measuring tools
2.2 Oil pressure and oil temperature measuring tools

Hydraulic tester
Oil temperature tester
2.3 Measurement skills of oil pressure and oil temperature
1. Measure the system pressure of the gearbox
1) Prepare oil pressure gauge
2) After the engine stops, dismantle the focus
pressure measuring plate, remove the cock (P) and
then install the pressure gauge. (4MPa)
LB
RC RB LC OUT P
IN
LGB32003074
3) Measure oil pressure

Turn the gear shift to (neutral position), and then
start the engine, and measure it with the low speed
and full speed rotation of engine.
RC • Oil temperature during measuring: 70-80 ℃
1 2
• The parking brake must be locked.
0 3
OU
L T
P
LGB32003075
3-56
2. Measure the inlet pressure of torque converter.

1 2 pressure measuring plate, remove the cock (IN)
0 3 and then install the pressure gauge. (4MPa)
L
LB
IN
OU
T
P
LGB32003076

RB
LC
LB • The parking brake must be locked.
IN
OU
T
P
LGB32003077
3. Measure the outlet pressure of torque converter.

pressure measuring cover, remove the cock (OUT)
and then install the pressure gauge (4MPa)
RC
RB
LC
LB
IN
OU
T
P
LGB32003078
3-57

1 2
0 3
L
• Oil temperature during measuring: 70-80 ℃
LC
LB
IN
OUT
P
LGB32003079
4. Measure the pressure of right steering clutches

pressure measuring cover, remove the cock (RC)
RC and then install the pressure gauge (4MPa).
RB
LC
LB
IN
OUT
P
LGB32003080

start the engine, pull the right steering rod to
separate or connect it, and then measure it with the
low speed and full speed rotation of engine.
RC
RB • Oil temperature during measuring: 70-80 ℃
LC
LB
IN • The parking brake must be locked.
1 2 OUT
P
0 3
LGB32003081
3-58
5. Measure the brake pressure of the right clutch.

pressure measuring cover, remove the cock (RB)
LB and then install the pressure gauge (4MPa).
RC RB LC OUT P
IN
LGB32003082

start the engine, pull the right steering rod to the
1 2
brake position, and then measure it with the low

0
3
speed and full speed rotation of engine.

L

RB • The parking brake must be locked.
LB
IN
OUT
P
LGB32003083
6. Measure the pressure of the left clutch.

pressure measuring cover, remove the cock (LC)
RC and then install the pressure gauge (4MPa)
RB
LC
LB
IN
OUT
P
LGB32003084
3-59

start the engine, pull the left steering rod to
1 2 separate or connect it, and then measure it with the
3
low speed and full speed rotation of engine.
0
L
LC • The parking brake must be locked.
LB
IN
OUT
P
LGB32003085
7. Measure the brake pressure of the left clutch.

pressure measuring cover, remove the cock (LB)
RC and then install the pressure gauge (4MPa)
RB
LC
LB
IN
OUT
P
LGB32003086

1 2 start the engine, pull the left steering rod to the
0 3 brake position, and then measure it with the low
L
speed and full speed rotation of engine.
RB • Oil temperature during measuring: 70-80 ℃
LC
LB • The parking brake must be locked.
IN
OUT
P
LGB32003087
3-60
8. Measure the speed-1 clutch pressure of hydraulic

gear box.
2) After the engine stops, dismantle the floor cover
and the gearbox valve cap, remove the cock and
then install the pressure gauge (4MPa)
LGB32003088

• Allow the vehicle to touch the ground, and lock the
parking brake. Turn the gear shift lever to (neutral
position), start the engine, change the gear shift
lever to forward or back 1st gear position and then
3
measure the pressure.
2
1 • If the engine runs at full speed, the vehicle may
move, so please be careful.
• Oil temperature during measuring: 70-80 ℃
LGB32003089
9. The measuring steps of the control force on each

parts.
1) Gearbox control lever
• After the engine stops, hang a draw-bar dynamom-
eter on the control lever knob.
• Draw out the draw-bar dynamometer, and measure
the force required to move the control lever to each
3
2
gear.
N
3
2
1
N
LGB32003090
3-61
2) Steering control lever

• Turn the gear shift to (neutral position), then start
the engine, run the engine at low speed, and buckle
the draw-bar dynamometer on the knob.
• Pull the draw-bar dynamometer towards yourself,
pull the control lever to clutch disengagement posi-
tion, and measure the control force at the moment.
• Pull the draw-bar dynamometer towards yourself
3
2
1
N
again, pull the control lever to brake enabling posi-
tion, and measure the control force at the moment.
3
2
1
N
LGB32003091
3) Foot brake pedal

• Set the shift control lever to (neutral position), then
start the engine, and run the engine at 1,000 rpm.
• Put the draw-bar dynamometer in the middle of
pedal, set the shift control lever to 1st gear, press
the pedal, then keep the engine stopped or stalled
with single brake, and measure the control force at
the moment.
LGB32003092
4) Fuel control lever

start the engine, and buckle the draw-bar dyna-
mometer on the knob.
• Measure the control force from slow speed to full
speed at 1/2~2/3 of full stroke.
• Measure the control force from full speed to slow
speed and at the time of stop.
3
2
1
N
R
LGB32003093
3-62
5) Decelerator pedal
start the engine, pull the fuel control lever to fuel
speed, and put the draw-bar dynamometer on the
decelerator pedal.
• Press the draw-bar dynamometer, and measure
the control force of pedal.
LGB32003094
10. Measurement skills of stroke

1) Steering lever
Set the shift control lever to "N" position, then start
the engine, run the engine at low speed, put the
tape on the steering lever, then pull the steering
10 11 12 13 14 15 16 17 18 19 9 8 7 6 5 4 3 2 lever to clutch full disengagement position, and
measure the stroke at the moment.
LGB32003095
11. Pressure measuring position of each pump

1) Pressure measuring position of working pump
The pressure measuring position of working pump
is on the discharge flange of the pump, remove the
cock, install the pressure gauge, and then measure
the pressure.
LGB32003096
3-63
2) The pressure measuring position of travel pump

The pressure measuring position of travel pump is
on the discharge flange of the pump, remove the
the pressure.
LGB32003097
3) The pressure measuring position of steering pump

The pressure measuring position of steering pump
is on the discharge flange of the pump, remove the
the pressure.
LGB32003098
3-64
3. Removal and installation
3.1 Removal of the torque converter as

3.1 Removal of the torque converter as
1. Remove the bottom guard (1) with adjustable frame
①.
In order to avoid the interference between the bot-
1 tom plate and trolley splay beam, while the bracket
is lowered gradually, the bottom guard shall be
pulled forward to the car body.
1
The weight of bottom guard is 172kg.

2. Release the oil in the converter housing.
Oil mass is 149L.
LGB32003099
3 2
3. Remove the cab and floor plate gp Refer to
"Removal of the cab and floor plate gp".
4. Take apart the torque converter oil temp sensor (2).
5. Take apart the hose (3).
4 6. Take apart the pipe (4) and (5).
7. Take apart breather valve (6).
8. Remove hose (7).
8
9. Take apart steering relief valve as (8).
7 Tie up the valve with ropes and remove it.
6 5 LGB320030100
3-65
3.2 Installation of the torque converter as
10. Remove the universal joint as (9).

11. Remove the tube (10).
10
9
LGB320030101
12. Lift the torque converter (11), remove the bolt, and
drive the torque converter from the bell housing
with the removed bolt.
11
LGB320030102
3.2 Installation of the torque converter as

• Install the torque converter in the reverse sequence of removal.
• After starting the engine, the oil will flow the converter, and then check the oil level.
3-66
3.3 Disassembly of torque converter as

1. Torque converter assembly
6
1) Place the torque converter on the mounting bracket
B.
2
2) Remove the safety valve as (2).
3
3) Remove relief valve as (3).
4) Remove the filter (4).
5) Remove the dump pump (5).
1
6) Remove the coupling (6).
5
4 LGB320030103
8 2. Oil drain plug

Open the cover, remove 2 oil plugs (7), and release
the oil.
3. For the removal of fastening bolts on the impeller
and the drive housing, 30 bolts (8) shall be
removed in total.
7 LGB320030104
4. Guide sleeve
Remove the bolts and drive the guide sleeve (9) out
with two bolts.
LGB320030105
3-67
5. Drive housing and turbine as

1) Remove the plate (10).
10
LGB320030106
2) Remove the drive housing and turbine as (11) with

special sling.
11
LGB320030107
3) Disassembly of drive housing and turbine as

I) Remove the drive gear (12)
12
LGB320030108
3-68
II) Drive the turbine (13) out with bolt ② .

III) Remove the bearing (14).
14
13
LGB320030109
6. Guide wheel
15 Remove the stator (15).
7. Stator support
Remove the snap ring (16), and demount the stator
support (17).
16
17
LGB320030110
8. Impeller trailing wheel

1) Remove the impeller as (18).
18
LGB320030111
3-69
2) Disassembly of impeller gp
I) Remove the bolt (19), and remove the gear (20).
II) Remove the outer ring (21).
21
19
20
LGB320030112
9. Turbine shaft and stator shaft gp

1) Remove the lower cap (23) with the removing bolt.
2) Remove turbine shaft and stator shaft gp (22) with
the lifting bolt ③ .
23
22
LGB320030113
3) Disassembly of the turbine shaft and stator shaft

I) Remove the oil seal (24) and dust cover (25).
24
25
LGB320030114
3-70
II) Put the turbine shaft and stator shaft gp on the

33 32 pressure machine, and then remove the turbine
shaft as (26).
29 III) Remove the seal ring (28) and snap ring (29) from
the turbine shaft (27), and then remove the washer
(30), bearing (31), seat (32) and O-ring (33).
27
26
31
28
LGB320030115
IV) Remove the bearing (35) and seal ring (36) from
stator (34).
34
35
36
LGB320030116
10. Scavenge pump drive gear

1) Remove the snap ring (37), and then knock the
shaft to remove the drive gear (38) in the housing.
38
37
LGB320030117
3-71
3.4 Assembly of torque converter as
2) Remove the bearing (39)
39
LGB320030118

Apply grease (G2-L1) on the O-ring and oil seal.
1. Housing
Install and place the housing (40) on the operation
platform and then install the plug.
37
LGB320030119
2. Scavenge pump drive gear

1) Press-fit the bearing (39) with press fitting tool.
Press fitting tool
39
LGB320030120
3-72
2) Install the drive gear in the hole of bearing (39) from

the reverse side.
3) Install the snap ring (37), and then fix the drive gear
on the bearing 39.
37
LGB32003121
4) Install the scavenge pump as (5) and strainer as

(6).
37
LGB32003122
3. Turbine shaft and stator shaft as

1) Assemble the turbine shaft and stator shaft as
34 I) Install the seal ring (36) on the stator shaft (34), and
then press-fit the bearing (35) on the stator shaft
with press fitting tool.
35
36
LGB32003123
3-73
II) Install O-ring (33) and seat (32) on the shaft (27),
press-fit the bearing (31) on the shaft with press
fitting tool ⑥ .
III) Install the snap ring (29), and then install the seal
ring (28).
27 33 32 31 29 28
LGB32003124
IV) Press-fit the stator shaft as and the turbine as (26)

together with press fitting tool ⑦ .
Press fitting tool

26
LGB32003125
V) Install the dust seal (25) and then compress the oil
seal (24) with the press fitting tool.
Apply seal (LG-5) on the press fitting sur-

22
face.
VI) Fitting cover (23).
25
24
LGB32003126
3-74
2) Install the turbine shaft and stator shaft gp (22) with

the lifting bolt ③ .
Apply adhesives (LT-2) on the bolt.
 The tightening torque of bolt: 112.5±12.5Nm
23
LGB32003127
4. Impeller as
21 1) Install the impeller as
I) Press-fit the outer ring (21) with press fitting tool.
II) Install the gear (20), and then tighten the bolt (19).
20
LGB32003128

III) Install the impeller as (18).
19 18
LGB32003129
3-75
5. Stator support
Install the stator support (17), and then install the snap
ring (16).
17
6. Guide wheel
Install stator (15).
15 Apply adhesives (LT-2) on the bolt.

16
LGB32003030
7. Drive housing and turbine as

1) Assemble the drive housing and turbine as
I) Install the drive gear (12).
II) Press-fit the bearing (14) with press fitting tool.
12 13
LGB32003131
III) Press-fit the turbine (13) with press fitting tool.
13
LGB32003132
3-76
2) Install the drive housing and turbine as (11) with

special sling.
11
LGB32003133
3) Install the plate (10), and then lock the gasket.
The tightening torque of bolt: 97.5±2.5Nm

10
LGB32003134
8. Guide sleeve
Install the extraction guide sleeve (9), and then lock
the gasket.
20  The tightening torque of bolt: 112.5±2.5Nm
LGB32003135
3-77
8
9. Binder bolt between the impeller and the drive.
Tighten 30 binder bolts (8).

10. Oil drain plug
Tighten the drain plug (7) and then install the cover.
The tightening torque of drain plug:

7
17.5±2.5Nm.
LGB32003136
11. Torque converter as

6
1) Install the coupling (6).
2) Install the relief valve as (3).
2
3 3) Install the safety valve as (2).
LGB32003137
3-78
3.5 Removal of the torque converter relief valve as
3.5 Removal of the torque converter relief valve as

1. Oil inlet lines of relief valve
1 2
Disconnect the oil inlet hose (1) on the relief vale of
torque converter.
Disconnect the oil inlet hose (2) of the gear shift
valve
4 3. Breather piping
Disconnect the breather hose (3) of the relief valve.
4. Disconnect the tube between the relief valve and oil
filter.
3
5. Relief valve as
LGB32003138
Remove relief valve as (5).
3.6 Assembly of torque converter relief valve as

• Install the relief valve in the reverse sequence of
removal.
Remove of the torque converter safety valve as
1. Pressure measuring piping
Disconnect the oil inlet lines hose (1) on the relief
vale of torque converter.
2. Disconnect the tube (2) connected with the
5 regulating valve.
3. Regulating valve as
Remove the regulating valve as (3).
LGB32003139
3-79
3.7 Disassembly of torque converter relief valve as
• Installation of the torque converter safety valve as

Install the safety valve in the reverse sequence of
removal.
The cotter pin must be bent.
2
LGB32003140
3.7 Disassembly of torque converter relief valve as

1. Remove the plug and then remove the block (1). Shim (2), spring (3), and slide valve (4).
3.8 Assembly of torque converter relief valve as

1. Install the slide valve (4), spring (3), shim (2) and
1 block (1) in the valve body, install the O-ring, and
then tighten the plug.
2
LGB32003141
3.9 Disassembly of torque converter safety valve

1. Remove the plug and then remove the spring (1) and slide valve (2).
3-80
3.10 Assembly of torque converter safety valve
3.10 Assembly of torque converter safety valve

1. Install the slide valve (2) and spring (1) in the valve
body, install the O-ring and then tighten the plug.
1
LGB32003142
3.11 Disassembly of gearbox

1
1. Release the oil in the gearbox.
2. Remove the bottom guard (1) with the Jack.
In order to avoid the interference between the bot-
tom plate and trolley splay beam, while the bracket
is lowered gradually, the bottom guard shall be
pulled forward to the car body.
LGB32003143
3-81
3 5
3. Remove the cab and floor plate as, and refer to the
disassembly of the cab and floor plate.
4. 1) Divide inlet pipe (2) (hoses connected with the
work tank can be removed) and outlet hose (3) of
main oil pump. 2)Separate the pilot oil pump inlet
pipe (4) (the hose connecting with the work tank
can be removed), and the outlet hose (5).
2 4 LGB32003144
5. Remove each link and remove the bracket (6).

7 6. Remove the vertical flexible shaft (7) of the
gearbox.
6
LGB32003145
12
9
8. Remove hose
14 9. Remove the tube (10).
10
11. Remove the breather tube (12).
12. Remove relief valve as (13).
13
11 • Tie the valve with ropes and then move the valve
backward and remove it.
• Remove the counterbalance valve (14) of torque
converter.
8 LGB32003146
3-82
13. Remove the universal joint (15).
15 LGB32003147
14. Remove hose.

15. Remove the hose (17).
16. Remove the hose(18).
16
17
18
LGB32003148
17. Leave 2 or 3 bolts to tighten the gearbox as,

remove the left bolts and then remove the gearbox
(19).
• Lift it slowly during the removal and protect other
components from being bumped.
Weight of gearbox is 900kg.
19
LGB32003149
3-83
3.12 Installation of gearbox
3.12 Installation of gearbox

• Install it in the reverse sequence of removal.
• Oil filling
Tighten the drain plug on the steering case and gearbox, and refuel the oil to the allowed position after the
tightening.
After starting the engine the oil will enter the circulation system, and then check the oil level.
3.13 Disassembly of the gearbox as

Place the gearbox as (1) on the repair platform, and
then place the friction plate and gasket on the platform
to protect it from being damaged.
LGB32003150
1. Remove the cover (2).

2. Remove the cover plate (3).
3. Remove the cover as (4).
2 3 LGB32003151
3-84
4. Remove binder bolt (5), and then remove the gear

shift valve as (6) together with valve seat (7).
LGB32003152
5. Remove the bearing support as (8) with cap opener

bolt.
10
6. Remove the snap spring (9), and then remove the
bearing (10).
8 9
Cover
bolt
LGB32003153
7. Remove the binder bolts (11) and (12).

12 13 8. Remove the gearbox housing (13).
11
LGB32003154
3-85
9. Remove the plate (14).

14
10. Remove the coupling (15) with special tools.
15
LGB32003155
16
11. Remove the binder bolt and lift the bearing support
as (16) with rings
LGB32003156
12. Disassemble the bearing support as

Press fitting tool 1) Remove snap spring (17).
2) Remove bearing seat (18) with press fitting tool.
17 18
LGB32003157
3-86
20 21
3) Remove the bearing (19).
4) Remove oil seal (20), snap spring (21), and gasket
(22), and then remove bearing (23).
23
20
19 LGB32003158
13. Remove washer (24).
24
LGB32003159
14. Remove the bolt (41).

Two of the 14 bolts are short, so pay attention to
them.
41
LGB32003160
3-87
15. Lift the cylinder body (42) and piston (43) with
rings.
Stick cylinder body and piston with clips to protect
47 them from falling off.
42 16. Take out the spring (44).

43 17. Remove the first spring pad (45), friction plate (46)
and plate (47).
44
45 46
LGB32003161
18. Remove the first level big gear ring (48).

19. Remove plate (49) with rings.
48
49
LGB32003162
20. Remove spring (50) and then remove the second

level spring pad (51), friction plate (52) and plate
(53) in sequence.
50
52 51 53 LGB32003163
3-88
21. Lift the first, second and third row planet carrier as
(29), input shaft as (25) with rings.
25
29
LGB32003164
22. Disassemble the input shaft as.

28 1) Remove the first sun gear (26).
27 26
2) Remove snap spring (27).
3) Remove bearing inner race (28).
LGB32003165
23. Disassemble the first, second and third row planet

carrier as.
1) Knock out shaft (30) gently with a hammer.
• Protect the steel ball from being lost and keep them
carefully.
2) Remove the gear (31), thrust shim (32) and bearing
(33).
30
32 33 31 33 32 LGB32003166
3-89
3) Knock out the shaft (34) gently with copper

hammer.
(37).
5) Take out the snap spring (38), and then take out
plate (39).
36 37 35 37 36 34 LGB32003167
6) Take out bearing (40).
38 39
40
LGB32003168
24. Take out the second level gear ring (54).

25. Take out he guide pin (55).
55
54
LGB32003169
3-90
26. Remove the first level cylinder (56) and piston (57)
with rings.
Hold the bottom to protect plug from dropping.
57
56 LGB32003170
27. Remove spring (58) and then remove the third level
spring pad (59), friction plate (60) and plate (61) in
sequence.
60
58
59 61 LGB32003171
28. Remove the snap spring (62), and then remove the
third level gear ring.
63
62 LGB32003172
3-91
29. Lift the third and fourth cylinder body (64) and
piston (65) with rings.
Hold the bottom to protect plug from dropping.
64
65
LGB32003173
30. Remove spring (66) and then remove the fourth

level spring pad (67), friction plate (68) and plate
(69) in sequence.
69
67 66
LGB32003174
31. Remove the fourth row planetary gear ring (70).

32. Remove plate (71) with rings.
33. Remove the guide pin (72).
72
71
70
LGB32003175
3-92
34. Remove the snap spring and remove the third,

73 fourth planetary rows of sun gear (73).
LGB32003176
35. Remove the binder bolt, and then remove the fifth
clutch and housing as (74) with rings.
74
LGB32003177
36. Disassemble the second clutch and rear housing

as.
75
1) Remove cushion (75), and then remove pin (76).
76
LGB32003178
3-93
2) Remove the nut

3) Remove bearing (78) and gear (79) with special
77 tool ⑥ .
4) Remove the clutch as (80) with rings.
Knock the rear end of the shaft gently with copper
hammer, and then remove the shaft.
78
79
80
LGB32003179
5) Take out bearing (81).
81
LGB32003180
6) Remove the bearing outer ring (82) and sleeve (83)

with pushing tool.
82
83
LGB32003181
3-94
37. Disassembly of the fourth planetary row.

1) Leave two bolts on the cross and then remove the
bolt (84).
84
LGB32003182
2) Remove the binder bolt (85), and then remove the

planetary carrier as (86) with special tools.
86
The planet carrier as is fixed with six dowel pins.
LGB32003183
3) Knock the rear end of the shaft gently with copper

hammer, and then remove the shaft (87).
• Protect the steel ball from losing and keep it care-
fully
88 (90).
89
89
87 90
LGB32003184
3-95
38. Disassemble the fifth clutch as.

1) Remove the bolts left in the process (37-1).
2) Remove housing (91).
91
LGB32003185
3) Remove friction plate (92), waved spring (93) and

plate (94).
93
92
94
LGB32003186
97
LGB32003187
3-96
5) Install the press fitting tool in the position shown on

the diagram to push the disc spring and then
remove the snap spring (98).
6) Remove spring (99).
7) Remove piston (100).
99
98
100
LGB32003188
8) Remove bolt (101), and then remove shaft (103)

from the cylinder body (102).
103 101
102
LGB32003189
39. Remove binder bolt, and then remove the bevel

pinion as (104).
40. Remove the gasket (105).
• Note the dimension between housing rear end sur-
face and gear rear end surface.
• Check the thickness and quantity of the gasket.
104
105
LGB32003190
3-97
41. Disassemble the pinion as.

106 1) Remove the lock plate (106).
LGB32003191
2) Place the pinion as on device.

3) Push out the shaft with press fitting tool, and then
remove inner ring (107), distance ring (108), gear
108 107 (109), distance ring (110) and bearing as (111).
Press fitting tool
111
109
110
LGB32003192
4) Remove lower cover (112) and gasket (113).

114
112
113
LGB32003193
3-98
44. Remove the bearing (115).

45. Remove bearing cover (116).
115
116
LGB32003194
3-99
3.14 Assembly of the gearbox as

Apply grease (F2-L1) on each seal ring and then install them.
• Seal rings must be installed in correct direction.
1. Install seal ring on piston and oil cylinder body.
LGB32003195
LGB32003196
3-100
2. Press the bearing outer ring (116) with press fitting

115 116 tool.
3. Press bearing (115) with press fitting tool.
LGB32003197
4. Install bevel gear as.

1) Place the bearing support on the press machine,
and then press bearing (114) with pushing tool.
114
LGB32003198
2) Install gasket (113), install cover (112) with bolt (11)

and then lock it.
Standard gasket thickness: 0.5mm
112
113
LGB32003199
3-101
3) Place output shaft on press machine, and then

install bearing support as (111) with pushing tool.
Pushing tool
111
LGB32003200
4) Put down distance ring (110), gear (109), backup

ring (108) and bearing inner ring (107), and then
108 install them with press fitting tool (13).
107 • Remove bolt (11).
• Check clearance "a".
Clearances "a" is: 0.05~0.15mm
109
110
LGB32003201
Press fitting
LGB32003202
3-102
5) Measure the size "b" between shaft end and

bearing inner ring and step size "c" of the cover,
and then determine thickness of the gasket in
b accordance with "b-c=x".
LGB32003203
LGB32003204
6) Install gasket in accordance with the size decided

Gasket
in step 5) and then install cover (106).
The tightening torque of bolt: 60±80Nm.
• Check the clearance between cover and gasket.
The clearance is: 0.05~0.15mm.
LGB32003205
3-103
106
LGB32003206
5. Assembly of the fourth clutch as

111
1) Install shaft (103) on cylinder body (102) and then
102 lock nut (101).
111
 Tightening torque of nut: 112.5±12.5Nm
• Lock gasket must be bent.
LGB32003207
2) Install seal ring and then install piston (100).

3) Install butterfly spring (99), hold the piston with
press fitting tool ⑦ , push the spring strongly and
111 then install snap spring (98).
98
100
LGB32003208
3-104
4) Install base plate (94), spring (93) and friction plate

(92) in sequence.
92
93
94
LGB32003209
5) Install housing (91), and then install 2 or 3 bolts

temporally.
91
LGB32003210
6) Tighten the bolt (84).
Apply adhesives (LT-2) on the bolt
 Tightening torque of bolt: 110±15Nm
84
LGB32003211
3-105
6. Install the fourth planet row as.

1) Install bearing (90) in gear (88), install thrust
washer (89) on both sides of the gear, and then fix
it on the planet carrier.
2) Install steel ball, and then install the shaft (87).
88
89 • Install steel ball on shaft so as not to forget it.
90 89
87
LGB32003212
3) Install seal ring on the shaft.

4) Install planet carrier as (86) and then tighten bolt
(85).
 The tightening torque of bolt: 175±25Nm
86
85
LGB32003221
7. Assembly of the fifth clutch housing as.

1) Press sleeve (82), pin and outer ring (82) with
press fitting tool.
82
83 LGB32003213
3-106
2) Install seal ring on the shaft.

• Protect the seal ring from being bumped.
Seal ring
LGB32003214
3) Install housing (80) with rings, and then install

bearing inner ring (81).
81
80
LGB32003215
Tool 4) Install gear (79), and then tighten bolt (77) with tool.
5) Press bearing (78) with press fitting tool.
77
78
79
LGB32003216
3-107
6) Install pin (76), and then install lock pad (75).
75
76
LGB32003217
8. 1) Install oil cylinder body and clutch as (74) with

rings, tighten bolt and then install gear ring (96).
74
96
LGB32003218
2) Press-fit the bearing (97) with press fitting tool.

97
LGB32003219
3-108
3) Install snap spring (95), and install seal ring on the

shaft.
95
LGB32003220
4) Install planet carrier as (86) and then tighten bolt

(85).
86
85
LGB32003221
9. Install the third, fourth sun gear (73) and then install
73 snap spring.
LGB32003222
3-109
10. Use lift ring mounting plate (71).

Knock the position of dowel pin with plastic hammer
until there is no clearance on the junction surface.
11. Install the guide pin (72).
70 12. Install the fourth level big gear ring (70).
72
71
LGB32003223
13. Install the fourth level plate (69), friction plate (68),
spring gasket (67) in sequence, and then install
spring (66).
The removal position of each friction plate must be
aligned (4 positions on periphery).
Spring free length: 59mm.
68
67
69 66 LGB32003224
14. Install seal ring on piston (65).

