Руководство по эксплуатации бульдозера shantui sd32

БУЛЬДОЗЕР SD32

Руководство по эксплуатации и

техническому обслуживанию

SHANTUI CONSTRUCTION MACHINERY CO., LTD

ПРЕДИСЛОВИЕ

Модель SD32 — это большой мощный бульдозер с гидравлической трансмиссией и двигателем мощностью 235 кВт (320 л.с.). Настоящее руководство описывает устройство машины, технические характеристики, правила эксплуатации и технического обслуживания, содержания машины и устранения неисправностей. Оно поможет операторам и управляющему персоналу получить необходимые знания о работе данной модели.

Прежде чем начинать эксплуатацию машины, необходимо внимательно прочесть данное руководство и не приступать к эксплуатации до получения необходимых профессиональных навыков. Не следует допускать небрежность в эксплуатации машины, это может привести к несчастным случаям.

Эксплуатацию двигателя, а также устранение неисправностей, связанных с его работой, необходимо производить согласно соответствующей инструкции. Необходимо тщательно соблюдать все правила по эксплуатации, осмотру и обслуживанию машины, уделяя особое внимание технике безопасности. В настоящем руководстве все правила техники безопасности помечены знаком “!”, а технические меры предосторожности – знаком “*”. Информация по технике безопасности, содержащаяся в данном руководстве, является лишь дополнением к основным правилам безопасности, требованиям по страхованию, нормам местного законодательства, правилам и положениям.

В связи с постоянным обновлением продукции настоящее руководство, возможно, не дает полной и исчерпывающей информации о работе вашей машины, необходимо принять это во внимание.

ОБЩИЕ ПРАВИЛА БЕЗОПАСНОСТИ

! 1. Перед использованием машины внимательно прочесть руководство по эксплуатации. Эксплуатировать машину в соответствии с инструкцией.

! 2. Операторы должны пройти необходимый инструктаж. Не управлять машиной в состоянии сильной усталости или алкогольного опьянения. Запрещено управлять машиной операторам без специальной подготовки.

! 3. Если работа требует дополнительных мер предосторожности, использовать каску, защитную обувь, специальную одежду и другие средства защиты.

! 4. Выяснить, какие защитные устройства находятся на машине и как ими пользоваться.

! 5. Изучить необходимые правила дорожного движения, а также правила пользования огнетушителем.

! 6. Запрещено курить на рабочем месте, а также проводить дозаправку или выполнять другие технические работы вблизи источников открытого огня.

! 7. Перед началом работы изучить геологическую структуру местности, природные условия, технические средства и аппаратуру, имеющиеся на поверхности и под землей.

! 8.Перед началом работы очистить детали или инструменты, находящиеся вблизи машины или на полу кабины оператора.

! 9. Перед началом эксплуатации убедиться, что машина находится в рабочем состоянии.

! 10. Во время работы всегда находиться на месте водителя. Не управлять машиной из иного положения. Посторонним лицам находиться в кабине водителя не разрешается.

! 11. После запуска машины убедиться, что она функционирует нормально. Скорость машины должна соответствовать выполняемой операции.

! 12. Если в результате вышеперечисленных проверок обнаружится какая-либо неисправность, обратиться к техническому специалисту и возобновлять работу только после его разрешения.

! 13. При запуске двигателя в плохо вентилируемых помещениях существует опасность отравления угарным газом, в этом случае необходимо обеспечить постоянный доступ свежего воздуха.

! 14. При посадке в машину или высадке из нее пользоваться поручнями и ступеньками. Не запрыгивать в машину и не выпрыгивать из нее.

! 15. При работе в темное время суток организовать необходимую систему освещения.

! 16. При работе на склонах, на снегу, в лесных массивах, где есть упавшие деревья, груды бревен или листьев, соблюдать предельную осторожность, так как существует вероятность опрокидывания машины на скользкой поверхности.

! 17. Оставляя машину на месте стоянки, поставить рычаг переключения скоростей в нейтральное положение, закрепить ручной тормоз, опустить отвал на землю и заблокировать все рычаги управления.

! 18. В целях собственной безопасности и во избежание повреждения машины не управлять машиной при наличии неисправностей или в условиях перегрузки.

* 19. При работе в экстремальных условиях предварительно изучить “Меры предосторожности при работе в экстремальных условиях”.

* 20. Тип используемого смазочного масла зависит от температуры окружающей среды. Выбирать его следует в соответствии с таблицей «ТОПЛИВО, ОХЛАЖДАЮЩАЯ ЖИДКОСТЬ И СМАЗОЧНЫЕ МАТЕРИАЛЫ».

* 21. Не использовать антифриз, содержащий метиловый или этиловый спирт, так как он может вызвать повреждение двигателя. Не использовать антифриз вблизи открытых источников огня, он легко воспламеняется.

* 22. Использовать только водопроводную воду в качестве охлаждающей жидкости. Не использовать грязную воду.

* 23. Никогда не добавлять в охлаждающую жидкость вещества, способные стать причиной протечки.

* 24. Производить чистку и замену частей всех фильтров в соответствии с таблицей по техническому обслуживанию.

* 25. Периодически проверять уровень охлаждающего средства, топлива, смазочных материалов и гидравлического масла и добавлять их при необходимости.

* 26. При запуске двигателя не оставлять ключ в замке зажигания более чем на 20 сек.

Если двигатель не запускается, повторите попытку примерно через 20 минут.

ВВОД НОВОЙ МАШИНЫ В ЭКСПЛУАТАЦИЮ

Каждая машина перед транспортировкой тщательно регулируется и испытывается. Однако новые машины требуют аккуратной эксплуатации в течение первой 1000 моточасов — для притирки различных компонентов.

Если машина подвергаются неоправданно небрежному обращению на начальном периоде эксплуатации, потенциальная эффективность будет преждевременно снижена. Срок службы машины также сократится. Новая машина должна эксплуатироваться с осторожностью, в соответствии со следующими правилами:

1. Подготовить машину к запуску.

2. После запуска двигателя дать ему поработать вхолостую в течение 5 минут, чтобы надлежащим образом прогреть двигатель перед эксплуатацией.

3. Избегать работы с тяжелыми грузами или на высокой скорости.

4. Избегать внезапного запуска двигателя или повышения скорости, ненужного прерывистого торможения и резких поворотов.

5. При любой возможности осматривать и производить регулировку машины, содержать ее в нормальном функциональном состоянии.

6. Через 250 моточасов эксплуатации машина должна пройти техническое обслуживание в соответствии с расписанием проведения первого технического обслуживания и следующими пунктами.

* Расписание проведения первого технического обслуживания при наработке 250 моточасов.

* Количество моточасов отображается на счетчике моточасов.

* При замене фильтрующих элементов воздушного фильтра их внутреннюю поверхность необходимо проверить на наличие грязи и пыли. При накоплении пыли и грязи проверить возможные причины этого перед заменой фильтрующих элементов.

СОДЕРЖАНИЕ

I. ОБЩИЙ ВИД, ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ И ОРГАНЫ УПРАВЛЕНИЯ

II. ПРАВИЛА ЭКСПЛУАТАЦИИ

III. ПОРЯДОК РАБОТЫ БУЛЬДОЗЕРА

IV. ПРАВИЛА ДЛИТЕЛЬНОГО ХРАНЕНИЯ БУЛЬДОЗЕРА

V.ТЕХНИЧЕСКОЕ ОБСЛУЖИВАНИЕ

VI.ВОЗМОЖНЫЕ НЕИСПРАВНОСТИ И СПОСОБЫ ИХ УСТРАНЕНИЯ

ТОПЛИВО, ОХЛАЖДАЮЩАЯ ЖИДКОСТЬ И СМАЗОЧНЫЕ МАТЕРИАЛЫ

ТАБЛИЦА СМАЗКИ БУЛЬДОЗЕРА SD32

СХЕМА СМАЗКИ БУЛЬДОЗЕРА SD32

ЭЛЕКТРОСХЕМА БУЛЬДОЗЕРА SD32

I. ОБЩИЙ ВИД, ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ И ОРГАНЫ УПРАВЛЕНИЯ

1.1. Общий вид (Рис. 1-1)

Рис. 1-1

1. Выхлопная труба с глушителем

2. Гидроцилиндр подъема

3. Кабина

4. Топливный бак

5. Гусеничная цепь

6. Рама гусеничной тележки

7. Поддерживающие катки

8. Опорные катки и ограждение гусеничной цепи

9. Рама отвала

10. Раскос

11. Отвал

1.2. Технические характеристики

Наименование	Характеристики	Примечания
Размеры, мм (длина, ширина, высота)	8650х4030х3640 6984х4030х3640	с рыхлителем без рыхлителя
Масса, кг (транспортное положение)	35780±1000 (41570±1250)	без рыхлителя с рыхлителем
Давление на грунт	0,105 МПа	с отвалом и гусеницами шириной 560 мм
Угол преодолеваемого уклона (º)	30
Ходовая скорость (км/ч)	вперед	1	0~3,6
2	0~6,6
3	0~11,5
назад	1	0~4,4
2	0~7,8
3	0~13,5
Двигатель
Модель	NTA855-C360	Cummins
Частота вращения, об/мин	2000
Номинальная мощность кВт (л.с.)	235 (320)
Максимальный крутящий момент, Нм (кгм)	1411 (144)	при 1400 об/мин
Способ запуска	Электромотор (24В 11кВт)

График соотношения скорости и тяги

1.3. Габаритные размеры (Рис. 1-2)

Рис. 1-2

1.4. Органы управления (Рис. 1-3)

Рис. 1-3

1. Рычаг управления подачей топлива 2. Рычаг переключения скоростей 3. Предохранительный рычаг (для рычага переключения скоростей) 4. Рычаг рулевого управления (левый) 5. Рычаг рулевого управления (правый) 6. Педаль замедлителя 7. Педаль тормоза (левая) 8. Педаль тормоза (правая) 9. Рычаг управления отвалом 10. Кнопка блокировки (для рычага управления отвалом) 11. Кнопка клаксона 12. Рычаг стояночного тормоза 13. Рычаг управления рыхлителем 14. Кнопка блокировки (для рычага управления рыхлителем)

1.5. Описание органов управления

1. Рычаг подачи топлива (Рис. 1-4).

При нахождении рычага в положении I, как показано на рисунке, двигатель работает на малых оборотах. При переводе рычага в положение II скорость вращения двигателя увеличивается. При переводе рычага в положение III двигатель достигает номинальной частоты вращения, это обычная скорость при эксплуатации бульдозера.

При выключении двигателя сначала необходимо переместить рычаг в положение I, а затем перевести пусковой переключатель в положение ”OFF” (“Выкл.”).

Рис. 1-4

2. Рычаг переключения скоростей (рис 1-5)

У этого рычага есть три положения как для движения вперед, так и для заднего хода. При запуске двигателя необходимо установить рычаг переключения скоростей в нейтральное положение (“N”), а после запуска перевести его в желаемое положение.

Рис. 1-5

3. Предохранительный рычаг (для рычага переключения скоростей).

Это блокировочное устройство рычага переключения скоростей.

! Оставляя машину на месте стоянки, необходимо вернуть рычаг переключения скоростей в нейтральное положение (“N”) и закрепить предохранительный рычаг.

Рис.1-6

4. Левый рычаг рулевого управления (Рис. 1-3).

При переводе левого рычага рулевого управления в среднее положение, освобождается муфта рулевого механизма, что позволит бульдозеру сделать плавный поворот влево. Если перевести рычаг рулевого управления назад, придет в действие тормоз рулевого механизма. Машина выполнит левый разворот.

5. Правый рычаг рулевого управления.

Чтобы выполнить плавный правый поворот или разворот, необходимо отрегулировать положение правого рычага управления, как описано выше.

6. Педаль замедлителя (Рис. 1-3).

Эта педаль применяется для замедления оборотов двигателя и может находиться в двух положениях. Обычно она используется для замедления частоты оборотов двигателя до 800~850 об/мин. (первое положение). Но при необходимости педаль может быть нажата сильнее, чтобы двигатель работал на малых оборотах.

! При выезде на вершину склона или при отсыпании грунта с крутых склонов, скорость машины увеличится из-за внезапной потери груза. В этих случаях необходимо замедлить движение машины, нажав на педаль замедлителя.

7. Педали тормоза.

Чтобы развернуть машину, помимо использования рычагов рулевого управления, необходимо также использовать педаль тормоза.

Переведите рычаг рулевого управления назад примерно на 67 мм, одновременно нажмите педаль тормоза с той же стороны, где находится рычаг. Машина сделает разворот. При выравнивании поверхности грунта также необходимо использовать педали газа во избежание несчастных случаев. В этом случае нажмите на правую и левую педали одновременно.

! Внимание: не следует ставить ноги на педали тормоза без необходимости.

8. Рычаг управления отвалом (Рис. 1-3).

Этот рычаг используется для управления отвалом бульдозера. См. раздел “Управление отвалом”.

9. Кнопка блокировки (для рычага управления отвалом) (Рис. 1-3).

Эта кнопка применяется для блокировки рычага управления отвалом.

! При проведении каких-либо технических работ или оставляя машину на месте стоянки, необходимо проверить, чтобы кнопка блокировки рычага управления отвалом была нажата.

10. Кнопка клаксона (Рис. 3).

Для подачи звукового сигнала необходимо нажать на кнопку.

11. Рычаг стояночного тормоза (Рис. 1-3).

Это рычаг используется для блокировки стояночного тормоза. После его нажатия приводится в действие тормозная система, однако ноги можно убрать с педалей тормоза.

Необходимо нажимать на центр педалей тормоза, как при закреплении стояночного тормоза, так и при его освобождении.

! Внимание: используйте стояночный тормоз только при включенном двигателе! Если двигатель выключен, гидроусилитель не работает и сила торможения снижается. Будьте особенно осторожны при остановке на склоне.

12. Кнопка холодного пуска

Устройство для эфирного пуска применяется для быстрого запуска двигателя. При его использовании необходимо сначала вытянуть рукоятку на себя, а затем вернуть ее в прежнее положение. Струя этилового эфира поступит в трубку воздухозаборника и двигатель легко запустится.

13. Индикатор состояния фильтров воздухоочистителя

Этот прибор показывает степень загрязнения фильтров воздухоочистителя. Появление красного поршня в прозрачной части индикатора свидетельствует о засорении воздухоочистителя. Необходимо немедленно почистить фильтры. После этого нужно нажать кнопку индикатора, чтобы вернуть красный поршень в первоначальное положение.

1.6. Измерительные приборы

Рис. 1-14

1.6.1. Приборный щиток (Рис. 1-14)

На приборном щитке расположены: масленый манометр, указатели температуры воды и масла, вольтметр, счетчик моточасов, систему аварийной сигнализации и некоторые другие измерительные приборы. Система аварийной сигнализации включает в себя сигнализатор низкого давления масла в двигателе, сигнализатор высокой температуры воды и масла, сигнализатор сбоя в работе генератора переменного тока, индикатор нейтрального сигнала и индикатор предварительного нагрева.

Рис. 1-15 Рис. 1-6 Рис. 1-17

1.6.2. Масляный манометр (Рис. 1-15)

Измерительная шкала прибора включает значения от 0 до 10 (0 — 1 МПа), рабочее значение может колебаться от 1 до 10. При низком давлении масла загорается предупредительный сигнал. В холодное время года давление масла может быть очень низким, в этом случае необходим предварительный нагрев до минимального рабочего значения.

1.6.3. Вольтметр (Рис. 1-16)

Перед запуском двигателя напряжение должно составлять более 24В, это нормальное напряжение. Если напряжение низкое, то возможны проблемы с запуском двигателя. В этом случае необходима подзарядка от аккумуляторных батарей.

При нормальной работе машины загорается зеленый сигнал, давление должно быть около 28В. Если давление ниже или выше данного значения, то необходимо выяснить причину и продолжить эксплуатацию машины после устранения неисправности.

1.6.4. Указатель температуры воды (Рис. 1-17)

Показывает температуру воды в двигателе. При нормальной работе машины загорается зеленый сигнал. При высокой температуре загорается красный сигнал. В этом случае необходимо уменьшить обороты двигателя до тех пор, пока температура не понизится до нормального уровня, а затем выключить двигатель и проверить уровень воды.

1.6.5. Указатель температуры масла (Рис. 1-18)

Показывает температуру масла в гидротрансформаторе. Нормальная температура при работающем двигателе составляет 50-120°С. Если температура выше нормы, загорается предупредительный сигнал. В этом случае необходимо сократить рабочую нагрузку, пока температура не снизится до нормального уровня.

Рис. 1-18 Рис. 1-19

1.6.6. Счетчик моточасов (Рис. 1-19)

Показывает общее время работы двигателя. На основании данных счетчика производится техническое обслуживание машины.

1.7. Другие приборы.

Стартер (Рис. 1-20)

”OFF” (”Выкл”) – положение ключа при запуске двигателя и по окончании работы. Все потребители выключены.

”ON” (”Вкл”) – включено зажигание, все приборы работают. Ключ должен находится в этом положении после запуска двигателя.

”START” (”Пуск”) – в этом положении ключа запускается двигатель. Необходимо отпустить ключ сразу после пуска. Он автоматически вернется в положение ”ON” (”Вкл”).

Рис. 1-20 Рис. 1-21

1.8. Регулировка кресла оператора (Рис. 1-23).

Регулировка вперед/назад

Поднимите рычаг 1, отрегулируйте положение кресла и отпустите рычаг.

Регулировка высоты

Для регулировки высоты кресла перемещайте рычаг 2 вправо или влево.

Регулировка наклона

Поднимите рычаг 4, установите кресло в желаемое положение и отпустите рычаг.

Регулировка жесткости пружины

Жесткость пружины кресла можно регулировать в зависимости от массы оператора. Для увеличения жесткости повернуть рычаг 3 по часовой стрелке. Для уменьшения жесткости, повернуть рычаг против часовой стрелки.

Рис. 1-23

II. ПРАВИЛА ЭКСПЛУАТАЦИИ

Следует соблюдать правила эксплуатации машины, это позволит продлить срок ее службы. Нарушения правил эксплуатации может привести к неисправностям или несчастным случаям.

2.1. Двигатель

1. Перед запуском двигателя (Рис. 2-1)

Рис. 2-1

1) Проводить ежедневную проверку деталей (подробнее см. секцию “Обслуживание”).

2) Убедиться, что педаль тормоза заблокирована.

3) Установить рычаг переключения скоростей 2 в нейтральное положение и заблокировать его с помощью предохранительного рычага 3.

4) Опустить отвал к земле и заблокировать рычаг управления отвалом с помощью предохранительного рычага.

5) Установить рычаг подачи топлива 4 на малые обороты.

2. Пуск двигателя (Рис. 2-2)

1) Поместить ключ в пусковой переключатель, затем повернуть ключ в положение «START» («Пуск»). Двигатель запустится.

2) После пуска двигателя проверить показания масляного манометра (давление масла должно соответствовать норме).

3) Не оставлять ключ в положении «START» («Пуск») более 20 сек.

4) Если двигатель не запускается, повторить попытку примерно через 2 минуты.

5) Если двигатель не запускается после второй попытки, проверить, открыт ли отсечной масляный клапан. Если необходимо, открыть его, повернув рукоятку. После запуска двигателя, вернуть рукоятку в прежнее положение.

6) После запуска двигателя ключ зажигания должен автоматически вернуться в положение «ON» («Вкл»).

Рис. 2-2

3. Защитный клапан

В случае сбоя в электросистеме при запуске двигателя отрегулировать отсечной масляный клапан вручную следующим образом: повернуть рукоятку 1 против часовой стрелки в вертикальное положение, чтобы открыть клапан. Топливо поступит из насоса в инжектор и двигатель запустится. После запуска двигателя вернуть рукоятку в первоначальное положение.

4. Работа двигателя

Не приступать к работе сразу после запуска двигателя. Сначала его необходимо прогреть следующим образом.

1) Двигатель должен работать на холостом ходу (установить рычаг подачи топлива на малые обороты), пока стрелка масляного манометра не достигнет зеленой зоны. Двигатель не должен работать на холостом ходу более 20 минут, так как это может привести к утечке масла из турбокомпрессора.

2) Установить рычаг подачи топлива в среднее положение. Двигатель должен проработать без нагрузки на средних оборотах примерно 5 минут.

3) Добавить обороты двигателя. Двигатель должен проработать в этом режиме до тех пор, пока стрелка указателя температуры воды не достигнет зеленой зоны.

После прогрева двигателя необходимо проверить:

1) все ли приборы работают нормально;

2) соответствует ли цвет выхлопных газов норме и не наблюдается ли посторонний шум или вибрация;

3) не наблюдается ли утечка масла, топлива или воды.

5. Остановка двигателя

1) Охладить двигатель. Для этого он должен проработать на холостом ходу около 5 минут.

2) Вернуть ключ зажигания в положение ”OFF” (”Выкл”) и вынуть ключ.

* Остановка двигателя без предварительного охлаждения может значительно сократить срок его службы. Остановка двигателя без охлаждения допускается только в случае крайней необходимости.

2.2. Начало движения

Если двигатель работает нормально, можно начинать движение (вперед).

1) Увеличить обороты двигателя, передвинув рычаг подачи топлива.

2) Разблокировать рычаг управления отвалом, поместить его в положение ”RAISE” (”Подъем”), чтобы поднять отвал на 40-50 см. от поверхности грунта.

3) Нажать на центральную часть обеих педалей тормоза, освободить рычаг стояночного тормоза и отпустить педали тормоза.

4) Разблокировать рычаг переключения скоростей. Переместить рычаг в положение 1 и начать движение вперед.

5) После того, как машина начала движение, нажать педаль замедлителя и медленно отпустить её, чтобы увеличить обороты двигателя. Это позволит машине начать движение без подергиваний.

6) Переместить рычаг переключения скоростей в желаемое положение.

2.3. Переключение скоростей (Рис. 2-1)

С помощью рычага переключения скоростей можно выбирать необходимую скорость. При переключении скоростей не требуется останавливать машину. При переключении на или с заднего хода сначала нажать педаль замедлителя, чтобы замедлить движение двигателя, а затем переводить рычаг переключения скоростей в необходимое положение.

2.4. Поворот

Чтобы выполнить поворот направо или налево, перевести соответствующий рычаг рулевого управления вперед в среднее положение (до стопора). Муфта рулевого механизма будет освобождена и машина начнет плавно поворачиваться (Рис. 2-3). Передвинуть рычаг рулевого управления назад и нажать соответствующую педаль тормоза, машина сделает резкий разворот (Рис. 2-4).

При выполнении поворота на склоне перевести правый рычаг рулевого управления в крайнее положение. Машина выполнит плавный поворот налево (управление с компенсацией).

Чтобы сделать резкий поворот налево, перевести левый рычаг рулевого управления назад (управление без компенсации).

2.5. Остановка машины

Чтобы остановить машину, выполнить следующее (двигатель выключать не требуется):

1) Уменьшить обороты двигателя с помощью рычага подачи топлива.

2) Перевести рычаг переключения скоростей в нейтральное положение. Заблокировать его с помощью предохранительного рычага.

3) Нажать на центральную часть обеих педалей тормоза и заблокировать их с помощью рычага стояночного тормоза.

4) При помощи рычага управления отвалом опустить отвал к земле. Заблокировать рычаг управления отвалом с помощью предохранительного рычага.

! Эксплуатировать бульдозер только на твердой поверхности.

2.6. Управление отвалом

1. Положения рычага управления отвалом

1) ”RAISE” (”Подъем”) (Рис. 2-5а)

2) ”HOLD” (”Удержание”) – отвал останавливается и остается в фиксированном положении.

3) ”LOWER” (”Опускание”) (Рис. 2-5а)

4) ”FLOAT” (”Выравнивание”) – отвал не фиксируется и может двигаться под воздействием внешних сил (например, при движении по неровной дороге). Если отпустить рычаг, то он останется в положении ”FLOAT”.

А. Правый наклон (Рис. 2-5).

Б. Левый наклон (Рис. 2-5).

С помощью этих положений рычага можно управлять наклоном отвала влево или вправо. Отвал можно наклонять, только если рычаг находится в положениях ”RAISE” (”Подъем”) или ”LOWER” (”Опускание”). Не наклонять рычаг вправо или влево, если отвал находиться в предельно верхнем или нижнем положениях. Во ходе выполнения операции наклона шток гидроцилиндра должен быстро вернуться в крайнюю точку своего хода.

	Рис. 2-5а

2. Изменение угла наклона

При помощи рычага управления отвалом можно наклонить отвал примерно на 560 мм. Но при необходимости возможен перекос отвала до 1000 мм. Для этого необходимо изменить длину левой тяги с помощью регулировочного стержня.

При увеличении длины тяги угол левого перекоса увеличивается, а угол правого перекоса уменьшается.

При уменьшении длины тяги угол левого перекоса уменьшается, а угол правого перекоса увеличивается.

Длина левой тяги составляет 1388 мм, а радиус перекоса может составлять до 1000мм. Не пытаться наклонить отвал на больший радиус.

Во время регулировки длины тяги отвал не должен соприкасаться с поверхностью грунта.

3. Регулировка шарового шарнирного соединения

На тяге отвала расположено 7 шаровых шарнирных соединений. Осуществляя регулировку шайбы, убедиться, что осевой зазор шарового шарнирного соединения не превышает 1 мм. (Рис. 2-6). Производить регулировку следующим образом:

1) Удалить шарнир 1 и закрепить болты 2.

2) Измерить зазор А и удалить болты 2.

3) Отрегулировать осевой зазор (он не должен превышать 1 мм.) с помощью шайбы соответствующей толщины.

4) После регулировки зазора и закрепления болтов убедиться, что шаровое шарнирное соединение работает без помех.

Рис. 2-6 Рис. 2-7

FOREWARD

REMINDERS

TRAINING

If you are a novice, please receive training by Shantui or its agent before operating the machine to ensure the safety of you and others.

SAFETY

Before operating the machine, please read this Operation and Maintenance Manual thoroughly first and ensure you can skillfully operate it. See Chapter 1 for details about the safety precautions.

INSPECTION

Before operating the vehicle, please check out the vehicle’s conditions, climate conditions, and your surroundings. You can only operate the machine when all these conditions meet the requirements.

CAUTION

Please properly use the machine in accordance with the conditions of the construction site.

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

I

FOREWARD

FOREWARD

The SD32, SD32D and SD32W Series Bulldozers are the hydraulically transmitted bulldozers with a rated power of 235kw (320HP). Among them, SD32 is the standard model, SD32D is the desert model, and SD32W is the rock model.

This manual provides detailed descriptions of the structures, performances, driving operation, maintenance, troubleshooting, as well as transportation and storage of the bulldozers in this series. It provides the basic knowledge for management personnel and operators to use the equipment efficiently, economically and properly.

This manual provides the rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

WARNING

Operators and maintenance personnel must always do as follows before beginning operation or maintenance:

• Always be sure to read and understand this manual thoroughly before performing operation and maintenance.

• Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.

• Keep this manual at the given storage location for the Operation and Maintenance Manual, and have all personnel read it periodically.

• If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Shantui or your Shantui distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

II

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

FOREWARD

LOCATION TO KEEP THE OPERATION & MAINTENANCE MANUAL:

As shown in the figure on the right, the Operation & Maintenance Manual is generally put in the magazine pockets on the right and left cab doors.

For the use, maintenance and troubleshooting of engine, apart from this manual, please also refer to the engine’s operation manual for details.

All the areas regarding the safety of people and machine as well as all the important technical requirements in this manual are marked with or . Please firmly remember them.

ABOUT THE WARRANTY

The warranty only covers faults caused by material or manufacturing defects, excluding other faults.

Shantui is not responsible for faults or damages caused by improper use or omission, including but not limited to damages caused by operation without sufficient coolant or lubricant; excessive supply of fuel; operation above the speed limit; lack of maintenance to the cooling and lubricating systems; improper storage, start, warm-up, break-in or stop operation; unauthorized repairing of the engine; using fuels or lubricants that are not recommended for the machine or using fuels or lubricants mixed with dirty substances such as water or mud.

For faults that are really caused by material or manufacturing defects, Shantui is not responsible for collateral costs as well as all the business expenses and losses caused by the repair work.

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

III

FOREWARD

BREAKING IN THE NEW MACHINE

Your Shantui machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.

Be sure to break-in the machine for the initial 100 hours.

During break-in operations, follow the precautions described below:

1. Check before starting;

2. Start the engine and let it run at idling for 5min, to let the temperature rise normally, and let the machine enter the working condition;

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

4. Do not start the engine in a rush, do not accelerate sharply, and do not make an emergency brake or a sharp turn;

5. Watch the machine and make adjustment at any time, to keep the machine in the normal condition;

6. After using the machine for 250 hours, performance maintenance according to the initial 250 hours service table and the items listed below.

► The initial 250 hours service table.

► The operation hours will be indicated by the hour meter.

► When replacing the fuel filter, check if there is dirty stuff in it. If it is severely clogged, try to find out the reasons before replacement if possible.

The disassembly and repair of the track tension must be performed under the guidance of the after-sales service personnel of Shantui (or its distributor), or damage may be caused to the track tension, resulting in danger!

IV

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

FOREWARD

SAFETY LABELS AND WORDS

Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard.

The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Example of safety label using words:

WARNING

When standing up from the operator’s seat, always place the safety lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

V

CONTENTS

CONTENTS

CHAPTER 1: SAFETY ……………………………………………………………………………….1

1.1 SAFETY LABELS …………………………………………………………………………………………..1

1.1.1 POSITIONS OF SAFETY PICTOGRAMS ………………………………………………………….. 2

1.1.2 SAFETY LABELS …………………………………………………………………………………………… 3

1.2 SAFETY RULES …………………………………………………………………………………………….7

1.2.1 SAFETY PRINCIPLES ……………………………………………………………………………………. 7

1.2.2 SAFETY FEATURES ………………………………………………………………………………………. 7

1.2.3 CLOTHING AND PERSONAL PROTECTIVE ITEMS …………………………………………… 8

1.2.4 UNAUTHORIZED MODIFICATION …………………………………………………………………… 8

1.2.5 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT …………………………….. 8

1.2.6 GETING ON OR OFF THE MACHINE ………………………………………………………………. 9

1.2.7 FIRE CAUSED BY FUEL OR OIL ……………………………………………………………………… 9

1.2.8 PREVENTION OF BURNS …………………………………………………………………………….. 10

1.2.9 BE CAREFUL ABOUT ASBESTOS DUST ………………………………………………………… 10

1.2.10 PREVENTING INJURY FROM SQUEEZING OR CUTTING ……………………………… 10

1.2.11 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE, IF

ROPS ARE INSTALLED) ……………………………………………………………………………………….. 11

1.2.12 PRECAUTIONS FOR OPTIONAL ATTACHMENTS ………………………………………….. 11

1.3 SAFETY PROCEDURES ………………………………………………………………………………..12

1.3.1 BEFORE STARTING ENGINE ……………………………………………………………………….. 12

1.3.2 OPERATION ……………………………………………………………………………………………….. 13

1.3.3 TRANSPORTATION ……………………………………………………………………………………… 16

1.3.4 BATTERY ……………………………………………………………………………………………………. 17

1.3.5 TOWING …………………………………………………………………………………………………….. 18

1.3.6 BEFORE CARRYING OUT MAINTENANCE …………………………………………………….. 19

1.3.7 DURING MAINTENANCE ……………………………………………………………………………… 20

CHAPTER 2: OPERATION ……………………………………………………………………….25

2.1 CONTROLS …………………………………………………………………………………………………25

2.1.1 GENERAL VIEW OF CONTROLS ……………………………………………………………………. 25

2.1.2 ROLES OF VARIOUS CONTROLS ………………………………………………………………….. 26

2.1.3 OTHER DEVICES ………………………………………………………………………………………… 31

2.2 THE ELECTRIC SYSTEM (WITHOUT GPS) …………………………………………………….37

2.3 THE ELECTRIC SYSTEM (WITH GPS) ……………………………………………………………39

2.3.1 PRECAUTIONS FOR TURNING ON AND OFF THE MAIN MACHINE …………………. 41

2.3.2 THE ENVIRONMENTAL REQUIREMENTS OF THE CONTROLLERS AND MONI-

TORS ………………………………………………………………………………………………………………….. 42

2.3.3 DESCRIPTION OF THE MONITOR PANEL ……………………………………………………… 42

VI

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

CONTENTS

2.3.4 DESCRIPTION OF THE SWITCH BUTTON PANEL ………………………………………….. 43

2.3.5 OPERATION OF THE ELECTRIC SYSTEM …………………………………………………….. 44

2.3.6 OPERATION OF THE HORN BUTTON ……………………………………………………………. 52

2.3.7 IN-LINE FUSE ……………………………………………………………………………………………… 52

2.3.8 POWER SOCKETS ………………………………………………………………………………………. 52

2.3.9 CAB’S HEAD LAMP SWITCH ………………………………………………………………………… 52

2.3.10 PRECAUTIONS FOR FUSE BOX …………………………………………………………………. 53

2.3.11 DESCRIPTION OF THE BOND STRAPS OF CONSTRUCTION MACHINERY’S

ELECTRIC SYSTEM ……………………………………………………………………………………………… 54

2.4 OPERATION ………………………………………………………………………………………………..55

2.4.1 CHECK BEFORE STARTING ENGINE ……………………………………………………………. 55

2.4.2 OPERATION METHODS AND STEPS …………………………………………………………….. 58

2.4.3 OPERATION WHEN MOVING ……………………………………………………………………….. 60

2.4.4 TURNING ……………………………………………………………………………………………………. 62

2.4.5 PARKING ……………………………………………………………………………………………………. 63

2.4.6 STOPPING ENGINE …………………………………………………………………………………….. 64

2.4.7 OPERATION IN SPECIAL CLIMATE CONDITIONS …………………………………………… 64

2.4.8 OPERATING ON SLOPES …………………………………………………………………………….. 65

2.4.9 PRECAUTIONS …………………………………………………………………………………………… 66

2.4.10 OPERATING IN WATER ……………………………………………………………………………… 67

2.4.11 OPERATING ON DESERT …………………………………………………………………………… 67

2.5 DOZING OPERATION …………………………………………………………………………………..68

2.5.1 OPERATION OF BLADE AND RIPPER …………………………………………………………… 68

2.5.2 BLADE ADJUSTMENT ………………………………………………………………………………….. 68

2.5.3 DOZING OPERATION …………………………………………………………………………………… 71

2.5.4 LEVELING OPERATION ………………………………………………………………………………… 71

2.5.5 DOZING SIDEWAYS …………………………………………………………………………………….. 71

2.5.6 METHODS FOR EXTENDING MACHINE LIFE ………………………………………………… 72

2.6 TOWING, LIFTING, TRANSPORTATION AND STORAGE …………………………………73

2.6.1 TOWING ……………………………………………………………………………………………………… 73

2.6.2 LIFTING ………………………………………………………………………………………………………. 73

2.6.3 TRANSPORTATION ……………………………………………………………………………………… 74

2.6.4 STORAGE …………………………………………………………………………………………………… 75

CHAPTER 3: STRUCTURE AND PRINCIPLE …………………………………………….77

3.1 MACHINE STRUCTURE AND MAIN PARAMETERS …………………………………………77

3.1.1 MACHINE APPEARANCE ………………………………………………………………………………. 77

3.1.2 MAIN PARAMETERS ……………………………………………………………………………………. 78

3.1.3 CHARACTERISTICS OF THE DRIVE SYSTEM ……………………………………………….. 78

3.1.4 WALKING SYSTEM ……………………………………………………………………………………… 78

3.1.5 TRIPLE-SHANK RIPPER ………………………………………………………………………………. 78

3.1.6 SINGLE-SHANK RIPPER ……………………………………………………………………………… 79

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

VII

CONTENTS

3.1.7 DOZING DEVICES ………………………………………………………………………………………… 79

3.1.8 HYDRAULIC SYSTEM (WORK EQUIPMENT) ………………………………………………….. 79

3.1.9 DRIVE SYSTEM: TRANSMISSION PRINCIPLE ILLUSTRATION …………………………. 80

3.1.10 DIMENSIONS……………………………………………………………………………………………… 81

3.2 ENGINE ………………………………………………………………………………………………………82

3.2.1 ENGINE APPEARANCE ………………………………………………………………………………… 82

3.2.2 ENGINE’S MAIN PERFORMANCE INDICATORS …………………………………………….. 83

3.2.3 DESCRIPTION OF ENGINE’S VARIOUS SYSTEMS …………………………………………. 83

3.2.4 POWER OUTPUT DEVICES ………………………………………………………………………….. 84

3.2.5 RADIATOR ASSEMBLY …………………………………………………………………………………. 86

3.2.6 OIL COOLER ASSEMBLY ………………………………………………………………………………. 87

3.2.7 ENGINE OPERATION ……………………………………………………………………………………. 88

3.2.8 FUEL PIPING SYSTEM ………………………………………………………………………………… 88

3.3 HYDRAULIC TORQUE CONVERTER ………………………………………………………………89

3.4 UNIVERSAL JOINT ……………………………………………………………………………………….91

3.5 TRANSMISSION CASE ………………………………………………………………………………….92

3.6 CENTRAL DRIVE ………………………………………………………………………………………….95

3.7 STEERING CLUTCH ……………………………………………………………………………………..98

3.8 STEERING BRAKE ……………………………………………………………………………………….99

3.8.1 WORKING PRINCIPLE ……………………………………………………………………………….. 100

3.8.2 SERVO MOTOR VALVE’S WORKING PRINCIPLE ………………………………………… 100

3.9 FINAL DRIVE………………………………………………………………………………………………101

3.10 DRIVE SYSTEM’S OPERATION …………………………………………………………………102

3.10.1 GEAR SHIFT …………………………………………………………………………………………….. 102

3.10.2 OPERATION OF STEERING BRAKE …………………………………………………………… 103

3.11 WALKING MECHANISM …………………………………………………………………………….104

3.11.1 TRACK TENSION DEVICE …………………………………………………………………………. 105

3.11.2 IDLER ………………………………………………………………………………………………………. 106

3.11.3 TRACK ROLLER ………………………………………………………………………………………. 107

3.11.4 CARRIER ROLLER …………………………………………………………………………………… 108

3.11.5 TRACK ……………………………………………………………………………………………………. 109

3.11.6 EQUALIZER BAR ………………………………………………………………………………………. 110

3.12 HYDRAULIC SYSTEM ……………………………………………………………………………… 111

3.12.1 WORK EQUIPMENT’S HYDRAULIC SYSTEM ………………………………………………..111

3.12.2 GEARSHIFT AND STEERING HYDRAULIC SYSTEM ……………………………………. 122

3.13 WORK EQUIPMENT ………………………………………………………………………………….133

3.13.1 STRAIGHT TILT BLADE AND SEMI U-BLADE ……………………………………………… 133

3.13.2 ANGLE BLADE ………………………………………………………………………………………… 135

3.13.3 TRIPLE-SHANK RIPPER AND SINGLE-SHANK RIPPER ……………………………….. 136

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CONTENTS

3.14 ELECTRIC SYSTEM ………………………………………………………………………………….137

3.14.1 DESCRIPTION OF THE ELECTRIC SYSTEM ………………………………………………. 137

3.14.2 ELECTRIC WIRING CHART ……………………………………………………………………….. 138

3.14.3 WIRE CODES ………………………………………………………………………………………….. 139

3.14.4 ELECTRIC PRINCIPLE DIAGRAM ……………………………………………………………… 140

CHAPTER 4: MAINTENANCE ………………………………………………………………..143

4.1 MAINTENANCE ………………………………………………………………………………………….143

4.1.1 SERVICE TABLE ………………………………………………………………………………………… 145

4.1.2 INITIAL 250 HOURS SERVICE …………………………………………………………………….. 147

4.1.3 EVERY 250 HOURS SERVICE …………………………………………………………………….. 147

4.1.4 EVERY 500 HOURS SERVICE …………………………………………………………………….. 153

4.1.5 EVERY 1000 HOURS SERVICE …………………………………………………………………… 154

4.1.6 EVERY 2000 HOURS SERVICE ………………………………………………………………….. 157

4.1.7 EVERY 4000 HOURS SERVICE …………………………………………………………………… 157

4.1.8 MAINTENCE WHEN NEEDED ……………………………………………………………………… 158

4.1.9 LUBRICATION DIAGRAM AND LUBRICATION TABLE ……………………………………. 164

4.1.10 ADJUSTMENT OF VARIOUS PARTS ………………………………………………………….. 166

4.1.11 SERVICE STANDARDS FOR MAIN PARTS ………………………………………………….. 170

4.1.12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ……………………… 202

4.2 TROUBLESHOOTING …………………………………………………………………………………204

4.2.1 ENGINE ……………………………………………………………………………………………………. 204

4.2.2 ELECTRIC SYSTEM …………………………………………………………………………………… 205

4.2.3 CHASSIS ………………………………………………………………………………………………….. 205

4.3 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY ………………………………….206

4.3.1 DISASSEMBLY ………………………………………………………………………………………….. 206

4.3.2 ASSEMBLY ……………………………………………………………………………………………….. 207

4.3.3 ASSEMBLY AND DISASSEMBLY OF BEARINGS …………………………………………… 207

4.3.4 OIL SEAL INSTALLATION ……………………………………………………………………………. 208

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

IX

NOTE PAPER

X

Note paper

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY LABELS

CHAPTER 1: SAFETY

1.1 SAFETY LABELS

The following warning signs and safety labels are used on this machine.

• Be sure that you fully understand the correct position and content of labels.

• To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off.

• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way.

• If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Shantui distributor.

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1.1.1 POSITIONS OF SAFETY PICTOGRAMS

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SAFETY LABELS | SAFETY

3

5

6

9

7

2 1

2

3

4

5

No.

1

2

Name

Caution signs

Sign (Warning: Backing)

Caution: Engine is running

Safety and use of working oil tank

Sign (Caution: High temperature)

4

No.

6

7

8

9

Name

Caution sign for track adjustment

Signs (battery cable)

Signs for water tank and radiator

Signs (battery)

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SAFETY | SAFETY LABELS

1.1.2 SAFETY LABELS

1. Precautions for operation, inspection, Leaving operator’s seat and maintenance (09967-

00200)

CAUTION

1. Read this manual carefully before operating the machine.

2. Before starting the engine, check if the water tank is full of cold water; and when the temperature is below 0°C, drain water or add coolant in a timely manner.

3. Before operating the machine each day, check if various oil levels meet the requirements, and drain the water from the fuel tank completely.

4. When starting or stopping the machine or leaving the operator’s seat, follow the rules below:

(1)Put the gear shift lever in the NEUTRAL position. If there is a safety mechanism, lock it with the safety lock lever.

(2)Lock the brake.

(3)When lowering the work equipment to the ground, set the work equipment’s control lever to the LOCK position.

5. When the engine is running, follow the rules below:

(1)Don’t open the engine’s side cover.

(2)Don’t get close to the fan or the fan’s belt.

(3)Make sure if the brake is reliable.

6. When you want to stop the engine, let it idle for 5min and then turn the key switch to the

“OFF” position.

7. Precautions for traveling on slopes

(1)Make sure if the brake is reliable.

(2)The fuel should be added to the required level.

(3)Don’t step on the deceleration pedal when going up a slope (see the manual).

8. Check the engine and the parts that are easy to catch fire frequently, and clear flammable materials (e.g. twigs and leaves) accumulated, to avoid hampering operation and catching fire.

9. Precautions for repair and maintenance:

(1)Park the bulldozer on a level ground.

(2)When lowering the work equipment to the ground, set the work equipment’s control lever to the LOCK position.

(3)When the bulldozer is jacked up by the work equipment, don’t go under the machine.

10. See the manual for lubrication points and lubrication cycles.

09967 — 00200

2. Precautions when traveling in reverse(09802-02000)

WARNING

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

To prevents SEVERE INJULY or DEATH, do the following before moving machine or its attachments:

• Honk horn to alert people nearby.

• Be sure no one is on or near machine.

• Use apotter if view is obstructed.

Follow above even if machine equipped with back-up alarm and mirrors.

09802- 02000

3

3. Precautions for high-temperature cooling water (09966-00200)

SAFETY LABELS | SAFETY

WARNING

When the water temperature is high, don’t turn off the radiator cap, to prevent the hot water from spurting out due to internal pressure.

1. Before operating the machine each

2. level be above the filter (screen.

3. fore beginning operation.

4. Precautions for high-temperature hydraulic oil (09965-02100)

CAUTION

• When opening the cap, must stop the engine first.

• When the oil temperature is high, don’t open the cap. to prevent the hot oil from spurting out.

• Slowly turn loose the cap of the oil tank, to completely release the internal pressure.

• When the oil temperature is high, don’t open the oil drain plug.

• The oil in the hydraulic tank and the filter element of the filter should be changed after the first 250 hours, and after that, should be changed every 1000 hours. (See the manual for the replacement requirements.)

• When replacing the filter element, lower the work equipment to the ground, and stop the engine from running.

09665 — 02100

5. Caution for hot surface of engine (09817-00880)

• This label indicates that touching hot parts such as a running engine, motor or muffler or one that has just run may have the risk of being scalded. Do not touch them at a high temperature.

4

09817- 00880

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY LABELS

6. Precautions for check and adjust track tension (09657-02100 is near or in the inner side of the track adjustment cover)

CAUTION

• When increasing track tension, inject grease from the grease fitting.

• When decreasing track tension, turn loose the screw plug by one turn and squeeze the grease out. (See the manual for details about the adjustment steps of track.)

• The screw plug should not be loosened by more than one turn. Never loosen any parts other than the screw plug, to prevent the internal high-pressure oil from spurting out to cause accidents.

• After the adjustment, tighten the screw plug.

Cap

Grease fitting

09657 — 02100

7. Precautions for handling battery cables (09808-02000)

WARNING

Improper use of the booster cable and the battery cable may cause explosion, leading to serious personal injury or even death.

• Use the booster cable and the battery in the manual.

09808- 02000

8. Caution for engine running (09607-10880)

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09607- 10880

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9. Caution for approach when machine moving (09806-10880)

SAFETY LABELS | SAFETY

09806- 10880

10. Precautions for handling accumulator (09664-02000)

WARNING

Explosive gases

Cigarettes, flames and sparks may cause the battery

Keep the breather tightened and level

Toxic gases may cause serious burning.

The material contains sulphuric acid. Prevent it from

Put in places not accessible by children

09664- 02000

6

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY RULES

1.2 SAFETY RULES

1.2.1 SAFETY PRINCIPLES

• Only trained and authorized personnel can operate and maintain the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired putting yourself and everyone else on your jobsite in danger.

• Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.

• When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used.

• If you find any abnormality in the machine during operation or maintenance, stop the machine immediately and check it out. Do not operate the machine until the abnormality has been corrected.

• Follow all the requirements.

• This machine is suitable for use below 3000 meters above sea level. With the increase of altitude, the power will decrease. If used in a place above the required altitude for a long time, the parts may be damaged. If above this altitude, we recommend the use of Shantui’s highland machines.