15. Install the fourth level piston (65) and the third and
fourth level oil cylinder body (64) by using ring.
When installing the fourth piston, hold it by hand to
protect it from falling.
Check whether the spring is in piston hole.
Knock the position of dowel pin with plastic hammer
65 16. Add sleeve on bolt hole.
LGB32003225
3-110
17. Install the third level big gears ring (63), and then fix
62 it with snap spring (62).
63
LGB32003226
18. Install the third level plate (61), friction plate (60),
spring (58).
60
19. Install seal ring on the second level piston.
61
59 LGB320030227
20. Installation of the first, second, third planet carrier

as
1) Press-fit bearing (40) with press fitting tool.
38 2) Install plate (39), and then install snap spring (38).
39 40
LGB32003228
3-111

washer (36) on both sides of the gear, and then
install it on the planet carrier.
4) Install steel ball and then press shaft (34).
• Install steel ball on shaft so as not to forget it.
34
36 37 35 37 36 LGB32003229

washer (32) on both sides of the gear, and then
install it on the planet carrier.
6) Install steel ball and then press shaft (30).
• Install steel ball on shaft so as not to forget it.
30
32 33 31 33 32 LGB32003230
21. Install planet carrier as (29) with rings.
29
LGB32003231
3-112
22. Install the second level cylinder (56) and piston (57)
with rings.
• Check whether the spring is in piston hole.
• Knock the position of dowel pin with plastic hammer
57
56 LGB32003232
23. Install guide pin (55).

24. Install the second level big gear ring (54).
• The surface with notch must be upward.
54
55 LGB32003233
25. Install the second level plate (53), friction plate (52),
spring (50).
50
53 51 LGB32003234
3-113
26. Use lift ring mounting plate (49).

Knock the dowel pin with plastic hammer until there
48 is no clearance on the junction surface.
27. Install the first level big gear ring (48).
• The surface with notch must be upward during the
installation.
49
LGB32003235
28. Install the first level plate (47), friction plate (46),
spring gasket (45).
aligned
46
47
45
LGB32003236
29. Install spring (44).

44
LGB32003237
3-114
30. Install seal ring on the first level piston (43).

31. Install the first level cylinder body (42) and piston
(43) with rings.
• Check whether the spring is in piston hole.
• Knock it with plastic hammer until there is no clear-
42 ance on the junction surface.
43
LGB32003238
32. Tighten binder bolt (41).
 The tightening torque of binder bolt:

170±10Nm
Two of 14 binder bolts are short, so install them in cor-
rect positions.
41
LGB32003239
33. Assembly of the shaft as

1) Press bearing inner ring (28) on shaft with sleeve.
2) Install snap spring (27) to lock it.
3) Install the first level sun gear (26).
27 28 26
LGB32003240
3-115
34. Install shaft as (25).

35. Install washer (24).
• The surface with notch must be upward during the
installation.
23
24
LGB320030241
36. Assembly of the bearing support

1) Press bearing (19) with press fitting tool.
2) Press bearing (23) with press fitting tool, and then
install gasket (22), snap spring (21) and oil seal
(20).
22
19 20 21 23
LGB320030242
3) Install seal ring on the support and then install

mounting support (18).
4) Install snap spring (17) to lock it.
18
17
LGB320030243
3-116
5) Upon the installation of O-ring, install bearing

support as (16) with rings.
14

37. Install the coupling (15).
38. Upon the installation, install cover (14).
6 15
LGB320030244
39. Check piston stroke with tool C2.

Pressure: 0.5~0.6MPa
Standard stroke:
No.1: 6mm
No.2: 4mm
No.3: 4mm
No.4: 4mm
LGB320030245
40. Upon the installation of gasket, install gearbox

housing (13).
41. Tighten the bolts (12) and (11).
12
13
11
LGB32003246
3-117
42. Install lubrication valve.

8 10 9
43. 1 Install bearing support (8) and bearing (10) with
press fitting tool 16, and then install snap spring (9).
LGB32003247
2) Install gasket (105), and then install bevel gear

shaft as (104).
105
Standard gasket thickness: 1.6mm
104
LGB32003248
44. Install O-ring, install valve support (7) and control

6
valve as (6) together, and then tighten bolt (5).
5
7
LGB32003249
3-118
45. Install gasket, and then install cover (4).

• Remove bolt (118) by aligning it to the positions of
fork and lever.
11
4
LGB32003250
46. Install O-ring, and then install valve bushing (3).

47. Install gasket, and then install cover (2).
3 2
LGB32003251
3-119
3.15 Disassembly of gear shift valve
3.15 Disassembly of gear shift valve

1. Remove the cab and floor plate, and refer to the
disassembly of cab and floor plate for details.
2. Remove link (1).
5
3. Unplug wire connector (2).
4. Remove the rod (3)
5. Remove bracket and switch (4).
1
3 6. Remove tube (5).
4
2
LGB32003252
7. Remove bushing and cover as (6).
6 8. Remove gear shift valve cover (7).

Remove bolt (8), check whether fork and level are
disconnected, and then disassemble lower cover.
9. Remove 4 fastening bolts (10), and then remove
gear shift valve as (9).
8 7
Mass of gear shift valve is: 35kg.
LGB32003253
3.16 Installation of gear shift valve

Check whether fork and lever aligned to each other
from plug hole.
During the installation of valve as, align the hole to
plug hole in order not to damage O-ring.
LGB32003254
3-120
3.17 Disassembly of gearbox control valve

1. Remove the cover (1) and then remove the sleeve
(2) and quick-return valve (3).
2. Remove the valve (4), and springs (5) and (6).
3. Remove the snap ring (7) and baffle (8), and then
remove the valve (9), spring (10), valve (11) and
regulating valve (12).
4. Remove the snap ring (13), spring seat (14), spring
(15), pressure reducing valve (16) and piston (17).
LGB32003255
1 2 3 17 16 15 14 13
4 5 6 12 11 10 9 8 7
LGB32003256
3-121
3.18 Installation of gearbox control valve

1. Install the piston (17) and spring (15) into the pressure reducing valve (16), and then install the pressure
reducing valve, spring seat (14) and snap ring (13) into the valve.
2. Install the valve (11), spring (10) and valve (9) into the regulating valve, and then install the regulating
valve, baffle (8) and snap ring (7) into the valve body.
3. Install the spring (6), (5) and valve (4).
4. Install the quick-return valve (2) and sleeve (2) into the valve body, put O-ring, and place the cover (1).

1. Remove the steering valve column (1).
2. Remove the speed valve column (2).
3. Remove the cover (3) and positioning seat (4).
4. Remove the snap ring (5) and then remove the
valve rod (6).
LGB32003257
3 4 2
LGB32003258
3-122

1. Install the valve rod (6), and then install the snap ring (5).
2. Install the positioning seat (4) and install the cover (3).
3. Install the speed valve column (2).
4. Install the direction valve column (1).
3.21 Removal of transmission lubrication valve assembly

1. Remove pipe (1).
1
2. Remove the transmission lubrication valve
assembly(2).
2 LGB32003259
3.22 Installation of gearbox lubrication valve as

Install it in the reverse sequence of removal.
3.23 Disassembly of gearbox lubrication valve as

1. Remove lower cover (1) firstly, and then remove sleeve (2), spring (3) and valve (4).
3-123

1. Install valve (4), spring (3) and sleeve (2) in the
1 valve body.
2. Place the O-ring and then install cover (1).
2
LGB32003260
3.25 Disassembly of cross shaft and bevel gear

1. Remove steering clutch as. Refer to the removal
item of "Steering control valve" for details.
2. Remove steering control valve as. Refer to the
1 removal item of "Steering control valve" for details.
3. Remove valve seat.
4. Disassemble tube (1).
LGB32003261
3-124
5. The bolt hole on bevel gear can be used to stop, so

loosen the mounting bolt (2) on bevel gear.
LGB32003262
6. Straighten lock plate, fix bevel gear with plate (),

E1 and then remove left and right bolts (3) by using
tool E1.
3
LGB32003263
7. Remove washer (4).

5 E2
8. Use tool E2, and then remove left and right hubs
(5).
4
LGB32003264
3-125
6 7 9. Lift bevel gear, cross shaft temporally, remove

mounting bolt, and then remove left and right
bearing supports (6) cover opening bolt.
Check the thickness and quantity of shim removed
from left and right bearing support, and keep them
carefully.
10. Remove bearing outer ring (7) from left and right
bearing covers.
1 LGB32003265
11. Knock bevel gear gently to separate the cross shaft

from it, and then remove cross shaft gp (8) from
clutch cavity side.
12. Remove left and right bearings (9) with press fitting
tool.
10
LGB32003266
13. Remove bevel gear (10).

10
Weight of bevel gear is 39.3kg.
LGB32003267
3-126
3.26 Assembly of cross shaft and bevel gear

1. Place bevel gear (10) on gear support.
10
LGB32003268
2. Press left and right bearing (9) on cross shaft (8)

8 with press fitting tool ().
3. Insert cross shaft gp (8) in clutch cavity, and then
install it on the bevel gear.
9 4. Fasten nuts on both ends of cross shaft
temporarily, and then lift cross shaft to align it to
bevel gear.
5. Install mounting bolt and lock plate of bevel gear,
and then tighten mounting bolt.
LGB32003269
6. Press the bearing outer ring (7) in bearing support

with press fitting tool ⑤ .
LGB32003270
3-127
7. Lift bevel gear and bevel gear shaft, install the

6 gasket, and then install left and right bearing
supports(6).
Install the same number of gaskets as that of the
removed ones.
Standard thickness of the gasket:2.5mm
LGB32003271
8. Install the bevel gear on the shaft temporarily,

install stopper on the snap bevel gear on the screw
hole, and then tighten the mounting bolt (2).
 Tightening torque of the mounting bolt on

bevel gear: 250~315Nm
2
LGB32003272
3-128
9. Adjustment of pretightening force, and tooth gap is

as follows:
When measuring pretightening force, remove
gearbox as.
• Refer to section "Removal of gearbox as" fro
details.
1) Adjustment of pretightening force
• Make dynamometer up against the tooth top of
bevel gear in a certain angle, measure the turning
force of bevel gear.
Standard value: 2~6kg.

LGB32003273 • If the turning force is higher than standard value,
add gasket on the bevel gear bearing support; con-
versely, decrease it.
• Turn the bevel gear for 2 to 3 rounds before the
measurement.
2) Measurement and adjustment of tooth gap
3
I) Fix the magnetic micrometer gauge ⑦ in the
steering case, lock bevel pinion and move big bevel
1
2
gear, measure at least three positions at the

relative location.
LGB32003274
3-129
II) Fuse valve measurement

Clip fuse (Φ1.5mm) between the bevel pinion and
gear on the bevel gear in forward state, turn the
bevel gear and then measure the thickness of fuse
with micrometer.
For the intermediate position on the pinched
position of fuse between bevel gears (position with
a distance of 30% to the small end), it is better to
measure three points trisecting the periphery.
1
0
Standard value: 0.25~0.33mm.
2
3
LGB32003275
III) Adjust the gasket in the bevel gear bearing support

to change shaft position, or adjust the gasket of
bevel pinion, so as to adjust the tooth gap to range
of 0.25~0.33mm.
In order to maintain pretightening force constant,
the numbers and thickness of left and right shim
must be same.
When adjusting bevel gear side, remove the
gearbox in advance.
LGB32003276
3) Adjustment of gear contact
D I) Apply a thin layer of red lead powder, turn bevel

gear forward and backward to check the contact
Big end condition of teeth.
E Correct condition of gear contact is: contact starts

near the small end surface, and then reaches 30%
of the whole gear and shall be in the intermediate
position of gear height. This adjustment condition
can get correct gear contact when it is subject to
load.
• If gear tooth contact positions of big and small gear
are not correct, adjust them in accordance with the
Small end
following steps:
LGB32003277
3-130
Contact trace position on passive gear Motivation method

Adjusting method
surface of gear
Close up the passive gear to

active gear, if tooth gap is too
small because of this, move
the active gear outward.
Move passive gear away from

active gear, if the tooth gap is
Forward
too big because of this, move
the active gear inward.
Move active gear away against

passive gear, if the tooth gap is
the passive gear outward.
Move active gear away from

Forward
the passive gear inward.
3-131
Contact trace position on passive gear Motivation method

Adjusting method
surface of gear
Move passive gear away from

active gear, if the tooth gap is
the active gear inward.
Close up the passive gear to

active gear, if tooth gap is too
small because of this, move
the active gear outward.
Backward
Move active gear away against

the passive gear outward.
Move active gear away from

the passive gear inward.
When adding or reducing the shim on bevel pinion side, remove mounting bolts of gearbox and bevel pinion,
and then make the cover opening bolt up against bevel gear to get enough clearance to adjust the gasket.
When adjusting bevel gear, in order to keep bearing pretightening force constant, add or reduce the same
number of gaskets on left and right sides.
3-132
If the gearbox is replaced as a whole, the adjustment of tooth gap and contact condition shall be carried out in
accordance with above mentioned method.
10. Install seal ring on hub, and then install the hub on
6 E3 bevel gear shaft.
11. Install left and right hubs (6) with tool E3.
Apply anti-friction composition (MOS2) on the
spline.
• Pressure: 30~40 T
• After compressing hub, measure the earned value
"a" (dimension between hub end and step surface
of bevel gear).
• Standard value of "a" is: 5~6.5mm.
LGB32003278
12. Install seal ring (4) between hub and bevel gear
shaft.
LGB32003279
13. Lock hub with plate (), tighten locknut (3) on left and
E1 right hubs with tool E1.
 Tightening torque of nut is 650-750Nm

When aligning to snap hole of locknut, never screw it to
ward to unscrewing direction, and it is not allowed even
it is within specified torque.
3
LGB32003280
3-133
3.27 Removal of steering clutch
14. Connect tube (1) after the installation of O-ring.

15. Install gasket and valve seat.
1 16. Install steering control valve as.

• Refer to "Installation of steering control valve as"
for details.
LGB32003281
17. Install steering clutch.

1. Release the oil in steering case.
2
• Oil no.: SAE10W-30
1 2. Remove fuel tank.
• Refer to "Removal of fuel tank" fro details.
3. Remove brake band (1).
4. Remove piping (2).
3 LGB32003282
3-134
5 8
7. Remove lower cap (5).
9. Loosen adjusting bolt (7) thoroughly.
10. Remove lower link (8).
6 7 LGB32003283
11. Remove brake housing (9) with rings.
Weight of brake housing: 74.35kg.

9
LGB32003284
• When removing right clutch, remove corresponding

brake assistor.
12. Remove spring
13. Lift carrier (11) temporarily, remove pin shaft (12),
and then lift it away.
Weight of carrier: (99) kg
10
11
LGB32003285
14. Remove hose (13).

3-135
3.28 Installation of steering clutch
15. Remove binder bolts (14) and (15) inside and

outside plate.
Leave two binder bolts on each side. Spring up
grouser with jack to rotate the track, so as to
14
remove bolts on each position.
15 16. Install pins and lift ropes on brake band, remove
remaining bolts, move the inner drum inward to lift
the clutch.
Weight of clutch: 150kg.
LGB32003286
3.28 Installation of steering clutch

Cotter pin must be bent.
Tightening torque of bolt: 29±6Nm

Tightening torque of inner drum binder
bolt (14): 283±30Nm
 Tightening torque of inner drum binder bolt

(18): 393±42Nm
When installing brake band, make the pin toward rear
of the machine.
LGB32003287 Oil filling.
Tighten the drain plug, and refuel oil to normal oil level.
After starting the engine, the oil will enter the piping
system, and then check the oil level.
SAE10W-30:149L
Adjustment.
Adjust the brake. Refer "Adjustment of brake opera-
tion" for details.
3-136
3.29 Disassembly of steering clutch as

1. Remove the brake bank (1).
2. Lift away the outer drum (2) with rings ① .
2
1
LGB32003288
3. Remove clutch gp (3) on press tool D.

4. Press out press tool piston, and then remove bolt
5
4 3 (4).
5. Take back the press tool piston, and then remove
pressure plate (5).
LGB32003289
6. Remove friction plate (6) and internal plate (7).
8
After removing it, place the friction plate and inter-
nal gear plate on the ground to prevent damage.
6
7. Remove clutch inner drum (8).
7
LGB32003290
3-137
3.30 Assembly of steering clutch as
8. Remove spring (9), (10) and bushing (11).
D 12 Installation pressure of springs (9) and (10):

10
11 9 9. Remove clutch piston (12) from press tool D.
LGB32003291
3.30 Assembly of steering clutch as

1. Install seal ring (12) on clutch piston, and then
9 place piston on press tool D.
8
2. Install guide bolt, and then install bushing (11),
spring (10), (9).
11 3. Install inner drum (8), and then tighten bolt.
10
LGB32003292
4. Remove friction plate (6) and inner disc (7).

5. Install pressure plate (5).
5
LGB32003293
3-138
3.31 Removal of brake assistor
6. Press out the press tool piston, remove guide bolt

and then tighten bolt (4).
LGB32003294
7. When continuing to press out the press tool piston,

the friction plate is separated from plate, install
1 brake drum (2) with rings ① , and then recycle
press tool piston.
2 8. Remove clutch gp from press tool D.
9. Install brake band (1).
LGB32003295

1. Remove brake assistor as (1).
1
LGB32003296
3-139
2. Remove cover; loosen 4 bolts with socket wrench;

and then remove lower cover (2).
2 3. Remove cover; screw lower cover (3) with socket

wrench.
LGB32003297
4. Remove shaft; loosen steel wire (4) and then

4 5 6 unscrew locking bolt. Turn the housing 180º.
Remove locking bolt (5), and remove shaft (6).
LGB32003298
9 5. Remove valve body as; planish lock plate (7), and

8
then unscrew 4 bolts; remove bolts; remove valve
body (8), and then remove piston (9).
7 LGB32003299
3-140
6. Remove shaft; unscrew bolt, turn the housing 180º;

remove lever as (10). Remove shaft (11).
LGB32003300
7. Drive out oil seal and bushing (12).
11
12
LGB32003301
11. Remove valve body as; drive the scroll, press

spring holder (13), and then remove split ring (14).
Loosen spring holder slowly. Remove spring (15).
13
Remove scroll, and remove spring holder.
Fix the holder firstly, and then remove snap ring,
otherwise when the snap ring is removed, seat and
14 spring may lose pretightening force and fly out.
Mounting load of spring: 10kg

15
LGB32003302
3-141
3.32 Installation of brake assistor
3.32 Installation of brake assistor

Installation of brake assistor is reverse to the assembly.
During installation of slide valve, cone sealing surface shall be close to piston side.
3.33 Removal of steering valve and brake valve

1. Remove fuel tank as.
• Refer to "Removal of fuel tank as" for details.
2. Remove shaft control flexible valve (1).
1 LGB32003303

4. Remove hose (3) and (4).
3 2 4 LGB32003304
3-142
3.34 Installation of steering valve and brake valve

6. Remove steering and brake control valve as (6).
5 6
LGB32003305
3.34 Installation of steering valve and brake valve

During installation of steering valve brake valve, observe cover from the back to check whether the tube (7) is
inserted into valve body.
3.35 Disassembly of steering valve as

1 1. Remove the brake valve (1).
LGB32003306
3-143
3.35 Disassembly of steering valve as
2. Loosen the bolt (2) and remove the lock plate (3),
3 4 8 10 guide spool (5) of I-plate (4), and pressure
regulating gp (7) for spring (6). Loosen the plug and
take out the spring (10), piston (9) and brake spool
(8).
2 5 6 7 9 11
LGB32003307
3. Remove the coupling hose (12)
12 LGB32003308
4. Take down the left swing arm (14) and right swing
18 17 16 arm (15), and take out the lever (13) and guide
15 shaft (16). Unscrew cock (19), remove spring (18),
clutch spool (17).
14
19 20 13
LGB32003309
3-144
3.36 Installation of steering valve as
3.36 Installation of steering valve as

1. Install the guide shaft (16) into the valve body (20), install the lever (13), and fasten the lever-lh (14) and
lever-rh (15) through the bolt on the lever (13).
2. Install the clutch spool (17) and spring (18), install O-ring on the plug (19) and then tighten. Tightening
torque of plug (19) is 95-125Nm.
3. Install the brake spool (8), piston (9) and spring (10), and tighten with the plug (11).
4. Install the pressure regulator gp (7), spring (6) and guide spool (5), tighten I-plate (4) by the bolt (2), and
lock the bolt (2) by the lock plate (3).
Tightening torque of plug (11) is 35-45Nm.
The bolt (2) must be locked by the lock plate (3).
3. Install O-ring onto the tube (12), and install the brake valve (1).
The tightening torque of bolts should be 60 -75Nm.
O-ring must be installed into the groove.
3.37 Removal of gear shift pump as

1. Bottom plate frame cover
Remove bottom plate covers (1) and (2) and foot
brake cover (3).
1 3 2 LGB32003310
3-145
3.38 Assemblyof gear shift pump as
6 5
2. Gear shift pump pipe line
4
Remove gear shift pump suction steel tube (4), out-
let tube (5).
3. Gear shift pump as
Remove gear shift pump captive bolt, and remove
gear shift pump (6) from transfer case.
LGB32003311
3.38 Assemblyof gear shift pump as

2
1. Install O-ring (1) on gear shift pump and apply a
1
little grease on O-ring.
2. Fix gear shift pump (2) on transfer case with bolt
washer.
O-ring is free of bump and damage.
The torque of bolt is: 120±10N•m
LGB32003312
3-146
3.39 Removal of steering pump as
3.39 Removal of steering pump as

1. Front bottom guard as
Remove front bottom guard as (1)
1
LGB32003313
2. Steering pump pipeline

Remove steering pump suction steel tube (2), out-
let steel tube (3).
4
3 2 LGB32003314
3. Steering pump as
Remove steering pump as (4)
2 LGB32003315
3-147
3.40 Assembly of steering pump as
3.40 Assembly of steering pump as

1. Apply a little grease on O-ring (1), and install
steering pump (2) on transfer case housing with
bolt and washer.
1 G1
• O-ring is free of bump and damage.
• Bolt torque is: 120±10N•m.
LGB32003316
3.41 Disassembly of level I pinion as

1. Remove steering clutch as.
3
• Refer to "Removal of steering clutch as".
2. Remove lock plate, and then remove nut (1) with
tool G1.
G3
LGB32003317
3-148
3.41 Disassembly of level I pinion as
3. Remove gasket (2).

4. Remove hub (3) with tool G2.
5. Remove bearing support as (4) with bolt ① .
4 2
LGB32003318
6. Disassembly of the bearing support as

5 1) Remove oil seal (5).
2) Remove the bearing (6)
LGB32003319
7. Remove level I pinion gp (7).

7
LGB32003320
3-149
3.42 Assembly of level I pinion as
8. Level I pinion gp.

8 1) Remove bearing inner race (8).
9
2) Remove bearing inner race (9).
LGB32003321

1. Assemble level I pinion
1) Press-fit bearing inner race (9) with press tool.
8
9 2) Press-fit bearing inner race (8) with press tool.
LGB32003322
2. Install level I gear gp (7).

7
LGB32003323
3-150
3. Assemble bearing support gp.

5 1) Press-fit bearing (6) with press tool.
2) Press-fit oil seal (5) with press tool.
LGB32003324
4. Install bearing support gp (4).

3 Install bolt and apply adhesives (LT-2) on it.
 Tightening torque of the mounting bolt:

G3 285~30Nm
Apply grease (G2-L1) on oil seal lip.
5. Press-fit flange (3) with tool G3.
Apply anti-friction composition (LM-P) on the spline.
4 Press-fitting force: 30 tons.
LGB32003325
• Measure size "a".

Runout Standard value "a" is: 0±0.5mm
2
Install micrometer gauge on surface of hub (10),
and then measure radial runout and end face
runout of flange. Revolve the cross shaft, measure
a radial runout and end face runout.
Measure the distance between hub (10) and flange
(3).
Standard distance: 218.5mm
10
LGB32003326
3-151
Install micrometer gauge on steering case, and then

measure the monomer runout of flange.
End face runout is less than 0.08mm, and radial runout
is less than 0.08mm.
6) Install lock washer (2)
2 7. Tighten nut (1) with tool G1, and lock nut with lock
pad.
 Tightening torque of nut is 700±50Nm

When the nut is aligned to stop hole, never reverse it to
2 the loosening side even if it is within tightening torque.
8. Install steering clutch as.
GB32003327
• Refer to "Installation of steering clutch as".
LGB32003328
1 G1
LGB32003329
3-152
3.43 Disassembly of final drive

1. Remove machine track and trolley frame, refer to
the removal of track and trolley frame for details.
2. Remove drain plug to release oil in steering case
and transmission case.
3. Loosen bolt 1 to remove lower cap 2.
2 LGB32003330
4. Remove locking piece 3, and then remove bolt 4

with tool.
LGB32003331
5. Remove washer 5 and bracket 6, keep the floating

6 oil seal gp carefully and then pull out the bushing
from bracket.
LGB32003332
3-153
6. Remove stopper 7, and then remove big nut 8 with

special wrench.
LGB32003333
7. Remove spacer bush 9, loosen captive bolt of

backup ring, and remove backup 10;
10
LGB32003334
8. Pull down hub as 11 with special tool shown in the

11
right figure.
LGB32003335
3-154
9. Upon the removal of hub, remove lower cover 12

and tooth piece 13 from hub.
12
13
LGB32003336
10. Loosen captive bolt of housing, and remove

housing 14.
14
LGB32003337
11. Pull out main gear ring and gear hub as with puller.
LGB32003338
3-155
12. Disassemble main gear ring and gear hub as,

loosen captive bolt of gear ring to remove gear hub
16 16 from gear ring 15.
15
LGB32003339
13. Upon the removal of gear hub, remove duplicate

17 gear as 17;
LGB32003340
14. Loosen the captive bolt of main nut lock plate on

flange, remove lock plate 18, and finally remove
main captive bolt 19 of flange.
19
18
LGB32003341
3-156
15. Install the tooling used to remove the flange on

flange 20, install screw rod in threaded hole in the
middle of tooling, screw the screw rod in it until the
flange and level I gear are separated; After the
separation, remove flange.
Special
tooling
20
LGB32003342
16. Upon removal of flange, remove level I gear 21

from the outside.
21
LGB32003343
17. Upon removal of level I gear, loosen the captive

bolt of bearing support 22 to remove bearing
support.
22
LGB32003344
3-157
3.44 Assembly of final drive

1. Assemble level I pinion 1, and press-fit bearing
2 inner race 2 and inner race 3 with press fitting tool.
LGB32003345
2. Assemble bearing support gp, press-fit bearing 4

with press tool, and press-fit oil seal 5 with press
tool.
LGB32003346
3. Install bearing support gp 6, and tighten it with bolt.

6
LGB32003347
3-158
4. Install level I gear gp 1.
LGB32003348
5. Install flange 7, press-fit flange with special

Press fitting machine
pressure machine, with pressure of 22-30MPa and

7 dimension after the press-fitting of 2-3.5mm.
Notice: Clean the conical surface of level I gear

and apply grease to it before press-fitting.
Upon completion of press-fitting, install micrometer
gauge on steering case, measure the monomer runout
of flange and the end face runout and radial runout are
all required to be less than 0.08mm.
Install micrometer gauge, rotate cross shaft, measure
radial runout and end face runout of flange, the end
face runout and radial runout are all required to be less
LGB32003349 than 0.4.
LGB32003350
3-159
6. After press-fitting the flange, install the big nut,

screw it with its special spanner to 1500-2000Nm,
and then install the lock plate 9 to the outer ring of
nut, and fasten the lock plate with bolts.
LGB32003351
7. Press-in the duplicate gear bearing with press

tools, and lift the duplicate gear, install the gear into
the bearing inner ring.
10 LGB32003352
8. Assemble the assembly of big gear ring 11 and

gear hub 12. After the installation is over, fasten it
12 with bolts and nuts, the torque of bolt as
700±50Nm; at last, lock the bolt with lock plate 13.
13
11
LGB32003353
3-160
9. Lift the gear hub gp, after meshing the big gear ring
with duplicate gear, press installing the gear nub
with special press-fitting machine into the pressure
gauge, and stop it after it starts to rise rapidly.
Gear hub
pressure fitting
machine
LGB32003354
10. Apply face seal on the inner housing surface, and

14 install the paper sheet 14 on the inner housing.
LGB32003355
11. Assemble the outer housing gp, press the first-level

gear and second-level gear bearing outer rings into
the outer housing with press tools, and install the
15 final drive inside fender on the bottom.
12. Lift the outer housing, after just align 1the bolt
mounting hole with the upper hole of inner housing,
the bolts shall be coated with thread seal, the
fastening torque is 600±55Nm. At last, install the
first-level gear bearing cover 15 and second-level
gear bearing cover 16.
16
LGB32003356
3-161
13. Assemble the sprocket as, install the gear block 17

on the sprocket hub 16, coat thread seal on the
bolts, fasten it to the torque 1200±100Nm, install
the cover 18 and O ring in the gear hub inside, and
install the O rings and floating oil seal rings on the
sprocket side and final transmission case side with
16
tools.
17
18
LGB32003357
14. Lift the sprocket as, and press installing the

sprocket with special press-fitting machine, the
press-fitting pressure is 30-35MPa. After press-in,
detect whether the difference between gear hub
end face and sprocket hub end face is within 40-
42mm.
Chain
wheel
pressure
fitting
machine
LGB32003358
15. After press-fitting the sprocket, install the backup

19
ring 19 on the gear hub end face, and fasten it with
bolts, the torque of bolt as 195±15Nm; at last, lock
the bolt with the cushion 20.
20
LGB32003359
3-162
16. After installing the backup ring, install the spacer

sleeve 21 on the half shaft. Pay attention to the
installation process, and ensure to align the spacer
sleeve keyway with the keys on the haft shaft.
21
LGB32003360
17. After installing the spacer sleeve, install the O ring

23 and floating oil seal 24 in the slot of sprocket big
nut 22, and install the big nut on the gear hub outer
end; after tightly locking the big nut with special
spanner, install the stopper 25; after aligning the
slot, install the dowel pin 26 into it; at last, fasten it
with bolts.
22
23
24
LGB32003361
18. After installing the big nut, install the O ring 23 and
25
26
floating oil seal 24 into the slot of bracket 27, and
then install the bracket on the big nut outside. Note:
Ensure the location of dowel pin hole on the
bracket is on the top during the installation. Later,
install the washer 28, and install the half shaft big
27 locknut 29 on the washer outside, and screw it with
special tools. The tightening torque of big nut is
1500-2000Nm.
29
28
LGB32003362
3-163
19. Align the ledge of lock plate with the gap of half
shaft, and then install the bolts to fasten the lock
plate 30, the fastening torque is 120±10Nm; at last,
fasten the bolts with the lock plate 31 to prevent
bolt looseness.
31
30
LGB32003363
20. At last, install the cover 32, and fasten it with bolts,
the fastening torque is 305±25Nm.
21. After the installation is over, fill CD diesel 55L into
each side final transmission case.
22. At last, install the engine track frames and tracks.
32
LGB32003364

1. Remove the brake bank (1).
2. Lift away the outer drum (2) with rings ① .
2
1
LGB32003365
3-164
3. Remove clutch gp (3) on press tool D.

4. Press out press tool piston, and then remove bolt
4 5
3 (4).
5. Take back the press tool piston, and then remove
pressure plate (5).
LGB32003366
6. Remove friction plate (6) and internal plate (7).

After removing it, place the friction plate and inter-
8
nal gear plate on the flat ground to prevent dam-
6
age.
7 7. Remove clutch inner drum (8).
LGB32003367
8. Remove springs (9) and (10) and bushing (11).

D 12 Installation pressure of springs (9) and (10) is:
10
9
11 9. Remove clutch piston (12) from press tool D.
LGB32003368
3-165
4. Service standard
4.1.Hydraulic torque converter
4. Service standard
(1) Hydraulic torque converter
10
14
11
6
15
12
13
LGB32003369
3-166
4. Service standard
Unit: mm
Countermeas
ure
Standard size Repair limit

1 The external diameter of a guider
78 77.75 Coat or
change the
The external diameter of seal holder hard chromes
2 80 77.9
on the sealed contact surface
The inner diameter of gear on the
3 150 150.3
seal ring contact surface
Standard size Repair limit Coat or

The inner diameter of guide wheel
4 change the
shaft on the seal ring contact surface
65 65.1 hard chromes
Width: 4.5 3.0

5 Stator shaft seal ring
Thickness 5.5 5.0
Width: 2.5 2.0
6 Turbine shaft seal ring
Thickness 2.7 2.5
Clearance of scavenge pump drive
7 0.16~0.43 0.5 Replace
gear
Clearance between scavenge pump
8 0.13 0.25
gear and pump body
9 Bottom clearance of scavenge pump 0.15 0.30
Tightening torque of case and driving

10 50~60Nm
box bolt
11 Tightening torque of stator bolt 55~75Nm
12 Tightening torque of stator shaft bolt 95~125Nm
13 Tightening torque of bleeder plug 15~20Nm Adjust
Tightening torque of driving box drive

14 95~125Nm
gear bolt
Tightening torque of turbine shaft
15 95~100Nm
holder assembling reamer bolt
Revolutions per minute of torque
16 1600±5.0rpm
converter during stall
3-167
4. Service standard
(2) Safety valve, pressure regulator valve
Pressure regulating valve Safety valve
1
1
3 2
LGB32003370
Unit: mm
3-168
4. Service standard
No. Check items Judgment standards Processing
Allowance
Clearance Basic Standard Allowable
between valve dimension clearance clearance
1 Shaft Hole
body and slide
valve -0.050 +0.025 0.050~0.0
3.2 0.2
-0.066 0 91
Basic dimension Allowable limit
Free length
Safety valve Installation Installation Allowable
* external Free length
spring length load load
2 diameter
137.7×24 98 63.5kg 134.2 57.9kg
Set pressure Replace
value of safety 0.87
0.03
0 MPa oil temperature75±5°C
valve
5.Pressure Free length

Installation Installation Allowable
regulator valve * external Free length
length load load
spring diameter
3
126.6×23.5 106.5 20.9kg 120 14.0kg
Set pressure 0.25±0.1MPaat50L/min
value of
0.35±0.05MPaat100L/min oil temperature75±5°C
pressure
regulator 0.45±0.05MPaat200L/min
3-169
4. Service standard
4.2 Gearbox
4.2 Gearbox
9 4 1 8 6 4 1
10
7
1
3 5
11 12 13
LGB32003371
3-170
4. Service standard
4.2 Gearbox
Unit: mm
No. Check items Judgment standards Countermeasure
Backlash between No.1/No.3/ Standard clearance Clearance limit

1 No.4 sun gear and planetary
pinion 0.14~0.37 0.75
Backlash between No. 2 sun gear

2 0.13~0.34 0.75
and planetary pinion
Replace
Clearance between No.2
3 0.13~0.34 0.75
planetary gear and planetary gear
Backlash between gear ring and
4 0.16~0.48 0.75
planetary pinion
Standard clearance Clearance limit

5 Backlash of transmission gear
0.21~0.51 0.75

Thicknesses of #1/#2/#3/#4 clutch
6
friction plate
5.4 4.6
Thickness of # 5 clutch friction

7 5.4 4.6 Replace
plate
Thicknesses of #1/#2/#3/# 4
8 7 6.2
clutch plate
9 Thickness of #1 clutch plate 5.4
10 Thickness of # 5 clutch disc 5 4.2
Installa
Free Installati Free
11 #1 Clutch spring tion Load
length on load length
length
83.5 70 11.7kg 78.5 10.5kg
12 #2 Clutch spring 66 56.6 13.3kg 62 12kg
13 # 3, # 4 clutch spring 59 46.2 13kg 55.5 12kg

3-171
4. Service standard
4.2 Gearbox
Gearbox control valve
2 3
13 1
8 18
19
7
9
4
15
14 6
16
10
17 5 LGB32003372
3-172
4. Service standard
4.2 Gearbox
Unit: mm
Counter
Check items Judgment standards
measure
Tolerance
Clearance between Standard Standard Clearance
direction slide valve/ size clearance limit
1 Shaft Hole
speed slide valve
and valve body -0.035 +0.013
28 0.035~0.058 0.064
-0.045 0
Clearance between
-0.035 +0.013
2 safety valve and 28 0.035~0.058 0.064
-0.045 0
valve body
Clearance between
-0.02 +0.021
3 piston and safety 20 0.02~0.051 0.056
-0.03 0
valve
Clearance between
-0.035 +0.011
4 rapid return valve 12 0.035~0.056 0.062
-0.045 0
and valve body
Clearance between
-0.035 +0.013
5 pressure reducing 28 0.035~0.058 0.064
-0.045 0
valve and valve body
Clearance between
-0.02 +0.018 Replace
6 piston and pressure 15 0.035~0.048 0.053
-0.03 0 compone
reducing valve
Clearance between nts
-0.035 +0.016
7 regulating valve and 35 0.035~0.058 0.064
-0.045 0
vale body
Clearance between
pressure reducing -0.035 +0.013
8 25 0.035~0.058 0.064
valve and regulating -0.045 0
valve
Clearance between
-0.02 +0.018
9 pressure reducing 15 0.02~0.048 0.053
-0.03 0
valve and piston
Clearance between
-0.035 +0.013
10 lubrication valve and 28 0.035~0.058 0.1
-0.045 0
valve body
1.6MPa - 2MPa at low speed of engine
Pressures of #1 to #4
Oil temperature: 50-55°C
clutches
11 2MPa - 2.5MPa at high speed of engine
Pressure of #5 clutch 1.25MPa oil temperature:50~55°C
Transmission
12 About 0.124 Mpa
lubricant pressure
3-173
4. Service standard
4.2 Gearbox
Counter
Check items Judgment standards
measure

Free length *
Installatio Installation Free
13 Safety valve spring external Load
n length load length
diameter
79×17.2 47 1.14 kg 75.8 1.35 kg
Regulating valve
14 53×37.9 35 8.65kg 51.2 7.79kg
spring
Pressure reducing Replace
15 42.4×22.9 39.5 3.5 kg 42.1 3.15 kg
valve spring (big)
Pressure reducing
16 41.5×22.5 40.5 3.5 kg 41.4 3.15 kg
valve spring (small)
Pressure reducing
17 52×18.2 44.2 13.4kg 51.2 12.1 kg
valve spring
Slide valve plug
18 59.5×17.6 62 9.1kg 59.8 8.2kg
spring
Slide valve plug
19 87×18 61 7.6kg 84.1 6.8kg
spring
3-174
4. Service standard
4.3 Cross shaft and steering part

(1) Cross shaft and steering part
5 4 3 1 2
9 6 7 8
LGB32003373
Unit: mm
Counterme
asure
End face runout Correct or
Repair limit: (measured value is 0.05 after it is installed on the
1 of rear plane of replace
cross shaft)
bevel gear components
Standard torque: 1) 4 - 12Nm
Preload of bevel
2 2) 2 - 6 kg (measured value on the bevel gear with bevel pinion Adjust
gear bearing
disconnected)
Clearance Standard clearance Clearance limit

Adjust or
3 between bevel
replace
gear and pinion 0.25~0.33 0.75
3-175
4. Service standard
Counterme
asure
Tolerance
Standard Standard Clearance
Bolt in bevel gear size clearance limit
4 Shaft Hole
reamed hole
0 +0.027
0~0.045 Replace
-0.018 0
External diameter
of bearing Standard size Repair limit
5 support on
contact surface of 145 145.3
seal ring
Width of seal ring
4.5 4
6
Standard clearance Clearance limit
Width of seal ring
groove
4.5 5
Press-fitting force
7 30~40T
of hub
End face
distance between Replace
8 hub and cross
5~6.5mm
shaft after press-
fitting
Tightening torque
9 of bevel gear 700±50Nm
shaft nut
Verticality of hub
10 Repair limit: 0.15 mm
over cross shaft
Coaxiality of hub
11 Repair limit: 0.15 mm
and hub
Tightening torque
12 130~180Nm
of bleeder plug
3-176
4. Service standard
(2) Steering clutch
1 2 5 6
7
9
8 4
3 LGB32003374
Unit: mm
Counter
measure
Thickness of inner disc Replace
2.9 2
1
Tolerance Repair limit Correct
Distortion of inner disc or
Below 0.2 0.3 replace

Friction plate thickness Replace
4.7 3.7
2
Tolerance Repair limit Correct
Distortion of friction plate or
Below 0.2 0.3 replace
3-177
4. Service standard
Counter
measure
Total assembling Standard size Repair limit
3 thickness of inner disc and
friction plate 88.3 81.6
Standard clearance Repair limit Replace

Backlash between inner
4
disc and inner clutch drum
0.3~0.4 1.0
Backlash between friction
5 0.3~0.4 1.0
plate and outer drum
Internal diameter of piston Standard size Repair limit
seal ring contact point on
inner clutch drum 245 245.5
6
Clearance between piston Standard clearance Repair limit
seal ring groove and seal
ring 0.07~0.18 0.4
Replace
Installa
Free Installatio
7 Clutch spring (large) tion Free length Load
length n load
length
145.15 105.8 243kg 141 229.1kg
8 Clutch spring (small) 137.83 105.8 138.8kg 134 132kg

External diameter of brake
9
drum (outer drum)
450 445
Correct
Tolerance Repair limit or
End face runout of brake
10 replace
drum
Below 0.3 0.5
11 Coaxiality of brake drum Below 0.15 0.3
Stroke of steering rod Clutch disengaged (1.5 - 2.5 kg) * (65 - 75 mm)
12
Operating force of steering
Operating brake (5 - 8 kg) * (120 - 130 mm)
rod
3-178
4. Service standard
(3) Steering control valve
B B
A A
20
Cover B-B 9 8 1 10 2
3
16
11
6
7
17
18 18
13
15 17 12 14 4 5
Cover A-A
LGB32003375
3-179
4. Service standard
Unit: mm
Counter
measure
Tolerance
Standar Standard Clearanc
Clearance between d size clearance e limit
1 steering valve and Shaft Hole
valve body
-0.035 +0.013
26 0.035~0.058 0.08
-0.045 0
Steering valve and -0.030 +0.015
2 10 0.030~0.055 0.08
piston -0.040 0
Steering valve and -0.035 +0.013
3 26 0.035~0.058 0.08
valve body -0.045 0
Brake valve and valve -0.030 +0.018
4 16 0.030~0.053 0.08
body -0.035 0
-0.030 +0.015
5 Brake valve and piston 9 0.030~0.055 0.08
-0.040 0
+0.023 +0.170
6 Rod shaft and bushing 22 0.063~0.168 0.2
+0.002 +0.086
+0.019 +0.156
7 Rod shaft and bushing 18 0.067~0.155 0.2
+0.001 +0.086
Replace
Free length
Steering regulating Installatio Installati Installatio
8 * external Free length
spring n length on load n load
diameter
36×19 27.2 6.02kg 35.3 5.7kg
9 Steering valve spring 62×23.4 15.3 3.5kg 60.9 3.2
Steering valve return

10 91.6×18.9 25 4.53kg 90.6 4.3
spring
11 Steering shaft spring 55×29.6 20 3.61kg 54.0 3.3
Brake regulating
12 27.9×14.3 25.5 3.0kg 27.4 2.8
spring
Brake valve return
13 50.5×11.9 14 2.36kg 49.5 2.2
spring
Brake valve sleeve
14 90×21.4 27 4.48kg 88.5 4.15
return spring
Distance between brake
15 valve sleeve and adjusting 15.8 Adjust
bolt
3-180
4. Service standard
Counter
measure
Tightening torque of
16 110±15Nm
steering valve
Tightening torque of shaft
17 2.5±0.5Nm
mounting nut
Tightening torque of brake Re-
18 40±5Nm
valve plug tighten
19 adjusting bolt locknut and 32±3Nm
rod mounting bolt
Tightening torque of brake
20 68±7Nm
valve mounting bolt
3-181
4. Service standard
(4) Steering brake
4 7 255 ±30N.m 9 118 ±7N.m
8
2
LGB32003376
3-182
4. Service standard
Unit: mm
Counter
measure
Total thickness Standard size Repair limit

1 of brake band
and lining 15.5 11.5 Replace
Thickness of
2 9.5 4.7
brake band
Clearance
between brake
3 0.3
band and brake
drum Adjust
Adjusting bolt of
4 Tighten to 50Nm and unscrew by 7/6 circles
brake band
Tolerance
Standar Standard Clearance
Clearance d size clearance limit
5 between valve Shaft Hole
body and piston
-0.030 +0.030
80 0.030~0.079 0.2
-0.019 0
Clearance
-0.005
6 between shaft 25 0.063~0.043 0.048~0.017 0.1
-0.014
and bushing
Standard size Repair limit Replace
Brake band Installation Installation Installation

7 Free length Free length
return spring length load load
78.3 97 20kg 82 16kg
8 Brake lift spring 42.4 47.4 4.54 43.4 3.6kg
Steering valve
9 89 58 10kg 85.9 9kg
return spring
3-183
4. Service standard
(5) Main steering pressure reducing valve
3 1 2
A A
Profile A-A
LGB32003377
Unit: mm
Counter
measure
Clearance Tolerance
Standard Standard Clearance
between main
size clearance limit
1 pressure Shaft Hole
reducing valve
and valve body -0.014 +0.013
28 0.014~0.036 0.08
-0.023 0
Clearance
between main
-0.02 +0.018
2 pressure 15 0.020~0.048 0.08 Replace
-0.03 0
reducing valve
and valve body
Standard limit Repair limit
Main pressure Free length *
Installation Installation Free Installation
3 reducing valve external
length load length load
spring diameter
48.9×18.9 40 19.2kg 48 18.2kg
3-184
4. Service standard
4.4 Final drive
4.4 Final drive
285± 30N.m 6 393 ±42N.m

7
900± 50N.m 4 10 3 700 ± 50N.m
18 19 14
5
9
8
1200 ±100N.m
17
16
11 113±12N.m
15
113±12N.m
283±32N.m
1750± 250N.m
1
12
2 13
180± 20 N.m
560± 60 N.m
945 ±105 N.m

LGB32003010
3-185
4. Service standard
4.4 Final drive
Unit: mm
Counter
measure
Standar Tolerance Standard Clearance
Clearance between half
d size Shaft Hole clearance limit
1 shaft and track frame
brace bushing -0.036 +0.035 0.036~ Replace
90 0.5
-0.071 0 0.106 bushing
Clearance between
-0.145 +0.080 0.105~
2 support bushing and 140 0.5
-0.208 -0.040 0.288
spacer bush
Backlash between Standard clearance Clearance limit
3 primary pinion and
primary large gear 0.27~0.68 1.5
Backlash of secondary
4 0.31~0.82 1.5 Replace
drive
External diameter of Standard value Repair limit
5 flange on oil seal
contact point 120 119.9
Press-fitting force of
6 30~40T
flange
Inner step dimension of
7 primary gear shaft - 0.5 ~ + 1.0 ("+" indicates the gear shaft shoulder protrudes)
shoulder and flange
End face runout of
8 Maximum 0.08
flange
9 Radial runout of flange Maximum 0.08
10 7~21T
primary large gear
11 70~80T Adjust
sprocket hub
End face distance
between gear hub and
12 40±1
sprocket hub after
press-fitting
Press-fitting force of half
13 15~54T
shaft
14 Dust cover clearance 4.3±1.0
Clearance between
15 sprocket hub nut and 3.4±1.2
support
Wear of sprocket tooth Standard value Tolerance Repair limit
16
top surface 1011.0
Wear of sprocket tooth
17 912.15 Repair or
root surface
Wear of sprocket tooth Standard value Repair limit replace
18
top surface width 83 75
Wear of sprocket tooth
19 103 95
root surface width
3-186
4. Service standard
4.4 Final drive
4 Travel system

1.1 Track..............................................................................................4-3
1.2 Track frame as...............................................................................4-4
1.3 Tensioner.......................................................................................4-5
1.4 Idler as ...........................................................................................4-6
1.5 Track roller (single rim) ..................................................................4-7
1.6 Track roller (double rim).................................................................4-8
1.7 Carrier roller...................................................................................4-9
1.8 Equalize bar devices....................................................................4-10
2 Removal and assembly ............................................................ 4-11
2.1 Removal of track frame as...........................................................4-11
2.2 Assembly of track frame as .........................................................4-16
2.3 Removal of track roller as ............................................................4-23
2.4 Installation of track roller as .........................................................4-24
2.5 Removal of riding wheel as..........................................................4-25
2.6 Installation of riding wheel as.......................................................4-25
3 Service standard ......................................................................... 4-26
3.1 Track............................................................................................4-26
3.2 Idler as .........................................................................................4-28
3.3 Track roller...................................................................................4-30
3.4 Carrier roller.................................................................................4-32
3.5 Track frame as.............................................................................4-33
3.6 Tensioner.....................................................................................4-34
3.7 Equalize bar devices....................................................................4-36
4-3
1.1 Track

1.1 Track
1 2 3 4 5 6 7 8 9 10 11 12
LGB32004001
1. Track 5. Seal ring 9. Gasket

2. Track link-lh 6. Pin 10. Pin bushing
3. Track link-rh 7. Pin bushing 11. Bolt
4. Gasket 8.Master pin 12. Nut
The track is used to support the weight of bulldozer, ensure adhesion of bulldozer, and provide enough driving
force. Due to adverse working conditions, the track is required to have sufficient strength, stiffness and wear
resistance.
4-4
1.2 Track frame as
1.2 Track frame as

The track frame as consists of track frames (6), idlers (1), carrier rollers (2) and track rollers (7) and (8)
installed in pair on the left and right.
The track frame plays a role in supporting the weight of bulldozer and distributing it on the ground. After power
is transferred to sprockets, the driving force transferred by sprockets changes into traction. The track around
each track frame is driven by sprockets, and its rolling is guided by idlers, carrier rollers and track rollers.
1 2 3 4
8 7 6 5
LGB32004002
1. Idler 4. Cover 7.Single rim track roller

2. Carrier roller 5.Protective devices 8.double rim track roller
3. Tensioner 6. Track frame
4-5
1.3 Tensioner
1.3 Tensioner
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
A-A
18
19
LGB32004003
1. Bracket 8. Guide 15. Nut

2. Shaft 9. Spring 16. Lock washer
3. Oil cylinder body 10. Bolt 17. Cover
4. Piston 11.Positioning pin hole 18. Valve
5. Bushing 12. Socket 19. Oil plug
6. Cover 13. Guide
7.Pin 14. Spring
The tensioner is installed on the track frame between the idler and sprocket. Its functions are: (1) To keep
proper track tension. (2) To absorb vibration of idlers when the vehicle is traveling.
One end of the tension shaft (2) is connected with the idler bracket (1), and the other end is connected with the
cylinder body (3). Compacted grease is filled in the cylinder body. Grease is forced into the cylinder body
through the nipple (18) of filling valve to make the cylinder piston push the idler forwards, which tensions the
track. On the other hand, loosen the nipple to drain grease, which decreases the track tension.
When the idler connected with the buffer spring through the cylinder body (3) is subjected to the impact force
exceeding the initial preload of tension spring, the tension spring will retract to absorb vibration. In addition,
mud, stone or snow blocks between the track and sprocket, the tension spring will absorb vibration caused due
to sudden increase in track tension, so as to prevent the track, sprocket or other track rollers or carrier rollers
from damage.
Notice: Loosen the nipple by one turn in order to reduce the track tension. If grease is difficult to
drain, try to drive the machine forwards or backwards for a short distance. Do not loosen the nipple by
above one turn in order to prevent grease from being sprayed at high pressure. Although the
protection shield is provided to prevent the nipple from flying away, this precaution shall be
remembered to ensure safety.
4-6
1.4 Idler as
1.4 Idler as
2
10
3
4
9
5
6
7
LGB32004004
1. Idler 5. Screw-plug 9. Washer

2. Socket 6.Idler shaft 10. Support-rh
3.Floating seal 7. Side plate
4. Support-lh 8. Guide frame
The idler is mainly used to guide the track line and track.
Idler as installed in the front of the track frame on each side is composed of idler (1), socket (2), floating seal
(3), support-lh (4), plug (5), shaft (6), side plate (7), guide (8), gasket (9) and support-rh (10).
Connect support-lh (4) and bracket (in tension gp) of the idler gp which can slide back and forth along the
frame through side plate (7) and guide (8) and guide plate installed in the track frame, and keep track rotating
steadily.
Lubricant enters the bushing through the hole in the shaft, to lubricate the sliding surface of bushing. Each end
of bushing is provided with a float oil seal to prevent oil leakage and prevent mud or water from entering.
4-7
1.5 Track roller (single rim)
1.5 Track roller (single rim)
3
5
LGB32004005
1.Single rim track roller 3.Track roller cover 5.Track roller shaft
2. Socket 4.Floating seal
4-8
1.6 Track roller (double rim)
1.6 Track roller (double rim)
3
5
LGB32004006
1.Double rim track roller 3.Track roller cover 5.Track roller shaft
2. Socket 4.Floating seal
The track roller, installed below the track frame at each side, can distribute the weight of machine evenly on
the track. It can prevent the track from horizontal derailing. Track roller as is composed of track roller (1),
socket (2), floating seal (4), shaft (5) and outer cover (3). It is made of special alloy steel by quenching and
tempering. There are two types of track roller: one is flange at the outer side, and the other are flanges at both
inner and outer sides. The track roller bears thrust load (axial load), and the single rim track roller and double
rim track roller are arranged alternately. The shaft has holes, through which lubricant can be filled to lubricate
the sliding surface of socket. Both sides of socket are provided with float oil seals to prevent oil leakage and
prevent mud or water from entering.
4-9
1.7 Carrier roller
1.7 Carrier roller
1 2 3 4 5
LGB32004007
1. Support 4.Floating oil seal 7. Cover

2. Shaft 5. Retainer 8. Nut
3. Retainer 6. Carrier roller
The carrier roller is arranged above the track frame at each side. It functions are to support the upper part of
complete track during normal driving, and to prevent the swing or shaking of track due to its weight. The carrier
roller race and flange are subjected to hardening, and the flange is used to bear thrust load (axial load) so as to
prevent the track from falling from the carrier roller.
There are oil holes on the shaft used for conveying lubricant (engine oil) to sliding surface of the retainer. One
end of bearing is provided with a float oil seal to prevent oil leakage and prevent mud or water from entering.
4-10
1.8 Equalize bar devices
A-A
2 3 4 LGB32004008
1. Cross beam 3. Bushing

2. Shaft 4. Seal ring
A semi-rigid suspension is used in this machine. As shown in the above figure, the equalizer beam (1) is
assembled on the main frame through center pin (2), with both ends supported on the track frame. Due to such
structure of equalizer beam, the weight of bulldozer front half is transferred to the track frame through the
equalizer beam, and vibration from the track frame to main frame is absorbed by the equalizer beam. Pins on
the track frames at both sides can restrict excessive lifting of bulldozer body front in driving and operation pro-
cess. The equalizer beam can rotate around the center shaft. The main frame is provided with a grease fitting
in order to lubricate the equalizer beam. Grease is delivered to the center shaft through the filling pipe and
holes in the center shaft, to lubricate the sliding surface between the shaft and its bushing.
4-11
2 Removal and assembly
2.1 Removal of track frame as

Remove blade as referring to removal of “blade as” for
details.
1. Loosen the track and unscrew the lubricant plug (1)
for less than one circle due to high internal
pressure of tension cylinder. Where the lubricant
plug is unscrewed with no reduction of track
tension, drive a vehicle forward and backward.
2. Adjust track position and use a 36# socket to
remove bolts of the track (1).
LGB32004009
3. First prepare to use slings to lift parts to be

removed and unplug the track guide pin (2) by a
pressing fit machine.
2
LGB32004010
4-12
4. Use slings to place removed track on the ground

(3) steadily.
• Unfasten the track and lift it, and start a vehicle
and drive backward slowly.
3 LGB32004011
5. Prepare to lift the track frame by a traveling crane

and unscrew bolts of (4) by a 50# socket.
4
LGB32004012
6. Remove bolts (5) of line guard plate by a 30#

socket and then remove internal tubes.
7. Operate a traveling crane to lift and put the track
frame in a designated area steadily.
5
LGB32004013
4-13
8. Remove eight bolts (6) of two carrier rollers by a

#36 socket and lift and put them on the ground
steadily by a traveling crane.
6
LGB32004014
9. Remove bolts of front and rear covers on the

track frame (7) by a #21 socket and put covers
on the ground.
7
LGB32004015
10. Remove bracket of carrier roller (8) by a #36

socket and put it on the ground steadily.
8 LGB32004016
4-14
11. Remove bolts of idler as and bracket joint (9) by

a #36 socket.
9 LGB32004017
12. Unscrew (10) and (11) on both sides by a #36

10 socket and lift and put them on the ground
steadily by a traveling crane.
11
LGB32004018
13. Remove parts of (12) and (13) by a #30 socket

and lift and put them on the ground.
12 13
LGB32004019
4-15
14. Unscrew bolts at (14) by a #18 socket and

remove cylinder as (15).
14 15 LGB32004020
15. Remove bolts of (16) by a #30 socket and take

17 out internal spring (17) by slings.
16 LGB32004021
16. Turn over and place the track frame by a

traveling crane, remove bolts of (16) and (17),
and remove the plate.
16 17 LGB32004022
4-16
2.2 Assembly of track frame as
17. Unscrew all bolts (18) of the frame track roller by

a #36 socket. Lift the track roller by a traveling
crane and put it on the ground.
18 LGB32004023

1. Place main part of the track frame (1) on the
operation platform with bottom upwards.
1
LGB32004024
2. Put plates on inner sides of fitting surfaces of

4 5
track frame and track roller, place track rollers (2)
and (3) on the sequence of single, double,
double, single, double, double and double on the
plate, and tighten them by bolts (4) and (5) and
washers. (Pay attention to that fillers on the side
of track roller are outside the track frame for
convenient maintenance). Tightening torque
1020 ± 90N)
2 3
LGB32004025
4-17
3. Install baffle (6) and bushing (7) by a #36 socket.