1.2.2 SAFETY FEATURES

• Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged.

• Understand the method of use of safety features and use them properly.

• Never remove any safety features. Always keep them in good operating condition.

• Improper use of safety features may cause serious personal injury or death.

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SAFETY RULES | SAFETY

1.2.3 CLOTHING AND PERSONAL PROTECTIVE ITEMS

• Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other protruding parts.

• Do not wear clothing with grease to prevent fire.

• You must wear helmets, safety glasses, masks, gloves and safety shoes when operating and maintaining the machine.

If your work has contact with splashing metal chips and other fine particles, you must wear safety goggles, a hard hat and thick gloves. Especially, when you use a hammer to knock a pin or use the compressed air to clean the filter element, you must check if there are people near the machine.

1.2.4 UNAUTHORIZED MODIFICATION

• Any modification made without authorization from Shantui can create hazards. Before making a modification, consult your Shantui distributor. Shantui will not be responsible for any injuries, accidents, or product failures resulting from modifications made without authorization from Shantui.

1.2.5 ALWAYS APPLY LOCK WHEN LEAVING OPERA-

TOR’S SEAT

• When leaving the machine, ensure to set safety lock lever

(1) and parking lever (2) securely to the LOCK position. If you accidentally touch the levers when they are not locked, there is a hazard that the machine may suddenly move and cause serious injury or property damage.

Lock

Free

Free

Lock

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SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY RULES

• When leaving the machine, always lower the work equipment completely to the ground, set safety lock lever to the

LOCK position, then stop the engine, and use the key to lock all the equipment. Always remove the key, take it with you.

1.2.6 GETING ON OR OFF THE MACHINE

• Never jump on or off the machine. In particular, never get on or off a moving machine. This may cause serious injury.

• To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself.

• Do not grip the control levers when getting on or off the machine.

• Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Repair any damage and tighten any loose bolts.

1.2.7 FIRE CAUSED BY FUEL OR OIL

• Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous.

• Keep the liquid away from flame.

• Stop the engine before refueling, and do not smoke.

• Tighten all fuel and oil caps securely.

• Use well-ventilated areas for adding or storing oil and fuel.

• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

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1.2.8 PREVENTION OF BURNS

• Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, and then turn the cap slowly to release the pressure before removing it.

• To prevent burns from hot water or hot oil spurting out, before removing the cap, you must stop the engine and let water or oil cool down, and then turn the cap slowly to release the pressure before removing it.

• (When checking after the water or oil is cooled down, you should use your hand to check the air temperature near the surface of the radiator and the hydraulic tank. Do not touch the radiator and the hydraulic tank.)

1.2.9 BE CAREFUL ABOUT ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled.

There is danger of inhaling asbestos when handling asbestos.

Always observe the following:

• Do not use compressed air for cleaning.

• Spray water to keep down the dust when cleaning.

• Operate the machine from an upwind position if possible.

• Use a respirator if necessary.

1.2.10 PREVENTING INJURY FROM SQUEEZING OR CUT-

TING

• Do not extend or put your hands, arms or other parts of your body between moving parts (such as between the working parts and oil tanks or between vehicle body and working parts). When the machine is running, the clearance may change, leading to serious damage of parts or personal injury.

SAFETY RULES | SAFETY

10

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY RULES

1.2.11 PRECAUTIONS WHEN USING ROPS (ROLL OVER

PROTECTIVE STRUCTURE, IF ROPS ARE INSTALLED)

• If ROPS is installed, do not remove it when operating the machine.

• ROPS is installed to protect the operator when machine rolls over. When machine rolls over, ROPS supports its weight and absorbs its impact energy.

• Shantui’s ROPS meets the ISO standard. If ROPS is modified without authorization, or if ROPS is deformed by falling objects or by rolling over, its strength may lower and it may no longer meet the designed functions.

• It can only play its role again when being repaired or reinstalled in the required way.

• When modifying or repairing it, consult your Shantui distributor. Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect you properly.

Always fasten your seat belt when operating the machine.

1.2.12 PRECAUTIONS FOR OPTIONAL ATTACHMENTS

• When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.

• Do not use optional attachments not authorized by Shantui or your Shantui distributor. Using unauthorized optional attachments may cause safety issues, and may also affect the normal operation and service life of the machine.

• Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Shantui.

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SAFETY PROCEDURES | SAFETY

1.3 SAFETY PROCEDURES

1.3.1 BEFORE STARTING ENGINE

Safety at worksite

• Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

• Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not carry out operations at places where there is a hazard of landslides or falling rocks.

• In particular, if you need to operate on a road, protect pedestrian and cars by designating a person for worksite traffic duty or by installing fences around the worksite.

• If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines.

• When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

Fire prevention

• Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine.

• Check if there is leakage in the fuel, lubricant and hydraulic systems, and repair any leakage.

Remove any excessive oil, fuel or other flammable liquid.

• Ensure to have a reliable fire extinguisher (optional or provided by the user).

• Do not operate the machine near flame.

Inside operator’s compartment

• Do not leave parts or tools lying around the operator’s compartment, to avoid them from damaging or breaking the control lever or switch. Put them in the tool box in the vehicle.

• Keep the floor of the operator’s compartment, the control lever, the pedal and the rail free of oil, grease, snow or other dirt.

• Check if the seatbelt, the buckles and the parts are damage or worn, and replace the damaged parts. You must wear the seatbelt when driving.

• Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

• Never smoke in the operator’s compartment.

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SAFETY | SAFETY PROCEDURES

Ventilation for enclosed areas

• If you have to start the engine in an enclosed area, be sure to maintain sufficient ventilation. Exhaust fumes from the engine can kill.

Precautions for rearview mirrors, windows and lamps

• Clean all the windows and lamps, to ensure a clear vision.

• You should use a cleaning fluid containing aldehyde. Do not use a cleaning fluid containing form aldehyde, as it irritating to your eyes.

• Adjust the rearview mirrors, so that you can have a clear vision of the right and left side of the vehicle on when sitting your seat. You should replace them immediately if they have cracks.

• Ensure that the head lamps and the working lamps can work normally.

1.3.2 OPERATION

Precautions when starting

• Before mounting, do a walk-around check again, to ensure that there are no people or other obstacles in the surrounding area.

• You can only start the engine when you are seated.

• Do not allow anyone apart from the operator to enter the cab or other area of the vehicle.

• For a vehicle installed with a back-up alarm, ensure that the alarm can function normally.

• When starting the engine, after the key is turned to the START position, the starting time should not exceed 10 seconds. The interval between two starts should not be less than 2 minutes.

Precautions when reversing

Before operating the machine or the work equipment, do the following first:

• When starting the engine, sound the horn as a warning.

• Ensure that there are no people around the vehicle. Pay special attention to areas behind the vehicle.

• If needed, assign someone to check it out for you, especially when reversing.

• When in dangerous areas or when the visibility is very poor, assign a signalman.

• No one should be allowed to enter the travel route of the vehicle.

• You must still follow this rule if even your vehicle is installed with the back-up alarm and the rearview mirror.

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SAFETY PROCEDURES | SAFETY

Safety precautions

• Before starting the engine or operating the machine, ensure that the control lever is reliably in the

NEUTRAL position.

Precautions when traveling

• When traveling on flat ground, pull the work equipment and keep its height at 40 to 50 cm above the ground.

• When traveling on rough ground, travel at low speed and do not operate the steering suddenly.

• Do not use cellular telephones inside the operator’s compartment when driving or operating the machine.

• If the engine or the control lever shows abnormalities when traveling, stop the vehicle immediately and repair it.

Traveling on slops

• When traveling on steep hills, dams or slopes, the machine may tip over or slip to one side.

• When traveling on slops, keep the blade approximately 20 to 30cm above the ground. In case of emergency, quickly lower the blade to the ground to help the machine to stop.

• Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, and then travel on to the slope again.

• Do not travel on grass, fallen leaves, or wet steel plates. The machine may slip on these surfaces. When traveling on the edge of a slope, maintain a very low speed.

• When driving down a slope, lower the travel speed and use the engine as a brake.

• When the engine stops on a slope, apply the brake immediately, lower the blade to the ground, and use the parking brake.

Precautions when operating

• Do not bulldoze against wind, to prevent dust.

• When the machine is under full load, avoid sudden start, sudden turn or sudden brake.

Ensure good visibility

• When working in a dark area, use working lamps and head lamps, and set up additional lighting in the work area if necessary.

• Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

Do not let the work equipment hit anything

• When operating in tunnels, under bridges, under electric wires, or in warehouses, be extremely careful not to let the work equipment hit anything.

14

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY PROCEDURES

Working on loose ground

• Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.

• When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse.

• When operating in a dangerous area or an area with the risk of falling objects, be sure to install the Falling Object Protective Structure (FOPS).

• When operating in an area with the risk of falling objects or in a dangerous area where the machine may tip over, be sure to install the Roll Over Protective Structure (ROPS) and seatbelt.

Do not go close to high-voltage cables

• Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On job sites where the machine may go close to electric cables, always do as follows:

• Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

• Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.

• To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body. Use a signalman to give warning if the machine approaches too close to the electric cables. When carrying out operations near high voltage cables, do not let anyone come close to the machine. If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator’s compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone come close to the machine.

Voltage of Cables

100V-200V

6600V

22000V

66000V

154000V

187000V

275000V

500000V

Safe distance

Over 2 m

Over 2 m

Over 3 m

Over 4 m

Over 5 m

Over 6 m

Over 7 m

Over 11 m

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15

SAFETY PROCEDURES | SAFETY

Parking machine

• When leaving the machine, lower the work equipment to the ground, set the safety lock lever to the LOCK position, stop the engine, and use the key to lock all the equipment.

• Always remove the key and take it with you.

1.3.3 TRANSPORTATION

Loading and unloading

• There are always potential risks in loading or unloading the machine, so be especially careful.

When loading and unloading the machine, the engine should run at a low speed and the machine should also travel at a low speed.

• Load and unload the machine on a flat firm roadbed, and keep a safe distance from the edge of the road.

• Before loading and unloading, be sure to insert cushion blocks beneath the trailer’s tires and ramp.

• Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.

• Make sure the ramp is stably placed and secured, and the two ramps are on the same plane.

• Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove the mud from the track of the machine.

• Never change the direction of travel when on the ramps. If it is necessary to change direction, drive off the ramps and correct the direction, and then drive on to the ramps again.

• After loading, use blocks to stop the track, and enable the machine to remain in place reliably.

Shipping

• When shipping the machine on a trailer, be sure to follow the rules of different countries and regions about the weight, transportation height, and overall length of the machine, and to abide by all the applicable laws.

• When determining the shipping route, take into consideration the length, the width and the height of the goods, to prevent them from exceeding the limits.

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SHANTUI CONSTRUCTION MACHINERY CO., LTD.

SAFETY | SAFETY PROCEDURES

1.3.4 BATTERY

• Battery electrolyte contains sulphuric acid, and once spilled, it may quickly burn your skin and clothes. If you spill acid on your clothes, immediately flush the area with large amount of water.

• If acid gets into your eyes (you may become blind from this), flush them immediately with large amount of water and seek medical attention.

• If you accidently swallow the acid, immediately drink large amount of water or milk or egg or canola oil and seek medical attention.

• When working with batteries, always wear safety glasses or goggles.

• The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery or do anything that will cause sparks.

• When checking or handling the battery, stop the engine and turn the starting key to the OFF position before starting.

• Check the positive and negative terminals carefully when removing or installing the battery.

• Tighten the battery caps securely.

• Tighten the battery terminals securely. If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

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► Starting with booster cable

• Always wear safety goggles when starting the engine with booster cables.

• When starting from another machine, do not allow the two machines to touch.

• When connecting booster cables, turn the start switch of the normal machine and the fault machine to OFF, or when power on, the machines may move.

• Be sure to connect the positive cable first when installing the booster cables. Disconnect the negative cable first when removing them.

• Note: Do not let the booster cable clamps contact each other or let the cable clamps contact the machine, as this may produce sparks, which are very dangerous. Therefore, be sure to operate carefully.

• When connection two batteries in parallel, connect the positive terminal to the positive terminal, and connect the negative terminal to the negative terminal.

• When connecting a ground cable to the chassis of a machine to be started, ensure that the connection is secure.

1.3.5 TOWING

► When towing, fit the wire to the drawbar pin

• Injury or death could result or the machine could be damaged if a disabled machine is towed incorrectly.

• When your machine is towed by another machine, ALWAYS use a wire rope with a sufficient towing capacity.

• Towing on slopes is prohibited.

• Do not use a broken, kinked or frayed wire rope.

• Do not straddle the towing cable or wire rope.

• When connecting up a towing machine, do not let anyone enter the area between the towing machine and the equipment being towed.

• Set the towing machine and the towing connection of the equipment being towed in a straight line when connecting it, and ensure they are in the correct position.

SAFETY PROCEDURES | SAFETY

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SAFETY | SAFETY PROCEDURES

1.3.6 BEFORE CARRYING OUT MAINTENANCE

Proper tools

• Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.

Periodic replacement of safety critical parts

• Periodically replace the following parts that are easy to age.

Fuel system: fuel inlet hose and fuel return hose. Hydraulic system: pump output hose and fuel pump’s front and back manifolds.

• The above parts must be periodically replaced even if it looks that they are not damaged, because they will age over time.

• Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified interval.

Stop engine before carrying out inspention and maintenance

• Stop the machine on flat hard ground when carrying out inspection and maintenance. Turn off the engine and take out the key before performing inspection and maintenance. Or, others may start the engine or operate the control levers when you are performing maintenance or lubrication,

• so that you could suffer injury.

• If maintenance must be carried out with the engine running, such as cleaning the inside of the radiator, place the parking lever and safety lock lever at the LOCK position to prevent the work equipment from moving and carry out the operation with two workers: One worker must always sit in the operator’s seat and be ready to stop the engine at any time. This worker must be very careful, to avoid mistakenly touch any control levers to injure the other worker who is performing maintenance.

• The worker who is performing maintenance must be very careful, to avoid touching moving parts or being caught by them.

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1.3.7 DURING MAINTENANCE

Personnal

• Only authorized personnel can service and repair the machine. Take precautions when grinding, cutting, welding or using a hammer.

Attachments

• Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.

Work under the machine

• Before performing maintenance or working under the machine, lower the work equipment to the ground or to the lowest position.

• Working under a machine that is not supported is prohibited.

SAFETY PROCEDURES | SAFETY

Keep machine clean

• Always keep the machine clean. If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.

• Do not use water or steam to wash sensors, connectors or the interior of the cab. If water gets into the electrical system, there is a hazard that it will cause malfunctions or miss-operation.

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SAFETY | SAFETY PROCEDURES

Principles for adding fuel and oil

• After adding fuel or oil, wipe up any spilled fuel or oil, to prevent people from slipping and falling.

• Tighten all fuel and oil caps securely.

• Do not use fuel to wash parts.

• Use well-ventilated areas for adding oil and fuel.

• The models and types of oil and water used by the machine depend on the working environment and temperature. Follow the table of the “SELECTION OF FUEL, COOLANT

AND LUBRICANTS”.

• Never use methanol, methanol or ethanol based antifreeze, to avoid engine from having faults. Antifreeze is flammable, so do not bring any flame close.

• Use “soft water” for cooling water if possible. Never use waste water for cooling water. Never add any leak preventive to the cooling water.

• Be sure to clean or replace various filters at required intervals.

• Check cooling water, fuel, lubricant and oil from time to time, and replenish them as required, to ensure the normal use of the machine.

Radiator coolant level

• When checking the cooling water level, check the sub-tank when the engine is cold.

• After the water temperature goes down, turn the cap slowly to release the pressure, and then remove it.

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Lighting

• When checking fuel, oil, coolant or battery electrolyte, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause serious injury.

SAFETY PROCEDURES | SAFETY

Precautions for maintenance battery

• When repairing the electrical system or when carrying out electrical welding, remove the negative terminal of the battery to prevent the flow of current.

Handling high-pressure hoses

• Do not bend or knock high-pressure hoses with a hard object. Do not use bent or cracked hoses or hard pipes, or there is a risk of burst during use.

• Be sure to repair loose or broken oil pipes. Oil leakage may cause fire.

Precaution with high-pressure oil

• The hydraulic system is always under internal pressure.

• Do not carry out inspection or replacement work when the hydraulic system is under pressure.

• There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. When carry out inspection, wear safety glasses and leather gloves.

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SAFETY | SAFETY PROCEDURES

• If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Precautions for maintenance under high-temperature or high-pressure

• When just stopped, the engine’s cooling water and the oil in various parts are still under a high temperature and high pressure. If you remove the cap, drain the oil or water, or replace the filters in this situation, you may suffer burns or other injuries. Wait for the temperature to go down before performing inspection and maintenance according to the steps in this manual.

Rotating fans and belts

• Do not get close to rotating parts, to avoid being caught by them.

• If your body or a tool touches the blades of a fan, they may be cut or hit away, so don’t touch any rotating parts.

Waste material

• Never drain oil directly onto the ground or dump into the sewage system or rivers.

• Always put oil drained from your machine in containers, not directly onto the ground.

• Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries and other toxic (harmful) substances.

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NOTE PAPER

24

Note paper

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OPERATION | CONTROLS

CHAPTER 2: OPERATION

2.1 CONTROLS

2.1.1 GENERAL VIEW OF CONTROLS (FIGURE 2-1)

Brake pedal

Deceleration pedal

Gear shift lever

Fuel control lever

Steering lever

Gear shift lock lever

Blade control lever lock button

Blade control lever

Brake lock lever

Ripper lock button

Ripper control lever

Figure 2-1

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2.1.2 ROLES OF VARIOUS CONTROLS (FIGURE 2-2)

3

1

7

2

9

8

6

11

10

4

Figure 2-2

CONTROLS | OPERATION

5

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OPERATION | CONTROLS

Fuel control lever (1) (Figure 2-3)

This control lever is used to control the engine speed and output.

(L) The Low idling position

(H) The High speed position

Figure 2-3

The gear shift lever (2) (Figure 2-4)

There are three forward gears and three reverse gears. The gear shift lever can be easily shifted, so that you can easily get the speed you want.

(F: Forward; R: Reverse; and N: Neutral)

Figure 2-4

The steering lever (3) (Figure 2-5)

When the steering lever on one side is pulled to the middle position, the vehicle will slowly make a big turn to this side, and when the lever continues to be pulled to the end, the vehicle will make a turn on the original position.

Figure 2-5

The brake pedal (4) (Figure 2-6)

If you step down the two pedals in the middle, both the left side and the right side will brake. Pull the steering lever on one side to the middle position, and simultaneously step down the brake pedal on the same side, the vehicle will make a turn on the original position to the same side.

CAUTION

Do not place your foot on this pedal unnecessarily.

Figure 2-6

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CONTROLS | OPERATION

Deceleration pedal (5) (Figure 2-7)

This pedal is used to reduce the engine speed.

CAUTION

When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly. To prevent this, depress the decelerator pedal to reduce the travel speed.

Brake lock lever (6) (Figure 2-8)

This device is used to lock the brake pedal when parking. Depress the brake pedal, and push the lock lever to the LOCK position, the brake will be locked. Depress the brake pedal, and push the lock lever to the FREE position, the brake will be released.

CAUTION

• No matter when and where the machine is parked, the brake pedal must be locked.

• Using the brake lock lever to lock the brake pedal to stop the bulldozer must be performed when the engine is running. This is because when the engine stops running, the hydraulic brake booster is in the non-working state, so that braking force will be reduced. Be especially careful that parking on a slope is very dangerous, so you must operate this locking mechanism when the engine is running.

Lock

Free

The gear shift’s lock lever (7) (Figure 2-9)

This device is used to lock the gear shift when parking.

CAUTION

When the vehicle is stopped for a while, you must push the gear shift lever to the NEUTRAL position, and push the lock lever to the LOCK position.

Free

Lock

Figure 2-7

Figure 2-8

Figure 2-9

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OPERATION | CONTROLS

Blade control lever lock button (8) (Figure 2-10)

Press the button, the blade control lever is locked; pull out the button, the blade control lever is free.

CAUTION

When the vehicle is parked or during troubleshooting, the blade should be put down, and the lock button should be put to the LOCK position.

Blade control lever (9) (Figure 2-11)

The control lever is normally in the fixed position (2), Pull the control lever to position (1), the blade is raised (Figure 2-12); and push it to position (3), the blade is lowered; continue to push it to position (4), the blade is in the floating state.

► When the control lever is in position (4), it cannot be automatically bounced back to the fixed position (2), and must be manually pulled back. When operating the straight tilt blade, the control lever is pulled to position (A), and the blade is tilted to the right; when it is pulled to position (B), the blade is tilted to the left. (Figures 2-11 and 2-13)

► The blade can tilt when it is in any position between (1) and (3);

► Positions (A) and (B) are used for straight tilt blade only;

► When the tilt cylinder reaches the end of its journey, the control lever should be immediately pulled to fixed position (2);

► When the blade is at the highest point or the lowest point, do not tilt the blade.

Free

Lock

Raise

8

Figure 2-10

Figure 2-11

Lower

Figure 2-12

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Right tilt

Figure 2-13

Left tilt

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CONTROLS | OPERATION

The ripper control lever (10) (Figure 2-14)

The control lever is normally in the fixed position (2). When the control lever is pulled to position (1), the ripper is raised (Figure

2-15a); and when it is pulled to position (3), the ripper is lowered.

Press the button in the center of the control lever to move the control lever to location (1), and the cutting angle of the ripper will become smaller (Figure 2-15b); if it is moved to location (3), the cutting angle of the ripper will become bigger.

Figure 2-14

Raise

Lower

Figure 2-15a

The ripper lock button (11) (Figure 2-16)

Press the button, the ripper control lever is locked; pull out the button, the ripper control lever is free and can go up and down.

CAUTION

When the vehicle is parked or during troubleshooting, the ripper must be put down, and the lock button be put to the

LOCK position.

Smaller

Bigger

Figure 2-15b

Figure 2-16

Free

Lock

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OPERATION | CONTROLS

2.1.3 OTHER DEVICES

Adjusting operator’s seat (Figure 2-17)

Fore-and-aft adjustment: Pull lever «(1)» , set the seat to a position where it is easy to operate, and then release the lever.

Height adjustment of seat: Pull up knob «(2)» with both hands to raise the seat. There is one knob «(2)» on left and right each in symmetry.

Adjust reclining angle: Pull up lever «(4)», set the seatback to a position where it is easy to operate, and then release the lever.

Adjust the softness of seat: Turn knob (3) clockwise, to make the seat harder; and turn it counterclockwise, to make the seat softer. You can adjust the seat to the most comfortable state based on your weight.

Seat belt (Figure 2-18)

Fasten the belt using the following methods.

1. Adjust the seat by following the above steps.

2. After adjusting the seat position, adjust tether belt (1).

Tense the tether belt and install it when there is no one sitting on the seat.

3. Sit on the seat and hold the buckle (2), insert the tongue

(3) in the buckle (2), and pull out the belt slowly so that the belt will cover your abdomen sufficiently.

CAUTION

• Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions.

• Inspect the belt for twisting.

Figure 2-17

Figure 2-18

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CONTROLS | OPERATION

► Fasten the belt along your body, but don’t wind the belt around your body. Belt length can be adjusted on both ends— the tongue end and the buckle end. The buckle should be right in front of your body.

Adjust belt length using the following methods. (Figure 2-19)

• In order to shorten the belt, you can pull any of the free ends of the belt—the buckle end or the tongue end.

• To increase the length, put the belt in right angle with the buckle or the tongue, and pull the belt.