7 (Bolt torque of external guard 1020 ± 90/distance
between internal and external guards 312 mm.)
6
LGB32004026
4. Lift and turn over the track frame by a traveling

8 9
crane and install spring (8), install rear cover (9),
and screw the grease fitting (10) (tightening
torque 1020 ± 90 Nm).
10
LGB32004027
• Clearance between M60 big nut (32) and spring

cavity is 6 mm.
• For the last 10 mm, install springs on the sprocket
side.
32 LGB32004028
4-18
5. Insert cylinder shaft as (11) into the spring box,

pass the base (12), crash pad (13) and bracket
(14) as through the cylinder shaft as and install it
on the track frame.
11 12 13 14
LGB32004029
6. Harness bracket welding fitting (15) to cylinder

shaft as, install washers (16), tighten them by
bolts (17) and lock plates (18), and coat lock
plates (tightening torque 1020 ± 90 Nm).
16 17 18 15
LGB32004030
7. Harness O-ring to plug (19) and install them on

19
the spring box. (Tightening torque: 110±15Nm).
LGB32004031
4-19
8. Lift idler as (20) by a crown block with fillers

outward, unscrew lateral adjusting bolt (21),
install base plates, springs and plate riveting
parts in bottom holes of both sides of the idler,
put idler as on slide track of the track frame,
connect idler as and the bracket by bolt (22) and
washer (23), and tighten them diagonally
(tightening torque 600 ± 55 Nm).
22 23 20 21
LGB32004032
9. Use adjusting shims (24, 25, 26, 27) to adjust

distances of idler from four directions (the idler
shall be in the middle and thicknesses of
24 25 adjusting shims are respectively 8 mm, 4 mm
and 5.5 mm).
26 27
LGB32004033
10. Screw adjusting bolts of two sides, measure

clearance of (28) by a filler gauge, and guarantee
clearance of (28) through adjusting quantity of
gaskets on (29). Clearance of (31) shall be
adjusted the same as (29).
Screw upper adjusting bolts (600 ± 55 Nm).
Clearances (28) and (29) are 0.5 - 1.0 mm
29 31
28
30
LGB32004034
4-20
11. Install bracket (32) on the track frame-lh/rh and

connect them with bolts (33) and washers (34),
and tighten them diagonally. (The tightening
torque should be 600 ± 55Nm)
33 34
32
LGB32004035
12. Install two carrier rollers (35) on the track frame

by slings, and tighten them diagonally (tightening
torque is 600 ± 55 Nm). Install the front cover
(36) and the middle cover (37). (The tightening
37 35 36
LGB32004036
13. Lift trunnion (38) by slings and install it on the

track frame, use bolt (39) and washer (40) to
connect it with the track frame, and tighten them
diagonally. (The tightening torque should be
1020 ± 90Nm).
37 39 40
LGB32004037
4-21
14. Hang track frame on mainframe and fasten bolt

(41). (The tightening torque should be 1020 ±
90Nm).
41
LGB32004038
15. After the installation of tubes, install external

covers (42) tightly by bolts. (The tightening
42 LGB32004039
16. Put track (43) steadily on a designated place.
43
LGB32004040
4-22
17. Lift track (44) by slings and connect two ends of

the track, align guide pin to the pin hole and
hammer it into track hole, and press and fit pin
(45) in the hole by special tools.
44 LGB32004041
18. Install track shoes and tighten track shoe bolts

(46).
& Tightening torque of track bolt is: 840–
1100 Nm
• If the tightening torque does not reach 800 Nm,
remove track and clean up chain link mating sur-
face and bolt threads and then tighten them.
• Tighten them on the sequence of ○1 to ○4
45
LGB32004042
19. Put a grease gun beside the vehicle in order to

add grease to the stretching device and thus
tighten the track.
46 LGB32004043
4-23
2.3 Removal of track roller as
1 3
4
2
LGB32004044
2.3 Removal of track roller as

1. Loosen the track
1
Internal pressure of hydraulic cylinder is high,
therefore, do not screw lubricant plug (1) for
more than one circle. If lubricant plug is
unscrewed with no reduction of track tension,
drive a vehicle forward and backward.
LGB32004045
2. Remove internal and external retainers (2).
3 2
LGB32004046
4-24
2.4 Installation of track roller as
3.Remove guards (3) and (4).
Weight: 97.5kg
4
LGB32004047
4. Remove track roller as (5)

• When starting an engine, operate dozer control
lever and ripper control lever to rise the rack.
LIU G
ONG
When a rack is risen, always use the brake and
LIU GONG lock the blade ripper control lever.
B320
Weight:107 kg
5
LGB32004048
2.4 Installation of track roller as

Installation is in the reverse order of removal.
Install bolt and apply adhesives (LT-2) on it.
& Tightening torque of the mounting bolt: 823~1029Nm
4-25
2.5 Removal of riding wheel as
2.5 Removal of riding wheel as

1. Tighten the track
1
Unscrew lubricant plug (1) for less than one
circle due to high internal pressure of tension
cylinder. If lubricant plug is unscrewed with no
reduction of track tension, drive a vehicle forward
and backward.
LGB32004049
2. Remove riding wheel as

2 3
• Jack tracks by putting two hydraulic jacks in both
sides of the track frame carrier roller (2).
• Screw mounting bolts temporarily (3).
Weight 63kg
LGB32004050
2.6 Installation of riding wheel as

The installation sequence is just opposite to the removal sequence. Install bolt and apply adhesives (LT-2) on
it.
 Tightening torque of the mounting bolt : 490~608Nm
4-26
3 Service standard
3.1 Track
3 Service standard
3.1 Track
5 6
8 LGB32004051
Unit: mm

1 Standard size Repair limit Revolve or replace
Calibra Measure Before After
Pitch of chain link tion installation installa
tion
228.6 228.85 231.85 233.85
2 High grouser or low 80 30 Weld, reassemble or
grouser (standard replace the grouser
track shoe)
High grouser or low 80 30
grouser (any
purchase: track shoes
for ground elements)
4-27
3 Service standard
3.1 Track

3 138 125 Reassemble or
Track link height
replace
4 Standa Tolerance Interfer Repair Replace
rd size ence of limit
Shaft Hole
dimens
Interference of chain
ion
link and bushing
77 +0.344 +0.074 0.230~ 0.100
0.344
+0.304 0
bushing
5 Standa Tolerance Standa Repair Replace
rd size rd limit
Shaft Hole
interfer
ence
link and standard pin
48.5 +0.434 +0.062 0.272~ 0.140
0.434
+0.334 0
Press-fitting force of 21.4~37.0T
standard pin
6 Standa Tolerance Standa Repair Correct or replace
rd size rd limit
Shaft Hole
interfer
ence
link and master pin
48.5 +0.230 +0.062 0.138~ 0.080
0.230
+0.200 0
Press-fitting force of 21.4~37.0T
master pin
7 Standard size Repair limit Revolve or replace
External diameter of
79.0 Press fitting Flat fitting
bushing
76 74.0
8 Standard Standard Repair limit Replace
Clearance of chain link clearance (one clearance (two
press fitting surface side) side)
0~1.4 0~2.8 8
9 Tightening torque of 1000 - 1200 Nm Re-tighten
track bolt
4-28
3 Service standard
3.2 Idler as
3.2 Idler as
5 13
3 4
12
2 1
10
11
9 LGB32004052
4-29
3 Service standard
3.2 Idler as
Unit: mm
Counterme
asure
External diameter of Standard size Repair limit

1
flange 850
External diameter of
2 800 781 Reassemble
rail surface
or replace
3 Flange width 120
4 Rail surface width 60 69
5 Overall width 240
6 Width of shaft flange 20 19
Stand Tolerance
Standard
ard Repair limit
Clearance between Shaft Hole interference
7 size
shaft and bushing
-0.130 +0.255
0.43~0.51
-0.260 +0.220 1.5
Tolerance Minimum Replace
Standard
interference
Clearance between Shaft Hole interference
8 limit
idler and bushing
+0.130 +0.10
0.02~0.180 -0.30
+0.080 -0.05
Axial clearance of Standard clearance Clearance limit

9
shaft 0.51~0.74 1.5
Clearance between
Reassemble
10 guide plate and 2.0
or replace
support
Clearance between
Adjust or
11 guide plate and side 0.5~1.0 3
replace
plate
12 210±50N/M Adjust and
lubricant plug
refuel
13 Fuel quantity 390~450ml (GO140B)
4-30
3 Service standard
3.3 Track roller
3.3 Track roller
13 11 12
14
2 3 1
15
10
7 5 9 6 8
4
LGB32004053
4-31
3 Service standard
3.3 Track roller
Unit: mm
Counterm
easure
Outward flange Standard size Repair limit

1
diameter 298
Interior flange
2 282
diameter
Rail surface diameter
3 255 230
(bilateral)
4 Overall width 292
Rail surface width Reassembl
5 65 74 e or
(unilateral)
replace
Rail surface width
6 62 80
(bilateral)
Flange width (bilateral
7 24 15
unilateral)
8 24 15
external)
9 22 13
internal)
10 Width of shaft flange 20 19
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
11
shaft and bushing
-0.210 +0.255 0.43~0.5
85 1.5
-0.260 +0.220 15
Tolerance Standard Replace
Standard Interferenc
interferen
Interference of wheel size Shaft Hole e limit
12 ce
body and bushing
+0.130 +0.063 0.067~0.
135 0.30
+0.080 0 130
Axial clearance of Standard clearance Clearance limit

13
shaft 0.50~0.76 1.5
14 840~1040N/M
track roller group bolts
Adjust
15 210±50N/M
strainer
16 Fuel quantity 390~450ml (GO140B) Refuel
4-32
3 Service standard
3.4 Carrier roller
3.4 Carrier roller
7
2 1
3 4
LGB32004054
Unit: mm

1 External diameter of flange 230
220
Reassemble or
200 181
2 External diameter of rail surface replace
190 171
3 Flange width 21 14
4 Rail surface width 63 72
Standard clearance Clearance limit Adjust nuts or
5 Axial clearance of shaft
0.10~0.13 0.20 replace bearings
6 Tightening torque of bracket mounting bolt 500 - 620 Nm

Adjust
7 Tightening torque of oil filler plug 210±50N/M
8 Fuel quantity 630~720 ml (GO140B) Refuel
4-33
3 Service standard
3.5 Track frame as
3.5 Track frame as
5 4 3 2
1
LGB32004055
Unit: mm

Item Repair limit
7 (every 100
Bending
1 Distortion of track frame horizontal length)
Winding
3 (every 300
Opening on the idler horizontal length)
installation site Repair or replace
5
Center distance of track
2 Distance shall not
frame-rh and track frame-lh 2000
exceed 15
Tolerance Cleara
Standard Standard
nce
Clearance between size Shaft Hole clearance
3 limit Replace
sprocket shaft and bushing
-0.036 +0.035 0.036~0.
90 0.5
-0.071 0 106
4-34
3 Service standard
3.6 Tensioner

Tightening torque of track
4 840 - 1050 Nm
roller guard bolt
Adjust
Tightening torque of space
5 840 - 1050 Nm
washer bolts and nuts
3.6 Tensioner
1 1 2 3
A
5
A-A
LGB32004056
4-35
3 Service standard
3.6 Tensioner
Unit: mm
Counter
measure
Free length X Installatio Installatio Free Load
outer diameter n length n load length limit
1 Tensioner
(big) 1008 * 304
769 22 tons 985 20 tons
(small)
564 7 tons 675 6.2 tons Replace
693.5x172
Tolerance Standard Clearan
Standard size
Clearance between Shaft Hole clearance ce limit
2
cylinder and bushing
-0.036 +0.070 0.036~0.
130 0.5
-0.090 0 160
3 40 tons
idler bracket plate
Clearance between
4 10 mm Adjust
backstand and nut
5 50±2.5N/M
lubricant plug
4-36
3 Service standard
A-A
LGB32004057
Unit: mm
Handling
S/N Check items Standard
suggestion
Basic Tolerance Standard Permissible

Clearance dimension clearance clearance
Shaft Hole
1 between pin Replace
and bushing -0.036 +0.279
90 0.249~0.369 0.5
-0.090 +0.213
5 Work implement hydraulic system
1 Functions and structures .......................................................... 5-3

1.1 Hydraulic oil line system ................................................................5-3
1.2 Working oil tank .............................................................................5-9
1.3 Working pump..............................................................................5-10
1.4 Hydraulic control valve.................................................................5-11
1.5 Accumulator.................................................................................5-16
1.6 Hydraulic cylinder ........................................................................5-17
1.7 Piston valve .................................................................................5-21
1.8 Rapid lowering valve....................................................................5-22
1.9 Gear motor (Parker).....................................................................5-23
1.10 Gear pump for the cooling system.............................................5-24
1.11 Safety valve for the cooling system ...........................................5-25
1.12 Pilot oil source valve ..................................................................5-26
1.13 Blade lift operation .....................................................................5-29
1.14 Ripper lift operation....................................................................5-30
1.15 Ripper lift operation....................................................................5-31
1.16 Ripper angle modulation operation............................................5-32
2 Check and adjustment .............................................................. 5-33
2.1 Overview......................................................................................5-33
2.2 Hydraulic pressure control ...........................................................5-34
2.3 List of oil pressure measurement items .......................................5-35
2.4 Measuring procedure of oil pressure ...........................................5-35
2.5 Measurement of work implement hydraulic settlement................5-37
2.6 Maintenance standard table ........................................................5-38
3 Removal and installation ......................................................... 5-39
3.1 Removal of hydraulic pump as ....................................................5-39
3.2 Installation of hydraulic pump as .................................................5-39
3.3 Installation of pilot lines as...........................................................5-40
3.4 Removal of ripper control valve as and blade control valve as....5-42
3.5 Removal of blade lift cylinder as ..................................................5-42
3.6 Assembly of blade lift cylinder as.................................................5-42
3.7 Removal of blade tilt cylinder as ..................................................5-43
5-2
3.8 Installation of blade tilt cylinder as .............................................. 5-43

3.9 Removal of ripper tilt cylinder as ................................................. 5-44
3.10 Installation of ripper tilt cylinder as ............................................ 5-44
3.11 Removal of ripper lift cylinder as ............................................... 5-45
3.12 Installation of ripper lift cylinder as ............................................ 5-45
3.13 Disassembly of hydraulic cylinders as ...................................... 5-46
4 Maintenance and standard ......................................................5-49
4.1 Hydraulic cylinder........................................................................ 5-49
5-3
1 Functions and structures
1.1 Hydraulic oil line system

Hydraulic devices can be divided into: blade system, ripper system, pilot control system and fan motor lines
system (320II phase).
Blade system is composed of work tank (1), multi-way valve (2), working pump (3), solenoid valve (4), blade
lift hydraulic cylinder (5), blade tilt hydraulic cylinder (6) and connecting pipes of various parts.
3 5
LGB32005001
1.Hydraulic oil tank 3.Working pump 5.Blade lift hydraulic cylinder

2.Multi-way valve 4.Solenoid valve 6.Blade tilt hydraulic cylinder
5-4
Constituent parts of ripper system. Work tank (2) outputs oil to the multi-way valve (1), and pipes outputs oil
to ripper shunt and then to ripper angle modulation cylinder (3) and ripper lift cylinder (4).
2
1
LGB32005002
1.Multi-way valve 3.Ripper angle modulation hydraulic cylinder

2.Working oil tank 4.Ripper lift hydraulic cylinder
5-5
Pilot control system enables to reduce valve operating force in the work tank, which is equipped with blade
pilot control valve (1) and ripper pilot control valve (2).
6
5
4 7
2 8
LGB32005003
1.Working pump 4.Multi-way valve 7.Working oil tank

2.Pilot oil source valve 5.Blade pilot control valve 8.Shunt
3.Accumulator 6.Ripper pilot control valve
5-6
Connection description of pilot lines
Blade, tooth ripper pilot valve
Unload valve Multi-way valve

LGB32005004
Oil outlet of pilot valve Oil outlets of multi-way valve and unload valve
1 a3
2 a4
3 b3
Blade pilot valve
4 b4
P P1
T Oil return
1 a1
2 b2
3 b1
Ripper pilot valve
4 a2
P P1
T Oil return
5-7
Fan motor lines apply to the cooling system of a bulldozer during 320II phase, where a gear pump drives a
gear motor and thus drives rotation of a fan, which is used for cooling the engine and hydraulic system.
At present, there are two configurations in accordance with different cooling motors, 1. Hudson Motor; 2.
Parker Motor. The main difference of the two motors is: safety valve as of Hudson Motor System is inside the
motor, but Parker Motor System has external safety valves which are connected by lines.
LGB32005005
1.Pump oil suction 3.Gear pump for the cooling system 5.Safety valve for the cooling system (for
2.Oil return of motors 4.Gear motor Parker system)
5-8
Fan motor schematic
2 4 2
6
1 3 1
3
LGB32005006
1.Filter 3.Gear pump 5.Safety valve

2.Radiator 4.Hudson motor 6.Parker motor
5-9
1.2 Working oil tank
1.2 Working oil tank

2
1
C1 3
4
C2
C3
LGB32005007
1: Air filter C1: From working pump

2: Tank C2: From blade pilot valve T
3: Dipstick and liquid temperature meter C3: From ripper pilot valve T
4: Return oil filter
5-10
1.3 Working pump
1.3 Working pump

Working pump is a tandem pump with the main working pump in the front (with displacement of 150 ml/r and
rated pressure of 21 Mpa). Rear pump is a pilot pump with displacement of 10 ml/r and rated pressure of
6MPa).
7 8 9 10 11
4
3
LGB32005008
1.Drive gear 5.Driven gear 8.Active gear of pilot pump

2.Front cover 6.Pump body 10.Slide bearing
3.Bearing 7.Middle part 11.Safety valve
4.Oil seal 8.Driven gear of pilot pump
5-11
1.4 Hydraulic control valve

(1) Multi-way valve
This manual uses 4-way valve (blade lift + tilt rag + ripper lift + angle modulation).
P T1
A4 B4
A3 B3
A2 B2
A1 B1
LSU
LGB32005009
A1: To ripper shunt (angle modulation P: From working pump B3: To rod port of blade tilt cylinder
cylinder) T2: To work tank B4: To rod port of blade lift cylinder
A2: To ripper shunt (lift cylinder) B1: To ripper shunt (angle modulation T1: To work tank
A3: To rod port of blade tilt cylinder cylinder) LSU: To work tank
A4: To rod port of blade lift cylinder B2: To ripper shunt (lift cylinder)
5-12
(2) Pilot control valve

Used for blade lift and tilt
2
T
3 1
P
4
Control lever device

(Movable device)
Wrinkled membrane Additional centering spring
Contorl lever location

MD2
Mounting plate
Oil tank connection
Control spool
Pump connection
Signal port LGB32005010
5-13
Used for angle modulation and lift of ripper
2
P
3 1
T
4
Control lever device

(Movable device)
Wrinkled membrane
Additional centering spring
Control lever location

MD2
Mounting plate
Oil tank connection
Control spool
Pump connection
Signal port
LGB32005011
5-14
(3) Solenoid valve
B A
P
LGB32005012
P: From working pump A: To blade lift hydraulic cylinder

T: To work tank B: To blade lift hydraulic cylinder
5-15
(4) Unload valve
P T AC P1
LGB32005013
P: From working pump T: To work tank

P1: To pilot control valve AC: To accumulator
1. Measure pressures of M port and MAc port of the pilot oil source valve block; pressure of M port swings
between 0.5MPa and 4 MPa; pressure of MAc swings between 3.2 MPa and 4MPa;
2. Measure pressure of pump lines; set working line pressure for at most 20MPa. During operation of blade
lift, working pressure will not reach 20 MPa due to functions of the cushion valve of lift cylinder. During
operations of blade tilt and ripper, cylinder runs to a limiting position, and system pressure will reach
20MPa.
3. Precharge pressure of an accumulator is 1.5MPa. It shall check whether precharge pressure of
accumulator is correct when pressures of M port and MAc port of pilot oil source valve block are abnormal.
4. If the maximum pressure of M port and MAc port of pilot oil source valve block cannot reach 4MPa, it shall
adjust unload valve pressure of the valve block.
5-16
1.5 Accumulator
1.5 Accumulator
Used for pilot control valve
1.Oil port
2.O-ring
3.Rubber ring
4.Gas capsule
5.Housing
6.O-ring
7.Inflation valve
Technical specifications:
Gas type: nitrogen
Nominal volume: 0.63L
Nominal pressure: 10MPa
LGB32005014
Function
Before oil absorption
• An accumulator is installed between an unload
A valve and a pilot control valve. If an engine shuts
down when hydraulic pressure is rising, nitrogen
pressure compressed in the accumulator will output
pilot pressure to the main control valve to start it
and make the hydraulic device drop relying on its
self weight.
LGB32005015
Operation
After oil absorption
• After shutdown of an engine, if the pilot control
valve is in the middle, the oil pressure in A cavity is
A
compressed by B cavity in the capsule.
• When operating a pilot control valve, if oil pressure
in B cavity is less than 4MPa, nitrogen pressure in
A cavity causes expansion of the capsule, and
therefore oil in B cavity is taken as the pilot pres-
sure and the main control valve is started.
B
LGB32005016
5-17
1.6 Hydraulic cylinder

Shovel blade lift hydraulic cylinder
LGB32005017
5-18
Shovel blade tilt hydraulic cylinder
LGB32005018
1.Bushing 8.Guide ring 15.Trim ring

2.Cylinder head cover 9.Seal ring 16.Piston
3.Cylinder body 10.wiper 17.Seat
4.Piston rod 11.wiper 18.Valve
5.Bushing 12.Seal ring 19.Cover
6.Piston nut 13.Seal ring
7.Seal ring 14.Check ring
5-19
Ripper lift modulation hydraulic cylinder
LGB32005019
5-20
Ripper tilt modulation hydraulic cylinder
LGB32005020
Unit: mm
Item Blade lift Blade tilt Ripper lift Ripper tilt
Piston rod OD 70 100 80 80
Inner diameter of hydraulic cylinder 140 200 180 180
Stroke 1532 152 540 500
Min assembling distance 783 1308 1300 1350
Width of piston nut lateral section 85 94 98 98
5-21
1.7 Piston valve
1.7 Piston valve

The piston valve is installed in piston part of the blade lift cylinder. Function of this valve is to discharge hydrau-
lic oil output from the working pump at the travel end of a piston rod.
If a piston rod stops suddenly at the travel end with a quite quick movement speed, temporary surge pressure
may occur in the oil line. If hydraulic oil is still output to a hydraulic cylinder, The circuit pressure can rise and
be assembled in the main unload valve of the control valve, and thus relief begins.
Surge pressure and regular overflow occurred at the travel end are not good conditions for oil hydraulic circuit,
therefore, before reaching the travel end, a piston of this structure can make the piston valve end touch bottom
or head of the hydraulic cylinder and thus discharge hydraulic oil around the piston valve.
When the piston is moving
Pressure oil from a working pump adds pressure to the
21 22 23 piston and piston valve.
Piston valve is pushed and moves to the direction
pointed by an arrow (→), and thus adds sealing to cone
part of the piston valve seat, therefore pressure inside
the hydraulic cylinder rises and the piston rod is
pushed to the direction pointed by an arrow (→).
LGB32005021
When the piston valve is moving

Before a piston rod reaches the travel end, the end of a
22 23 piston valve touches the cylinder bottom (or cylinder
21
head), the piston valve stops, and only the piston rod
still keeps moving.
This moment, hydraulic oil sealed in the cylinder by the
piston valve is discharged from a piston seat, and
hydraulic pressure in the cylinder stops rising at once.
Touch Therefore surge pressure in the circuit can be pre-
vented, overflow will not occur for the main relief valve
of the control valve, and circulatory flow of hydraulic oil
is completed by piston valve movement.
LGB32005022
5-22
1.8 Rapid lowering valve
1.8 Rapid lowering valve

Structure
1 5 4 3 2 Rapid lowering valve includes a valve body, springs,
slide valves, check valves and neck straps. Function of
a rapid lowering valve is to reduce vacuum generated
inside a hydraulic cylinder. This kind of vacuum is gen-
erated when descent speed of a blade increases,
which can reduce loss of time until excavation opera-
tion begins.
Descent speed of a blade is determined by displace-
ment of a pump, therefore, installation of the rapid low-
ering valve can obtain a faster descent speed.
1.Valve body 2.Spring
3.Slide valve 4.Check valve 5.Neck strap
LGB32005023
Operation
1. When a blade begins to drop
When placing working equipment - a control lever
in “L” position, oil from a control valve flows into the
1
bottom of a hydraulic cylinder through port A.
Meanwhile push the piston, and oil in the hydraulic
cylinder head is pushed to port B and flows to the
tank.
2. When a blade begins to drop:
C
Oil from the hydraulic cylinder head flows to port C
through port B.
5 4 3 2 LGB32005024
In the meantime, differential pressure will occur in

the front and rear of an eyelet due to functions of
the throttle valve in an oil line. If the differential
pressure is higher than spring force, the spring is
shortened, and the slide valve and valve are moved
1
to the right.
Part oil flowing into a tank from the hydraulic cylin-
der head flows into the channel connected with the
hydraulic cylinder bottom. Due to this result, the oil
and oil from the control valve flow into the hydraulic
C
cylinder bottom together.
It is known from above description that descent
5 4 3 2
speed of a blade increases due to installation of the
LGB32005025
rapid lowering valve. The reason is that oil flows
into the hydraulic cylinder and thus vacuum gener-
ated in the hydraulic cylinder bottom is reduced.
5-23
1.9 Gear motor (Parker)
1.9 Gear motor (Parker)
Oil inlet 4
Drain port
Return port 2
LGB32005026
Displacement: 37ml/r Rated pressure: 25MPa.

1.Output shaft 3.Gear 1
2.Bearing 4.Gear 2
5-24
1.10 Gear pump for the cooling system
1.10 Gear pump for the cooling system
2 3
1
Oil suction port
Oil outlet
LGB32005027
Displacement: 50ml/r Rated pressure: 21MPa.

1.Pump cover 3.Pump body
2.Drive gear 4.Driven gear
5-25
1.11 Safety valve for the cooling system
1.11 Safety valve for the cooling system
3
2
LGB32005028
Rated pressure: 20MPa

1.Pressure regulating lever 3.Pressure port
2.Oil drainage port
5-26
1.12 Pilot oil source valve

Main functions of the pilot oil source valve are to keep stable pressure of the pilot system, control work of the
pilot system, provide an emergency pressure source by an accumulator when the system shuts down, and
unload the system.
Connect the pilot pump to port P, blade and ripper pilot valve to port P1, accumulator to port Ac, tank to port T,
and port M is the pressure measuring port.
Principle description:
Connect a pilot pump to port P to provide pressure oil. If a solenoid valve does not reverse, an accumulator will
be charged by pressure oil through port Ac. If a solenoid valve reverses, connect the pilot handle to port P1 to
control actions of the main valve by pressure oil. The check valve can prevent oil from backstreaming, and the
relief valve ensures the system pressure less than 4MPa and prevents overload. If working pressure of a pilot
pump is over 4MPa, unload valve 2 begins to load shedding and differential pressure occurs in the front and
rear of the middle throttle valve between B and C. If pressure of A is higher than that of C, the spring is com-
pressed, logical valve 4 is opened, and unloading is completed. If pressure of port Mac is lower than 3.2MPa,
close the unload valve, stop unloading, and the logic valve spring is reset. Disconnect port P and port T, and
pressure of the line rises.
3
2
4
5
LGB32005029
5-27
Schematic diagram
4
3
B C
2
5
LGB32005030
1.Valve body 3.Solenoid valve 5.Check valve

2.unload valve 4.Logic valve
5-28
Neutrality 1
10
3
12
4
11
11
5
12
6
13
7
14
15
8
LGB32005031
1.Hydraulic oil tank 6.Accumulator 11.Rapid lowering valve

2.Filter 7.Blade control valve 12.Blade lift hydraulic cylinder
3.Hydraulic pump 8.Ripper control valve 13.Blade tilt hydraulic cylinder
4.Main safety valve 9.Multi-way valve 14.Ripper angle modulation hydraulic cyl-
5.Unload valve 10.Solenoid valve inder
15.Ripper lift hydraulic cylinder
5-29
1.13 Blade lift operation
1.13 Blade lift operation

1
10
3
12
4
11
11
5
12
6
13
7
14
15
8
LGB32005032
9

3.Hydraulic pump 8.Ripper control valve 13.Blade tilt hydraulic cylinder
5-30
1.14 Ripper lift operation

1
10
3
12
4
11
11
5
12
6
13
7
14
15
LGB32005033
8

3.Hydraulic pump 8.Ripper control valve 13.Shovel blade
5-31

1
10
3
12
4
11
11
5
12
6
13
7
14
15
8
LGB32005034
9

2.Filter 7.Blade control valve 12.Shovel blade lift hydraulic cylinder
3.Hydraulic pump 8.Ripper control valve 13.Shovel blade tilt hydraulic cylinder
15.Ripper lift modulation hydraulic cylinder
5-32
1.16 Ripper angle modulation operation
1.16 Ripper angle modulation operation

1
10
3
12
4
11
11
5
12
6
13
7
14
15
LGB32005035
8
1. Hydraulic oil tank 6. Accumulator 11. Rapid lowering valve

2. Filter 7. Blade control valve 12. Shovel blade lift hydraulic cylinder
3. Hydraulic pump 8. Ripper control valve 13. Shovel blade tilt hydraulic cylinder
4. Main safety valve 9. Multi-way valve 14. Ripper angle modulation hydraulic cyl-
5. Unload valve 10. Solenoid valve inder
15. Ripper lift modulation hydraulic cylinder
5-33
2 Check and adjustment
2.1 Overview

2.1 Overview
The hydraulic system can act normally only when the flow and oil pressure are ensured. When analyzing and
checking the hydraulic system, pay special attention to those items.
Oil flow is closely related to the engine speed. Oil pressure is produced by restricting oil flowing.
The check of hydraulic system consists of the following 3 stages.
The first is check by eye, the next is check after start, and the last is measurement by measuring instruments.
The test of hydraulic system can be done by hydraulic measuring tools.
Therefore, pay attention to the following basic items of hydraulic system, and you can find out the fault point
easily.
Prevent danger
When testing and adjusting the hydraulic system, drive the vehicle away from the site and the crowd, only one
person is allowed to get on, and others stay together beside the machine and within the driver’s vision.
1. Visual inspection
When checking the fault, the first is check by eye.
Stop the engine, lower the work implement on the ground, and check the following items.
1) Oil quantity
2) Take out the filter element, and check for inclusions.
Use magnets to distinguish ferrous metal, non-ferrous metal and non-metal sealing material (piston ring, O-
ring, etc.).
3) Check all oil pipes and joints for damage and external leakage.
4) Check the control device for bend and damage.
2. Check after start
Check and run the system by check after start to find out internal leakage and damage to valve and pump.
5-34
2.2 Hydraulic pressure control
2.2 Hydraulic pressure control

12
1
11
3
2
2
10
3
4
9
5
6
LGB32005036
8
1. Solenoid valve 5. Ripper angle modulation hydraulic cylin-9. Blade control valve
2. Rapid lowering valve der 10. Unload valve
3. Shovel blade lift hydraulic cylinder 6. Ripper lift modulation hydraulic cylinder 11. Hydraulic pump
4. Shovel blade tilt hydraulic cylinder 7. Multi-way valve 12. Filter
8. Ripper control valve
5-35

Oil Set oil pressure (MPa)
Size of
Measurement temperature
Item measuring Low-speed Remarks
items °C in Engine all
plug gauge rotation of
measuring speed
engine
Work
hydraulic Main safety
PT1/8 45~55 20 20
system pressure
pressure
2.4 Measuring procedure of oil pressure

1. Measure the pressure of main safety valve
1) Make work implement touch the ground, turn off
engine, operate work implement control lever for
two to three times, eliminate residual pressure in
the circuit, and lock control lever during operating
state (in any position except floating position).
Disconnect circuit of work tank (control valve) -
working pump
LGB32005037

3) Remove floor cover and plug cock, and install
pressure gauge (35MPa)
LGB32005038
5-36
2.4 Measuring procedure of oil pressure
Return the control lever to "N" position, then start the

engine, operate the control lever to move the mea-
sured cylinder to travel end, and measure the oil pres-
sure when the engine runs at idle speed and full speed.
• Oil temperature during measuring: 45-55°C
LGB32005039
2. Adjust oil pressure

If necessary, adjust the oil pressure according to
the following points.
1) Release oil in work tank and remove the tank
cover.
2) Unscrew adjusting bolt and locknut of main
safety valve and adjust them by rotating
adjusting bolt.
Pressure rises when rotating to the right and
drops when rotating to the left.
Bulge size of standard bolt:
LGB32005040
Pressure adjusting range of a rotation:
3.19MPa
2.92MPa
3. Measure oil temperature
1) Remove the filling oil cover of a work tank.
Remove split ring first, then filter, and insert the
temperature sensor.
HPM Dala Logger
29.2
W WEBTEC
LGB32005041
5-37
2.5 Measurement of work implement hydraulic settlement
2) Connect the sensor with the thermal rheostat,

and then measure the oil temperature.
a Logger
HPM Dal
31.4
W WEBTEC
LGB32005042
2.5 Measurement of work implement hydraulic settlement

1. Lift
1) Start engine, lift a blade (or other work
implements) for 800 mm away from the ground
and turn off the engine.
2) Place control lever in a "positioning" position,
stagnate a vehicle for 15 min, and measure
blade cylinder settlement.
LGB32005043
2. Tilt
1) Start engine, tilt a blade to the left in maximum
degree and land the right side, and turn off the
engine.
2) Place control lever in a “Locating” position,
stagnate a vehicle for 15 min, and measure
blade cylinder settlement.
LGB32005044
5-38
2.6 Maintenance standard table
2.6 Maintenance standard table

Standard Allowabl
Item Conditions
value e value
Oil pressure
Idle speed and full

Main relief Oil temperature: 45-55°C
speed
Increase idle speed

to full speed
Oil temperature : 45-55°C
Lower idle speed to
No load on blade
full speed
Ground to lifting limit
Floating, idle speed
Shovel blade
and full speed

Stop engine when oil temperature
Natural
reaches 40°C - 50 °C
drop
Drop amount of blade center 800
amount
mm away from the ground
Vehicle
The amount of stator center when
drop
there is only blade for support
amount
Left tilt, idle speed
Oil temperature reaches 45°C - 55
Performance
Full speed
Tilt speed °C and no load is applied to blade.
Right tilt, idle speed
Tilt one side to the other side
Blade tilt
Full speed
Tilt return Down on the ground: tilt it, support
Natural the vehicle and stop the engine Left tilt
drop when oil temperature reaches Right tilt
amount 40°C - 50°C.
Increase idle speed
From ground to lifting limit when oil
Ripper to full speed
temperature reaches 45°C - 55°C
speed Lower idle speed to
and one tooth is in high position
full speed
Drop amount of tooth root 500 mm
Natural
Ripper
above the ground: stop the engine

drop
when oil temperature reaches
amount
45°C - 55°C
Drop amount of sprocket center:
Vehicle
support ripper and stop the engine
drop
when oil temperature reaches
amount
45°C - 55°C
5-39
3 Removal and installation
3.1 Removal of hydraulic pump as

3.1 Removal of hydraulic pump as
Place work implement on the ground completely, turn
2 4
off engine, operate control lever for several times to
release residual pressure in the hydraulic lines, and
loosen oil filler cap slowly to release pressure inside
the hydraulic oil tank.
1. Oil mass flowed from the hydraulic oil tank is 218L
2. Remove cab and floor plate as referring to removal
of cab and floor plate as for details.
3. 1) Divide inlet pipe (1) (the hose connecting with
the work tank can be removed) and outlet hose (2)
of main oil pump.
2)Separate the pilot oil pump inlet pipe (3) (the
1 3 LGB32005045 hose connecting with the work tank can be
4 Lift hydraulic pump as temporarily, remove
mounting bolts, and remove hydraulic pump as
(5). Weight of hydraulic pump as is 15kg.
5
LGB32005046
3.2 Installation of hydraulic pump as

• Install according to the reverse procedure of removal.
• Refuel engine oil again
Screw bolts of the tank and refuel specified engine oil through the oil filler.
• Start engine to make engine oil cycle in the whole system and recheck oil level.
• The refueled engine oil is 218L.
5-40
3.3 Installation of pilot lines as

1. Install hoses on the pilot control valve in
Ripper pilot valve accordance with requirements of the installation
Pilot valve port,
Multi-way valve, Hose
drawing. The installed ripper control valve as (1)
connector code
unload valve,
block port code
as PN and blade control valve as (2).
Blade
pilot
valve
Ripper
Blade pilot valve
pilot
valve
Fitting (00A3399)
Fitting (00A3399)
1 2
LGB32005047
2. Install ripper control valve as (1) and blade

control valve as (2) on the floor plate.
LGB32005048
5-41
3. Install ripper control valve and blade control valve in accordance with numbers on the installation drawing,
which shall be connected with multi-way valve, unload valve and block.
LGB32005049
Oil outlet of pilot valve Oil outlets of multi-way valve and unload valve
1 a3
2 a4
3 b3
Blade pilot valve
4 b4
P P1
T Oil return
1 a1
2 b2
3 b1
Ripper pilot valve
4 a2
P P1
T Oil return
5-42
3.4 Removal of ripper control valve as and blade control valve as
3.4 Removal of ripper control valve as and blade control valve as

Notice: Conduct installation in reverse order of removal
3.5 Removal of blade lift cylinder as
Place blade as on a level ground
1. Put blade horizontally on the ground, remove four
bolts of lift cylinder by a wrench, lift blade slowly,
and remove bush (1).
• Start engine, retract piston rod completely and tie it
with steel wires to prevent from falling out.
Operate control lever for several times to release
residual pressure in the hydraulic lines.
• After removal of cylinder from dozer blade. Pay
attention not to lose gaskets, otherwise sinker will
occur for next installation and the use of cylinder
will be affected, and piston rod will be broken under
1 2
LGB32005050
serious conditions.
2. Remove hose (2).

4 3
3. Lift blade lift cylinder as temporarily, remove
cover (4), and remove blade lift cylinder (3).
Weight is 208kg
LGB32005051
3.6 Assembly of blade lift cylinder as

• Install according to the reverse order of removal
• Bleeding air
• Bleed air out of hydraulic oil cylinder
5-43
3.7 Removal of blade tilt cylinder as
3.7 Removal of blade tilt cylinder as

Place blade as on a level ground
2 1 4
2. Lift tilt cylinder as temporarily and remove cover
(2).
• Start engine and retract piston rod completely.
residual pressure in the hydraulic lines.
3. Remove hose (3).
Remove pin (4) and remove tilt cylinder as (5).
Weight is 190kg
LGB32005052
3.8 Installation of blade tilt cylinder as

• Install according to the reverse order of removal
Adjust gasket thickness to make axial clearance of
ball head less than 1 mm and this part rotates
smoothly with gasket thickness less than 3 mm.
5
3 LGB32005053
5-44
3.9 Removal of ripper tilt cylinder as
3.9 Removal of ripper tilt cylinder as

1. Lift the lift cylinder as temporarily and remove pin
(1).
• Start engine, retract piston rod completely, and
put it on the arm.
Operate control lever to release residual pres-
sure in the hydraulic lines.
LGB32005054
2. Remove hose (2).

4 2
3. Lift tilt cylinder as temporarily, remove pin (3),
then remove lift cylinder as (4)
Weight is 290 kg
LGB32005055
3.10 Installation of ripper tilt cylinder as

• Installation is in the reverse order of removal.
• Bleeding air.
• Bleed air out of hydraulic oil cylinder.
5-45
3.11 Removal of ripper lift cylinder as
3.11 Removal of ripper lift cylinder as

1. Lift tilt cylinder as temporarily and remove pin (1).
• Start engine, retract piston rod completely, and
put it on the arm.
residual pressure in the lines.
1 4 3 LGB32005056
2. Remove hose (2).

remove cover (4), and remove tilt cylinder as (4)
down.
Weight of cylinder is 310 kg
2 LGB32005057
3.12 Installation of ripper lift cylinder as

• Bleeding air.
• Bleed air out of hydraulic oil cylinder.
5-46
3.13 Disassembly of hydraulic cylinders as

1. Tube for cylinder
1 Remove oil pipe (1).
2. Quick drop valve (only for blade lift cylinder).
LGB32005058
3. Piston rod gp
1) Remove bolts and take apart cylinder head.
• Unscrew bolts.
LGB32005059
2) Pull out piston rod as (4) and pay attention to

hold the piston end when the piston rod is going
4 to fall out to prevent it from falling on the ground
and being damaged.
• Put a container under the cylinder in order to col-
lect oil.
• After removal of piston, check O-ring of piston
seal cylinder head for damage.
• After removal of cylinder body, check inside of
the cylinder body by a flashlight for foreign mat-
ters and damage.
LGB32005060
5-47
4. Piston gp
• Blade lift, blade tilt, ripper lift, ripper tilt cylinder.
1) Put piston rod as on the fixture.
LGB32005061
2) Remove pistons and nuts (5) by a hydraulic

pump.
5
3) Remove piston as (6).
4) Decomposition of piston as.
LGB32005062
① Remove snap ring (7).

② Remove wear ring (8).
③ Remove piston ring (9).
8 9
LGB32005063
5-48
④ Remove bracket (10) and valve (11).
12
11
10
7
7
LGB32005064
5. Cylinder head as
17 1) Remove cylinder head as (3).
2) Remove cylinder head as.
① Remove snap ring (12) and dust seal (13).
② Remove seal ring (14)
12 13 14 15 16 15
③ Tap out seal ring (15)
④ Remove seal ring (16)
⑤ Remove O-ring (17)
LGB32005065
5-49
4 Maintenance and standard

(1) Blade lift hydraulic cylinder
LGB32005066
Unit: mm
Counterm
easure
Tolerance
Standard Standard Clearanc
Clearance between size clearance e limit
1 Shaft Hole
piston rod and bushing
0.030~
70 -0.030-0.076 +0.074+0
0.150
2 1500 ± 300 N.m (transverse section width is 85mm)
piston nut
Tolerance
3 piston rod shaft and Shaft Hole
bushing
+0.300+0.10
45
0
Clearance between
4 hydraulic cylinder 85 -0.150-0.250
shaft and bushing
5-50
(2) Blade tilt hydraulic cylinder
LGB32005067
Unit: mm
Counterm
easure
Tolerance
1 Shaft Hole
0.036~
100 -0.036-0.090 +0.087+0
0.177
2 4800 ± 250N.m (transverse section width is 94mm)
piston nut
Tolerance
Clearance between Standard Standard Clearanc
bottom bushing of size clearance e limit
3 Shaft Hole
hydraulic cylinder and
pin +0.220+0
60
.100
4 hydraulic cylinder 600±50N·m
head mounting bolt
5-51
(3) Ripper lift hydraulic cylinder
LGB32005068
Unit: mm
Counterm
easure
Tolerance
1 Shaft Hole
0.030~
80 -0.030-0.076 +0.074+0
0.150
piston nut
Tolerance
3 piston rod bushing and Shaft Hole
pin
+0.260+
110
0.120
Clearance between
bottom bushing of +0.260+
4 110
hydraulic cylinder and 0.120
pin
5-52
(4) Ripper tilt hydraulic cylinder
LGB32005069
Unit: mm
Counterm
easure
Tolerance
1 Shaft Hole
0.030~
80 -0.030-0.076 +0.074+0
0.150
piston nut
Tolerance
3 piston rod bushing and Shaft Hole
pin
+0.260+
110
0.120
Clearance between
bottom bushing of +0.260+
4 110
hydraulic cylinder and 0.120
pin
6 Work implement system
1 Structure and function............................................................... 6-3

1.1 Straight tilt blade ........................................................................... 6-3
1.2 3-tooth ripper ................................................................................ 6-6
2 Maintenance standard ............................................................... 6-8
2.1 Straight tilt blade ........................................................................... 6-8
2.2 3-tooth ripper .............................................................................. 6-12
2.3 1-tooth ripper .............................................................................. 6-14
3 Test and adjustment ................................................................. 6-16
3.1 Key points of installing and adjusting straight tilt blade .............. 6-16
4 Disassembly and assembly ................................................... 6-18
4.1 Removal of blade as ................................................................... 6-18
4.2 Installation of blade as ................................................................ 6-19
4.3 Disassembly of blade as............................................................. 6-20
4.4 Assembly of blade as.................................................................. 6-22
4.5 Removal of 3-tooth ripper as ...................................................... 6-23
4.6 Installation of 3-tooth ripper as ................................................... 6-24
4.7 Installation and removal of 1-tooth ripper ................................... 6-27
4.8 Installation of pin puller ............................................................... 6-27
4.9 Removal of pin puller .................................................................. 6-28
6-2
6-3
1.1 Straight tilt blade

6
3
4
LGB32006001
LGB32006002
6-4
A-A
LGB32006003
10 11 12
C-C D-D
B-B
LGB32006004
6-5
E-E
13 14 P Q
F-F
LGB32006005
1.Cutting tool 6.Trunnion 11.Pin

2.Arm 7.Cutting edge 12.Connector
3.Oblique support 8.Blade angle 13.Bush
4.Push rod 9.Inclining oil cylinder 14.Pin
5.Arm 10.Lock plate
Structure
Straight tilt blade
The arc plate of cutting tool (1) is made of high-strength wear-resistant plates, with high wear resistance and
impact-resistant mechanical property.
The cutting edge (7) and angle (8) are made of high wear-resistant and high-strength steel plates, with good
core toughness and high impact resistance. And middle cutting edge is divided into three pieces to facilitate
reverse operation.
The push rod is made of section steel square pipe and high-strength cast steel seat by welding. Its section is
rectangular, with strong resistance to bending. Its front is connected with the cutting tool through ball contact;
its rear is fixed to the track frame through the trunnions (6). It can rotate around the trunnion through the lift cyl-
inder.
The tile angle of blade can be adjusted through the tilt cylinder (10). The blade is supported by the oblique sup-
port (3) and tilt cylinder.
Maximum lifting capacity of a dozer: 1380mm
Maximum dropping capacity: 560mm
Maximum tilt regulating capacity: 1000mm
6-6
1.2 3-tooth ripper
1.2 3-tooth ripper

B
2
3
1 B
W
C
C
5
4
7 6
LGB32006006
C-C
A-A B-B D-D
LGB32006007
6-7
1.2 3-tooth ripper
D D
LGB32006008
1.Holder 4.Ripper tooth 7.Connecting bracket

2.Ripper cylinder 5.Shield
3.Beam 6.Tip
For 3-tooth ripper, bracket (1) is installed on the steering case by bolts, both ends of connecting bracket (7) is
respectively fixed to bracket (1) and beam (3) by pin C, one end of ripper cylinder (2) is fixed to bracket (1) by
pin A, and piston rod is fixed to beam (3) by pin B.
The riper tooth (4) is installed on the beam (3) by pin, and the tip (6) is installed on the ripper tooth (4) by pin.
Elongate and shorten ripper cylinder by controlling it to make gear rack up and down to adapt requirements of
working conditions.
6-8
2 Maintenance standard
LGB32006009
(1)Cutting tool, support, push rod
LGB32006010
6-9
B-B C-C D-D

2 7 5
6
3
E-E P Q
F-F
8 9
1 LGB32006011
Unit: mm
Judgment standards
Counterm
No. Check items Standar Tolerance Standard Clearan easure
d size Shaft Hole clearance ce limit
Spherical clearance between -0.5 +0.5
1 160 0.5~1.5 10
trunnion cover and trunnion -1.0 0
-0.5 +0.3
2 Clearance between pin and joint 70 0.5~0.9 3
-0.6 0
-0.5
3 Clearance between pin and joint 70 +0.30 0.5~0.9 3
-0.6
Clearance between blade carrier Replace
-0.2 +0.8
4 and joint and clearance between 140 0.5~1.5 3
-0.7 +0.3
push rod and hinge
Clearance between key-bolt and -0.3 +0.5
5 60 0.5~1.0 2
carrier -0.5 +0.2
Clearance between key-bolt and -0.3 +0.5
6 60 0.6~1.0 2
screw rod -0.5 +0.3
Clearance between arm ball joint -0.2 +0.3
7 115 0.2~0.6 1 Gasket
and cover -0.3 0
6-10
Judgment standards
Counterm
No. Check items Standar Tolerance Standard Clearan easure
Clearance between arm pin and -0.3 +0.5
8 60 0.5~1.0 2 Replace
blade carrier -0.5 +0.2
Clearance between arm pin and -0.3 +0.5
9 60 0.6~1.0 2 Replace
arm rod -0.5 +0.3
(2) Blade angle and cutting edge
3
2
LGB32006012
6-11
Unit: mm
Judgment standards
No. Check items Countermeasure
Replace or rotate
1 Cutting edge width 254 215 (175, after rotation)
(to 175 after rotation)
Blade angle width
2 315 235
(external measuring)
Blade angle width (internal
3 254 215 Replace
measuring)
4 Blade angle length 540 440
Tightening torque of 642-868Nm

5
mounting bolt 753-1019Nm
6-12
2.2 3-tooth ripper
2.2 3-tooth ripper
2 3,4
6
5
2
7
5,6,7
LGB32006013
6-13
2.2 3-tooth ripper
Unit: mm
Judgment standards
Counter
No. Check items Standar Tolerance Standard Clearan measure
Clearance between mounting -0.036 0.156~0.29
1 110 1.5
pin and bushing -0.090 7
Clearance between ripper
-0.036 0.156~0.29
2 hydraulic cylinder and 110 1.5
-0.090 7
mounting pin
+0.3
3 75
Clearance between ripper -0.3
3.7~6.3 15
tooth and mounting pin +1.0
80
-1.0
+0.3
4 75
Clearance between -0.3
0.4~1.6 10
connecting bracket and pin +0.3 Replace
76
-0.3
0
5 24.5
Clearance between shield -0.1
0.3~0.85
and pin +0.25
25
-0.25
6 Basic dimension Operating limit

Wear of tip
335 225
7 Wear of shield 115 90
Tightening torque of ripper

8 3600~4400Nm
carrier mounting bolt
6-14
2.3 1-tooth ripper
2.3 1-tooth ripper
2
2
3,4
1
5
1 7
5,6,7
LGB32006014
LGB32006015
6-15
2.3 1-tooth ripper
Unit: mm
Judgment standards
Counterm
No. Check items Standar Standard Clearance
Tolerance easure
d size clearance limit
Clearance between mounting -0.036 +0.207
1 110 0.156~0.297 1.5
pin and bushing -0.090 +0.120
Clearance between ripper
-0.036 +0.207
2 hydraulic cylinder and 110 0.156~0.297 1.5
-0.090 +0.120
mounting pin
+0.3
80
Clearance between ripper -0.3
3 6.7~9.3 15
tooth and mounting pin +1.0
80
-1.0
+0.3
80
Clearance between -0.3
4 1.4~2.6 10
connecting bracket and pin +0.3
82
-0.3 Replace
0
24.8
Clearance between shield -0.1
5 0.3~0.85
and pin +0.25
25
-0.25
Standard size Operating limit

6 Wear of tip
335 225
7 Wear of shield 115 90
Tightening torque of ripper

8 3600~4400Nm
carrier mounting bolt
6-16
3 Test and adjustment
3.1 Key points of installing and adjusting straight tilt blade

1. Cutting tool is in horizontal condition
1) Set distance L1 between mounting pins of tilt
cylinder as 1388 mm.
1
2) Also set distance L1 between mounting pins of
left support as 1388 mm.
L1 3) If cutting tool is not in horizontal condition under
1) and 2) states above, it shall first fix the
distance between mounting pins of tilt cylinder
and rotate left supporting arm to make cutting
tool in horizontal condition.
• Clearance of supporting arm shaft direction shall
be adjusted within 1 mm by gasket (1).
LGB32006016
Gasket (1) standard：4mm
2. Push rod shall be in horizontal condition

1) Install left and right front arms (2) and (3), and
adjust gasket (4) to make clearance of shaft
6
direction within 1 mm.
<
Standard of the gasket (4): 4mm
5 2) Install left and right oblique arms (5) and (6), and
adjust gasket (7) to make clearance of shaft
direction within 1 mm.
2
4

/
3 $ 3) In above 1) and 2) states, push or pull cutting tool
back and forth to make clearance between push
rod (8) and track (9) reach A dimension.
5 9 LGB32006017
A dimension: 222 mm (left and right sides must
be equal)
4) In the meantime of above item 3), for clearance B
between interlink ball carrier and reverse side of
cutting tool of the left front arm and height C of
central ball joint carrier, their positions must be
determined.
B dimension: 45mm
C dimension: 150mm
5) Fix the position of central ball joint carrier,
measure clearance between gaskets (10) of left
and right front arms, and determine quantity of
gaskets and fasten them.
6-17
6) Clearance of shaft direction of left and right

oblique arms shall be adjusted within 1 mm by
gasket (11).
7) Pay attention to distance (L2 dimension) between
mounting pins of left and right oblique arms.
L2 distance: 1367 mm.
Standard thickness 4
L
8
Q
LGB32006018 LGB32006019
Sta
nda
rd th
ickn
e
ss 4
LGB32006020 LGB32006021
6-18
4.1 Removal of blade as

4.1 Removal of blade as
• Place blade on a level ground and place blocks ①
under left and right push rods firmly.
LGB32006022
1. Remove bush (1)

Put blade horizontally on the ground, remove four
1
bolts of lift cylinder by a wrench, lift blade slowly, and
remove bush.
Operate handle for several times to release

pressure of oil in hydraulic tube
LGB32006023
6-19
4.2 Installation of blade as
2. Remove the cover (2).