4. When removing the belt, raise the cusp of the buckle lever and loosen the belt.

5. When operating a machine equipped with ROPS, be sure to use the seat belt.

► Check the bolts and fasteners on the chassis and re-tighten if necessary, to ensure that the tightening torque reaches

2-3kgm.

► If the seat belt is scratched or frayed, if any fittings are broken or deformed from long service, replace the seat belt immediately.

► The shock absorption ability of the seat meets the ISO7096 standard.

Figure 2-19

Air outlet of the A/C

Wind direction-adjusting blade

Wind direction and wind volume tuning knob

A/C switch/tuning knob for refrigerating capacity

Figure 2-20

The use of the air conditioner (Figure 2-20, Figure 2-21, and Figure 2-22)

► When there are air bubbles in the window of the liquid container, or when the cooling effect is not very obvious, ask a specialised maintenance person to fix it.

Liquid container’s window

Liquid container

Figure 2-21

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Compressor

Figure 2-22

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OPERATION | CONTROLS

The use of the air conditioner’s fresh air ventilator (Figure

2-23)

In order to keep the air in the closed space clean, the air conditioner’s fresh air ventilator is provided.

► When the fresh air effect is not obvious after long-time use, please replace the internal filter of the fresh air ventilator.

Fresh air button

Fresh air

Fresh air ventilator

Figure 2-23

Front and rear window defroster

Front window defroster (Figure 2-24)

Front window defroster uses the warm air from the A/C to heat the front window, so as to achieve the purpose of defrosting.

Rear window defroster (Figure 2-25)

Rear window defroster uses the resistance wire on the rear window to heat the window after being charged with electricity, so as to achieve the purpose of defrosting.

A/C heater’s start valve

Figure 2-24

Rear window defrost switch

Rear window defroster wire

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Figure 2-25

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When there is dust on the front or the rear window obstructing your view, use the windshield wiper along with the windshield washer to clean them. (Figure 2-26)

CONTROLS | OPERATION

Front & rear windshield washer’s button

Figure 2-26

Front windshield washer nozzle

Rear windshield washer nozzle

Figure 2-26

Frequently check the liquid level of the windshield washer tank, which is located within the battery cover on the left side of the vehicle. (Figure 2-27)

► If the liquid level of the windshield washer tank is too low, add some windshield washer. Loosen the screw on the back of the windshield washer tank, pull it out from the bottom, and add the windshield washer from the mouth.

When the temperature is too low, be careful to prevent the liquid from freezing.

Windshield washer

Figure 2-27

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OPERATION | CONTROLS

The use of the monitor (Figure 2-38 and Figure 2-39)

To make up for the inadequacy of the operator’s visual field, a monitor camera is installed, which is located above the front part of the front hood. The LCD screen of the monitor is above the instrument box. A remote is also provided.

Camera

LCD Screen

Figure 2-28 Figure 2-29

The centralized pressure measurement system (Figure 2-30)

To facilitate routine maintenance and troubleshooting, the centralized pressure measurement system is designed. The pressure detection of all the seven key points of the entire vehicle is concentrated on a pressure measurement plate (located on the right side of the floor frame).

FORWARD DIRECTION

Right steering pressure

Left steering pressure

Left brake pressure

Right brake pressure

Pressure at torque converter’s inlet

Pressure at torque converter’s outlet

Transmission case’s set pressure

Figure 2-30

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CONTROLS | OPERATION

Items to be checked

Left and rightsteering pressure

Left and right brake pressure

Pressure at torque converter’s inlet

Pressure at torque converter’s outlet

Transmission case’s set pressure

Measurement conditions Designed values

The engine is running at a low speed, and the steering clutch’s oil temperature is: 50±5°C

The engine is running at a high speed, and the steering clutch’s oil temperature is: 50±5°C

1.6±0.2MPa

1.6±0.2 MPa

The engine is running at a low or high speed, and the brake’s oil temperature is: 50±5°C

The engine is running at a high speed, and the hydraulic torque converter’s oil temperature is:

50±5°C

The engine is running at a low speed, and the hydraulic torque converter’s oil temperature is:

75±5°C

The engine is running at a high speed, and the hydraulic torque converter’s oil temperature is:

75±5°C

The engine is running at a low speed, and the transmission case’s oil temperature is: 50±5°C

The engine is running at a high speed, and the transmission case’s oil temperature is: 50±5°C

1.8-2.2MPa

0.85±0.1 MPa

0.2-0.3 MPa

0.3-0.55 MPa

1.9±0.2MPa

2.2±0.25 MPa

Noise

When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

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OPERATION | THE ELECTRIC SYSTEM (WITHOUT GPS)

2.2 THE ELECTRIC SYSTEM (WITHOUT GPS)

Functions of the combination meter (Figure 2-31)

The combination meter mainly includes engine oil pressure gauge, the water temperature gauge, the oil temperature gauge, the voltmeter, fuel level gauge and the hour meter.

bar

0

2 4 5 6 7

V

20 24 28 32

℃

0

60 80 100 120

℃

0

80 100 120 130

0

1/2

1/1 mur phy

Figure 2-31

The engine oil pressure gauge (See Figure 2-32)

The range of the oil pressure gauge is 0bar-10bar (about

0MPa-1 MPa), the engine oil pressure during idling is 1.03bar, and the engine oil pressure of 3.4 bar-5 bar at the rated RPM is the normal operating range of the engine. During cold start, the pressure is sometimes not normal, so you should warm-up the engine first to bring the readings of the meters within the normal operating range before starting operation.

bar

0

2 4 5 6 7

Figure 2-32

The voltmeter (See Figure 2-33)

The range of the voltmeter is 16-36V. Before the normal operation, the reading of the voltmeter is over 24V, indicating that the battery’s voltage is normal; if the reading is below 24V, it means that the battery’s voltage is too low and may make it difficult to start the vehicle. If you cannot start the engine, charge the battery.

When the machine is running normally, the engine charges the battery, and the voltmeter’s reading is around 28V. If the voltage is too low or too high, find out the reason and eliminate the problem before operation.

℃

0

60 80 100 120

Figure 2-33

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THE ELECTRIC SYSTEM (WITHOUT GPS) | OPERATION

The water temperature gauge (See Figure 2-34)

The range of the water temperature gauge is 40-120°C, indicating the engine’s water temperature. When the machine runs normally, the reading of the water temperature gauge is

40-100°C. If the temperature is too high and above 100°C, reduce the engine speed, to bring the reading back to the normal range; stop the vehicle to check the water level if necessary.

0

℃

80 100 120 130

The oil temperature gauge (See Figure 2-35)

This indicates the oil temperature of the hydraulic torque converter, and the normal operating range is 60°C-120°C. During operation, if the temperature is too high and above 120°C, reduce the load, to bring the reading back to the normal range.

Figure 2-34

V

20 24 28 32

Figure 2-35

Fuel level gauge (See Figure 2-36a)

The fuel level gauge indicates the percentage of the liquid within the fuel tank in the total capacity of the fuel tank. When the dipstick is near 0, please add fuel in time.

0

1/2

1/1 mur phy

Figure 2-36a

The hour meter (See Figure 2-36b)

This meter records the operation time of the engine, to be used as the basis for regular maintenance.

CAUTION

Check the instruments from time to time during operation, to ensure that the operation is normal.

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Figure 2-36b

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OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3 THE ELECTRIC SYSTEM (WITH GPS)

The bulldozer’s GPS electric system mainly includes the temperature sensor, the pressure sensor, the fuel level sensor, the smart unit for signal collection & conversion, and the LCD smart monitor, and the GPS smart service terminal etc. The sensors are installed in various working parts of the bulldozer, to collect working parameters in real time, and to transmit the data through LAN; various smart units can use each other’s data and share the same ports, to carry out various safety protection and strategic actions.

Note: If the product pictures in this manual are different from the actual products, the actual products should be based on, and the pictures in this manual are for reference only.

This section aims to provide instructions for users to realize safe and efficient operation as well as the effective maintenance of the vehicle’s electric system. Understanding the various precautions as well as the repair & troubleshooting instructions can help effectively avoid various dangerous accidents.

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

WARNING

• Before operating or maintaining and troubleshooting the electric system, you must read this section thoroughly.

• The meters are precision instruments, and in the installation process you should handle them gently. You cannot directly wash the instruments and any part of the entire electric system with water.

• The negative pole’s wire of the meters and the earth wire’s calibration wire should be separately connected to the main switch end of the power supply or be connected to the ground through a reliable nearby bond strap; never connect them together with other equipment to the battery’s negative pole using the same wire.

• The connection of all the signal lines of meters (switch value and analog value) should be reliable and firm.

• The four screws connecting the dashboard and the instrument box should be tightened to ensure the normal use of the meters.

• The installation of all the sensors should ensure that the sensor’s outer threads and their surface are connected properly, to ensure that the sensor’s bond strap is in good condition. (We don’t recommend the use of sealant on the mounting face)

• Before the installation of cables, the installation points of all the bond straps (the surface in contact with the cable’s terminals) must be rigorously treated to remove the paint and the oxidized substance, to ensure that the contact surface is smooth and flat and has good conductance.

• The protective insulating rubber cover at the end of all the bond straps should not be too long to negatively affect the normal connection of the bond strap surface.

• When multiple bond straps are installed at one bond strap point, they should be alternated with each other, to ensure the complete contact after installation.

• The bond strap’s mounting pedestal should be fully soldered, and should not be coldsoldered or contain slag.

• Ensure that the power switch has good contact during operation, and the contact resistance of the switch’s contact should be within 0.001Ω.

CAUTION

• To avoid causing vehicle-locking fault, the users are strictly forbidden to modify or remove the GPS system’s elements and circuits.

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OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3.1 PRECAUTIONS FOR TURNING ON AND OFF THE MAIN MACHINE

STARTING UP——

1. Put the mains switch to ON

2. Apply the brake

3. Adjust the seat and tighten the seat belt

4. Ensure that all the work equipments (blade and ripper etc.) are on the ground

5. Put the gear on NEUTRAL

6. Ensure that the control levers (for blade and ripper etc.) are locked

7. Ensure that people around the bulldozer are in safe places

8. Put the valve control to LOW IDLE

9. Put the key switch to ON, and the monitor will begin self-test

10. Put the key switch to START to start the engine: in winter when temperature is low, start the engine after the automatic warm up

WARMING UP——

1. Warm up the machine for 5min when the engine is idling

2. Unlock the control levers of the work equipments, and cycle the control levers, to ensure that the work oil runs through all the cylinders and pipes

3. Check the instruments and monitors

WORKING——

1. Observe the surroundings of the bulldozer to ensure clear vision

2. Raise all the work equipments (blade and rippers etc.)

3. Ensure that the walking control lever is being pressed down

4. Release the brake

5. Change the gear to the needed position

6. Release the walking control lever to begin operation appropriate to the conditions

SHUTTING DOWN——

STEPS

1. Stop the bulldozer in a level area

2. Apply the brake

3. Reduce the speed of all the hydraulic elements

4. Let the engine idle for 5min

5. Put the key switch to OFF

6. Get off the vehicle safely with the help of hands

7. Observe if there are obvious issues around the bulldozer that need to be addressed after operation

REMARKS

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.2 THE ENVIRONMENTAL REQUIREMENTS OF THE CONTROLLERS AND MONITORS

1. Power supply: 18~32VDC

2. Operating temperature: -30~+70°C

3. Storage temperature: -40~+85°C

4. Relative humidity: (30~90)%RH

5. Atmospheric pressure: 86~106KPa

6. Protection class: IP65

When one or more of the above parameters is out of the required range, the electric system may not work normally or may become damaged. Please use the system strictly following the above requirements on the operating environment, to ensure that the system can work normally.

2.3.3 DESCRIPTION OF THE MONITOR PANEL

100

150

F

℃

40

180

210

250

80

120

140

180 210

F

℃

60

100

250

300

150

16

20

24 28

32

36

VOLTS

0 rpm

28.5v

Figure 2-37: GPS system’s monitor panel

This monitor panel consists of 5 dial pointers and 1 LCD smart monitor, as shown in Figure 2-37.

No.

1

3

5

Name

Meter displaying system voltage

Meter displaying oil temperature of the hydraulic torque converter

Hour meter

No.

2

4

6

Name

Meter displaying water temperature of the engine

Meter displaying engine oil pressure

LCD Smart monitor

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OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3.4 DESCRIPTION OF THE SWITCH BUTTON PANEL

5 4 3 2

8 7

6

Figure 2-38: GPS system’s switch button panel

1

This switch panel consists of 3 reset switch buttons, 4 toggle switches and 1 key switch, as shown in

Figure 2-38:

No.

1

3

5

7

Name

Key starting switch

Front lamp switch

Instrument light switch

K2—LCD smart monitor’sUP/Down key

No.

2

4

6

8

Name

Side lamp switch

Rear lamp switch

K1—LCD smart monitor’s Mute/OK key

K3—LCD smart monitor’s Menu/Left &

Right key

Operation of the reset switch buttons:

1. K1 Mute/Confirmation Key:

a. When there is a warning buzz, activating this key can stop the buzz;

b. Choose the confirmation function in the menu, to enter the next level of menu;

c. In the setup state, press this key to confirm the current operation.

2. K2 Up/Down Key:

a. Move the cursor up or down;

b. Display the next page or the previous page;

c. Change value (i.e. the increase or decrease function).

3. K3 Menu/Left and Right Key:

a. Enter the main menu, exit to the last menu, and return to the main window;

b. Move the cursor left or right to select the numerical digits.

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.5 OPERATION OF THE ELECTRIC SYSTEM

The power supply’s main switch

The power supply’s main switch is installed near the battery, to connect the battery’s negative terminal and the bulldozer’s body; the power supply’s main switch has a switch-blade structure, and has two positions: ON and OFF (as shown in Figure

2-39); When the bulldozer does not work for a long time, you should push the knob of the power supply’s main switch to the

OFF position, to reduce the battery’s consumption. Before the bulldozer is started, push the knob of the power supply’s main switch to the ON position.

Figure 2-39: Power switch

Key starting switch

The starting switch is located on the instrument box’s switch panel. It has four positions (as shown in Figure 2-40), which are the HEATER position, the OFF position, the ON position and the START position. When the starting switch is in the

OFF position, the system is in the power off state; when you insert the key, and turn the starting switch from OFF to ON, the entire electric system is powered on, and after a short selftest, the monitors enter the main working window, as shown in Figure 2-40. Turn the starting switch from ON to START, and release the key after ensuring that the engine is started, the starting switch will automatically return to the ON position.

When the starting switch is turned to the OFF position, the engine will stop working.

Figure 2-40: Key starting switch

Smart monitor

The main working window of the smart monitor displays the fuel level (%), the system’s voltage, the current gear position, the engine speed and the warnings, as shown in Figure 2-41.

The main functions of this monitor are as follows: a. Displays the operation the vehicle’s parameters in real time b. Provide warning information c. System setup and vehicle management

Engine does not generate power

Figure 2-41: Smart monitor’s window

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OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

1. The smart monitor’s working menu is as follows:

Window

Main window

Operation parameter

Alarm parameters

Check content

Fuel level %

Engine speed rpm

System voltage

Warm-up indication

Gear position indication

Alarm for parameters out of range

Fault alarm Device fault alarm

Vehicle management alarm

Fuel level %

Cooling water temperature °C

Torque converter’s oil temperature °C

Engine oil pressure Bar

Engine speed rpm

System voltage

Flywheel’s number of teeth

User setup

System setup

Language setup

Alarm parameter setup

Testing information (backup)

Setup management

Chinese

English

Flywheel’s number of teeth

(range: 000.00-300.00)

Vehicle management On-site unlocking (dynamic password)

Vehicle is unlocked on-site to be opened

Vehicle is unlocked on-site to be closed

Monitor’s information

Hardware: D2460-00030

Software: V10

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2. Illustration of work menu cascade (Chinese)

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OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

3. Warnings

When the LCD smart monitor detects a fault of the bulldozer, it will display the related warnings in its main window, and give out the buzz to alert the operator. Types of the warning information are as follows:

Chinese

水温传感器断路

水温传感器短路

发动机水温高

燃油传感器断路

燃油传感器短路

燃油液位低

油温传感器断路

油温传感器短路

传动油温高

油压传感器断路

油压传感器短路

机油压力过低

预热进行中

空档

发电机不发电

车辆故障：0010

车辆故障：0011

车辆故障：0012

车辆故障：0020

车辆故障：0030

车辆故障：0031

车辆故障：0032

English

Water temp sensor open

Water temp sensor short

Engine water too hot

Fuel sensor open

Fuel sensor short

Fuel level low

Oil temp sensor open

Oil temp sensor short

Trans oil temp too high

Oil pressure sensor open

Oil pressure sensor short

Engine oil pressure low

Warming

Neutral

Alternator failed

Vehicle fault: 0010

Vehicle fault: 0011

Vehicle fault: 0012

Vehicle fault: 0020

Vehicle fault: 0030

Vehicle fault: 0031

Vehicle fault: 0032

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

Check system voltage

The dial pointer intuitively displays system voltage in real time

(as shown in Figure 2-42). When the key starting switch is in OFF, the pointer is back to zero, and when it is in ON, the pointer points at around 24V. When the engine is running, pointer should point at around 28V. This meter has a backlight in purple red, to facilitate use during nighttime.

The LCD smart monitor’s main window dispalys system voltage.

When the system voltage is lower than 22V, the charging indicate on the smart monitor will blink, the warming message

“System voltage low” will occur, and the buzzer will sound.

Figure 2-42: Meter displaying system voltage

Check the temperature of the cooling water

The dial pointer displays the temperature of the cooling water in real time (as shown in Figure 2-43), and the display range is

40-120°C. This meter has a backlight in purple red, to facilitate use during nighttime.

The LCD smart monitor displays the engine’s cooling water temperature in real time, and you can check it out by entering the menu of operation parameters.

1. When the water temperature sensor’s circuit is open, the pointer is back to zero, the smart monitor gives warning

“Water temperature sensor’s circuit is open”, and the buzzer sounds.

2. When the water temperature sensor’s circuit is short, the pointer is at full scale, the smart monitor gives warning

“Water temperature sensor’s circuit is short”, and the buzzer sounds.

3. When the water temperature sensor detects a temperature

≥100°C, the smart monitor gives warning “Engine water temperature high”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-38) can shield the buzzer’s sound.

Figure 2-43: Meter displaying the temperature of the cooling water

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Check the oil temperature of the torque converter

The dial pointer displays the hydraulic oil’s temperature intuitively and in real time (as shown in Figure 2-44), and the display range is 60-150°C. This meter has a backlight in purple red, to facilitate use during nighttime.

The LCD smart monitor displays the oil temperature of the torque converter in real time, and you can check it out by entering the menu of operation parameters.

1. When the oil temperature sensor’s circuit is open, the pointer is back to zero, the smart monitor gives warning

“oil temperature sensor’s circuit is open”, and the buzzer sounds.

2. When the oil temperature sensor’s circuit is short, the pointer is at full scale, the smart monitor gives warning

“oil temperature sensor’s circuit is short”, and the buzzer sounds.

3. When the oil temperature sensor detects a temperature

≥120°C, the smart monitor gives warning “Transmission oil temperature high”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-38) can shield the buzzer’s sound.

Check engine oil pressure

The dial pointer intuitively displays engine oil pressure in real time (as shown in Figure 2-45), and the display range is

0-700KPa. This meter has a backlight in purple red, to facilitate use during nighttime.

The LCD smart monitor displays engine oil pressure in real time, and you can check it out by entering the menu of operation parameters.

Figure 2-44: Meter displaying hydraulic oil temperature

Figure 2-45: Meter displaying engine oil pressure

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

1. When the oil pressure sensor’s circuit is open, the pointer is back to zero, the smart monitor gives warning “oil pressure sensor’s circuit is open”, and the buzzer sounds.

2. When the oil pressure sensor’s circuit is short, the pointer is at full scale, the smart monitor gives warning “oil pressure sensor’s circuit is short”, and the buzzer sounds.

3. When oil pressure sensor detects a pressure ≤1Bar, the smart monitor gives warning “Engine oil pressure too low”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-38) can shield the buzzer’s sound.

Check bulldozer’s operation hours

The dial pointer intuitively displays the bulldozer’s operation hours in real time (as shown in Figure 2-46), the time is show in hours, and the smallest display unit is 1/10h.

Check fuel level

Fuel level is displayed as a percentage in real time in the smart monitor’s main window (as shown in Figure 2-41).

1. When fuel level sensor’s circuit is open, the smart monitor gives warning “Fuel sensor is open”, and the buzzer sounds.

2. When fuel level sensor is short, the smart monitor gives warning “Fuel sensor is short”, and the buzzer sounds.

3. When fuel level sensor detect fuel level ≤10%, the smart monitor gives warning “Fuel level low”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-38) can shield the buzzer’s sound.

Check engine speed

Engine speed is displayed in real time in the smart monitor’s main window (as shown in Figure 2-41).

Figure 2-46: Hour meter

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Definitions and descriptions of other warnings

1. When the engine does not have output, the smart monitor gives warning “Engine does not generate power”, and the buzzer sounds.

2. When the smart monitor detects that the gear is in the NEUTRAL position, it blinks to remind

“NEUTRAL position”; and when it detects a gear, it blinks to remind the gear.

3. When warm-up is normal, the smart monitor reminds “Warming up”, and also blinks to remint it.

4. When the bulldozer’s smart monitor gives warning “Vehicle fault 0010”, all the dial pointers (except for the meter displaying battery voltage) are back to zero. You need to contact your equipment supplier.

5. When the bulldozer’s smart monitor gives warning “Vehicle fault 0011”, all the dial pointers (except for the meter displaying battery voltage) are back to zero. The GPS antenna is not properly connected, and you should check it out and fix it.

6. When the bulldozer’s smart monitor gives warning “Vehicle fault 0012”, all the dial pointers (except for the meter displaying battery voltage) are back to zero. The communication card of the smart service system does not work properly, and you should check it out and fix it.

7. When the bulldozer’s smart monitor gives warning “Vehicle fault 0020”, all the dial pointers (except for the meter displaying battery voltage) are back to zero, and the engine cannot be started normally. You need to contact your equipment supplier.

8. When the bulldozer’s smart monitor gives warning “Vehicle fault 0030”, all the dial pointers (except for the meter displaying battery voltage) are back to zero, and the engine cannot be started normally. You need to contact your equipment supplier.

9. When the bulldozer’s smart monitor gives warning “Vehicle fault 0031”, all the dial pointers (except for the meter displaying battery voltage) are back to zero, and the engine cannot be started normally. You need to contact your equipment supplier.

10. When the bulldozer’s smart monitor gives warning “Vehicle fault 0032”, all the dial pointers (except for the meter displaying battery voltage) are back to zero, and the engine cannot be started normally. You need to contact your equipment supplier.

CAUTION

The display of the oil level gauge has a delay. Please pay special attention to this during operation.

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.6 OPERATION OF THE HORN BUTTON

When you press this button (as shown in Figure 2-47), the horn will sound.

Figure 2-47: Horn button

2.3.7 IN-LINE FUSE

There are some in-line fuses in the instrument box of this machine, as shown in Figure 2-48. When the meters and the GPS system do not have power supply, you need to check the corresponding inline fuses to see if they are already blown. Replace the fuses after eliminating the corresponding faults.

► Replace a fuse with another of the same capacity.

Before replacing a fuse, be sure to turn off the starting switch.

2.3.8 POWER SOCKETS

This machine provides the 24V power socket in the accumulator box. If you repair the machine during nighttime and temporarily need the 24V power supply, you can open the accumulator box’s cover to see the 24Vpower socket.