2
LGB32006024

4. Remove left and right blind nut (4)
• Start engine, back away slowly, and remove
blade as.
3 1 LGB32006025
4.2 Installation of blade as

LGB32006026
6-20
4.3 Disassembly of blade as
• Support left/right push rods by block ① to make it

reach the dimension required for installation.
• Standard values of dimension "a" and "b"
A:2980mm B:630mm
745±100Nm
b
LGB32006027

4 1 3
Place wooden blocks under the left and right push rod
2 5
and blade, and place the blade as at a proper position
safely.
1. Remove the cover (1)
2. Remove hose (2)
remove cover (4), and lift tilt cylinder as (5) down.
LGB32006028
4. Lift tilt support temporarily, remove pin (6) and

cover (7), and lift tilt support as (8) down.
7 8 6 LGB32006029
6-21
5. Lift linkage-lh temporarily, remove pin (9) and

cover (10), and lift linkage-lh (11) down.
Notice: Remove linkage-rh below in the same

way
6. Lift left push rod temporarily, remove pin (12) and
remove left push rod as (13).
 Notice: Remove right push rod in the same

way
10 11 9 12 13
LGB32006030
7. Remove blade foot (14) and blade cutting edge

(15).
15
14
LGB32006031
8. Lift blade as slowly and turn it over.

9. Lift linkage-lh temporarily, remove cover (17) and
binder bolt (18), and remove linkage-lh (19).
Notice: Remove linkage-rh in the same way
18 19 17 LGB32006032
6-22
4.4 Assembly of blade as
4.4 Assembly of blade as

 Notice: Install gaskets of which the number
shall be the same as that dismantled when
installing ball joint.
Notice: Adjust gasket to keep clearance of ball
head within 1 mm. The section must be able to turn
flexibly. The gasket thickness shall be no lower
than 3 mm.
1. Install gasket, put linkage-lh (10) in the installation
site, and install cover (18) and binder bolt (16).
Standard gasket thickness:
e
c: 4mm
c d
LGB32006033 d: 4mm
e: 5mm
Notice: Install linkage-rh in the same way.

2. Turn blade as (14) over and support it by wood
blocks.
3. Put left push rod (13) in installation site and install
pin (12).
Notice: Install right push rod in the same way.

4. Place gasket, put linkage-lh (11) in installation site,
and install pin (9) and cover (10).
Standard thickness of the gasket: 4mm
 Notice: Install linkage-rh in the same way.

5. Place gasket, put tilt support (8) in installation site,
and install cover (7) and pin (6).
6. Install gasket, install tilt cylinder as (5) in installation
site, and install cover (4) and pin (3).
7. Connect tube (2) and hose (1).
8. Install cover plate.
9. Install blade foot (14) (75.3 - 101.9 Kgm) and blade
cutting edge (15) (75.3 - 101.9 Kgm)
6-23
4.5 Removal of 3-tooth ripper as
4.5 Removal of 3-tooth ripper as

1. Remove three scarifiers
Respectively remove pin (2), collar (3) and pin
bushing (4), and remove three scarifiers (1).
 Notice: Lift bulldozer beam by sling during

removal, and underlay the beam by tooling.
1 2 3 4 LGB32006034
2. Ripper oil cylinder

Ripper oil cylinderRipper oil cylinder 1) Lift cylinder by sling and remove pin shaft and
stop plate, and take cylinder linkage back.
2) After cooling of oil temperature, remove hoses
connected with ripper cylinder.
Notice: Take cylinder linkage back before

removal of oil pipe.
LGB32006035
3) Lift four cylinders by sling and remove them.
LGB32006036
6-24
4.6 Installation of 3-tooth ripper as
5 6 4. Ripper beam
Remove stop plate and pin shaft and remove
ripper beam (7).
5. Ripper connecting bracket
Remove stop plate and pin shaft and remove
ripper connecting bracket (8).
7 8 LGB32006037
6. Left and right carriers of ripper

Remove captive bolts and nuts and remove left
and right carriers of ripper (9).
9
LGB32006038

1. 3-tooth ripper lines
1) Install steel tube of ripper cylinder.
 Notice: After installation of steel tube, steel

tube with connector exposed in the air must be
sealed to ensure cleanliness of hydraulic oil.
LGB32006039
6-25
2) Install eight hoses of the block.

Block
Lock Hose as Tube as Connect eight corresponding hoses of the block
in accordance with the figure.
a1 07C5021 09D1043
a2 07C5020 09D1044 a2 a
a1 Notice: Ensure whether O-ring meets
requirements when installing the hose, and seal
b1 07C5023 09D1044 connectors exposed in the air by plastic bags to
b2 b
b1 ensure cleanliness of hydraulic oil.
b2 07C5022 09D1043
d1 07C5017 09D1046 c2 c c1
d2 07C5017 09D1045
c1 07C5016 09D1045 d2 d
d1
c2 07C5016 09D1046 LGB32006040
2. Installation of 3-tooth ripper bracket

1) Installation of threaded link. Blow threaded link
into steering case by blower gun.
LGB32006041
2) Install left and right carriers

Install left and right carriers (9) in steering case
and screw bolts and nuts by 60# socket (3800 ±
350N. m).
9
LGB32006042
6-26
3. Connect connecting bracket

Connect left and right carriers by connecting
bracket and tighten them with pin shaft and stop
plate (600 ± 55N. m).
4) Install beam
Connect beam to connecting bracket and tighten
them with pin shaft (5) and stop plate (6) (600 ±
55N. m).
5,6
7
8
LGB32006043
5) Lift and install four cylinders

Block
Lock Hose as Tube as Respectively lift four cylinders to installation sites
of the left and right carriers by sling and tighten
a1 07C5021 09D1043 them with pin shafts and stop plates.
a2 07C5020 09D1044 a2 a
a1 （600±55N.m)
b1 07C5023 09D1044 6) Connect cylinder with beam

b2 b
b1 Connect hose to cylinder tube (connect them as
b2 07C5022 09D1043
shown in the figure), stretch oil rod to beam joint
d1 07C5017 09D1046 c2 c c1 by ripper operating handle and tighten them with
d2 07C5017 09D1045 pin shaft and stop plate. （600±55N.m)
c1 07C5016 09D1045 d2 d
d1
c2 07C5016 09D1046 LGB32006044
6-27
4.7 Installation and removal of 1-tooth ripper
7) Lift and install scarifier

Respectively lift and install three scarifiers (1), fix
them by pin guide and connecting bracket, and
respectively tighten the two sides with pin (2),
collar (3) and pin bushing (4).
1 2,3,4
LGB32006045
4.7 Installation and removal of 1-tooth ripper

Notice: Except for the pin puller, installation and removal steps of 1-tooth ripper are the same as
that of 3-tooth ripper
4.8 Installation of pin puller
1. Install pin puller.
1) Install pin puller (1), pin puller link (2) and pin
2
puller bracket (3)
LGB32006046
6-28
4.9 Removal of pin puller
2) Install pin puller lines.

For the two hoses, install one end to pin puller
cylinder (1), and another end to valve (4).
LGB32006047
4.9 Removal of pin puller

Notice: Installation and removal processes of
pin puller are opposite.
4
LGB32006048
7-1
7 Electrical system
1 Foreword ........................................................................... 7-3

2 Main components ............................................................. 7-4
2.1 34B0118 electric lock.....................................................................7-4
2.2 Plate-type fuse...............................................................................7-5
2.3 Alternator .......................................................................................7-9
2.4 Start motor ...................................................................................7-11
2.5 Working principle of start motor ...................................................7-12
2.6 Disconnect switch ........................................................................7-14
2.7 Battery .........................................................................................7-15
3 Instrument system .......................................................... 7-27
3.1 Brief introduction of function ........................................................7-27
3.2 Major component .........................................................................7-28
4 Light gp ........................................................................... 7-34
4.2 Major component .........................................................................7-34
5 Electric horn .................................................................... 7-40
5.2 Major components .......................................................................7-41
6 A/C system ...................................................................... 7-42
6.1 A/C system arrangement drawing ...............................................7-42
7 Specifications and technical descriptions for A/C 
system component ............................................................ 7-43
7.1 Compressor .................................................................................7-43
7.2 A/C control panel: ........................................................................7-44
7.3 Condenser as ..............................................................................7-44
7.4 Evaporator as: .............................................................................7-45
7.5 Refrigerant receiver as ................................................................7-45
7.6 A/C hose ......................................................................................7-46
7.7 Solenoid valve .............................................................................7-46
7.8 Water pipes..................................................................................7-47
7-2
8 Working principle for A/C system ................................. 7-48

8.1 Refrigerating system ................................................................... 7-48
8.2 Heating system ........................................................................... 7-49
9 Common fault and service for A/C system .................. 7-50
10 Fault diagnosis of A/C system .................................... 7-51
11 A/C system fault and maintenance flow ..................... 7-52
11.1 Control circuit troubleshooting flow ........................................... 7-52
11.2 Overhauling flow for poor refrigeration...................................... 7-54
11.3 Overhaul flow for abnormal noise fault...................................... 7-56
7-3
1 Foreword
1 Foreword in the Manual.

Full consideration to the relationship between the
The Manual is written by introducing the different general and the individual (system and component)
modules divided by the main functions of electrical when determining the failures will contribute to the
system, whereby, the maintenance operations of rapid, accurate and facilitated troubleshooting.
maintenance technicians are facilitated as they are
enabled to promptly find the chapters and sections On condition that digital multimeter (hereinafter
corresponding to the failure at any time. Besides, the referred to as DMM) is applied to detect faults, the
professional descriptions are compiled to be accessi- inherent measuring errors might result in a value
ble in the Manual, nonetheless, the maintenance per- slightly differing from that described in the Manual.
sonnel shall be provided with necessary professional
knowledge to understand the Maintenance Manual.
Usage of special probe
When dividing the modules, the Manual starts from
introducing the functions of the module, then presents For example, when you use 200 measuring range of
the main components of the functions, including the Ω gear of a digital multimeter to measure a measuring
object with its resistance described as "0", it shall
principles, functions and electrical diagrams of main
make red clock pen and black clock pen shorted and
components. Whereafter, operation of module func-
measure the lead resistance. Then when measuring
tion and the diagnosis and test of module failure are
circuit resistance, use the measured value to subtract
introduced.
lead resistance, circuit wire resistance and contact
The component symbols on the schematic diagram resistance of plug connector, and then compare it
indicate the representing methods of components on with described value in the manual. Description of
the diagram. The majority of component symbols sig- measured value in the manual ignores circuit wire
nify the actual schematic diagram of the components, resistance and contact resistance of plug connector.
whereas, the exceptions are specified when introduc- Deviation of described measured value and mea-
ing the components. It will help to judge the failure sured value will not exceed 10 Ω.
symptom of components.
In case of fault problems not specified in the manual,
Introduction of components in this manual only intro- conduct electric checkout and comply with following
duces fault detection methods of part components. steps:
And the method only aims at the component itself. In
1. Power voltage
other words, you can only check the components in
accordance with methods introduced above by 2. Short circuit to ground
removing components from the complete machine 3. Clock pen short circuit
when detecting. As it is unfeasible to detect the fail-
ures in accordance with the above-mentioned meth- 4. Open circuit
ods if the components are mounted on the complete 5. Function test
machine. Then determine in line with the failure
detection methods described behind the system, or
disassemble the components if necessary, to judge
the condition of components based on the component
troubleshooting method.
The module failure diagnosis and test introduced in
the Manual does not cover all the faults, thus please
rack your brain and focus on the accumulation of
experience during the troubleshooting.
In order to describe the electrical principles intuitively,
colored filling lines are applied to present the current
flow when introducing the electrical system principles
7-4
2 Main components
2.1 34B0118 electric lock
2 Main components
2.1 34B0118 electric lock
Electric lock S1
LTB32007001
Electric lock pin
OFF
ON
START
LTB32007002
Six electric lock pins are shown in the figure above: they are "B1";"B2";"G1";"G2";"M";"S".
B1 - B2 Power supply end (Line #110); G1 - reserved cold start end; M - switch on complete machine power,
and when electric lock is in "ON" or "START" position, switch on B1-M; S - start end of diesel engine, and when
electric lock is in "START" position, switch on B2-S.
Procedures of failure detection for electric lock
1. Disconnect all the connectors on the electric lock pin, to separate the electric lock from the machine circuit.
2. Turn the digital multimeter to 200 Ω of Ω position.
3. Set electric lock in “OFF” position, and use two clock pens of a digital multimeter to measure two of the six
electric pins except combination [B1, B2]; for [G2, S], indicated value of multimeter is “0”; indicated value of
any other uncombined digital multimeter is “1”, which means that resistance between them is infinite.
4. Set electric lock in “ON” position, as described in step 3, use two clock pens of a digital multimeter to
measure two of the six electric pins; wherein, during measurement of [B1, M]; [B1, B2]; [G2, S]; [B2, S],
indicated value is “0”, which means that resistances of the two pins are “0”. Indicated values of other pins
are all “1”.
7-5
2 Main components
2.2 Plate-type fuse
5. Switch the electric lock to gear "START", then repeat the operations introduced in step 3 to measure
randomly two of the six electric lock pins with both probes of the DMM. There into, other than the value "1"
of combinations containing G1 pin, that of the rest pins shall be "0".
Upon test of above steps, if displayed value of a multimeter is the same as step description, it may judge
that the electric lock is available.
2.2 Plate-type fuse

The fuse plays the roles of short-circuit and over-cur-
rent protections in the circuit.
Different series of fuses are applied in the CLGB320I
power system, such as plug-in fuse and bolt-type fuse.
The specifications of plug-in fuse diversified from 20A
to 15A, 10A, 7.5A and 5A, for the branch circuits.
Specifications of various fuses are labeled on fuse
housings. Observed by eyes.
LGB32007003
The colors of plug-in fuse vary in accordance with the specifications, the specifications and colors of plug-in
fuses applied in the machine, together with the corresponding LiuGong part numbers are listed in the table
below for reference only.
Riveter component number Specifications Color
37B0359 5A Tawny
37B0360 7.5A Brown
37B0361 10A Red
37B0362 15A Light blue
37B0363 20A Yellow
Notice: The specifications of different fuses are calculated during the circuit design, accordingly,
so the blown fuse shall be replaced with that of the same series and specifications. Don’t replace the
fuse with a fuse of different specifications.
The replaced fuse is likely to be blown again, so the replacement should be performed after checking the
circuit of the fuse and troubleshooting.
The troubleshooting method of fuse
The inspection methods of bolt-type fuses can also be applied in the judgment.
Adjustment steps for blowout of bolt-type fuse:
7-6
2 Main components
2.2 Plate-type fuse

2. Connect both terminals of the fuse with the DMM probes respectively.
3. The indicated value "1" of the DMM indicates that the fuse is blown and shall be replaced.while the value
"0" displayed on the DMM indicates the good service condition of fuse.
31B0083 (JQ202SK-ED-P) relay
LTB32007004
Relay parameters and internal schematic are all

labeled on the relay housing. Pay attention to the gen-
erality in use.
%26&+
Rated current at normally open contact of relay contact
9 circuit is 30A, at normally closed contact 10A.
9$ After adding +24V voltage to relay coil, electromagnetic
attraction generated by coil energization attracts arma-
tures inside the relay and thus make normally open
contact close and normally closed contact open.
LGB32007005
7-7
2 Main components
2.2 Plate-type fuse
31B0006 relay
LGB32007006
31B0011 relay
LGB32007007
This machine uses six relays which are respectively used for starting protection and quick lowering function of
relay and cylinder.
Both the relay parameters and internal schematics are labeled on the relay housing.
Steps of relay troubleshooting
1. Remove the relay from the relay socket.
2. Turn the digital multimeter to 2KΩ at the Ω position.
3. Connect the red probe of DMM to the terminal "86" or "1" of relay, while the black probe to terminal "85" or
"2",
(a) For 31B0095 relay, displayed value of the multimeter is about “255”.
(b) For 31B0173 relay, displayed value of the multimeter is about “155”.
5. Connect one probe of DMM to the terminal "30" or "5"of relay, while the other probe to terminal "87" or "3",
thereby, the value displayed on DDM shall be "1". Shift the probe at terminal "87" to terminal"87" or "4", the
7-8
2 Main components
2.2 Plate-type fuse
value displayed on DMM shall be "0".

6. Apply +24V external power (+) to the terminal "86" or "1" of relay, while (-) to terminal "85" or "2"; on the
other hand, connect one probe of DMM to the terminal "30" of relay, the other probe to terminal "87" or "3",
thereby, the DMM displayed value shall be "0". Shift the probe at terminal "87" to terminal "87" or "4", the
value displayed on DMM shall be "1".
After completing the above steps, if the values displayed on DMM conform to that described in the steps,
the relay is in good service condition.
The above steps are inapplicable to the operating contacts (both normally open and closed
contacts) where the abrasion is very severe.
7-9
2 Main components
2.3 Alternator
2.3 Alternator
Alternator installed in the complete machine is Commins diesel engine accessory with specification of 24V/
70A. It is 24SI series alternator of DelcoRemy with electronic voltage adjuster.
The alternator is connected in parallel with the battery to power the machine. The battery supplies power to the
electrical components before the diesel engine starts; then after it starts, alternator powers the electrical com-
ponents while charging the battery. Once the energy of alternator fails to meet the needs of the electrical com-
ponents, the alternator and battery jointly power the machine.
Alternator appearance and schematic symbol
This machine uses three connection ports of the alter-
nator, they are: anode of battery, ground connection
and indicator.
LGB32007008
As the main power unit of the machine, the alternator

translates the energy from diesel engine into service-
Circuit Schematic able electric energy of electrical components.
B+
W D+
N V
LGB32007009
The alternator consists of rotor, stator, belt pulley, fan, front and rear end caps, brush and other components.
The exciting winding is generally wound around the rotor in a triangular linkage with the stator; the rectifier is a
six-tube bridge full wave rectifier.
1. If direct voltage acts on two ends of a magnet winding, electric current will generate magnetic field which
will rotate with rotor driven by the diesel engine, and that is so-called rotating magnetic field. Under the
action of rotating magnetic field, three symmetrical windings of alternator stator will generate three
electromotive forces with same frequency and amplitude and sin 120° deviation.
7-10
2 Main components
2.3 Alternator
2. Use the unidirectional conductivity of silicon diode for rectification, only the positive diode connected with a
phase of winding at the highest potential is conducted at any moment; similarly, only the negative diode
connected with a phase of winding at the lowest potential is conducted; repeatedly, 6 diodes are conducted
in turn, and a steady pulsating DC voltage is obtained on either end of load.
3. The terminal voltage of alternator is in direct proportion to the alternator speed; since the variation range of
engine speed is very large, the terminal voltage of alternator will also vary over a wide range, which cannot
meet the requirement for application of constant voltage to electric equipment on the loader. So a constant
voltage regulator must be provided.
4. Voltage adjuster changes field current size through switching on and off internal electronic circuit, and thus
changes magnetic field strength to stabilize output voltage of an alternator.
Notice: The alternator of the machine is strictly prohibited to power the electrical equipment on the
machine separately in the absence of battery.
Metal tools or other metal conductors shall be kept away from the "B +" (Battery Positive) terminal and
“Ground” terminal of alternator during operating the diesel engine, in order to avoid short-circuit. Short circuit
on the engine will lead serious results.
Steps of alternator troubleshooting
Differing from the introduced fault detection methods for other components, the alternator fault detection is
implemented on the entire machine, which shall not be removed for individual inspection.
The following detection steps are inapplicable to the cases where the battery is fully charged and the terminal
voltage reaches 28V or above.
1. Turn the digital multimeter to 200V of voltage position.
2. Turn on disconnect switch of the machine, do not start the diesel engine, put red clock pen of a digital
multimeter over "B+" end of an alternator, put black clock pen over “Ground” terminal of the alternator, and
write down displayed value of the digital multimeter. The normal value is about 24-26 V.
3. Start diesel engine, follow the measuring method described in step 2, and note down the value on DMM
again. Such value shall be higher than the measured value in step 2, whereby, the alternator is in normal
condition.
The above test procedures shall be implemented on unloaded machine (unloaded: the condition that the
electric lock is switched on, yet all the electrical switches or components on the machine are switched off).
If the value on DMM is unchanged through the tests in steps 2 and 3, switch off the electric lock to inspect the
alternator as per the following steps.
1. Inspect the transmission belt of alternator in accordance with the methods introduced in the specification.
Readjust if the over-looseness occurs.
2. Check the security of alternator terminal, and fasten it with a wrench if necessary.
If the above-mentioned methods fail to solve the problem, please contact maintenance service sites of
LiuGong and Cummins.
7-11
2 Main components
2.4 Start motor
2.4 Start motor

Alternator appearance and schematic symbol
M12×1.75
Battery terminal
M5×0.8
Switch terminal
M12×1.75
Ground terminal
Start motor
LTB32007010
Start motor installed in the complete machine is Commins diesel engine accessory with specification of 24V/
11KW. It is ST4028 start motor with full sealed structure.
The DC motor within the start motor translates the electrical energy of battery into mechanical energy, whereby
the internal transmission gear drives the motor flywheel to start the engine.
7-12
2 Main components
2.5 Working principle of start motor

Structural drawing of start motor
LTB32007011
1.Solenoid switch 3.Fork 5.Stator winding of the start motor

2.Big contact of start motor 4.Rotor winding of start motor
Start motor is mainly composed of electromagnetic switch, DC motor, fork and drive gear. Electromagnetic
switch of a starter is controlled by a starting contactor. When an electric lock rotates to "III" position (start),
starting contactor begins to work. The normally open contact switches on electromagnetic switch power of the
start motor and thus makes the electromagnetic switch work. After turnon of the electromagnetic switch, attrac-
tion generated by internal electromagnetic coils make the iron core move towards the right and drive move-
ment of the moving contact panel. After that, two big contacts of the start motor are switched on and current
from the battery flows from two big contacts of the start motor to rotor winding and stator winding of the start
motor. Electric rotation is generated by the powered-on rotor winding under magnetic field action generated by
stator winding. Right movement of the electromagnetic switch iron core drives a start motor fork move towards
the left in the meantime and push transmission gear of the start motor move towards the left and thus mesh
with flywheel of a diesel engine; the start motor drives rotation of diesel engine flywheel and the diesel engine
begins to start.
7-13
2 Main components
Working Diagram of Starter Motor
From start relay
Solen oid Hold in windings

Full in windings
Plunger From battery
Contacts
To motor windings
Shift lever
Start motor
Starter solenoid
LTB32007012
Notice: It shall often check whether the wiring terminal of a start motor is connected reliably. Make
sure to turn off the disconnect switch during checking.
After start of a diesel engine, ensure to stop the start motor at once, or transmission gear of the start motor will
be damaged, the start motor will be burned away, and battery capacity and service life will be affected seri-
ously.
Metal conductor is not allowed to be close to the battery terminal and switch terminal after disconnect switch is
in “I” position.
Especially ensure fuel hoses and other metal conductors passed near the start motor will not have contact and
friction with the terminals above during long-term operation and driving process of machine; otherwise, it may
cause fire on the vehicle.
Fault detection steps for start motor
Usually start motor will make a sound when it runs. If start motor does not make a sound or diesel engine can
not be started when electric lock is in “START” position, the start motor and start circuit need testing.
The fault detection methods described here are completed on the machine, which are not applicable to remov-
ing start motor and detecting it individually. Machine must be in the emergency braking state and control lever
shall be in neutral position during detection.
Because of the automatic reset function, electric lock cannot be in "START" position for long time, so a com-
panion is needed in this detection step.
7-14
2 Main components
2.6 Disconnect switch

2. Turn electric lock to the “START” position and keep it to Step 2, and then release it until the Step 2 is
finished. Connect the black probe of digital multimeter to the metal conductor on the machine frame,
connect the red probe with big contact terminal (the “start motor wire” terminal is shown in Starter Motor
Operation Diagram) on the start motor, and the displayed value on digital multimeter shall be about “24”. If
displayed value is correct, but start motor has no response, it can be judged that the start motor is faulty. If
displayed value is incorrect, go on with the following steps.
3. Turn electric lock again to the “START” position and keep it to Step 3, and then release it until Step 3 is
finished. Connect the black probe of digital multimeter to metal conductor on the machine frame, connect
the red probe to “switch” terminal on the start motor, and the displayed value on digital multimeter shall be
about “24”. If displayed value is correct, but start motor has no response, it can be judged that the start
motor is faulty. If displayed value is incorrect, continue detecting the fault of start motor control circuit.
Refer to System Fault Detection for the fault of start motor control circuit.
There are quite some start motors that can start when electric lock is turned to “START” position, and you
can hear the start sound they made, but they cannot drive diesel engine to run. At this moment, you may
consider whether the drive gear in the start motor meshes normally, or the fuel injection pump fault of
diesel engine, or other faults of diesel engine. Please contact LiuGong and Cummins maintenance service
outlets.
2.6 Disconnect switch