2.3.9 CAB’S HEAD LAMP SWITCH

When the switch is pulled to the “ON” position, the cab’s head lamp lights up. as shown in Figure (2-49)

Figure 2-48: Illustration of

In-line fuse

Figure 2-49

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2.3.10 PRECAUTIONS FOR FUSE BOX

If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the holder, replace the fuse.

► Replace a fuse with another of the same capacity.

Before replacing a fuse, be sure to turn off the starting switch.

The arrangements and capacities of the fuses are shown in Figure 2-50:

FUSE BOX WIRING CHART

To Battery

Figure 2-50: Fuse box wiring chart

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THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.11 DESCRIPTION OF THE BOND STRAPS OF CONSTRUCTION MACHINERY’S ELECTRIC

SYSTEM

The bond straps of construction machinery’s electric system can have many types of faults. For example, the engine does not have sufficient power or is not easy to be started, the lamps are not lit up, the meters do not have accurate displays or are easy to give false alarms, etc.

The construction machinery’s electric system uses the low-voltage DC power supply, adopts the serial connection, parallel connection or mixed connection circuits, and all the circuits have a positive terminal and negative terminal. All the circuits from the loads would need to be directly connected to the battery’s negative terminal through wires. If separate wiring is adopted, there would be more than one hundred wires on the battery. In order to save the wires and to facilitate installation, the circuits of general construction vehicles would use a single wire, which means that the battery’s positive terminal is directly connected to various electric devices, the battery’s negative terminal is directly strapped to the metal part of the vehicle’s frame, the negative terminals of electric devices are strapped to the nearby metal part of the vehicle’s frame, and the metal part of the engine and the chassis (beam frame) is used as the public pathway. This type of connection in which the negative terminal is connected to the body of the vehicle is called bond strapping. It is also known as earthing or metal connecting. Negative terminal’s bond strapping has a number of benefits including less interference to the electronic devices, less electrochemical corrosion to frame and body, and firm connection. Today most construction machines and vehicles adopt negative terminal’s bond strapping.

The body of a construction machine generally has more than two main bond straps. One of them is the battery’s negative terminal wire, and the other is the bond strap between the engine and the beam. The form of these bond straps is different from ordinary wires. They are usually copper wires above 50mm2, and the current carrying capacity is large. Malfunction of bond strap is very easy to occur. For example, the failure to clean the paint on the frame before the entire vehicle leaves the factory, a loose fastening bolt of the engine’s bond strap, the makeshift installation during the reconnection of bond straps, or the increased resistance of bond strap’s connector due to corrosion all can cause improper contact, forcing the current to try to go through other circuits, causing voltage drop or failure. Malfunction of bond straps can cause many obvious or hidden faults to circuits. In the ignition system, if engine’s bond strap does not function properly, the engine may not be started.

In the starting circuit, if engine’s bond strap does not function properly, the starter’s speed will be reduced, the armature will be heated, and over time, it will be very easy to have the starter burned. In the lighting circuit, if the bond straps of the lamps do not function properly, the lamps may not be lit or the lamps may be dim. Therefore, knowing the role of bond straps can avoid many faults and the wrong judgment during the troubleshooting of the electric system.

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2.4 OPERATION

WARNING

Please read and make sure that you understand the SAFETY section before reading this section.

2.4.1 CHECK BEFORE STARTING ENGINE

► Form a habit to check before starting engine. Never be imprudent and careless. This is good for the safety of both people and vehicle.

Check oil or water leakage

Before starting the engine, look around the machine and under the machine to check for loose nuts and bolts, or leakage of oil, fuel, or coolant, and check condition of the work equipment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures.

Check bolts and nuts

Check for loose nuts and bolts, and tighten them if necessary. Pay special attention to air cleaner, carrier roller bracket and track shoe bolts.

Check electric circuits

Check to see if the wires are damaged or shorted or if the terminals are loose.

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OPERATION | OPERATION

Check cooling water level (Figure 2-51)

Turn open the radiator cap (1) (Figure 2-51), and check if the water is at the required level. Add water if necessary.

Add cooling water after the engine has stopped. Add water to the sub-tank to the full (until the water overflows), and then start the engine and let it idle for 5min and check again. If the water level is lower than required, continue to add water. If the water added is increased abnormally, look for leakage and solve it in time.

CAUTION

When cooling water is overheated, turn the cap (1) loose slowly, to release the internal pressure before opening it, to avoid boiling water from spurting out to have people injured.

Check oil level in engine oil pan (Figure 2-52)

When the engine has stopped, take out the dipstick(G), and check the oil level on the side marked “Engine stopped”. When the engine is idling, check to see if the engine oil pressure gauge and water thermometer are within the normal range first, and then take out the dipstick (G) to look at the oil level on the side marked “Engine idling”. If oil needs to be added, open the injection mouth to add oil. The types of engine oil depend on the ambient temperature. See the “USE OF FUEL,

COOLANT AND LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE”. When checking oil level, park the vehicle on a level ground. When adding engine oil, do not let the oil level be higher than the “(H)”mark. When checking oil level, do not rely on engine oil level monitor alone.

Check fuel level

Remove the fuel tank cap, and pull out the dipstick (G) (as shown in Figure 2-53) to check the oil level.

After completing work, fill the fuel through filter screen. Before operating the bulldozer, make sure there is plenty of fuel in the tank so that the engine fuel line does not become aerated.

Fuel tank capacity: 450L

CAUTION

When adding fuel, never let the fuel overflow. This may cause a fire.

56

Figure 2-51

Figure 2-52

Figure 2-53

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Check steering clutch case oil level (including transmission case and torque converter)

As shown in Figure 2-53, use dipstick (G) to check the oil level. If needed, oil should be added through the filter screen (F).

The lubricant type used depends on the ambient temperature.

See the “USE OF FUEL, COOLANT AND LUBRICANTS AC-

CORDING TO AMBIENT TEMPERATURE” for reference.

Figure 2-54

When checking oil level, stop the engine.

When operating on a slope of over 20 degree, the oil level should be at the (H) HIGH level.

Drain the sediment in fuel tank (Figure 2-55): Turn loose the valve (1) on the bottom of fuel tank, to drain the water and sediment in the fuel.

Figure 2-55

Check brake pedal’s journey (Figure 2-56)

When the engine is running, the standard journey is 110-

130mm (operating force is 15kg). When the engine stops, the stroke is about 75mm. If the pedal’s stroke is over 190mm, the brake function is not adequate, and you should make adjustment following the “Adjustment” section.

Figure 2-56

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OPERATION | OPERATION

2.4.2 OPERATION METHODS AND STEPS

1. Check the positions of various control levers before starting (Figures 2-57 and 2-58a). (1)—Brake lock lever, (2)—

Gear shift lock lever, (3)—Steering control lever, (4)—Gear shift lever, (5)—throttle gear shift lever. Adjust the operator’s seat, so that the operator can completely step down the brake pedal while leaning against the seat back.

2. Brake lock lever (1) is in the LOCK position, as shown in

Figure (2-57)

Lock

Free

Figure 2-57

3. Gear shift lever (4) is in the NEUTRAL position, and gear shift lock lever (2) is in the LOCK position (Figure 2-58a and Figure 2-58b).

4. The blade and ripper should be lowered to the ground, and their control lever lock button should be in the LOCK position. (Figure 2-59)

Free

Lock

Free

Lock

Figure 2-58a

Figure 2-58b

5. Starting engine

• Pull the throttle level (5) to the idling position. (Figure 2-58a)

Turn the starting key (1) to the starting position . (Figure

2-60)

• When engine started, release the starting key (1), and the key will automatically return to the (ON) position. (Figure

2-60)

Lock

Figure 2-59

Lock

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OPERATION | OPERATION

• If engine is not started, re-start it after 2min.

• The key should not stay in the “Starting” position for more than 10s.

• When the fuel is empty and you want to start the engine, add sufficient fuel first and then let the fuel fill the core of fuel filter and exhaust the air in the fuel system before starting the engine again.

Key starting switch

Figure 2-60

6. Checks after starting engine

• After starting the engine, perform the following checks:

• Let the engine run at a low speed, until the engine oil pressure is within the normal range.

• Pull the throttle control lever (5) to let the engine idle at a mid-range speed for about 5 min. (Figure 2-58a)

• Do not run the engine at low or high idle for more than 20 minutes. If it is necessary to run the engine at idling, apply a load from time to time or run the engine at a mid-range speed.

• After engine temperature is increased, check various meters for abnormality.

• Let the engine continue to run at a low-load, to let water temperature rise. Water temperature between 74-91°C is most ideal.

• Check the color of exhaust for abnormalities, such as abnormal sound or vibration.

• Do not suddenly accelerate the engine before the machine reaches full operating temperature.

• If engine oil pressure is not within the normal range, stop the engine immediately, and check for reasons.

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2.4.3 OPERATION WHEN MOVING

Before moving, check the safety around you.

1. Release blade and ripper lock button (1) and (2) respectively. (Figures 2-61 and 2-62)

2. Pull blade and ripper control lever (3) and (4), to raise blade and ripper 40-50cm above ground. (Figures 2-61 and 2-62)

OPERATION | OPERATION

Figure 2-61

3. Step down the crossing part in the middle of the left and right brake pedal, put the brake lock lever (1) to the FREE position, and then release the brake pedal. (Figures 2-63 and 2-64)

Figure 2-62

Figure 2-63

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Figure 2-64

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OPERATION | OPERATION

4. Release the gear shift lock lever (2) (Figure 2-57)

• Step down the deceleration pedal (1) to reduce engine speed, so that there is no impact when the vehicle is started (Figure 2-65).

Figure 2-65

• Put the gear shift lever (4) to the needed position, and the vehicle will start to move (Figure 2-66)

5. Pull throttle control lever (5), to accelerate the engine (Figure 2-66)

6. Through the gear shift lever (4) you can select any speed without stopping the vehicle. (Figure 2-66)

• Forward←→Reverse

• After reducing vehicle speed, change Forward←→Reverse.

This can preventing impacting vehicle. Step down the deceleration pedal, to reduce engine speed, bring the gear shift lever to the needed Forward or Reverse gear, and then release the deceleration pedal, to accelerate the engine.

Figure 2-66

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2.4.4 TURNING

Make a big turn to the left (right):

Pull left (right) steering lever half way, and the vehicle will make a big turn to the left (right) (Figure 2-66 and Figure 2-67);

OPERATION | OPERATION

Make a small turn to the left (right):

Pull the left (right) steering lever to the bottom, the left (right) steering clutch will detach, the brake will be activated, and the vehicle will make a small turn to left (right). (Figure 2-68)

Figure 2-67

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Figure 2-68

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OPERATION | OPERATION

2.4.5 PARKING

Push the throttle control lever (5) to the idling position, to reduce engine speed. Push the gear shift lever (4) to the NEU-

TRAL (N) position. (Figure 2-66)

Step down the crossing part in the middle of the left and right brake pedal (2), and the vehicle stops (Figure 2-65); pull the brake lock lever (1) to the LOCK position (Figure 2-69), to lock the gear shift lock lever (2) (Figure 2-66).

Push the blade control lever (3) and ripper control lever (4) to the Lowering position, to lower the blade and ripper to the ground. And then press the blade control lever’s lock button (1) and ripper control lever’s lock button (2). (Figure 2-70, 2-71)

CAUTION

Park the vehicle on a firm and level ground as far as possible, and avoid parking it in a dangerous place.

Figure 2-69

Figure 2-70

Figure 2-71

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OPERATION | OPERATION

2.4.6 STOPPING ENGINE

Let the engine idle for 5min, to cool it down. Turn the key to the

(OFF) position, and the engine will stop running. Pull out the key. If you suddenly stop the vehicle when the engine is not cooled, it will dramatically shorten the lifecycle of the engine. Never suddenly stop the vehicle unless in emergency.

2.4.7 OPERATION IN SPECIAL CLIMATE CONDITIONS

Precautions for low temperature:

1. If the temperature is too low, it will be difficult to start the engine, and the cooling water will be frozen, causing negative impacts on the vehicle, so you should take appropriate measures, and select oil and water according to the “USE OF FUEL, COOLANT AND LUBRICANTS ACCORD-

ING TO AMBIENT TEMPERATURE”.

2. When the atmospheric temperature is lower than 0°C, to prevent the cooling water from freezing, you can use the antifreeze based on the lowest temperature. For the mixing proportion and usage methods of water and antifreeze, see “CLEAN INSIDE OF COOLING SYSTEM”.

3. Before adding the mixed antifreeze, thoroughly clean the cooling system.

4. When the weather becomes warm, drain the antifreeze (except for the permanent antifreeze), and clean the cooling system, before replacing the clean water.

5. Be sure to clean the snow or water on the hydraulic oil cylinder’s piston rod. If they freeze into ice, they will damage the oil cylinder’s oil seal.

CAUTION

• Water without antifreeze should be thoroughly drained during the nighttime of winter, to prevent the parts from being cracked by freezing. Note: Do not drain water in areas such as oil cooler.

• Use standard antifreeze. Never use methanol or ethanol based antifreeze, as it may cause malfunction of engine.

• Antifreeze is flammable, so be careful of fire.

• When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it against cold temperature so that the machine can be started easily the next morning.

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OPERATION | OPERATION

2.4.8 OPERATING ON SLOPES

Make a big turn to left (right) :

When going down a slope (Figure 2-72). Pull the right (left) steering control lever half way, and the vehicle will make a big turn to left (right).

Make a small turn to left (right):

When going down a slope (Figure 2-73). Pull left (right) steering control lever to the bottom, and the vehicle will turn to left

(right).

Figure 2-72

Figure 2-73

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65

OPERATION | OPERATION

2.4.9 PRECAUTIONS

1. Do not park vehicle on a slope unless in special situations.

• If you do need to park the vehicle on a slope, face the head of vehicle downhill, and lock the brake pedal. When the slope is big, you can slightly cut the blade into the ground, to prevent vehicle from slipping.

2. When the vehicle travels on a slope, the longitudinal slope should not be over 30 degree, and when going uphill, do not travel backward.

3. When you start the vehicle on a slope, step down the left-right brake pedal first, and then pull the gear shift lever to Gear 1, while slowly releasing the brake pedal. If the engine speed is too fast, you can use the brake pedal to reduce speed.

4. When going downhill, pull the gear shift lever to a low-speed gear, and use the engine to brake.

5. When operating machine on sloped areas of more than 20°, fill all appropriate components with oil to H level.

CAUTION

• Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous.

• Do not shift gear or cross obstacles on a slope.

• If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. If this makes the engine stop, the braking effect will be reduced, so be careful not to let the fuel level in the fuel tank become too low.

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OPERATION | OPERATION

2.4.10 OPERATING IN WATER

When the vehicle is travelling in water, check out water depth and the soil under water first, to avoid accidents because the water is too deep and the soil sinks from carrying the load.

Water level should not exceed the center of the idler (Figure

2-74).

When operating in sea water or other corrosive water, wash the vehicle with clean water after completion.

2.4.11 OPERATING ON DESERT

When operating on desert or other types of dusty ground, try to keep the vehicle sealed off from the outside world, and clean the air cleaner at any time.

Figure 2-74

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2.5 DOZING OPERATION

Reasonably choosing the models as well as the adjustment and operation methods of the blade according to the dozing objects is very important to extending the lifecycle of the vehicle, reducing the operator’s fatigue, and increasing productivity.

The SD22 bulldozer is suitable for the general operating conditions. The SD22E bulldozer is suitable for loose soil. The

SD22S is suitable for operating in swamps.

There are three types of blades: the “straight tilt blade”, the

“angle blade”, and the “Semi-U Blade”. They are suitable for different terrains and operation objects.

The effective dozing distance is 70m at the maximum. For long-distance application, using a fork lift is more economical.

2.5.1 OPERATION OF BLADE AND RIPPER

The control levers and buttons of the work equipments. See

“The Roles of Various Controls” (See 2.1.2)

DOZING OPERATION | OPERATION

2.5.2 BLADE ADJUSTMENT

Angle blade adjustment

1. Adjustment of angle blade’s turning angle

► The two sides of the blade can be adjusted to be 25º. (Figure 2-75)

• Raise the blade to be 400-500mm above ground, and put a block under the C-Frame.

• Pull out the pins (1) on both sides to remove the push rod’s arm (2) from the C-Frame (Figure 2-76)

• After putting the blade into an angle, install the push rod’s arm (2) to the needed position. (the push rod frame has three supports on each side), and then insert the pin (1).

CAUTION

After removing push rod’s arm, be careful that the blade will swing freely.

Figure 2-75

Figure 2-76

68

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OPERATION | DOZING OPERATION

2. Adjust of angle blade’s tilt

► The biggest tilt of blade: 500mm (Figure 2-77) a. Raise the blade to be 600-800mm above ground, and put a block under the C-Frame.

Figure 2-77 b. Loosen jack bolt (1), insert an iron bar into the hole of the support rod (2) to rotate the support rods on the two sides, to elongate and shorten them respectively. Tilt the blade to the required height, and then tighten jack bolt. (Figure 2-78)

• L, the length of the support rod (Figure 2-78), is generally

1486mm, and the blade’s tilt should be within 500mm.

• Do not attempt to tilt the blade to more than 500mm, to prevent unwanted effect.

► When using the adjusting rod to turn the support arm, the blade should be above ground before tilting it.

c. Adjustment of gaskets

• The standard thickness of the adjustment gaskets between the blade lift cylinder’s piston rod and cap is 4mm (Figure

2-79).

• Remove some gaskets, to adjust the spherical clearance between oil cylinder’s piston rod and cap. The suitable clearance maintained with gaskets is 0.2~0.6mm.

Figure 2-78

L

Figure 2-79

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Adjustment of straight tilt blade

1. Adjustment of straight tilt blade’s tilt

• Simply operate blade control lever to let the blade tilt

850mm. If necessary, changing the left support arm’s length

L (Figure 2-80) can further tilt it to 1000mm. The support rod’s length L is generally 1388mm, and the blade’s tilt should be within 1000mm. Do not attempt to tilt the blade to more than 1000mm, to prevent unwanted effect.

DOZING OPERATION | OPERATION

Figure 2-80

2. Adjustment of gaskets

• Adjust the thickness of the gaskets, to let the clearance of the spherical joint in the axle direction be not over 1mm

(Figure 2-81, the position pointed by arrow).

• Remove gasket (1), and tighten bolt (2), to eliminate the spherical joint’s clearance. (Figure 2-82) Measure the clearance A, and remove bolt (2). Put in a gasket with a thickness of A+1mm (1), and tighten bolt (2). Confirm if after the bolt is tightened the spherical joint can flexibly rotate.

Figure 2-81

70

Figure 2-81

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

OPERATION | DOZING OPERATION

2.5.3 DOZING OPERATION

Cutting of hard earth or frozen earth (Figure 2-83)

When operating on hard earth or frozen earth, using straight tilt blade or angle blade can effectively dig; if the earth is very hard, using ripper can increase efficiency.

Figure 2-83

2.5.4 LEVELING OPERATION (FIGURE 2-84)

The uneven ground after excavating dozing can be leveled using the following methods:

• Fill the blade with soil, let the vehicle run at a low speed, and level the uneven areas when moving.

• Put the blade in the “floating” state, move the vehicle slowly backward to smooth the ground.

Smoothing cannot be used on rocks, as it can damage the blade.

2.5.5 DOZING SIDEWAYS

When dosing sideways, use the angle blade. (Figure 2-85)

CAUTION

• Do not use the blade to dig tree root etc.

• During dozing and moving, avoid sudden start, sudden brake and sudden turn if possible.

Figure 2-84

Figure 2-85

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2.5.6 METHODS FOR EXTENDING MACHINE LIFE

The life of the vehicle, especially the walking parts, is dependent on the maintenance and operation methods to a big extent. Therefore, remember the following points:

1. Select different models with different types of tracks according to soil type.

2. During operation, reduce track slip as far as possible. If the track slips, reduce the load until it no longer slips.

3. Avoid sudden start, sudden acceleration, unnecessary high-speed operation, as well as sudden brake or sudden turn if possible.

4. Always operate the vehicle to travel in a straight line as far as possible. Do not always turn to one side. Turn to left and right alternately and at the biggest radius.

5. During dozing, if the terrain forms a gentle slope to left or right, reverse the vehicle to the level ground and level it again. Do not continue to operate on the slope.

6. Do not let the vehicle try to handle a hard object or an obstacle that is hard to handle, or the idler or Sprocket will leave the ground. (Figure 2-86)

7. When operating on an inner slope, the vehicle should travel along the slope from top to bottom, and should not cross the slope. When travelling uphill, do not back. (Figure 2-87)

• Before operation, clear the big rocks and other obstacles from the jobsite.

DOZING OPERATION | OPERATION

Figure 2-86

Figure 2-87

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OPERATION | TOWING, LIFTING, TRANSP. & STORAGE

2.6 TOWING, LIFTING, TRANSPORTATION AND STORAGE

2.6.1 TOWING (FIGURE 2-88)

Towing is the operation to draw the bulldozer using the front and rear towing devices for drawing or self-rescue.

► When using front and rear towing devices for drawing or self-rescue, ensure that the towing cables and the towing devices can be reliably connected and locked, and that the towing cables can safely carry the towing load.

Front towing hook

CAUTION

The effective safe load of the bulldozer’s front and rear towing devices is 15tons.

Rear traction frame

Figure 2-88

2.6.2 LIFTING (FIGURE 2-89)

When the bulldozer is lifting, operate in the way shown in the figure below.

► During lifting, ensure that the lift rope can be reliably locked, and avoid the direct contact between the weight-bearing point and the bulldozer’s edge (put a block beneath the corner of the track). (Bulldozer’s dead weight: 37.2tons)

CAUTION

During lifting, ensure that the bulldozer is locked. (Step down the brake pedal, and raise the brake lock lever)

The craning positions of the entire bulldozer

Craning position Craning position

1. The craning positions of the vehicle are shown in the figure.

2. Prior to craning, shut down the engine, and put the entire vehicle in the parked, braked and locked state.

09963- 02100

Figure 2-89

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TOWING, LIFTING, TRANSP. & STORAGE | OPERATION

2.6.3 TRANSPORTATION

During the vehicle transportation process, be familiar with and abide by various road rules as well as the traffic rules including the rules about the transportation of vehicles on the road and the restrictions on vehicles. When going through bridges and tunnels, measure the allowed weight of the bridges and the space sizes of the tunnels.

It’s best to create a special loading/unloading platform. If using a ramp to load the machine to a trailer, follow the rules below.

(Figure 2-90)

CAUTION

When traveling up a ramp, do not adjust the travel direction. If you need to adjust the direction, back the vehicle to the ground and make the adjustment.

1. The brake of the trailer should be applied, and the wheels are secured with blocks.

2. Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.

3. Make the ramp properly aligned, and then slowly load/ download the machine.

4. The vehicle should be put in the trailer’s appropriate position, insert blocks beneath the track in front and back, and then use solid and firm chains or ropes to secure it, to prevent it from falling off during the transportation process to cause accidents.

5. Lower the blade, and put various levers to the following positions.

• Put the throttle control lever in the low-speed position, and remove the starting key.

• Put the gear shift lever in the NEUTRAL position.

• Put the blade control lever in the KEEPING position.

• Put the brake lock lever in the LOCK position.

CAUTION

• If the blade head’s width is wider than the trailer’s width, you can change the blade’s angle or unload it and load it again.

• For long-distance water transportation, take anti-rust measures, and apply anti-rust oil to the exposed oil cylinder’s piston rod etc.

Figure 2-90

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OPERATION | TOWING, LIFTING, TRANSP. & STORAGE

2.6.4 STORAGE

Before storage

When you expect the machine will be stored for a significantly long period of time, be sure to take the following measures, to reduce the repair work when using the machine again.

1. After cleaning each part of the machine, store the machine in a dry building. If the machine has to be put outdoors due to limited conditions, put wood planks on the ground, put the machine on the wood planks, and cover the machine with canvas.

2. Before putting into garage, add sufficient fuel and lubricant, and change new engine oil.

3. Apply a layer of lubricant on metal surface. (At the piston rod)

4. Remove the terminals of the battery, cover them properly or store them separately.

5. If you expect the ambient temperature can be lowered to below 0°C, add antifreeze to the cooling water beforehand.

6. Set various control levers and pedals as follows:

► Put the gear shift lever to the NEUTRAL position.

► Put the throttle control lever to the LOW SPEED position.

► Put the blade control lever to the KEEPING position.

► Put the brake pedal to the FREE position.

During storage

Start the engine once a month, and operate the vehicle for a distance. This is in order to let the machine’s parts and the surface of the engine’s various areas have a new layer of oil membrane.

► When operating the work parts, wipe off the lubricant grease on the hydraulic piston rod.

After storage

After storage (if not covered or not performing the anti-rust operation once a month), you must do the following before use:

1. Remove the engine oil pan and other drain plugs of the oil tank, to drain the mixed water.

2. Remove the cylinder cap, lubricate various air throttles and rock arms, and check the action of air throttles.

3. In order to exhaust hydraulic system’s air, run the engine at a low speed, and operate as follows:

• Operate each hydraulic cylinder back and forth 4-5 times, and let the piston stop at a place

100mm from the end of its journey.

• Continue to operate each hydraulic cylinder back and forth 3-4 times to the end of its journey.

► If the engine runs at a high speed at the beginning or if the piston runs to the end of its journey, then the air getting into it may damage piston disc.

4. After the engine is started, let it run, until the temperature reaches the required value.

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75

NOTE PAPER

76

Note paper

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | MACHINE STRUCT. & MAIN PARAMETERS

CHAPTER 3: STRUCTURE AND PRINCIPLE

3.1 MACHINE STRUCTURE AND MAIN PARAMETERS

3.1.1 MACHINE APPEARANCE (FIGURE 3-1)

1

2

4

3

5

6

No.

5

7

1

3

9

11

7

8

9

10

Name

Exhaust pipe and muffler

Cab

Track

Carrier roller

Push rod

Blade

Figure 3-1

No.

6

8

2

4

10

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

11

Name

Blade lift cylinder

Fuel tank

Track frame

Track roller and Guard

Tilt cylinder

77

MACHINE STRUCT. & MAIN PARAMETERS | STRUCTURE & PRINCIPLE

3.1.4 MAIN PARAMETERS (SEE THE TABLE BELOW)

Parameter

Model

Operating weight (kg)

Max. travel speed

(km/h)

Engine

FORWARD (F)

REVERSE (R)

Model

Rate power

Maximum torque

SD32 SD32D SD32R

37200 37600 37600

Remark

With straight tilt blade and cab, not inc. ripper and ROPS

Frame

11.5

13.5

11.5

13.5

11.5

13.5

Cummins NTA855-C360

235kW/2000rpm

1411N.M/1400rpm

3.1.2 CHARACTERISTICS OF THE DRIVE SYSTEM

1. Hydraulic torque converter: three-component, one-stage and one-phase

2. Transmission case: planetary gear, multi-piece clutch, hydraulic, and forced lubrication.

3. Central drive: spiral bevel gear, primary reduction, and splash lubrication.

4. Steering clutch: wet, multi-spring pressed, hydraulic detach, and manual-hydraulic operation.

5. Steering brake: wet, floating, direct clutching, hydraulically assisted, and interlocked operation

6. Final drive: two-stage straight gear reduction, and splash lubrication.

3.1.3 WALKING SYSTEM

Type:

Number of carrier roller

Swing type of sprayed beam, suspended structure of equalizer bar

2/each side

Number of track rollers:

SD32, SD32D and SD32R: 7/each side (2 pieces for one-sided, 5 pieces

Track type: for two-sided)

SD32, SD32D and SD32R: Assembled single-track tooth (41 pieces each

Track shoe width:

Track pitch: side)

SD32: 560mm

SD32D and SD32R: 760mm

228.85mm

3.1.5 TRIPLE-SHANK RIPPER

Type:

Parallelogram adjustable and removable

Number of gear teeth:

Three-tooth

Pitch:

1120mm

Maximum ripping depth:

842 mm

Maximum lift height:

883 mm

Mass:

4800 Kg

78

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | MACHINE STRUCT. & MAIN PARAMETERS

3.1.8 SINGLE-SHANK RIPPER

Type:

Parallelogram adjustable and removable

Maximum ripping depth:

Maximum lift height:

Mass:

1250 mm

955 mm

4260Kg

3.1.7 DOZING DEVICES (SEE THE TABLE BELOW)

Model

Parameter

Blade width (mm)

Blade height (mm)

Maximum Cutting Depth

(mm)

Maximum lift height (mm)

Blade-maximum tilt (mm)

Maximum blade angle (°)

Cutting angle (°)

Blade capacity (m

3

)

Mass (Kg)

Straight tilt blade

4130

1590

560

1560

1000

—

55°

10

4520

SD32, SD32D and SD32R

Angle blade

5000

Semi

U-blade

4030

Straight tilt blade for desert use

4300

1140 1725 1554

630

1703

560

25

55°

6

4855

11.9

4868

1560

1000

—

55°

10.4

5018

Sanitation shovel

4130

2314

22.8

5077

3.1.6 HYDRAULIC SYSTEM (WORK EQUIPMENT)

Maximum operating oil pressure: 14Mpa (140kg/cm

2

)

Oil pump type: gear oil pump

Flow: 355L/min (engine speed 2000rpm)

Control value type: Lubricating valve

Tilt cylinder’s inner diameter×quantity: Φ140mm×2 (dual-acting)

Tilt cylinder’s inner diameter×quantity: Φ225mm×1

Ripper lift cylinder’s inner diameter×quantity: Φ225mm×2

Ripper angle adjusting cylinder’s inner diameter×quantity: Φ225mm×2

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MACHINE STRUCT. & MAIN PARAMETERS | STRUCTURE & PRINCIPLE

3.1.9 DRIVE SYSTEM: TRANSMISSION PRINCIPLE ILLUSTRATION (SEE FIGURE 3-2)

80

1

11

2

4

3

5

7

6

8

9

10

Figure 3-2

2

3

No.

1

4

Name

Engine

Hydraulic torque converter

Transmission case

Universal joint

6

7

No.

5

8

Name

Central drive

Steering clutch

Steering brake

Final drive

No.

9 Sprocket

Name

10 Track

11 Transfer case

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STRUCTURE & PRINCIPLE | MACHINE STRUCT. & MAIN PARAMETERS

3.1.10 DIMENSIONS (UNIT: MM) (SEE FIGURE 3-3)

4670

4445

3150

8650

1235

Figure 3-3

GL

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81

3.2 ENGINE

3.2.1 ENGINE APPEARANCE (SEE FIGURE 3-4)

6

1

7

11

ENGINE | STRUCTURE & PRINCIPLE

2

3

4

5

8

9

10

82

2

3

No.

1

4

Name

DC generator

Air cleaner

Fuel filter

Bypass filter

Figure 3-4

6

7

No.

5

8

Name

PT-Fuel pump

Muffler

Anti Corrosion tank

Tubocharger

No.

9

10

11

Name

Engine oil filter

Starting motor

Damper

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STRUCTURE & PRINCIPLE | ENGINE

3.2.2 ENGINE’S MAIN PERFORMANCE INDICATORS

Main performance parameters

Engine Model

Number of cylinders-cylinder diameter × stroke (mm)

Total replacement (t)

Ignition sequence

Net weight(kg)

Rate speed (rpm)

Rate power (kw)

Maximum torque (N•m/rpm)

Highest speed without load

(rpm)

Lowest speed without load

(rpm)

Minimum fuel consumption rate (g/ kw•h)

Charging engine

Starting form

Accumulator (battery)

Lubricant capacity (L)

Cooling water capacity (L)

Suitable altitude

NTA855-C360S10

6—139.7×152.4

14.01 (t)

1—5—3—6—2—4

1750

2000

235(320PS)

1440/1400

2000~2100

600~700

<217

Silicon rectified generator 24V35A

Silicon rectified generator 24V100A

(Model for extremely cold weather)

Starting motor 24V7.5KW

24V75A-h×2

45

79

Below 2000m

3.2.3 DESCRIPTION OF ENGINE’S VARIOUS SYSTEMS

See engine’s User Manual for details.

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83

3.2.4 POWER OUTPUT DEVICES

1. FLYWHEEL HOUSING ASSEMBLY (SEE FIGURE 3-5)

ENGINE | STRUCTURE & PRINCIPLE

3

5

No.

1

Name

Flywheel housing

Bearing

Bearing

Its main function is power output.

Figure 3-5

4

6

No.

2

Name

Idler(Z=51)

Transfer case’s drive gear (Z=56)

Cover

84

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STRUCTURE & PRINCIPLE | ENGINE

2. TRANSFER CASE (FIGURE 3-6)

Figure 3-6

2

3

No.

1

4

Name

Flywheel housing

Transfer case body

Driven wheel

Transfer case cover

No.

Name

5 Main shaft

6 Driving wheel

7 Cover

8 Driven wheel

No.

9

10

Name

Lubrication tube

Distributer

Damper

Transfer case is installed in the upper part of the flywheel’s housing. The gear in the upper part of the flywheel’s housing drives the main axle (5) and the driving wheel (6) to rotate, thus making the driven wheels (3) and (8) rotate. Remove cover (7) to install the working oil pump. Driven wheel (3) drives the transmission pump. Install the steering pump on the front side of the flywheel’s housing.

The lubricating oil of the transfer case’s gear and bearing comes from the oil cooler’s oil returning hose, to be distributed by the distributor (10), and drop to various related parts via the lubricating pipe (9).

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ENGINE | STRUCTURE & PRINCIPLE

3.2.5 RADIATOR ASSEMBLY (SEE FIGURE 3-7)

Radiator mainly consists of upper box (1), radiator (12), lower box (10) and related attachments.

The cooling water flows through thermostat to enter upper box (1), removes air from water, and then flows through the radiator core (12) to enter lower box (10). When the cooling water flows through the radiator core (12), due to the role of the fan in the back end of the radiator, the water in the core is cooled. The cooled cooling water is pumped out from lower box by water pump to the engine’s cylinders.

This radiation system is a closed system. The pressure valve installed on the water tank maintains water tank pressure within a range 0.075MPa lower than the gauge pressure, so as to increase the evaporation temperature of the cooling water, to reduce water loss, and to increase cooling efficiency. The fan’s (13) power is transmitted by the V-belt wheel on the front of the engine. The forced air from the fan can enhance the cooling effect.

From thermostat

86

Figure 3-7

No.

1

2

3

4

5

Name

Upper tank

Hose

Inlet pipe

Fan cover

Hose for adding water

No.

6

7

8

Pulley

Shaft

Casing

Name

9 Outlet pipe

10 Lower tank

No.

11 Guard

Name

12 Radiator’s core

13 Fan

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | ENGINE

3.2.6 OIL COOLER ASSEMBLY (SEE FIGURE 3-8)

Oil cooler cools the transmission & steering system’s hydraulic oil

1

2

Water outlet

Water inlet

7 8

9

3

10

11

4

2

3

No.

1

4

5

Tube

Nipple

Tube

Tube

Plate

Name

5

6 13

Figure 3-8

No.

6 Cover

7 Tube

8 Hose

9 Tube

Name

10 Housing part

12

No.

11 Flange

Name

12 Oil cooler

13 Valve

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87

3.2.7 ENGINE OPERATION (SEE FIGURE 3-10)

Decelerator pedal

Fuel control lever

ENGINE | STRUCTURE & PRINCIPLE

Fuel injection pump

Figure 3-10

3.2.8 FUEL PIPING SYSTEM (SEE FIGURE 3-11)

88

Figure 3-11

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC TORQUE CONVERTER

3.3 HYDRAULIC TORQUE CONVERTER (FIGURE 3-12)

Figure 3-12

No.

1

2

3

4

5

6

7

Name

Driving gear

Drive shell

Turbine

Torque converter housing

Pump impeller

Driving gear

Guide roller’s axle

No.

8 Cover

Name

9 Shaft coupling

10 Turbine output shaft

11 Guide roller axle’s hub

12 Guide roller

13 Fuel pump housing

14 Driving gear

No.

Name

15 Coarse strainer

16 Discharge outlet

17 Turbine hub

18 Binder plate

19 Guider

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89

HYDRAULIC TORQUE CONVERTER | STRUCTURE & PRINCIPLE

This machine uses the three-component one-stage and one-phase hydraulic torque converter.

The pump impeller (5), turbine wheel (3) and guide roller (12) are full of the operating oil. When the pump impeller (5) rotates, the pump impeller will force the oil to impact the turbine wheel’s blade, so as to make the turbine wheel rotate. The oil flows from the turbine wheel into the guide roller, and flows out of the guide roller, to enter the pump impeller’s intake and complete the cycling process of the oil.

The guide roller can change the rotation movement of the liquid, so it make increase the turbine wheel’s torque. But the turbine wheel’s torque changes with the operating conditions. Therefore, when load increases, the turbine wheel will bear a higher resisting torque, so as to automatically reduce speed. Therefore, the hydraulic torque converter can ensure the smooth operation of the machine.

The power input route is: Driving gear (1) → Drive shell (2) → Pump impeller (2).

The power output route is: Turbine wheel (3) → Turbine hub (17) → Turbine wheel’s output shaft (10).

90

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | UNIVERSAL JOINT

3.4 UNIVERSAL JOINT (FIGURE 3-13)

The role of the universal joint is to transmit the power between the hydraulic torque converter and the transmission case. It can ensure that when the coaxiality of the turbine wheel’s output shaft and the center line of the transmission case’s main is within the allowed range, the power can be smoothly transmitted.

No.

1

3

Figure 3-13

Name

Cross shaft coupling assembly

Bolt

No.

2

4

Name

Connecting plate

Bolt

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

91

TRANSMISSION CASE | STRUCTURE & PRINCIPLE

3.5 TRANSMISSION CASE (FIGURE 3-14 AND FIGURE 3-15)

The role of the transmission case is:

1. To realize the machine’s FORWARD and REVERSE.

2. To get different transmission ratios (including stopping).

• The transmission case is consisted of the planetary gear gearshift mechanism. It is the combination of the planetary gear train and the disc clutches, having three FORWARD positions and three

REVERSE positions.

• No.1 clutch is FORWARD, No.2 is REVERSE, No.3 is the third gear, No.4 is the second gear, and No.5 is the first gear.

1

View Z

1

2

3

4

Z

92

No.

1

3

Name

Shaft coupling

Transmission Valve

Figure 3-14

No.

2

4

Name

Box body

Housing

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

View Z

STRUCTURE & PRINCIPLE | TRANSMISSION CASE

1 2

3

4

5

6

7

8

9 10

11 12

13

14

41

33

32

38

37

36

40

39

35

34

43

42

B

A

C

L

G

I

J

N

M

H

K

D

E

N

31 30 29

28 27 26 25

Figure 3-15

24 23

22

15

P

18

19

20

21

16

17

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

93

TRANSMISSION CASE | STRUCTURE & PRINCIPLE

94

Name

Pin

Piston

Spring washer

Piston

Shaft

Piston

Snap ring

Piston

Gear

Outer drum

Butterfly-shaped spring

Housing

Steel ball

Rear housing

Piston

Housing

Output shaft

Nut

Bearing

Cover

Bearing support

Bearing

Shaft

Spring

Plate

Seat

Oil cylinder body

Bolt

Bushing

Oil cylinder body

No.

24

25

26

21

22

23

27

28

29

30

18

19

20

15

16

17

10

11

12

13

14

7

8

9

4

5

6

1

2

3

No.

K

L

M

H

I

J

N

O

P

E

F

G

B

C

D

40

41

42

43

A

37

38

39

34

35

36

31

32

33

Name

Plate

Oil cylinder body

Bolt

Carrier

Box body

Gasket

Shaft coupling

Seat

Bolt

Input shaft

Retainer bracket

Bearing support

Binder plate

No.1 sun gear

No.1 planetary gear

No.1 gear ring

No.2 sun gear

No.2 planetary gear

No.2 planetary gear

No.2 gear ring

No.3 sun gear

No.3 planetary gear

No.3 gear ring

No.4 sun gear

No.4 planetary gear

No.4 gear ring

Final primary driving gear

Final primary driven gear

Small bevel gear

FORWARD

REVERSE

Gear position

Gear 1

Gear 2

Gear 3

Gear 1

Gear 2

Gear 3

Working clutch

No.1, No.5

No.1, No.4

No.1, No.3

No.2, No.5

No.2, No.4

No.2, No.3

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | CENTRAL DRIVE

3.6 CENTRAL DRIVE (SEE FIGURE 3-16)

The main role of the Central drive is: 1. To change the power transmission direction (to change from longitudinal to horizontal). 2. To apply primary reduction, to increase torque. The Central drive, the steering clutch and the steering brake are all installed in the cavity of the steering case.

2

3

No.

1

4

5

Name

Outer hub

Platen

Outer friction disk

Inner blade

Inner drum

Figure 3-16

No.

6 Hub

Name

7 Bearing support

8 Big bevel gear

9 Cross shaft

10 Adjusting gasket

No.

Name

11 Big spring

12 Small spring

13 Bolt

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95

CENTRAL DRIVE | STRUCTURE & PRINCIPLE

The central drive consists of the big bevel gear (8) (engaged with the transmission case’s output gear (Q)), the cross shaft (9), the bearing support (7), and the bearings. The correct engagement of a pair of bevel gears can be achieved by adjusting the adjusting gasket (10) as well as the adjusting gasket between the transmission case’s small bevel gear assembly and the housing. You can judge it by checking the tooth side’s clearance and the engagement impression.

The standard clearance of a pair of the spiral bevel gears is 0.25~0.33mm. The engagement impression along the tooth length direction should not be smaller than half of the tooth’s length, and should be closer to the smaller end along the tooth length direction (30% more on the smaller end). The height should be half of the tooth’s height. See Figure 3-17.

Figure 3-17

96

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STRUCTURE & PRINCIPLE | CENTRAL DRIVE

If the engagement is not normal, make adjustment using the methods in the table below.

Position of the contact impression on the passive tooth surface

Adjustment method

Gear moving direction

Move the driven gear toward the driving gear. If this makes the clearance too small, move the driving gear outward.

FORWARD

Move the driven gear away from the driving gear. If this makes the clearance too big, move the driving gear inward.

Move the driving gear toward the driven gear. If this makes the clearance too small, move the driving gear outward.

REVERSE

Move the driving gear away from the driven gear. If this makes the clearance too big, move the driving gear inward.

Move the driven gear away from the driving gear. If this makes the clearance too big, move the driving gear inward.

Move the driven gear toward the driving gear. If this makes the clearance too small, move the driving gear outward.

Move the driving gear toward the driven gear. If this makes the clearance too small, move the driving gear outward.

Move the driving gear away from the driven gear. If this makes the clearance too big, move the driving gear inward.

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97

STEERING CLUTCH | STRUCTURE & PRINCIPLE

3.7 STEERING CLUTCH (FIGURE 3-18~FIGURE 3-19)

The steering clutches are located in the left & right chambers of the steering case, with one on each side. Their role is to connect or cut off the power from the central drive to the final drive, to realize various actions including the entire vehicle’s forward, reverse, turn, and stop.

Steering clutch’s structure mainly consists of the inner & outer drums, the platen, the inner & outer friction disks, and the spring.

This machine adopts a wet, multi-piece, spring-pressed, hydraulically-detached long-engagement structure.

Normally, due to the spring, the inner & outer friction disks are connected, and the power from the cross shaft is transmitted to the final drive disc through wheel (6)→inner drum (5)→inner tooth (4)→outer friction disk (3)→outer drum (1).

When the steering lever is pulled, the pressure oil from the steering control valve enters the inner cavity of the inner drum

(6) (See Figure 3-18) to push the piston (10), bolt and platen

(2) to move to the arrow direction (Overcome the pressure of the big and small springs), so as to disengage the friction connection between the inner tooth (4) and the outer friction disk

(3), to stop the outer drum (1) from rotating, so as to cut off the power transmission.

When the steering lever is released, the oil pressure is cut off, and due to the pressure of the big & small springs, the above parts are forced to move in the direction indicated in the figure, to enable the inner tooth (4) and the outer friction disk to become engaged, to realize the transmission of power. (See

Figure 3-19)

Figure 3-18

Figure 3-19

No.

4

5

6

1

2

3

Name

Outer hub

Platen

Outer friction disk

Inner blade

Inner drum

Hub

No.

Name

7

8

9

Bearing support

Big bevel gear

Cross shaft

10 Adjusting gasket

11 Big spring

12 Small spring

98

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | STEERING BRAKE

3.8 STEERING BRAKE (FIGURE 3-20)

This machine uses the wet, belt-style floating brake with a hydraulic booster.

A

B

A

B

A-A

B-B

Figure 3-20

3

4

5

No.

1

2

6

7

8

Name

Brake cover

Rock arm

Rock arm

Spring

Slide valve

Valve body

Piston

Rock arm

No.

9 Cover

10 Studs

Name

11 Adjusting spring

12 Cover

13 Adjusting bolt

14 Bracket

15 Lever

16 Block

No.

17 Lever

18 Tail end

Name

19 Brake lining

20 Brake band

21 Spring

22 Bushing

23 Spring seat

Its role is to hold the steering clutch’s outer drum tightly, to stop the final drive’s gear from rotating, so as to let the vehicle turn or stop.

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99

STEERING BRAKE | STRUCTURE & PRINCIPLE

3.8.1 WORKING PRINCIPLE

When the vehicle moves forward, the steering clutch’s outer drum rotates forward (See Figure 3-21A).

Slightly apply brake force on the brake pedal, the clearance between the brake band and the outer drum will be reduced until certain points are in contact. Due to the friction force, the upper part of the brake band pushes against the tail end, to let Pin A enter the groove of lever (15). If the brake force continues to be applied, lever (17), Pin (B), and lever (15) will move in the arrow direction, to hold the outer drum tight. At this point, (A) is the fulcrum of rotation.

When the vehicle moves in the reverse direction, the clutch’s outer drum rotates backward (See Figure 3-21B), whereas lever (17), Pin (B), and lever (15) move in the direction indicated in the figure, to hold the outer drum tight. But at this point, the rotation fulcrum has already been transferred Point

(C).

The brake results of the two are basically the same.

Forward rotation

Backward rotation

A B

Figure 3-21

3.8.2 SERVO MOTOR VALVE’S WORKING PRINCIPLE

The use of the servo motor valve can dramatically reduce the brake operation force of the driver.

During braking, rock arm (2) pushes slide valve (5), to make the clearance between slide valve (5) and piston (7) disappear, and the oil pressure from the pump pushes piston (7) to operate rock arm

(8) to realize braking. But due to the movement of piston (7), a clearance will appear again between slide valve (5) and piston (7) for sure. In order to ensure uninterrupted move, the brake pedal must move continuously.

100

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | FINAL DRIVE

3.9 FINAL DRIVE (FIGURE 3-22)

This machine uses the two-stage straight gear reduction mechanism.

The role of the final drive is to increase the output torque through the two-stage reduction, and at the same time, to transmit the power through the sprocket (8) to the walking mechanism.

6

7

4

5

No.

1

2

3

Figure3-22: The final drive’s mechanism of SD32, SD32D and SD32R

Name

Drive disc

Bearing support

Primary driving gear

Primary driven gear

Secondary driving gear

No.