Disconnect switch regulates the connection between
battery (-) and the machine frame. Turn the disconnect
switch to "O" (OFF), the power (-) of the whole machine
is disconnected. The complete vehicle electrical equip-
ment cannot work, even turning on the electrical lock.
Turn the disconnect switch to "I" (ON), the power (+) of
the whole machine is connected. Whereby, the electric
lock controls the connections between the electrical
components and powers throughout the machine, as
well as starts the diesel engine.
Disconnect Switch
LTB32007013
Notice: Be sure to turn off the disconnect switch at the end of each operation or driving, or else
severe consequences (such as electric leakage) might be resulted
Don’t close the disconnect switch during engine’s running. Such error has a severe influence on the electrical
systems of the complete machine. Turn off the electric lock and then the disconnect switch to halt the machine.
Turn on the disconnect switch and then the electric lock to start the machine. Be sure to turn off the disconnect
switch before connecting battery cable, fastening the pile tip of battery cable or disassembling battery cable.
Be sure to turn off the disconnect switch before implementing welding operation on the whole machine.
Fault detection steps for disconnect switch
1. Remove the cables of disconnect switch.
7-15
2 Main components
2.7 Battery
3. Turn disconnect switch to the “I” position according to the mark in warning sign, respectively connect the
two probes of digital multimeter with two studs on the back of disconnect switch, and the displayed value
on digital multimeter shall be “0”.
4. Turn disconnect switch to the “O” position according to the mark in warning sign, respectively connect the
two probes of digital multimeter with two studs on the back of disconnect switch, the displayed value on
digital multimeter shall be “1”.
If displayed values on the multimeter are the same as described in the steps after the steps above are
over, it can be judged that disconnect switch is good.
The Detection Steps above is not applicable to the condition of seriously worn contact (plate) in disconnect
switch.
2.7 Battery
The machine obtains +24 V power through the series
connection of 2 batteries,of which the rated capacity is
120Ah, and cold-starting current is 850CCA.
As reversible DC (direct current), the battery connects
in parallel with the alternator to jointly power the electri-
cal equipment of the complete machine. Battery sup-
plies great starting current in a short time, to start the
electromotor and further the diesel engine. Besides,
the battery serves as an electrical appliance, which
safeguards the machine through absorbing the over-
voltage arising from the circuit at any moment.
LTB32007014
Detection of the state of the battery

Observe the built-in hydrometer of the battery cover in well-lighted condition, to figure out the charge state of
battery or take appropriate measures in accordance with the color displayed in the hydrometer, in particular:
Indicator color Green Black Transparent
State or solution Good Shall be charged Shall be replaced
Check battery hydrometer regularly or in case of various abnormalities (especially difficult vehicle start). Judge
it in accordance with the methods as described in “Battery Charging” once finding it presents translucent.
Please immediately change battery if it still presents translucent.
Battery charging
For the batteries whose hydrometer is black, recharging is required. For the batteries whose hydrometer has
transparently light color, there might be bubbles in the hydrometer. Whereupon, disconnect all the battery con-
necting cables and shake the battery gently after it is fully cooled. The battery shall be scrapped, provided that
the above-mentioned transparently light color remains.
1. Turn the disconnect switch to "O" position. Turn the electrical lock to "O" position, and put out the key.
7-16
2 Main components
2.7 Battery
2. Disassemble the battery from the machine. Turn through halving the charging current.
off the battery cable (-) and battery cable (+)
9. Check the hydrometer state once every hour
successively before disassembling the battery.
during battery charging. The green battery
3. Wipe the battery terminal and surface with a clean hydrometer indicates that the battery has been
cloth, to remove the oxide scale on the surface. fully charged, and stop charging at this time.
4. Connect the charger positive (+) clip to the battery 10. Coat the terminal with Vaseline after the charging
positive (+) terminal, while charger negative (-) is completed, to prevent galvanic corrosion.
clip to the battery negative (-) terminal at room Precautions during charging
temperature. Confirm that the battery terminal are
clean, and the charging circuit is in good 1. Never charge two batteries in series. Maintain a
connection. ventilated environment during charging, and
charge at a normal temperature. If acid is sprayed
5. Charge the battery with the charger of 16V (within from the battery vent during charging, the
16.2V) constant voltage until the battery charging shall be stopped immediately.
hydrometer turns green. The green hydrometer
indicates that the battery is fully charged. 2. Charge the battery in well-ventilated area, and
pay attention to the electrical safety.
6. On condition that constant voltage is unavailable,
use constant current instead. Charge the battery 3. Any battery that leaks or has a broken housing,
with 12A charging current until the battery shall rather be scrapped than recharged.
hydrometer turns green. The green hydrometer
indicates that the battery is fully charged. 4. Any battery that has a broken terminal, shall
rather be scrapped than recharged.
The relative relationship of auxiliary charging
5. Any battery that is inflated or bulged for over-
time with voltage of battery:
discharge or overcharge, shall rather be scrapped
than recharged.
Battery 12.45~ 12.45~ 12.35~ 12.20~
voltage 12.55V 12.35V 12.20V 12.05V 6. If the hydrometer remains black after being
charged for a period of time, check whether the
Rechargin 2 3 4 5
charging cable is well connected, the joint point is
g time hours hours hours hours
clean, or the charging voltage reaches 16V.
Battery 12.05~ 11.95~ 11.80~ 11.65~ Notes on battery operation
voltage 11.95V 11.80V 11.65V 11.50V
1. All operations on battery must comply with the
Rechargin 6 7 8 9 requirements of warning label stuck on the battery
g time hours hours hours hours surface.
Battery 11.50~ 11.30~ Below 2. Do not connect in series two batteries with
voltage 11.30V 11.00V 11.00V different models or different brands, nor connect
in series two batteries with the same model and
Rechargin 10 12 14
brand but large terminal voltage differences.
g time hours hours hours
3. Disconnect switch must be turned off before
assembling and removing battery cables. Cable
7. For the battery suffering severe power loss, it may
(+) must be assembled first, and cable (-) shall be
be non-chargeable at the beginning of charging.
assembled finally. Cable (-) must be removed
As battery charging proceeds, the charging
firstly, and cable (+) shall be removed finally.
current of battery can return to normal gradually.
It takes about 14 hours to complete the charging 4. The battery must be installed firmly and reliably to
process. prevent damage due to machine’s traveling jolt.
8. If the battery temperature gets too high 5. The jolt during machine’s traveling and operation
(approximately 45 °C) during the charging will cause loose connection between battery
process, stop charging the battery until the battery terminal and cable. Therefore, regularly check the
is cooled to room temperature, then recharge it cable connection terminal, disconnect switch
7-17
2 Main components
2.7 Battery
cable connection terminal and ground point of terminal of one battery, while the black probe to
battery. In case of looseness, disconnect switch the negative terminal, the value displayed on the
must be turned off, and fastened with tools. DMM is around "12" to "16" V.
6. All battery terminals have appropriate protective 4. Inspect the other battery according to step3. The
shields. Protective shields must be put on the displayed value is the same as the step 3.
terminals in order to protect them after the battery
Any battery that fails to implement the test
cable is connected or the detection and
maintenance on battery is over. procedures, shall be replaced.
 Notice: Do not allow metal conductor to touch

battery positive and negative terminals, or it will
cause major short circuit fault and cause fatal
damage to battery.
Steps of battery troubleshooting
The machine is in emergency braking state and con-
trol lever is in neutral position during detection. The
densimeter mounted inside the battery cover is
green. The test in this step need assist of partner.
1. Turn the disconnect switch to "O".position
2. Turn the digital multimeter to 200V of voltage
position.
3. Connect the red probe of DMM to the positive
terminal of one battery, while the black probe to
the negative terminal of the other battery. Be sure
not to connect them to the cable terminals. The
value displayed on the DMM shall be controlled
within "24" to "31" V.
4. Keep the two pointers of the digital multimeter
still. Put disconnect switch in the "I" position.
Switch on the electrical lock and start the diesel
engine.
5. The value displayed on the DMM is between "20"
and "24"V at the moment the cranking motor
starts running. The value returns to that described
in step 3 once the diesel engine starts smoothly.
Any battery that is capable of completing the
above steps and successfully starting the diesel
engine, is in good service condition; otherwise,
test by following steps.
1. Disconnect all the battery connecting cables,
thereby, two batteries are completely
disconnected.
2. Turn the digital multimeter to 200V of voltage
position.
3. Connect the red probe of DMM to the positive
7-18
2 Main components
2.7 Battery
Functional operation
Power supply system mainly achieves the following functions:
1-A Machine power-on Achieve machine power-on, which needs the following electrical components:
1. Disconnect switch 4. Various fuses

2. Battery 5. Power contactor
3. Electric lock 6. Diode assembly
1-B Diesel engine start Achieve machine start, which needs the following electrical components:
1. Diesel engine 6. Power contactor

2. Disconnect switch 7. Start the contactor
3. Battery 8. Gear/start interlock relay
4. Electric lock 9. Diode assembly
5. Start motor 10. Fuse
1-C Power supply to operation of machine’s electrical appliances Achieve power supply to the electrical appli-
ances after diesel engine starts, which needs the following electric appliances:
1. disconnect switch 5. Power contactor

2. Battery 6. Diode assembly
3. Electric lock 7. Alternator
4. Various fuses
After diesel engine starts, single power supply by the battery is changed, alternator becomes main supply for
the electric appliances of machine. The energy provided by it is from diesel engine.
7-19
2 Main components
2.7 Battery
LGB32007015
System fault detection and maintenance

The descriptions of this section about the fault diagnosis and test methods of power supply system mainly
focus on the functions introduced in “Functional Operation”. The rest faults are other common faults.
In the schematic, functional actuation units will be identified according to Step "A" or “B”. Units that actuate in
the same step will be identified with the method of “Step + S/N”, such as B1; B2; B3, etc.
7-20
2 Main components
2.7 Battery
Alternator
Start relay K2
Start protection relay K3

Diode
Start motor
Diode
Main power relay K1
Fuse distribution
1. Start switch
2. Spare
3. Refule pump
4. Instrument
5. Work implement lock
6. Backword alarm
7. Horn
8. Front lamp
9. Solenoid valve
10.Work lamp
11.Warning lamp
12. A/C
13.Pull-pin solenoid valve
14.Instrument light
15. Spare
LTB32007016
7-21
2 Main components
2.7 Battery
1-A-F1 detection flow for power supply fault of machine’s main electrical appliances
The main electrical appliance

has no power for
starting up 1-A-F1
Whether the battery No 1. Detect whether the disconnect switch is damaged in

positive terminal accordance with the method described in the document.
connected to 2. Judge whether the battery has loss of electricity.
the ground is +24V.
TEST STEP1
Yes
Whether there is sound No Yes

when turning on the electric Whether the 10A Whether the 10A electric
lock and main power relay electric lock fuse is blown lock fuse is still blown after replacing it
TEST STEP5
Troubleshooting TEST STEP2
No No
Yes
No
Troubleshooting
Yes
Yes Yes
Whether the 60A fuse Whether #123 wire Detect whether the main power relay
Exclude the short-circuit Whether 60A fuse is blown
is still blown after replacing it of the main power is damaged in accordance with the
fault of wiring. relay is +24V method described in document.
TEST STEP12
TEST STEP3 TEST STEP6
No No
Yes Yes The wiring from the electric lock to

Check whether the Check whether the the main power relay has fault or the
Yes #123 wire is +24V. #123 wire is +24V. connector from the electric lock to
Fuse box fault Check whether the the main power relay is loose.
#122 wire is +24V. TEST STEP7 TEST STEP11
No
TEST STEP4
No
The electric
lock is damaged
No
The wiring from the fuse box to the
Whether the #110 wire
Yes electric lock has fault or the connector
of the fuse box is +24V. from the fuse box to the
electric lock is loose.
TEST STEP8
Check the wiring from the
#102 wire of the power No
elay to the 60A fuse for fault.
Yes No
Whether the electric Whether the electric
lock and the start lock fuse is still blown Troubleshooting
fuse are blown after replacing it
TEST STEP9
No
Yes
Check whether the Respectively check whether the #102
#109 wire is +24V. and #101 wires of the fuse are +24V.
TEST STEP10
No
The battery cable (+)

connector is loose.
1-A Principle description for machine power-on function
A step: 1. As shown in schematic, when disconnect switch is in the “I” position, the battery
supplies power to start motor. Voltage passes #101 wire → 60A fuse → #102 wire
→ two paths. One path passes K1 main power relay → goes out to public terminal
of #122 wire, which is ready to supply power to fuse box common wiring, and also
supplies power to the cab; the other path passes #109 wire and flows into electric
lock by passing #110 wire of fuse box.
2. Meanwhile, start motor connects with one end of battery, #106 wire → 60A fuse →
two paths: one path is connected with alternator, and the other path is connected
with start relay.
7-22
2 Main components
2.7 Battery
B step: 1. When operators turn on electric lock, in other words, when placing electric lock in
“ON” position, the voltage reaches #110 wire → #123 wire → main power relay
wire → #201 wire → ground, the normally open contact of relay is closed and
works, #102 wire is connected with #122 wire, one path supplies power to the cab,
and the other path supplies power to the fuse box. Thus, power supply to
corresponding vehicle’s electric appliances is achieved.
C step: 1. When operators turn the electric lock and the electric lock is in “START” position,
the engine can start. #125 wire of electric lock passes → limit switch → #126 wire
→ passes start protective relay K3 → normally closed contact connects with #301
wire → start relay coil K2 → #200 wire is grounded → the normally open contact of
relay K2 is closed → #105 wire to start motor solenoid switch control terminal →
start motor operates → engine starts.
2. After starting, the engine drives alternator to operate, alternator R terminal is
electrified → from #311 wire to start relay K3 coil → normally closed contact is
opened → #126 wire is disconnected with #301, in order to prevent damage due to
non-operating start motor after engine operates.
Fault symptom description:
Detection step 1: Detect the ground voltage of battery positive terminal to nearby machine body.
2. Place disconnect switch in “I” position (turn on disconnect switch).
3. Open battery box, pull battery positive terminal protective shield, connect the red
probe of digital multimeter to battery positive terminal, and connect the black probe
to nearby machine body (ground).
Test results: The value displayed on the DMM shall be controlled within "24" to "31" V.
Conclusions: OK – Go to detection step 2.
NOTOK – Detect in accordance with the following steps.
1. Firstly ensure all battery cables are connected well. Disconnect switch is grounded
well.
2. Then measure the voltage between battery positive terminal and negative terminal.
If the displayed value on digital multimeter is the same as that in Detection Step 1, it
shows the battery is undercharged. Charge it in accordance with the battery
charging procedure.
3. Otherwise, detect disconnect switch in accordance with the disconnect switch
detection methods as described in “Major Components”, and judge whether it is
damaged.
Detection step 2: Listen to pick-up sound from main power relay.
1. Put disconnect switch in the "I" position. Place electric lock in “ON” position (turn on
electric lock).
2. Pay attention to listening to whether there is crisp pick-up sound “click" from main
power relay under the mast’s right side.
7-23
2 Main components
2.7 Battery
Detection step 3: Detect whether 60A fuse is blown.

1. Keep disconnect switch and electric lock in “I” position.
2. Find out the 60A bolt-type fuse on the fuse mounting as in the mast, and detect it
with digital multimeter at Ω position.
Detection step 4: Detect the fault of wiring from power relay #102 wire connection point to 60A fuse.
1. Keep disconnect switch and electric lock in “I” positions.
3. Connect the red probe of digital multimeter to main power #102 wire, and connect
the black probe to nearby machine body (ground).
Detection step 5: Detect whether the 10A electric lock fuse is blown.
1. Keep disconnect switch and electric lock in “I” and “ON” positions.
2. Keep electrical appliances on, find out 10A electric lock fuse in the fuse box, and
pull out it.
3. Visually inspect whether the 10A fuse is blown. If you cannot judge it, you can
detect it with digital multimeter at Ω position according to the detection method
about whether fuses are blown as described in “Major Component”.
Detection step 6: Detect the voltage of main relay coil terminal #123 wire connection point.
3. Connect one end of the red probe of digital multimeter to main relay #123 wire, and
connect the black probe to nearby machine body (ground).
Detect main relay in accordance with the relay detection method as described in “Major
Component”.
Detection step 7: Detect the voltage of electric lock #123 wire connection point.
3. Connect the red probe of digital multimeter to the connection point terminal of #123
wire, and connect the black probe to nearby machine body (ground).
3. Connect the red probe of digital multimeter to the fuse box of #110 wire, and
connect the black probe to nearby machine body (ground).
7-24
2 Main components
2.7 Battery
Detection step 9: Detect whether the electric lock fuse is blown.

2. Find out fuse in the fuse box, and detect it with digital multimeter at Ω position.
Detection step 10: Check the voltage of fuse #109 wire.
Detection step 12: Replace 60A main fuse.
1. Keep disconnect switch in “I” position, and place electric lock in “OFF” position.
2. Replace 80A fuse.
3. Place the electric lock in “ON” position.
Turn disconnect switch to the “I” position, turn electric lock to the "ON" position, and all electrical equipment on
the vehicle have no response.
1-A-F2 Detection of engine failed to start
Detection Step 1: Confirm whether it is machine’s main electrical appliances failed to power on.
1. If it is the fault that main electrical appliances fails to power on, carry out detection
according to 1-A-F1 machine’s main electrical appliances failed to power on.
2. If machine’s main electrical appliances can power on, go to detection step 2.
Detection Step 2: Check whether the battery has enough power
1. Turn the disconnect switch to position "O".
3. Connect the red probe of DMM to the positive terminal of one battery, while the
black probe to the negative terminal of the other battery. Be sure not to connect
them to the cable terminals.
Test results: Whether the value displayed on the DMM shall be controlled within "24" to "27" V.
Conclusions: YES – Go to detection step 3.
NO – Battery power is insufficient, replace battery.
7-25
2 Main components
2.7 Battery
Detection Step 3: Detect the voltage of start terminal #105 wire of start motor.
1. Put disconnect switch in the "I" position.
2. Clockwise rotate the electric lock to “START” position.
4. Connect the red probe of digital multimeter on the start terminal #105 wire of start
motor, and connect the black probe with nearby machine body (ground).
Conclusions: NO – Go to detection step 4.
YES – It may be start motor internal fault, detect the start motor according to the fault
detection method for start motor as described in “Major Component”.
Detection Step 4: Detect the voltage of start relay coil.
4. Respectively connect the red and black probes of digital multimeter on the
connection terminals of start motor #301 and #200 wires.
Conclusions: NO – Go to detection step 5.
YES – It may be start relay internal fault, detect the start motor according to the fault
detection method for relay as described in “Major Components”. If the relay is dam-
aged, replace the start relay.
Detection Step 5: Detect the voltage of start protective relay No.126 terminal.
2. Clockwise rotate the electric lock to “I” position.
4. Connect the red probe of digital multimeter above the start protective relay No.126
terminal, and connect the black probe on nearby machine body (ground).
Conclusions: NO – Check wiring
YES – It may be start relay internal fault, detect it according to the fault detection
method for relay as described in “Major Components”. If the relay is damaged, replace
it.
7-26
2 Main components
2.7 Battery
Detection Step 6: Detect whether the limit switch of electric lock is in good condition, and whether #125
wire is electrified.
4. Connect the red probe of digital multimeter on the #125 wire terminal of electric
lock, and connect the other probe on nearby machine body (ground).
Conclusions: NO – Electric lock internal fault, detect the electric lock according to the fault detection
method for electric lock as described in “Major Components”. If the electric lock is dam-
aged, replace it.
YES – Detection is over.
Definition of fault symptom: Place disconnect switch in "I" position, clockwise rotate the electric lock to
“STARAT” position, the engine can not start.
 Notice: If fault cannot be eliminated by detection according to the steps above, refer to Electronic
Injection Diesel Engine System in the Electrical System Service Manual for troubleshooting. In
addition, engine failed to start is likely to be caused by mechanical fault. Therefore, after excluding the
fault from the electrical system, if the fault still exists, refer to the Engine System Service Manual.
7-27
3 Instrument system
3.1 Brief introduction of function
3 Instrument system
The instrument configured for this machine is an electronic combination instrument.
The instrument consists of a voltmeter, an engine oil

pressure gauge, a water temp gauge, a torque con-
verter oil temp gauge and a service hour meter.
LTB32007017
7-28
3 Instrument system
3.2 Major component
3.2 Major component

Instrument
Detailed description of the instrument external signal
source will be made in Fault Detection and Mainte-
nance.
H5 Voltmeter
The instrument is shown in Schematic Block Diagram.
H4 Timer
Torque converter oil
temperature gauge
H2 Oil pressure gauge
H1 Water thermometer
Charging indicator
LTB32007018
Temperature sensor
LTB32007019 LTB32007020
7-29
3 Instrument system
3.2 Major component
Part No. Name Thread Range of measured value (°C)
30B0392 Torque converter oil temp sensor M14×1.5 50~150
Operating principle of temp sensor

The temperature sensor used in the machine is resistance thermometer of contact type and negative tempera-
ture coefficient.
When the temp sensor is used, generally the copper housing in it is in contact with the measured medium. Due
to excellent thermal conductivity of copper, the resistance value of temp sensitive components in the copper
housing will vary with the temperature of the measured medium. The higher the temperature of the measured
medium is, the lower the resistance value of the temp sensitive components is. Once the circuit is connected,
the characteristics of resistance changing with temperature are converted to that of voltage varying with tem-
perature. The changing voltage signal enters into the microcontroller of combination instrument, which outputs
signal through the operation processing of microcontroller, to drive the stepping motor-type instrument for tem-
perature indication.
Notice: Switch off the electric lock, and replace the temperature sensor until the machine is
completely cooled if necessary. Thereinto, measured liquid overflows once the temperature sensor is
loosened, which shall be supplemented timely after the replacement.
Temperature sensor
LTB32007021 LTB32007022
Part No. Name Thread Range of measured value (°C)
30B0391 Water temperature sensor M14×1.5 40~120
Operating principle of temp sensor

The temperature sensor used in the machine is resistance thermometer of contact type and negative tempera-
ture coefficient.
When the temp sensor is used, generally the copper housing in it is in contact with the measured medium. Due
7-30
3 Instrument system
3.2 Major component
to excellent thermal conductivity of copper, the resistance value of temp sensitive components in the copper
housing will vary with the temperature of the measured medium. The higher the temperature of the measured
medium is, the lower the resistance value of the temp sensitive components is. Once the circuit is connected,
the characteristics of resistance changing with temperature are converted to that of voltage varying with tem-
perature. The changing voltage signal enters into the microcontroller of combination instrument, which outputs
signal through the operation processing of microcontroller, to drive the stepping motor-type instrument for tem-
perature indication.
Notice: Switch off the electric lock, and replace the temperature sensor until the machine is
completely cooled if necessary. Thereinto, measured liquid overflows once the temperature sensor is
loosened, which shall be supplemented timely after the replacement.
Engine oil pressure sensor
A-direction
LTB32007023 LTB32007024
Operating principle of engine oil pressure sensor

After the engine is started, engine oil will exert
pressure onto the inside through the pressure port,
Pressure indicator G Pressure indicator
G
and the sensor chassis will travel up, drive springs
-
to change the resistance value of the slide rheo-
Resistor winding +
Wiper arm
stat, and output signals.
Resitor
Pivoting bracket
Winding
Pushrod
Wiper arm
Diaphragm
Pressure
chamber
Pressure chamber
Restrictore bore
Restrictor bore
Ground
LGB32007025
7-31
3 Instrument system
3.2 Major component
Instrument distribution diagram

When the machine is not started after the electric lock
is turned on, because the diesel engine is not started,
pressure has not been generated in the hydraulic sys-
tem, the brake system, the shift control system, etc.,
and most alter indicators will give an alarm and flash.
After the diesel engine is started, all systems run nor-
mally, and these alter indicators will go out one by one.
But when the machine is in the process of normal oper-
ation or running, if an alerting signal appears in the
combination instrument, the fault which triggers alerting
must be checked in details. The possible faults with
high frequency of occurrence which trigger alerting are
listed in the table below. This table can not list all the
LGB32007026 faults which trigger alerting one by one, and they shall
be handled according to actual situations.
Left floodlight Right floodlight Electric horn

H5 Voltmeter H4 Timer H3 Torque converter H2 Oil pressure gauge H1 Water thermometer
oil temperature gauge
Compressor clutch
Charging
indicator Air conditioner
Sen1 Water temperature sensor
Sen3 Engine oil pressure sensor
Sen2 Torque converter oil temp sensor
Y2 Choke control solenoid valve
Y12 Cold start solenoid valve
Alternator
Starter relay K2
Start protection relay K3

Diode
Starter motor
Negative switch
LTB32007027
7-32
3 Instrument system
3.2 Major component
Fault detection of torque converter oil temp gauge

Definition of fault symptom:
Check the torque converter oil temp gauge in the instrument for fault if it has no indication or inaccurate indica-
tion.
Detection step 1: Check whether the torque converter oil temp gauge is damaged. (Implementation of
this step requires participation of the second party).
1. Turn on the electric lock. The torque converter oil temp gauge shall rotate and point
to the minimum reading. Turn off the electric lock. The indicator shall fall back to the
limit position from the minimum reading. If the indicator of the torque converter oil
temp gauge does not move, it proves that the instrument has been damaged.
2. Turn off the electric lock, and remove the copper wire connector of the torque
converter oil temp sensor on the machine.
3. Turn on the electric lock, and overlap the copper wire connector of the torque
converter oil temp sensor with the metal complete machine body (not coated with
paint). At this moment, the indicator of the torque converter oil temp gauge on the
combination instrument will point to the maximum reading of the instrument.
4. Suspend the copper wire connector of the torque converter oil temp sensor in
midair. The indicator of the torque converter oil temp gauge on the combination
instrument will point to the minimum reading of the instrument.
Conclusions: OK – Go to detection step 3.
NOTOK – Go to detection step 2.
Detection step 2: Check whether there is wiring fault from the torque converter oil temp gauge to the sen-
sor.
1. Prepare an approximately10m-long wire, and strip the insulating layer at both ends
of the wire by approximately 10~20mm.
2. Pull off the connection-peg of the instrument, twine one end of the wire prepared in
step 1 with the removed copper wire connector of the torque converter oil temp
sensor together, and pull the other end into the cab.
3. Gently pull the #702 wire connected with the instrument connector with hands,
judge whether the wire is loose and crimp it with special crimping tools if it is loose.
4. Adjust the digital multimeter to the 200Ω range of Ω position, connect one probe
with the wire end pulled into the cab, and connect one probe with the connection-
peg core of the combination instrument pulled off.
Test results: The displayed value on the digital multimeter is “0” Ω.
Conclusions: OK – Without wiring fault, go to detection step 3.
NOTOK – With wiring fault
(1) Check whether the #702 core in the connectors X31, X32 is loose.
(2) Check whether the harness between the connector of the torque converter oil temp
gauge and the sensor is crushed or rubbed off.
7-33
3 Instrument system
3.2 Major component
Detection step 3: Detect whether the torque converter oil temp sensor is damaged.
1. After completion of the above 2 steps, if there are no problems, we can preliminarily
doubt that the torque converter oil temp sensor is damaged.
2. Turn off the electric lock, wait for cooling of the torque converter housing, remove
the torque converter oil temp sensor, and replace it with a new one. During the
process of replacement, the torque converter oil will gush. Promptly supplement the
torque converter oil according to its gush quantity.
3. For fault exclusion, if inaccurate indication still occurs, the combination instrument
must be replaced.
Conclusions: Laboratory environment is required to judge whether the parameters of the torque con-
verter oil temp sensor are accurate or not. Therefore, if it is highly doubted that the
torque converter oil temp sensor is damaged, replace the sensor with a new one. Then,
send the replaced sensor back to the complete machine manufacturer for detection.