8

9

10

11

12

Support

Cover

Name

Drive sprocket

Sprocket hub

Driving wheel’s nut

Secondary driven gear 13 Floating oil seal

Hub 14 Oil seal cover

No.

Name

15 Floating oil seal

16 Oil seal cover

17 Casing body

18 Guard plate

19 Half shaft

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

101

DRIVE SYSTEM’S OPERATION | STRUCTURE & PRINCIPLE

3.10 DRIVE SYSTEM’S OPERATION

3.10.1 GEAR SHIFT (SEE FIGURE 3-23)

2 3

21

3

No.

1

Name

Gear shift lever

Figure 3-23: Gear shift system

No.

2

Name

Gear shift lock lever

No.

3

Name

Transmission Valve

102

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | DRIVE SYSTEM’S OPERATION

3.10.2 OPERATION OF STEERING BRAKE (SEE FIGURE 3-24)

No.

1

2

Name

Brake pedal

Brake lock lever

Figure 3-24: Operation of steering brake system

No.

Name

3 Steering control lever

4 Steering valve

No.

5

Name

Brake valve

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

103

WALKING MECHANISM | STRUCTURE & PRINCIPLE

3.11 WALKING MECHANISM (FIGURE 3-25)

The walking mechanism mainly consists of the track frame (7), the driving wheel (4), the idler (1), the track roller (6), the carrier roller (3), as well as the track and the track tension device, to realize the walking of the bulldozer.

1

2

3

4

5

7

D

D

D s

D D s

8

9

10

Figure 3-25: The walking mechanism of SD32

2

3

No.

1

4

Idler

Name

Connecting rod

Carrier roller

Tension spring

6

7

No.

5

8

Name

Carrier roller

Track frame

Driving wheel

Track roller’s guard plate

No.

9

10

Name

Track roller, Double flanges

Track roller, Single flange

Content

Model

SD32

SD32D

SD32R

104

Number and sequence

7(D. D. D. S. D. D. S)

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | WALKING MECHANISM

3.11.1 TRACK TENSION DEVICE (SEE FIGURE 3-26)

The role of the tension device is to ensure that the track has sufficient tension, to reduce the shock jump of track during walking and prevent it from falling off during winding.

1 2

3 4 5 6

7

8

A

9

10

11 12

19

18

17

16

13

14

Profile A-A

15

Figure 3-26

5

6

3

4

7

No.

1

2

Name

Connecting rod

Piston

No.

8 Cover

Name

9 Oil cylinder

Sleeve, Guide

Buffering spring (big)

10 Oil seal

11 Piston ring

Buffering spring (small) 12 Pin

Sleeve 13 Spacer ring

Nut 14 Bolt

No.

Name

15 Guide seat (Rear)

16 Guard

17 Grease fitting

18 Oil nozzle

19 Oil drain plug

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

105

1

2

3

4

5

6

WALKING MECHANISM | STRUCTURE & PRINCIPLE

3.11.2 IDLER (SEE FIGURE 3-27)

The idler is mainly to guide the track link and track.

A

A

9

3

10

11

12

7

8

13 6

5

2

3

No.

1

4

5

Name

Idler

Sleeve

Guide roller bracket

Sleeve

Guide frame

Figure 3-27

7

8

No.

6

9 Plate

10 Plate

Idler axle

Name

Floating seal ring

Track frame

No.

11 Spring

Name

12 Seat, Guide

13 Bolt

106

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | WALKING MECHANISM

3.11.3 TRACK ROLLER (SEE FIGURE 3-28)

It supports the weight of the bulldozer, to prevent the lateral derail of the track. Track roller can have a single flange and double flange structure. This figure shows a double flange track roller’s structure.

Except for the shape of the track roller’s hub (1), other structures of the single-flange track roller and the double-flange track roller are the same.

No.

1

2

Name

Track roller hub

Bushing

No.

Figure 3-28

3 Cover

Name

4 Floating oil seal

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

No.

5 Shaft

Name

107

WALKING MECHANISM | STRUCTURE & PRINCIPLE

3.11.4 CARRIER ROLLER (SEE FIGURE 3-29)

It supports the upper track, to prevent the track from dropping too much, and to reduce the track’s shock-jump during moving as well as void the track from fall slipping off sideways.

1 2

3

4

8 7

2

3

No.

1

Name

Bracket

Shaft

Floating oil seal

Figure 3-29

5

6

No.

4

Name

Carrier roller

Cover

Nut

No.

7

8

Name

Floating seal seat

Floating seal seat

5

6

108

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | WALKING MECHANISM

3.11.5 TRACK

Track’s role is to support the bulldozer’s weight, to ensure the bulldozer’s traction, to enable it to have sufficient driving force.

Figure 3-30 is the track assembly of bulldozers SD32, SD32D, and SD32R.

2

3

No.

1

4

Name

Ring, Dust

Fixed pin

Seal ring

Master pin

No.

5

6

7

8

Figure 3-30

Track link

Name

Spindle sleeve

Sleeve

Track shoe

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

No.

9 Track bolt

10 Track Nut

Name

109

WALKING MECHANISM | STRUCTURE & PRINCIPLE

3.11.6 EQUALIZER BAR (SEE FIGURE 3-31)

It connects the frame and the walking system, to play a buffering role; at the same time, when the ground is not even, it can ensure that the track frame can swing up and down.

110

No.

1

3

Name

Equalizer Bar

Sleeve

Figure 3-31

No.

2

4

Name

Shaft

Sleeve

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

3.12 HYDRAULIC SYSTEM

Hydraulic system consists two parts: the work equipment’s hydraulic system and the gearshift steering hydraulic system.

3.12.1 WORK EQUIPMENT’S HYDRAULIC SYSTEM (SEE FIGURE 3-32)

1. Straight tilt blade and ripper

22

23

17

1

28

21 20

12

14

24

15

18

19

11

13

10

5

4

26

1

27

16

29

9

7

To Steering valve

8

6

3

A

2

Figure 3-32: Schematic of the hydraulic system

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

25

From Steering case

From Hydraulic oil tank

111

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

22

8

21

W

Tilt to right

20

Tilt to right

W

28

Tilt to left

9

16

19

18

W

15

W

12

W

14

Hold

Raise

10

13

11

Lower

Lower

17

W

Raise

W

27

W

W

29

W

23

6 7

W

5

W

Raise

4

Hold

Lower Floating

Lower

Raise

26

3

30

2

M

1

25

24

M

Figure 3-33: Illustration of the hydraulic principle

To Steering valve

112

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

14

15

12

13

10

11

8

9

6

7

4

5

2

3

No.

1

Name

Hydraulic oil tank

Hydraulic pump

Main overflow valve

Check valve

Blade lift valve

Oil-replenishing valve (blade-raising end)

Oil-replenishing valve (blade-lowering end)

Quick drop valve

Blade lift cylinder

Check valve

Ripper’s valve

Oil-replenishing valve (ripper-raising end)

Oil-replenishing valve (ripper-lowering end)

Safety valve

Selector valve

29

A

27

28

25

26

23

24

21

22

19

20

No.

16

17

18

Name

Ripper lift cylinder

Change valve

Tilt safety valve

Ripper tilt oil cylinder

One-way throttle valve

Blade tilt valve

Blade tilt cylinder

Hydraulic oil filter

Steering case

Steering pump

Blade lift servo valve

Ripper’s servo valve

Blade tilt servo valve

Pull pin valve

Pressure measuring point

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113

HYDRAULIC OIL TANK (SEE FIGURE 3-34)

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

H

G

F

Y

Y

X

X

1

Z

5

4

8

2

A

B C

D

E

3

6

Profile Y-Y

9

Profile X-X

10

View Z

7

Figure 3-34

114

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

6

7

4

5

2

3

No.

1

8

9

10

Name

Oil level indicator

Tilt control valve piping

Ripper control valve’

Oil filter of ripper’s safety valve

Main overflow valve’s oil level indicator

Blade lift valve

Oil filter of the blade’s oil-replenishing valve

Ripper’s oil-replenishing valve

Oil filter

Coarse strainer

F

G

D

E

H

No.

A

B

C

Name

To work pump

From work pump

Blade lift cylinder’s head

To blade lift cylinder’s bottom

To ripper oil cylinder

To the bottom of ripper’s cylinder

To the bottom of blade tilt cylinder

To blade tilt cylinder’s head

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

115

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

Working pump (see figure 3-35)

Type: Gear pump; Displacement: 355L/min at 17700rpm; Rated pressure: 14 Mpa

No.

1

2

3

Name

Driving gear

Front pump cover

Bushing

Figure 3-35

No.

4

5

6

Name

Body, Pump

Rear pump cover

Sealing film

No.

7

8

9

Ring

Seal ring

Name

Driven gear

116

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

The gear pump sucks out the operating oil from the hydraulic tank, and pumps it into the bladelifting-and-tilting control valve (the angle blade only has the blade control valve). If various work equipment is not operated, the oil will return to the hydraulic tank through the blade-lifting-and-tilting control valve, the ripper control valve (with ripper ) and the oil filter. If the oil filter is blocked at this point, the oil will push open the oil filter’s safety valve to return to the hydraulic tank. If you operate the blade-lifting-and-tilting control valve, you can control the blade’s cylinder to raise, lower, keep or float the blade, as well as control the tilting cylinder to tilt the blade to the left or to the right or to keep the blade unmoved. Operating the ripper control valve can control the ripper oil cylinder, to realize the ripper’s raising, lowering and keeping.

There is an intake check valve before each control valve to overcome the possible “nodding impact” from the circular movement of various working mechanisms.

The safety valve is provided in order to avoid that the system pressure from becoming too high due to the exessive load during the ripping operation.

During operation, if the load is too high, system pressure will exceed the set pressure of 14Mpa for a short time. In this case, the main overflow valve is opened, and the operating oil returns to the oil tank through the overflow valve, to protect the system .

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117

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

In order to let the tilt cylinder have an ideal movement speed, we have provided the flow control valve. (See Figure 3-36)

Figure 3-36

118

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

The overload valve (3) is provided in order to avoid that the system pressure from becoming too high due to the exessive load during the ripping operation.

During operation, if the load is too high, system pressure will exceed the set pressure of 14Mpa for a short time. In this case, the main overflow valve (3) is opened, and the operating oil returns to the oil tank through the overflow valve, to protect the system . The main overflow valve’s structure is shown in

Figure 3-37.

When the external force’s direction is the same as the oil cylinder piston’s moving direction, in order to avoid a vacuum from occurring within the oil cylinder, the oil-replenishing valves (6),

(7), (12), (13) are provided (See Figure 3-33) Oil-replenishing valve’s structure shown in Figure 3-38 and Figure 3-39

In order to prevent dust from contaminating the operating oil, the operating oil tank is made into a closed structure.

Figure 3-37

Figure 3-38

Figure 3-39

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119

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

ROTARY SERVO VALVE (SEE FIGURE 3-40)

A rotation servo valve is provided in order to reduce the force needed to operation the work equipment’s change valve and improve its tuning performance.

2

3

No.

1

4

Name

Sleeve

Oil seal

Oil seal

Pin

6

7

No.

5

8

Figure 3-40

Name

Spring

Lever

Roller

Piston

No.

9

10

11

Name

Detent

Spring

Lever

120

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

The oil of the rotation servo valve comes from the steering pump, and the oil returns to the steering case. (See Figure

3-41)

No.

1

7

12

Name

Valve cover

Valve core

Oil cylinder

No.

6

8

13

Name

Handle

Piston

Connecting rod

The action output end of the rotation servo valve connects to the valve stem of the work equipment’s change valve through the connecting rod, to operate the change valve t change direction. There is a positioning mechanism in the floating position.

If lever (6) is operated to let valve core (7) rotate clockwise for an angle (see Figure 3-42), the passage between (A) and

(C) will be opened, the pressure oil will enter the bottom of oil cylinder (12) to push piston (8) and valve cover (1) to rotate clockwise for an angle too, and the connecting rod (13) will operate the change valve’s stem to move a distance. As at this point the rotation of valve cover (1) cuts off the passage between (A) and (C), piston (8) will stop moving immediately.

It can move continuously only when (6) continues to be operated.

If lever (6) is operated to let valve core (7) rotate clockwise for an angle (see Figure 3-43), the passage between (B) and

(C) will be opened, the pressure oil will enter the oil cylinder to push piston (8) and valve cover (1) to rotate clockwise for an angle too, and the connecting rod (13) will operate the change valve’s stem to move a distance. As at this point the rotation of valve cover (1) cuts off the passage between (B) and (C), piston (8) will stop moving immediately. It can move continuously only when (6) continues to be operated.

Figure 3-41 shows a neutral operating condition. At this point, neither the passage between (A) and (C) nor the passage between (B) and (C) is opened, the oil cylinder’s piston does not move, and the valve cover does not rotate either.

As the operation force to the lever just needs to overcome the friction between valve cores (7) and (1), and the output force is provided by the oil cylinder, the operation force is dramatically reduced.

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

Figure 3-41

Figure 3-42

Figure 3-43

121

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

3.12.2 GEARSHIFT AND STEERING HYDRAULIC SYSTEM

GEARSHIFT HYDRAULIC SYSTEM (SEE FIGURE 3-44, 3-45)

8

9

No.1 clutch

(F)

No.2 clutch

(R)

No.3 clutch

(Gear 3)

No.4 clutch

(Gear 2)

No.5 clutch

(Gear 1)

7

B

6

5

4

10

11

D

3

From Steering cycle system

18

21

A

From Steering

1

cycle system

2

19

To Steering cycle system

22

Figure 3-44

20

16

17

C

12

Water

13

15

14

122

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STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

No.

7

8

9

4

5

6

10

1

2

3

11

12

13

A

3

FAR45

93 L/min

2030 RPM

A

W

4

Set pressure: 2Mpa

W

1

From steering control valve

5

6

Set pressure:

1.25Mpa

7

No.5 clutch (No.1)

No.3 clutch (No.3)

W

9

8

21

12

B

To Torque converter’s cycle system

No.2 clutch (R)

No.1 clutch (F)

D

C

From Steering cycle system

13

Set pressure:

0.45Mpa

11

W

Start pressure:

0.121MPa

To Steering cycle system

Set pressure:

0.124Mpa

15

W

14

M

18 16

10

Set pressure:

0.87Mpa

M

2

22

20 20

W

17

19

22

Set pressure:

0.13Mpa

Back Pressure Valve

Oil cooler

Name

Coarse strainer

Transmission pump

Oil filter

Pressure-adjusting valve

Fast return valve

Pressure relief valve

Speed valve

Direction valve

Safety valve

Overflow valve

Hydraulic torque converter

Figure 3-45

No.

Name

14

15

16

Transmission case’s lubricating valve

Transmission case’s lubrication

PTO lubrication

20

21

22

17

18

19

Hydraulic torque converter’s housing

Oil scavenger pump

Brake’s lubricating valve

Brake’s lubrication

Servo valve

Steering case

A

B

Transmission pressure measuring point

Pressure measuring point at the inlet of the hydraulic torque converter

Pressure measuring point at the outlet of the

C hydraulic torque converter

D Oil temperature gauge

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HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

Transmission pump is a gear pump. The transmission pump is connected with the transfer case, to convert the mechanical energy into the hydraulic energy. The transmission pump sucks the hydraulic oil from the steering case through the strainer (1), and the exhausted oil enters the pressureadjusting valve (4) through the fine filter (3). After pressure adjustment, the oil enters the hydraulic torque converter’s overflow valve (10), and the overflow oil returns to the steering case. Pressurized oil going through the overflow valve enters the hydraulic torque converter(11), to let the hydraulic torque converter’s back pressure valve (12) ensure that the oil in the torque converter has sufficient operating pressure. Some of the oil going through the back pressure valve, after being cooled by the oil cooler, returns to the lubricating valve (20), to lubricate the transmission case due to the lubricating valve being pressed. After lubrication, the oil flows to the bottom of the transmission case; another part of the oil goes to lubricate the PTO, and after lubrication, the oil flows to the bottom of the torque converter. The oil scavenger pump ensures that the oil within the torque converter’s housing can continuously returns to the transmission case.

Oil inlet

Oil outlet

No.

1

2

Name

Driving gear

Bracket

Figure 3-46

No.

3

4

Gearbox

Name

Cover

No.

5

Name

Driven gear

124

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STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

COARSE STAINER’S STRUCTURE (SEE

FIGURE 3-47)

GEARSHIFT FINE FILTER’S STRUCTURE

(SEE FIGURE 3-48)

Figure 3-47

3

4

5

No.

1

2

Name

Filter screen cap

Spring

Filter screen box

Magnet

Filter screen

Figure 3-48

6

7

4

5

8

No.

1

2

3

Name

Oil filter cover

Spring

Filter cartridge

Valve body

Spring

Seat

Nut

Filter element

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125

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

INSTALL TRANSMISSION VALVE (15~20) ON THE TRANSMISSION CASE (SEE FIGURE 3-49)

Figure 3-49

Valve (15) is the pressure-adjusting valve, and the adjusting pressure is 2.5Mpa, to ensure the engagement of all the clutches except for Gear 1. After reaching this pressure, the pressure-adjusting valve is opened, to supply oil to the torque converter. Valve (16) is the fast return valve. The joint action of this valve and the pressure-adjusting valve (15) can ensure that when the transmission case’s various clutches are activated, they can be smoothly engaged or thoroughly disengaged.

When the transmission case’s control lever is operated, the system’s pressure changes according to the curve in Figure 3-50. At the moment the transmission case is operated to shift a gear, the pressure drops suddenly, to have the clutch be thoroughly separated. And then, the pressure slowly rises, to let the clutch smoothly engage, to avoid shock, and to help increase the service life of the drive system.

126

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STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

Valve (17) is the pressure relief valve, provided specifically for the Gear 1clutch, and the pressure at its exit is 1.25MPa. (i.e. the engagement pressure of the Gear 1 clutch)

Valve (19) is the starting safety valve. It is provided in order to avoid the unexpected accidents when the engine is started while the gearshift knob is on a gear (Gear I, II, III) to let the vehicle move suddenly. the vehicle will only start to move when the gearshift knob is in the NEUTRAL position, and then is put on a gear.

Valve (18) is the speed valve. It is used to operate the transmission case’s clutches to get different forward and reverse speeds.

Valve (20) is the direction valve. It is used to operate the transmission case’s first clutch and second clutch , to let the bulldozer move forward or backward. Valves (15) through (20) return oil into the steering case.

Pressure rising time

Pressure

Gear shift Engagement Time

Figure 3-50

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HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

STEERING HYDRAULIC SYSTEM (SEE FIGURE 3-51, 3-52)

8

9

5

5a

To Hydraulic torque converter’s cycle system

5a

5b

4

7

3

2

A

1

6

To Transmission cycle system

Figure 3-51

128

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STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

5

5a

Disconnected

W

Connected

Disconnected

W

Connected

Connected

W

W

Disconnected

To servo valve

Start pressure:

0.121MPa

W

3

Set pressure: 2.2Mpa

4

To Torque converter’s cycle system

M

1

2

A

FAR100

1725 L/min

B

1.725 RPM

To Torque converter’s cycle system

8

7

D

6 6

E

7

C

No.

Name

3

4

1

2

Coarse strainer

Steering pump

Steering oil filter

Steering adjusting valve

5

5a

Steering brake valve

Steering valve

5b Brake valve

6 Steering clutch

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

Figure 3-52

No.

D

E

B

C

9

A

7

8

Name

Brake booster

Servo valve

Steering case

Steering pressure measuring point

Left steering pressure measuring point

Right steering pressure measuring point

Left brake pressure measuring point

Right brake pressure measuring point

129

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

Steering pump is a gear pump. The transmission pump is connected with the transfer case, to convert the mechanical energy into the hydraulic energy. The transmission pump sucks the hydraulic oil from the steering case through the strainer (1), and the exhausted oil enters the pressure-adjusting valve (4) through the fine filter (3). The oil enters the hydraulic torque converter’s overflow valve after pressure adjustment. Some of the oil goes to drive the servo valve.

When the steering lever is pulled to “Steering”, pressure oil will flow from steering valve (5a) to the steering clutch. When the steering level is pulled to “Brake”, pressure oil will flow from brake valve (5b) to the brake booster, to operate the steering brake.

No matter if the steering lever operates, when the brake pedal is pressed down, pressure oil will flow from brake valve (5b) to the brake booster, to operate the steering brake.

STEERING BRAKE VALVE’S STRUCTURE (SEE FIGURE 3-53)

The right brake booster’s pressure

From Steering

The right steering clutch’s pressure pump

A A

The left steering clutch’s pressure

The left brake booster’s pressure

Profile A-A

From pump

130

To Steering clutch

To Brake booster

Figure 3-53

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STRUCTURE & PRINCIPLE | HYDRAULIC SYSTEM

STEERING ADJUSTING VALVE’S STRUCTURE (SEE FIGURE 3-54)

3

1 2

A

A

Profile A-A

No.

1

Name

Valve core

No.

2

Figure 3-54

Name

Plunger

STEERING PUMP’S SCTRUCTURE (See Figure 3-55)

No.

3

Name

Spring

Oil inlet

Oil outlet

No.

1

2

Name

Driving gear

Bracket

No.

3

4

Figure 3-55

Name

Gearbox

Cover

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

No.

5

Name

Driven gear

131

HYDRAULIC SYSTEM | STRUCTURE & PRINCIPLE

STEERING FINE FILTER’S STRUCTURE (SEE FIGURE 3-56)

2

3

No.

1

Name

Oil filter cover

Spring

Filter cartridge

Figure 3-56

5

6

No.

4

Name

Valve body

Spring

Seat

No.

7

8

Name

Nut

Filter element

132

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STRUCTURE & PRINCIPLE | WORK EQUIPMENT

3.13 WORK EQUIPMENT

The work equipment mainly refers to the blade and the ripper, used to perform various operations of the bulldozer. Bulldozers SD32, SD32D, and SD32R have three types of blades: straight tilt blade, angle blade, and Semi U-blade.

3.13.1 STRAIGHT TILT BLADE AND SEMI U-BLADE (SEE FIGURE 3-57)

The push rod of the straight tilt blade is a box-shaped structure, with a good anti-bending strength, a good anti-pressure stability and good rigidity. The front end is hinged together with the blade using a cross connector, and the back end is hinged together with the seat (8) fixed on the track frame.

Under the action of the blade’s oil cylinder, both the push rod and the blade’s head rotate with the seat (8) as the axle, to realize the blade’s raising and lowering. Changing the length of adjusting screw (5) can change the cutting angle of the blade. Tilting the oil cylinder (6) can enable the blade to tilt to left or right in a direction perpendicular to the ground.

After being used for a period of time, the cutting edge (2) can be turned around and used again.

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WORK EQUIPMENT | STRUCTURE & PRINCIPLE

Figure 3-57

No.

1

5

Name

Dozer blade

Adjusting screw

No.

2

6

Name

Edge, Cutting

Tilt oil cylinder

No.

3

7

Name

End bit

Arm

No.

4

8

Name

Push rod

Seat

134

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STRUCTURE & PRINCIPLE | WORK EQUIPMENT

3.13.2 ANGLE BLADE

Angle blade’s structure is shown in Figure 3-58.

Figure 3-58

No.

1

5

9

13

Name

Pin

Upper support

Edge, Cutting

Nut

No.

2

6

10

14

Name

Seat

Screw

Pin

Pin

No.

3

7

11

15

Name

C-Frame

End bit

Pin

Pin

No.

4

8

12

16

Name

Lower support

The blade’s head

Bolt

Pin

The blade (8) is hinged together with the C-Frame (3) through the upper support (5) and the lower support (4). The C-Frame (3) is hinged together with the seat (2), which is fixed on the track frame.