The torque converter oil temp sensor can be removed only after the machine stops and the machine body
cools down sufficiently. High-temperature water and oil may cause harm to the human body, so wear protec-
tive glasses and protective gloves when necessary.
7-34
4 Light gp
4 Light gp
Open the appropriate light switch, which can provide
lighting supply to the vehicle. The following lighting
Wall light
appliances are installed on the machine:
Name Quantity
Work light 2
Wall light 1
Floodlight 2 LTB32007029
Floodlight 2 List of bulb specifications for dome light:
Bulb
4.2 Major component Function
Rated
specificati
Rated
voltage power
on
Dome light
Dome light and schematic symbols CFA092?2 Operation
Dome light 24V
4V) time
In the light assembly of the complete machine, except

that the dome light bulbs comply with the Chinese
Standard, the other bulbs comply with European SAE
Standard.
LTB32007028
Brief introductions of functions of various

lighting appliances
The work light is located above the front hood and
used for lighting in working.
The dome light is located in the cab and used for
lighting in the cab.
The two front floodlights and two rear floodlights are
located outside the cab and used for lighting in work-
ing.
7-35
4 Light gp
4.2 Major component
Front hood work light

Front hood work light and schematic symbols
Mounting bolt
/7% LTB32007031
Work light in the diagram above:
Colors of light
Function Rated voltage Bulb specification Rated power
hoods
Work light 24V 1GA996.506-52 70W Black
Rear floodlight
Rear floodlight and schematic symbols
Rear floodlight-lh
Rear floodlight-rh
Front floodlight-lh
(spare)
Front floodlight-rh
(spare)
LTB32007032
7-36
4 Light gp
4.2 Major component
List of bulb specifications for rear floodlight:
Front and rear floodlights 24V L3 70W
Plate light
Plate light and schematic symbols
Tin
soldering
LTB32007033 LTB32007034
List of bulb specifications for plate light:
Plate light 24V L3 70W
Rocker switch
Rear light, wiper and schematic symbols
Rear light switch S12
Front light switch S12
Front wiper switch S9
Rear wiper switch S10
Rear floodlight switch Rear wiper switch

Front wiper switch Cover
LTB32007035
7-37
4 Light gp
4.2 Major component
Ripper, blade quick-drop function and schematic sym-

bols
Cover Cover Cover
plate plate plate
Pilot cut-off switch Pull-pin switch
Belt positioner RE
Belt positioner RE
LTB32007036
S7 Pilot solenoid switch

S8 Pull-pin solenoid switch
LTB32007037
Cover
Rear light, wiper and schematic symbols
Work light sw
Cover
Instrument light switch

Front floodlight switch
LTB32007038
7-38
4 Light gp
4.2 Major component
Operators can achieve the following functional opera-

tions by using switches: (For specific operation meth-
S2 Front floodlight switch
ods, refer to the operating instructions accompanied
with the machine).
S3 Work light sw
1.Pilot function
2.Ripper
3.Front floodlight
4.Plate work light
5.Instrument light
S4 Instrument light switch
6.Cab rear light
7.Electric horn
8.Front wiper I position
9.Front wiper II position
LTB32007039 10.Rear wiper I position
11.Rear wiper II position
 Notice: The switch achieves the linkage with the external operation by the coordinated movement
between the internal minitype switch and micro switch and the machinery mechanism. Therefore, the
current which can be borne by the internal contact of the switch is small, and connection with an
external relay is required to achieve functional control.
Fault detection steps for combination switch
The switch consists of internal independent switches, so we can detect the conditions of the combination
switch by measuring the switch at the multimeter resistance position. However, this method does not apply to
the switches whose contacts have been damaged partially. Such switches usually appear in good condition
when measured, but they cannot be used when connected in the circuit. This section is not intended to solve
this kind of problems, because their occurrence probability is not high. When it is highly doubted that this kind
of faults occur, replace the combination switch with a new one. Only common detection methods will be intro-
duced here.
When judging that the combination switch is damaged, we must replace it with a new combination switch as.
LG does not recommend repairing the inside of the combination switch, because the assembly of the combina-
tion switch needs special technology guarantee.
The steps for judging whether the combination switch is damaged:
2. Pull off the connector of the combination switch from the harness. The position of the digital multimeter is
the copper end of the combination switch connector, regardless of the positive and negative of the probes.
If the indicated value of the digital multimeter is “1”, it means that the switch is being disconnected. Turn on
the switch. The indicated value of the digital multimeter is “0”, it means that the switch is connected it is in
good condition, and it can be used continually.
The combination switch which can complete the above steps is in good condition. In addition, during detection,
it is not necessary to exactly take the steps above. When it is doubted that there are problems of a certain
function, firstly detect the relevant function.
7-39
4 Light gp
4.2 Major component
Fault detection for front hood work light
Detection step 1: Check whether the 10A work light fuse is blown.
1. Open the fuse box, find the dome light fuse according to the indications on the fuse
nameplate, and check whether it is blown.
Conclusions: Blown—Replace the fuse
Detection step 2: Detect the dome light bulbs.
1. Turn on the dome light shade, and note that there is a right bulb and a left bulb.
Check whether the dome light bulbs are burnt out or the filament is disconnected.
Conclusions: Bulb fault – Replace bulbs.
Detection step 3: Detect the voltage of the dome light.
2. Place both the disconnect switch and electric lock in “I” and “ON” positions (turn on
the electric lock).
3. Remove the mounting screws of the work light, and pull out connectors X60/X61.
4. Measure the voltage of #1 and #2 cores in the connectors X60/X61 of the harness
terminal with the digital multimeter.
Detection step 4: Detect whether the ground wire of the work light is firm.
2. Place both the disconnect switch and electric lock in “I” and “ON” positions
3. Connect one end of the digital multimeter with the ground terminal of the 123 wire,
and connect the other end with the iron.
4. If the indicated value of the digital multimeter is “0”, it means that there are no
problems; and if the indicated value of the digital multimeter is “1”, it means that the
ground wire is disconnected.
Detection Step 5: Detect the problems of work light wiring
2. Place both the disconnect switch and electric lock in “I” and “ON” positions.
3. Detect #302 wire from X53 to X32, #302 wire from X32 to X30, #137 wire from X30
to X33
problems, and if the indicated value of the digital multimeter is “1”, it means that the
corresponding wire is disconnected.
7-40
5 Electric horn
5 Electric horn
Turn on the electric lock and press the group power
horn, which can make electric horn work.
LTB32007040
7-41
5 Electric horn
5.2 Major components
5.2 Major components

38V0001 electric horn
Fault phenomenon:
When opening the disconnect switch and turning on the electric lock, press the horn button, and the electric
horn does not make a sound.
Detection step 1: Check whether 10A electric horn fuse is blown.

1. Open the fuse box, find the dome light fuse according to the indications on the fuse
nameplate, and check whether it is blown.
Conclusions: Blown - Replace the fuse
Detection step 2: Detect the electric horn.
2. Place both the disconnect switch and electric lock in “I” and “ON” positions (turn on
the electric lock).
3. Measure the voltage of #313 wire connected with the electric horn harness terminal
with the digital multimeter.
Detection step 3: Detect whether the ground wire of the work light is firm.
2. Place both the disconnect switch and electric lock in “I” and “ON” positions.
3. Connect one end of the digital multimeter with the ground terminal of the
connectors, and connect the other end with the iron.
problems; and if the indicated value of the digital multimeter is “1”, it means that the
ground wire is disconnected.
Detection step 4: Detect the problems of work light wiring
2. Place both the disconnect switch and electric lock in “I” and “ON” positions .
3. Detect #313 wire from X53 to X32, #313 wire from X32 to X33, #313 wire from X33
to the horn button, and #138 wire from the horn button to the fuse box.
problems, and if the indicated value of the digital multimeter is “1”, it means that the
corresponding wire is disconnected.
7-42
6 A/C system
6.1 A/C system arrangement drawing
6 A/C system
6.1 A/C system arrangement drawing
Compressor Reservoir tank A/C pipe Evaporator A/C control panel Condenser as LTB32007041
The A/C system is used for adjusting the parameters such as air temperature, etc. in the cab, so as to provide
a comfortable work environment for operators.
Main performance parameters of air conditioning system
Refrigerating capacity 4000W

Cooling air output 600m3/h
Voltage 24VDC
Total power consumption 350W
Heating capacity 5000W
Refrigerant HFC134a

For this A/C system, adopt HFC134a as the refrigerant. It is strictly prohibited to use other non-HFC134a as
the refrigerant, so as to prevent the A/C system fault.
7-43
7 Specifications and technical descriptions for A/C system component
7.1 Compressor
7 Specifications and technical descriptions for A/C system

component
7.1 Compressor
PN: 46C0110
LTB32007042
List of technical parameters and specifications for compressor
Compressor model SE-5H14
Refrigerant HFC134a
Service speed 700~3000rpm
This compressor is used for compressing the gaseous refrigerant at low temperature and low pressure into
that at high temperature and high pressure by serving as a swash-plate compressor. It is used for delivering
and compressing the refrigerant steam, and ensuring normal operation of refrigeration cycle.

It is strictly prohibited to use the refrigeration oil other than the special oil for ND-OIL8 Denso compressor. Oth-
erwise, abnormal operation of the compressor may happen and consequently and refrigerating system fault
will occur.
7-44
7.2 A/C control panel
7.2 A/C control panel

PN: 46C5561
The panel is used for issuing instructions, and con-
trolling the temperature, air volume, refrigeration sta-
tus, etc.
A A
LTB32007043
7.3 Condenser as
PN: 46C0881
This A/C condenser as mainly consists of a condenser
and a condenser fan unit. The condenser adopts the
two-pass pipe racks-condenser, and it is used for dissi-
pating heat of the high-temperature and high-pressure
refrigerant gases exhausted from the compressor into
the air outside the vehicle via the condenser, so as to
condensate the high-temperature and high-pressure
refrigerant gases into high-pressure liquid at high tem-
perature.
LTB32007044

When storing the condenser, it is strictly prohibited to open the sealed caps of the refrigerant inlet and outlet,
so to prevent moist air and sundries from entering the condenser;
Protect the pipes and fins of the condenser from deformation and damage when installing and moving the con-
denser.
7-45
7.4 Evaporator as
7.4 Evaporator as
PN: 46C5562
The A/C evaporator mainly consists of an evaporator
shell, a refrigeration unit, an expansion valve, high &
low pressure protective switches, a temp sensor, a
ventilation door motor, a blower unit, a return air
strainer, a heating unit and other components. It is
mainly used for boiling and gasifying the liquid refriger-
ant upon throttling and depressurization in the evapo-
rator, absorbing the air heat around the evaporator
surface to achieve cooling, and blowing the cold air into
the cab by the fan through the air flue, so as to achieve
the purpose of cooling.
LTB32007045
7.5 Refrigerant receiver as

PN:46C2423
LTB32007046
Technical parameter table
Quality capacity 370cc

The ability of moisture absorption 32g
The receiver-drier is used for storing the refrigerant liquefied by the condenser and drying and filtering the
refrigerant; and meanwhile, the refrigerant in the system can be observed via the sight glass on the refrigerant
receiver connector.

During the storage of the receiver-drier, it is strictly prohibited to open the plug of the receiver-drier, so as to
prevent moist air from entering the receiver-drier and causing faults.
7-46
7.6 A/C hose
7.6 A/C hose

The A/C hoses are used for delivering the refrigerant,
and connecting main components such as the com-
pressor, condenser, evaporator, receiver-driver, etc.
into a whole to constitute a sealed refrigeration system.

During the installation of the A/C hoses, rub between
the A/C hoses and the rotation components as well as
the components with relativly violent movement is pro-
hibited, and they shall be fixed firmly with ties or
clamps.
LTB32007047
7.7 Solenoid valve

The solenoid valve is used for controlling the on-off
function of the water in the heating lines.
LTB32007048
7-47
7.8 Water pipes
7.8 Water pipes

The water pipes are used for water circulation in the
whole heating system.
LGB32007049
7-48
8 Working principle for A/C system
8.1 Refrigerating system

8.1 Refrigerating system
PN: 23E0291
Working Schematic for Refrigerating System Cold air
Evaporator
Expansion valve
Humid warm air
Low-temperature
low-voltage liquid
High-temperature high-voltage gas

Low-temperature high-voltage liquid
Compressor
Hot air
Transparent Condenser
glass
Reservoir tank
Wind from condenser fan
LTB32007050
This A/C system adopts the refrigeration cycle in steam compression mode, and mainly consists of a compres-
sor, an expansion valve, a condenser, a receiver-drier and an evaporator. Its operating process is mainly
divided into four processes:
(1) Compression process: Operating substances become low-temp & low-pressure gaseous refrigerant after
absorbing heat in the evaporator, and they are absorbed into the compressor and compressed by the
compressor into high-temp & high-pressure gaseous refrigerant, and discharged into the condenser.
(2) Condensation process: After the high-temp & high-pressure gaseous refrigerant entering the condenser,
under the drive of the engine blower, the forced air take away the heat of the gaseous refrigerant via the
condenser, and the gaseous refrigerant is condensed into high-temp & high-pressure liquid refrigerant.
(3) Throttling process: After the high-temp & high-pressure liquid refrigerant is filtered by the receiver-driver
and throttled,cooled and depressurized by the expansion valve, it becomes low-temp & low-pressure liquid
refrigerant and enters the evaporator.
(4) Evaporation process: Low-temperature low-pressure refrigerant liquid formed by the throttling of expansion
valve is vaporized in the evaporator, the air in the cab is driven by the evaporator fan unit to pass the
evaporator surface, refrigerant absorbs the heat of air in the cab to reduce the air temperature, and
condensate water is separated out. Refrigerant absorbing heat is evaporated into low-temperature low-
7-49
8.2 Heating system
pressure refrigerant vapor, and is sucked into the compressor and compressed again, and one
refrigeration cycle is completed.
8.2 Heating system

This system mainly makes use of the waste heat of the engine to cool circulating water as the heat source
serving as a waste heat heating system.
When heating is needed, turn on the warm water valve switch on the engine and turn on the A/C switch. After
the engine cooling circulating water passing through the heating unit in the evaporator assembly, the heated
air will be blown off by the blower unit of the evaporator, so as to achieve heat supply to the cab.
7-50
9 Common fault and service for A/C system
8.2 Heating system
9 Common fault and service for A/C system


• When maintaining the A/C system, the high pressure, high temperature and chemical substances of the
system will cause injuries to human body.The moving parts and rotating belt pulley may also cause injuries
to human body.
• Operators must be well-trained and qualified personnel. When using the refrigerant, detecting the leakage
with a refrigerant air leakage detector, adjusting the lines connectors, and connecting the high & low pres-
sure combination instrument connectors, protective glasses or protective masks shall be worn.
• In the maintenance and repair process of the A/C system, protective glasses shall be worn. If the liquid
refrigerant splashes into the eyes, it will cause serious injuries. If the refrigerant splashes into the eyes or
around the eyes, wash the eyes with water for 15 minutes and immediately send the injured to the hospital
for treatment.
• If the refrigerant splashes on the skin, it will cause frostbite. When required by maintenance, the connector
must be opened slowly and carefully. If the refrigerant splashes on the skin, treat the skin or go to the hos-
pital for treatment.
• The reservoir for storing the refrigerant shall not be directly exposed to the sun, and it shall be protected
from other heat sources. The storage temperature of the reservoir shall be kept below 40°C.
• The refrigerant reservoir shall be protected from collision, because severe collision may result in explosion
and consequently causes human injury.
• The refrigerant shall not be used in the airtight indoor with an open fire, because the phosgene produced
after the refrigerant contacts the open fire is highly toxic, which will cause injuries to human body.
• When any refrigerant leakage is found, promptly let in fresh air. When the refrigerant gas content in the air
exceeds 25%, it will cause human death by suffocation.
7-51
10 Fault diagnosis of A/C system
8.2 Heating system
10 Fault diagnosis of A/C system

The fault diagnosis of A/C system is carried out by observing, listening, touching, testing, etc. And meanwhile,
carefully inquire the driver about fault conditions, judge whether the fault is caused by an improper operation or
the equipment itself has a fault. If the fault is caused by an improper operation, introduce correct operational
methods to the driver in details; and if the equipment itself has a fault, comprehensively analyze the A/C sys-
tem in accordance with the above four aspects, and repair the A/C system after finding out the fault and the
causes thereof.
Observe – Observe A/C system with eyes
1. Observe the flow condition of the refrigerant in the receiver-drier sight glass. If there are many bubbles in
the centre of the flowing refrigerant, it indicates that the refrigerant in the system is insufficient; and it is
supposed to supplement the refrigerant to appropriate amount.
2. Observe whether the connection between all components and lines in the system is reliable and airtight,
and whether there is micro quantity of leakage. If leakage occurs, there will be moist trace at the leakage,
and adhered dust can be seen.
3. Observe whether the condenser is clogged with sundries and whether the cooling fin is toppled and
deformed.
Listen –Listen whether there is abnormal sound during operation of the A/C system.
Touch –Touch the surfaces of all components and the connecting lines in the A/C system.
1. Touch the high-pressure loop (from compressor outlet →condenser → reservoir →expansion valve inlet).
They shall be hot. If there is big temperature difference at the inlet and outlet of a component, it indicates
that the system is blocked.
2. Touch the low-pressure loop (from expansion valve outlet →evaporator →compressor inlet). They shall be
cold. If there is no obvious temperature difference on the high & low pressure sides of the compressor, it
indicates that there is leakage or no refrigerant in the system.
Test –Test the system with relevant instruments and gauges, analyze the test results, and find and
eliminate the faults.
7-52
11 A/C system fault and maintenance flow
11.1 Control circuit troubleshooting flow

No gas flow (evaporator does not operate)
Yes
Turn on the power switch, press the air No When selecting high air volume, The blower unit has fault or is
regulation switch (HI), and check check whether the voltage of the not properly connected to the
whether the blower unit is rotated. blower unit is 24V. ground.
No
Whether there is connection No

between the switch and the Wiring is impassable.
blower unit
Yes
Yes
Yes
Whether the switch voltage is 24V Switch fault
No
No
Whether the switch is connected
with the fuse Switch fault
No
Fuse burnout
When the air-volume switch is in
the High (H), Medium (M) and Low
(L) positions, check whether the
blower unit operates.
There is fault in the pwm module.
No cool air (compressor does not

operate)
7-53
No cool air (compressor does not operate)
Turn on the power switch, press the

air regulation switch, press the
refrigeration switch, and check No No
whether the compressor clutch is Whether the voltage of the
actuated. compressor clutch is 24V Compressor clutch fault
Yes
Whether the thermostat is No

The thermostat has fault.
connected
Yes
Whether the pressure switch is No

The pressure switch has fault.
connected
Yes
Yes
Whether the connection wiring

is connected
Yes
Wiring is impassable.
The A/C wiring is normal.

7-54
11.2 Overhauling flow for poor refrigeration

Insufficient refrigerant
Symptoms Basis Reasons Improvement measures

1. The pressure readings of 1. Check leakage with a leak
both low pressure side detector, repair it when
and high pressure side necessary.
are low 2. Supplement refrigerant to
Refrigerant in system is
Insufficient 2. Continual bubble can be specified quantity. If the
insufficient (refrigerant
cool air seen via observation readings in pressure
leakage)
window. manifold gauge are low
3. Outputted air is little cold all the time, check
leakage and repair it.
Vacuumize the system.
Too much refrigerant is filled or the condenser cooling has a fault.

1. The pressure readings of 1. Refrigerant is filled too 1. Adjust refrigerant to
low pressure side and much specified quantity
high pressure side are 2. Condenser cooling has a 2. Clean condenser cooling
over high
Insufficient fault fins
2. Make no bubbles in
cool air 3. Condenser cooling fan 3. Check and repair
receiver-drier sight glass
can be seen when the has a fault condenser fan
engine revolution speed
reduces.
There is air in the air conditioner pipe

1. The pressure readings of 1. Replace the receiver-drier
both low pressure side 2. Check the quantity of
and high pressure side
compressor lubricant and
are high
Insufficient There is air in air conditioner pollutions in lubricant
cool air 2. Low pressure side pipe is (poor evacuation)
not cool 3. Vacuumize the system
and newly fill the
3. Bubble can be seen via refrigerant
receiver-drier sight glass
7-55
There is air in the air conditioner pipe

1. Check the expansion
valve
When air conditioner
Because there is moisture in 2. Replace the receiver-
Cool air and operates, low pressure side
the system, when expansion drier
non-cool air sometimes indicates negative
valve freezes, temporarily
cycle mode pressure, and sometimes 3. Vacuumize the air
interrupt the cooling cycle.
indicates normal pressure.
conditioner system and
newly fill the refrigerant
Refrigerant dose not cycle (filth blockage)

1. The low pressure side 1. There is dust or water 1. Clean the expansion
reading as negative drops adhered or frozen valve, change it if unable
pressure, the high in the expansion valve, to clean it
pressure reading is little which prevents the 2. Replace the receiver-
low. refrigerant from flowing.
No cool air drier, vacuumize the
or cool air is 2. There are frostings and 2. Thermosensitive pipe air system, and newly fill the
interrupted dewdrops around leakage prevents the refrigerant
receiver-drier and refrigerant from flowing
expansion valve. 3. If the thermosensitive
pipes have a fault,
change the expansion
valve
The expansion valve has a fault (it is opened all the time) or poor installation for thermosensitive pipes

1. The pressure readings of 1. Fault for expansion valve 1. Check whether there is
both low pressure side or poor installation for poor installation for
and high pressure side thermosensitive pipes thermosensitive pipes
Insufficient are low
cool air 2. Poor adjustment for 2. Check the expansion
2. There is a great quantity refrigerant flow valve, replace it when
of frost and dew on the necessary
low pressure pipe
7-56
11.3 Overhaul flow for abnormal noise fault
Poor compression of compressor

The pressure of the low-
pressure side is higher, and The high-pressure and low-
the pressure of the high- pressure chambers of the
pressure side is lower; after compressor are in series Replace the compressor or
No cool air
operation is stopped, the connection, and the valve repair it
pressures of the high and low blocks of the compressor are
pressure sides are balanced damaged.
quickly.

Abnormal noise from compressor
Symptom Reasons Improvement measures

A noise is heard when the
The clearance between pistons
compressor runs, and it is Repair or replace the compressor
(piston or swashplate) is not
proportionate with the engine when necessary.
proper.
speed.
A loud noise is heard when the 1. The V-belt is loose or has a 1. Adjust the tension of the V-belt
engine operates at a certain speed fault. or replace it.
and it is disproportionate with the 2. Mounting bolts become loose. 2. Tighten the mounting bolts.
engine speed.
1. Tighten the mounting bolts.
Loud sound of “knock” is heard
The mounting bolts of the 2. If the compressor operates in
when the engine operates at a low
compressor are loose. this state for a long time,
speed.
replace it.
Abnormal noise of magnetic clutch

The noise of rumble is heard when
The bearing is worn or damaged Replace the bearing
the compressor does not operate
1. The clearance of the clutch is 1. Adjust the clearance of the
excessive. clutch.
2. The friction plates of the clutch 2. Replace the clutch.
The sound of “knock” is heard are worn.
3. Replace the oil seal of the
when the compressor engages. 3. The compressor lubricant compressor.
leaks from the shaft oil seal,
which pollutes the friction
plates.
7-57
Abnormal noise from the pipes

1. Pipe clamps are ineffective. 1. Replace the location of the
2. The resonance is caused by clamps or increase the
The sound of “buzz” is heard in the quantity.
vehicle, but it is not notable in the the pulse of the refrigerant
engine compartment. pressure change. 2. Install the cushions for the
pipes or replace the location
and length of the pipes.
Abnormal noise from condenser

1. Vibration of the condenser is 1. The resonance between the 1. Tightly insert the cushion
big. mounting bracket and the between the bracket and the
2. There is a sound of “rattling” in housing of the condenser housing of the condenser.
the condenser. 2. The fan unit of the condenser 2. Adjust the clearance between
collides with the protective the fan blade and the
cover of the condenser. protective cover.
Abnormal noise from the crank pulley

Loud sound of “rattling” is heard 1. Belt mounting bolts are loose. 1. Tighten the bolt.
during idling or abrupt 2. The bearing is worn or broken. 2. Replace the bearing.
acceleration.
Abnormal noise from the tension pulley.

The sound of “click” is made by the Replace the bearing or the tension
The bearing is worn or damaged.
tension pulley. pulley.
The sound heard when the tension
The bracket is broken or loose. Replace or screw the bracket.
pulley contacts the belt.
Abnormal noise from the cooling units

Under certain conditions, the
At this moment, slightly reduce the
refrigerant ejected from the
refrigerant, which can muffle the
expansion valve will make a
Squeal is made by the cooling noise.
squeal, which depends on the
units. Check the expansion valve, and
internal and external temperature
promptly replace it if there is no
combination, engine revolution
problem.
speed and refrigerant temperature.
7-58
Abnormal noise from the blower electromotor

1. The noise from the 1. The brush of the electromotor 1. Repair or replace the blower
electromotor is proportionate or commentator is worn or electromotor.
with the revolution speed. damaged. 2. Remove the sundries, and
2. Loud sound of “buzz” is made 2. Leaves or sundries enter the keep the air suction strainer in
by the electromotor. blower electromotor through good condition.
the air suction strainer.

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Service Manual

Applicable type and model: B320

Power train system ...................................................3-1

Travel system ............................................................4-1

Work implement hydraulic system .........................5-1

Work implement system ..........................................6-1

Electrical system ......................................................7-1

Structure and function

Test and adjustment

Disassembly and assembly

Preventive measures during work:

Pay special attention to the safety during work

● Pay special attention to the technical requirements during work to

Tightening During the installation, pay special attention to the tightening

Coating During installation, use adhesive to coat at this position.

Oil, water Position filled with oil or water. Volume

Discharge Position discharging the oil, total oil discharged

Exterior drawing of the machine ..................................... 1-2

Exterior drawing of the machine

1. Blade lifting oil cylinder 8. Track roller

Cab interior drawing

13. Torque converter oil temperature gauge

Technical specification table

Operation quality 38000 38500 38985

Minimum turning radius (mm) 3800 3870 3910

Stability (front, rear, left and right)

Forward Gear 2 0 ~ 6.8

Backward Gear 2 0 ~ 8.2

Overall Vehicle length 8995 9065 9125

Overall vehicle width 4130 4030 4030

Overall vehicle height 3590 3590 3590

Track gauge (mm) 2140

Ground contact length of track 3150

Track shoe width 560610660

Average Bulldozer 0.107 0.099 0.092

Minimum ground clearance 500

Chongqing Cummins Chongqing Cummins

Starter motor 24V 24V

Alternator output quantity 35 35

Torque converter 3-element, single stage, single phase

Planetary gear, manual control hydraulic gearshift, forced

Braking device Wet-type, belt-type, direct clutch and hydraulic power

Central drive Spiral bevel gear, splash lubrication

Wet-type, multi-disc, spring press, hydraulic disengagement,

Final drive Spur gear, 2 -stage reduction, splash lubrication

Suspension mode Semi-rigid, walking beam

Track roller (unit) (one side) 2

Thrust wheel (unit) (one side) 7

Maximum pressure MPa 20

Oil Mode Gear type

Control valve Pilot type

Cylinder Double-acting piston type

Hydraulic oil tank Plate welding type

Maximum lifting height 1380

Phys Dozer form Straight tilt blade Semi-U shovel U shovel

Cab General cab or anti-tilting cab

List of parts quality (kg)

Final drive cover (single side) 184

Gear hub and gear ring as (single side) 300

The first gear and second gear as (single side) 77

Sprocket block as (single side) 286

Half shaft (single side) 143

Main frame 2854