The blade’s cylinder lets the C-Frame (including the blade) make the fixed-axis swing with seat (2) as the axis.

Installing the lower support (4) on the C-Frame’s different seats through the unplug pin (1) can let the blade have three different work positions, to realize 25° rotation to the left or right.

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135

WORK EQUIPMENT | STRUCTURE & PRINCIPLE

3.13.3 TRIPLE-SHANK RIPPER (SEE FIGURE 3-59) AND SINGLE-SHANK RIPPER (SEE FIGURE

3-60)

The ripper can be used in conjunction with the straight tilt blade and the angle blade.

14

14

13

1

2

16

15

13

5

3

2

1

16 15

12

3

5

4

6

Figure 3-59

7

9

8

11

10

4

11

10

Figure 3-60

6

12

9

8

7

5

9

No.

1

Name

Tilt cylinder’s pin

Connecting frame

Ripper shank

13 Shank pin

No.

2

6

10

Name

Lift cylinder’s pin

Tooth tip’s pin

Connecting frame’s pin

Tilt cylinder’s pin

No.

3

Name

Bracket

7

11

Tooth tip

Lift cylinder’s pin

15 Tilt cylinder

No.

4

8

Name

Connecting frame’s pin

Guard plate

12 Cross beam

16 Lift cylinder

Both the triple-shank ripper and the single-shank ripper are the variable rippers. Bracket (3) is installed on the back end of the steering case. Bracket (3), connecting frame (5) and cross beam (12) are hinged together with tilt oil cylinder (15) and lift oil cylinder (16). Ripper shank (9) is installed on cross beam (12), and pin (6) is used to install guard plate (8) and tooth tip (7) on the shank.

The triple-shank ripper’s shank (9) has three groups of holes, and the single-shank ripper’s shank (9) has four groups of holes. The mounting position of the holes can be adjusted to adjust the digging depth. After being used for a while, the tooth tip (10) can be turned 180° to be installed again, to extend its service life.

136

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STRUCTURE & PRINCIPLE | ELECTRIC SYSTEM

3.14 ELECTRIC SYSTEM

3.14.1 DESCRIPTION OF THE ELECTRIC SYSTEM

The bulldozer’s electric system is mainly used to start the diesel engine, the lamps, the air conditioner, the meters and other electric equipment. It consists of the starting motor, the silicon rectified AC generator, the voltage stabilizer, the relays, the air blower, the meters, the horn, as well as other electric devices and two 12V75Ah batteries.

Notes:

• The entire machine uses the negative terminal bond strap, to ensure that the bond strap is securely fixed;

• The silicon rectified generator is used, together with an IC adjuster;

• The advanced electromagnetic relay and voltage relay are used, to better protect elements such as the starter and starting switch;

• When the starting switch is in the “open” position, the accumulator’s relay can automatically cut off the power supply, to prevent electric leakage;

• When installing the connectors of various electric elements, pay attention to the color, specification and position of various connecting wires, to prevent wrong wiring;

• When replacing the battery, product of the same model should be used. If a battery with a small capacity is used, it may be damaged during the starting process due to overload;

• Each time the engine should not be continuously started for over 10s, and the interval between two starting attempts is 2min;

• The wiring position of the starting switch:

• Starting switch’s operation position and wiring diagram

Autom atic re set

Sta rt p

Auto mat ositi on ic re set

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137

ELECTRIC SYSTEM | STRUCTURE & PRINCIPLE

3.14.2 ELECTRIC WIRING CHART (SEE FIGURE 3-61)

9

7

8

2

3

4

5

6

A

1

15

13

14

View A

21

20

19

18

17

16

10

11

12

22

138

No.

6

7

4

5

1

2

3

10

11

8

9

Figure 3-61

Name

Headlight and lamp shade

Starting motor

Starting relay

Air cleaner’s mounting pedestal

Lamp on the right side

Motor’s cable

Instrument box assembly

Horn’s switch

Rear Working lamp

Safety relay

Fuse box for charging

No.

15

16

17

18

12

13

14

19

20

21

Name

Fuse box

Battery pack

Battery relay

Neutral position switch

Lamp on the left side

Oil temperature sensor

Engine oil’s pressure sensor

Water temperature sensor

Generator

Horn

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STRUCTURE & PRINCIPLE | ELECTRIC SYSTEM

3.14.3 WIRE CODES

The following wire codes can help to understand circuit diagrams

Example: wire code 70A01

“70” represents the wire’s standard cross-section, as shown in the table below:

Clutch’s number of teeth

0.5

0.75

1

1.5

2.5

4

6

10

16

25

70

95

Number of strands

16

24

32

30

49

59

84

84

126

196

360

475

Diameter of each strand

(mm)

0.2

0.2

0.2

0.25

0.25

0.3

0.3

0.4

0.4

0.4

0.5

0.5

Wire’s outer diameter (mm)

3.7

4.5

5.1

6.7

2.4

2.6

2.8

3.1

8.5

10.6

15.7

18.2

Main application circuit

Instrument, Lighting, Signal

Instrument, Lighting, Signal, Start

Lighting, Signal

Power supply, Start

Start, Warm-up, Charge

Start, Warm-up, Charge

Starting circuit

Starting circuit

Starting circuit

Starting circuit

“A” represents circuit or functional group, as shown in the table below:

Code

A

B

C

D

E

Circuit or functional group

Starting

Charging

Lighting

Signal, instrument

Functional assembly

Main circuits for starting, pre-heating, and stopping as well as their control circuits, main power cables

Circuits for charging and charging indication etc.

Lighting by front and rear working lamps, indoor lighting, and lighting of the dashboard

Various meters and alarms, braking, steering, backing, and horn etc.

Various bond straps

F

G

H

Bond strap

Windshield wiper and cigarette lighter

Air conditioner, radio & tape recorder

Automatic control

Windshield wiper, cigarette lighter, and washer etc.

Air conditioner, fan, heater, and radio & tape recorder etc.

Oil temperature sensor

“01” represents numbering within the group.

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139

ELECTRIC SYSTEM | STRUCTURE & PRINCIPLE

3.14.4 ELECTRIC PRINCIPLE DIAGRAM

0

4

1D2

1C1

0

4

1D2

1C1

0

4

1D2

1C1

0

4

1D2

1C1

1E30

1E30

1E30

1D25

1E30

1E30

1D21

1E30

1E30

1E30

1E30

1D22

1.5D10

2.5C10

1H10

1.5K20

2.5K10

2.5A90

1.5G10

1D40

1.5H20

(A)

(B)

(C)

(D)

CN13 13-7

CN13 13-1

CN13 13-9

CN13 13-10

1.5C13

CN12 9-2

1.5G20

CN12 9-3

2.5G10

2.5G10

2.5G10

1D12

1.5D11

1D21

CN10 21-10

CN2 21-7

1E30

1D25

CN2 21-8

1D22

CN2 21-9

1H11

1.5H20

CN13 13-11

1E41

1.5D11

CN12 9-5

CN70 1-1

1D41

1E71

CN12 9-8

CN12 9-4

CN12 9-1

1D22

1D25

1D21

1C14

1C14

1.5C13

1.5C11

1.5C12

1E06

1.5H21

1B20

1.5D20

1.5D20

6B10

1B20

CN2 21-6

CN2 21-4

CN13 13-13

CN13 13-5

1B20

CN12 9-6

1B20

1.5A33

1.5A60

1.5A40

1.5A60

1.5A30

2.5A20

CN2 21-14

CN2 21-3

CN2 21-2

CN2 21-1

CN13 13-3

CN13 13-4

CN13 13-8

CN12 9-7

1A35

1.5A32

1.5C13

1.5G20

1.5C12

1.5C11

CN25 3-2

CN25 3-1

1.5E05

1.5G21

1.5A34

1B20

6B10

1.5A60

CN36 2-1

CN35 2-1

CN34 2-1

CN33 2-1

CN32 2-1

1D22

1D25

1D21

1.5D11

1E72

CN36 2-2

CN35 2-2

1.5E13

1.5E13

CN34 2-2

CN33 2-2

CN32 2-2

1.5E12

1.5E11

1.5E11

1E11

6E03

1.5E04

140

6A15

2.5A21

4A11

2.5A20

4A11

1.5A30

4A12

70A10

70E02

1A35

1.5A40

1.5E01

70A02 12V200A 70A01 12V200A 70E00

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STRUCTURE & PRINCIPLE | ELECTRIC SYSTEM

21

22

23

24

17

18

19

20

25

26

13

14

15

16

No.

1-10

11

12

27

28

29

30

31

32

Name

Fuse

Hour meter

Voltmeter

Oil temperature gauge

Engine oil pressure gauge

Water temperature gauge

Starting switch

Alarm unit

Horn relay

Ripper tilt switch

Battery relay

Horn’s switch

Reversing switch

Relay

Switch of front & rear lamps

Side lamp switch

Instrument light switch

Starting relay

Safety relay

Back-up alarm

Thermostat

Battery

Starter

44

45

46

47

A

B

40

41

42

43

36

37

38

39

No.

33

34

35

E

F

C

D

G

Name

NEUTRAL switch

Solenoid valve

Generator

Oil temperature sensor

Pressure sensor

Water/oil sensor

Horn

Ripper tilt solenoid valve

Rear lamp

Left front lamp

Right front lamp

Lamp on the left side

Lamp on the right side

Compressor

High and Low Voltage switch

Spare

Spare

To Cab

A/C control panel

Power Supply

Button

Horn

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141

NOTE PAPER

142

Note paper

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MAINTENNANCE | MAINTENANCE

CHAPTER 4: MAINTENANCE

4.1 MAINTENANCE

PRECAUTIONS:

Properly servicing and maintaining the vehicle is very helpful for extending the vehicle’s service life, ensuring personal & machine safety, increasing productivity, and improving economic benefits.

Operators and maintenance personnel, apart from reading the related requirements mentioned in the “safety precautions”, should also observe the following.

• Servicing and maintenance personnel must be very familiar with the machine’s structure, performance, assembly & disassembly procedures, technical requirements and precautions etc. before doing related work. Never act blindly. For a difficult service & maintenance project, if you are not very sure you can do it, you’d better consult your Shantui distributor. Routine maintenance is usually performed before the vehicle is started and after work each day. Before maintenance, park the vehicle on a level ground, lower the blade and ripper, lock the locking mechanisms, and then go ahead with the maintenance. If maintenance is performed without stopping the engine, it must be carried out by two persons. One person sits in the cab, and the other person performs the maintenance. Be careful not to touch the moving parts with your body.

• Prior to maintenance, thoroughly clean, brush or wash the surrounding areas of the parts to be maintained. Pay special attention to the surrounding areas of the oil injection port, the air cleaner, the oil nozzle, and the housing cover, and these places must be made very clean, to prevent dust from entering the oil.

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CAUTION

• Do not handle electric systems in rain;

• When checking or cooling water, be careful, as hot water may spurt out to injure people;

• After the engine oil filter or strainer is replaced, exhaust the air from the oil circuit;

• Never add oil by taking out the filter screen of the oil injection port.

Remember that there is high pressure within the hydraulic oil circuit. When you add oil, drain oil or perform check and maintenance, release the pressure first. The method for releasing pressure is as follows:

• Lower the blade and ripper to ground, extinguish the engine, pull the hydraulic system’s control lever to each gear position 2-3 times continuously, and then slowly turn loose the oil tank’s cap or the pipe connector;

• Before changing engine oil, start the vehicle to raise the oil temperature to 30-40°C strain the oil;

• Use clean oil and grease. When checking or changing oil, do not do it in a dusty location, or the dust can get into the oil;

• Before servicing the gearbox, take all the objects out of your pockets. Be careful, wrenches or nuts may fall into the box, to create a big trouble;

• Fuel and oil should be kept away from fire;

• Do not use fire to replace lamps for lighting; When changing O-rings, gaskets or other sealing items, rigorously clean part’s surface, and install them carefully;

• Within the battery box, there is a 24V DC socket, which can be used directly during servicing & maintenance.

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4.1.1 SERVICE TABLE

NO.

6

7

4

5

8

9

10

1

2

3

1

2

3

4

5

6

1

2

3

4

5

6

MAINTENANCE ITEMS

CHECK BEFORE STARTING

Checking oil or water leakage Checking

Checking bolts and nuts

Checking electric circuits

Checking coolant water level

Checking oil level in engine oil pan

Checking and tightening

Checking and tightening

Checking and replenishing

Checking and replenishing

Checking fuel level

Checking oil level in steering clutch

Discharging impurities from fuel tank

Checking dust indicator

Checking brake pedal travel

Checking and replenishing

Checking and replenishing

Draining water and sediments

Checking and cleaning air filter

Checking and adjusting

Fuel filter, Oil filter

INITIAL 250 HOURS SERVICE

Replacing filter element

Changing oil Engine oil pan

Steering clutch case (including transmission case and torque converter)

Hydraulic tank and filter

Final drive case

Engine valve’s clearance

Changing oil and washing the strainer

Changing oil and Replacing filter element

Changing oil

Checking and adjusting

EVERY 250 HOURS SERVICE

Lubricating (Checking the following areas, lubricating them and applying grease to them)

Fan pulley 1 place

Tension roller and tension roller’s bracket 2 places

Support arm’s screw rod

1 places of straight tilt blade, and 2 places of angle blade

Oil cylinder bracket shaft 2 places

Oil cylinder bracket yoke 6 places

Tilt oil cylinder ball joint

Support arm’s spherical hinge

Blade arm ball joint

Oblique arm’s spherical hinge

Straight tilt blade: 1 place

Straight tilt blade: 1 place

3 places

2 places

Various hinged joints of the ripper 18 places

Engine oil pan and oil filter

Draining oil and replacing the filter element

Gearshift’s oil filter and steering oil filter Replacing filter element

Final drive case

Hydraulic tank

Generator’s driving belt

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MAINTENANCE CONTENTS

Checking oil level and replenishing

Checking oil level and replenishing

Adjusting tension

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146

1

2

3

7

8

1

6

7

8

4

5

2

3

1

2

3

4

5

1

2

1

4

5

2

3

CONTINUED

EVERY 250 HOURS SERVICE

Water pump’s driving belt

Battery electrolyte

Fuel filter

Adjusting tension

Checking level

EVERY 500 HOURS SERVICE

Replacing filter element

Breather

Fan belt

Washing

Adjusting tension

EVERY 1000 HOURS SERVICE

Lubricating (Checking the following areas, lubricating them and applying grease to them)

Universal joint 8 places

Oblique support arm 2 places

Idler’s tensioning rod 2 places

Water tank’s radiation fin

Steering clutch’s case

Final drive case

Hydraulic tank and filter

Checking and cleaning

Changing oil and washing the strainer

Changing oil

Changing oil and Replacing filter cartridge

Walking parts

Tubocharger

Checking and lubricating

Checking roller’s clearance

Corrosion resistor Replacing filter element

Lubricating

Equalizer bar’s shaft

EVERY 2000 HOURS SERVICE

(Checking the following areas, lubricating them and applying grease to them)

1 places

Brake pedal 5 places

Breather of the engine’s crankcase

Tubocharger

Valve clearance

Engine’s damper

Washing

Washing

Checking and adjusting

Checking or changing

Water pump

EVERY 4000 HOURS SERVICE

Checking if the belt is loose and if there is water leakage

Fan pulley and tension wheel Checking if it is loose

MAINTENCE WHEN NEEDED

Air cleaner

Coolant system

Track tension

Cleaning and changing

Washing the inside and changing the coolant

Checking and adjusting

Track bolt

End bit and cutting edge

Checking and tightening

Inverting or changing

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4.1.2 INITIAL 250 HOURS SERVICE

Perform the following maintenance only after the first 250 hours:

1. Fuel filter

2. Engine oil pan

3. Steering clutch case (including transmission case and torque converter)

4. Hydraulic tank and filter

5. Final drive case

6. Engine valve’s clearance

For the replacement and maintenance methods, see “Maintenance for Every 250 Hours, 1000 Hours and 2000 Hours”.

4.1.3 EVERY 250 HOURS SERVICE

Inject grease to the grease nozzle shown in the figure.

1. 1 place: Fan pulley (Figure 4-1)

2. 2 places: Tension roller and tension roller’s bracket

Figure 4-1

3. 3 place of the support rod (Figure 4-2) 3 places of straight tilt blade, and 2 places of angle blade

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Figure 4-2

147

4. 4 places of oil cylinder’s bracket (Figure 4-3)

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Figure 4-3

5. 1 place of the tilt cylinder’s spherical hinge (straight tilt blade) (Figure 4-4)

Figure 4-4

6. 1 place of the support arm’s spherical hinge (straight tilt blade) (Figure 4-5)

Figure 4-5

7. Oblique arm’s spherical hinge (Straight tilt blade) (Figure

4-6) 2 places

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Figure 4-6

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8. Applying grease to the connector of the blade’s oil cylinder

9. Ripper’s various hinges (Figure 4-8-4-13):

a. Upper connecting rod (8 places);

b. The top part of the oil cylinder’s piston rod (2 places);

c. The lower connecting frame’s pin (4 places).

d. The lower connecting frame’s shaft (4 places).

Figure 4-7

Figure 4-8

Figure 4-9

Figure 4-10

Figure 4-11 Figure 4-12

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Figure 4-13

149

10. Engine oil pan and air cleaner

• Remove the cover installed on the bottom of the body.

Remove the drain plug and release the drain valve. After draining, tighten the drain valve and the drain plug.

• Use filter wrench to rotate it counterclockwise, to remove the engine oil filter’s and bypass oil filter’s element. Fill the new engine oil filter’s and bypass oil filter’s elements with engine oil, apply a small amount of the engine oil on the gasket, and screw it on the filter’s seat. When the gasket touches the sealing surface, make 3/4-1 more turns. After replacing the filter element, add engine oil through the oil injection port (Figure 4-14).

• And then, let the engine idle for a while, and detect the oil level. The type of lubricant used depends on the ambient temperature. See the “USE OF FUEL, COOLANT AND LU-

BRICANTS ACCORDING TO AMBIENT TEMPERATURE” for reference. The oil should be changed every 6 months.

Before installing the filter element, you must inject the engine oil into the filter element.

Always use Shantui genuine filters.

11. Gearshift’s oil filter and steering oil filter.

• Remove the bolt (1), pull up the cap (2), and take out the filter element and the valve along with the cap (2). Remove the butterfly-shaped nut of the tightening valve (4), and take out the filter element (3) from the oil filter. Clean the inner part of the housing and the parts removed, and install the new filter element in the oil filter. Always use Shantui genuine filters. (See Figure 4-15 and Figure 4-16)

Always use Shantui genuine filters.

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Figure 4-14

Figure 4-15

150

Figure 4-16

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12. Final drive case (Figure 4-17)

• Remove Plug (G). If it is found that the oil is not filled near the bottom side of the plug’s hole, add lubricant via the plug’s hole. The lubricant used depends on the ambient temperature. See the “USE OF FUEL, COOLANT AND LU-

BRICANTS ACCORDING TO AMBIENT TEMPERATURE” for reference. When performing maintenance, park the vehicle on a level ground.

Figure 4-17

13. Hydraulic tank (See Figure 4-18)

• Put the blade and the ripper on the ground horizontally, stop the engine, and wait for 5min to check the oil level. If the oil level is not within the red circle in the Observation

Window (G), replenish the hydraulic oil to the oil tank via the Oil Injection Port (F).

CAUTION

• When the oil temperature is high, do not remove the cap. Hot oil sometimes can spurt out. When removing the cap, slowly rotate the cap, to release the internal pressure. The lubricant type used depends on the ambient temperature. See the “USE OF FUEL, COOLANT

AND LUBRICANTS ACCORDING TO AMBIENT TEM-

PERATURE” for reference.

• Before the engine is started, perform the routine check.

Figure 4-18

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14. Generator’s driving belt

• The standard is that when you use a force of about 60N to press the belt in the direction shown by the arrow in Figure

4-19, you can press it down by 10mm, or adjustment should be made. You should also check the belt for damage. When the belt is extended and cannot be adjusted any more, or when there are cuts and cracks, replace the belt immediately. The two belts should be replaced. After the new belts are installed, test run them for one hour before check and adjusting. The V-belt is not allowed to contact the V-groove’s bottom.

Generator

Accessory transmission pulley

Figure 4-19

15. The water pump’s driving belt (Figure 4-20)

• The check and adjustment method is the same as that of the engine’s driving belt.

Water pump pulley

Tension roller

Accessory transmission pulley

Figure 4-20

16. Battery electrolyte (Figure 4-21)

• If the liquid level of the battery is lower than the required level (10-12mm above the limit level), distilled water will need to be added. If the electrolyte is reduced because of overflow, inject dilute sulphuric acid of the same concentration to the battery. Clean the breather hole on the battery’s cap when checking the liquid level.

• Don’t use the metal funnel to add liquid.

WARNING

• To avoid the gases from explosion, keep fire or sparks away from the battery.

• If the electrolyte is spilled to skin or clothes, wash with plenty of clean water immediately.

Figure 4-21

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17. Exhaust impurities and water from fuel tank (Figure 4-22)

• Open the back cover, and loosen the valve on the fuel tank’s bottom, to exhaust water and impurities.

Figure 4-22

4.1.4 EVERY 500 HOURS SERVICE

Maintenance for every 250 hours service should be carried out at the same time.

1. Fuel filter

• Close the valve on the fuel tank’s bottom (See Figure 4-22), and use the filter’s wrench to remove the fuel filter element

(Figure 4-23). Fill the new filter element with clean fuel, and apply a small amount of engine oil on the gasket. Install the filter element, tighten it with hand until the gasket contacts the air cleaner’s seat, and then tighten it 1/2-3/4 more turns

(Do not tighten it too much).

Always use Shantui genuine filter cartridge.

2. Breather

Remove the breather, and use diesel to flush the dust accumulated within it.

• Steering clutch’s case (1 place)

• Final drive’s case (2 places)

3. Fan belt

• Check the V-belt, and if there are the following circumstances, replace the V-belt:

• When the V-belt contacts the bottom of the pulley’s groove; when the V-belt is worn, and its surface is lower than the pulley’s outer diameter;

• when the V-belt has cracks or peels off. For details about the replacement procedure, see the “Fan belt adjustment”.

Figure 4-23

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4.1.5 EVERY 1000 HOURS SERVICE

Maintenance for every 250 and 500 hours service should be carried out at the same time. Inject grease to the grease nozzle shown in the figure.

1. Universal joint (8 places)

2. Add lubricating grease to the half shaft’s bush (Figure 4-24)

(2 places)

3. Oil cylinder for idler tension (Figure 4-25) (2 places)

4. Water tank’s radiation fin (Figure 4-26)

• Loosen the guard gate’s bolt, and open the guard gate.

Use compressed air to blow sundries such as mud, dust or leaves off from the water tank’s radiation fin. You can also use steam or water to replace the compressed air. Check the water tank’s rubber tube for cracks or embrittlement, and replace it if necessary. Check the rubber tube’s clamp to see if it’s loose.

5. Steering clutch case (including the bevel gear case) and transmission case.

• Screw off the oil drain plug on the transmission case’s housing, and tighten it again after draining the old engine oil.

• Screw off the oil drain plug on the torque converter’s housing, and tighten it again after draining the old engine oil.

• Add the engine oil to the required oil level through the transmission case’s oil port.

• Choose an oil listed in the “USE OF FUEL, COOLANT AND

LUBRICANTS ACCORDING TO AMBIENT TEMPERA-

TURE”, and add it from the oil injection port.

• Remove the drain plug on the bottom of the body (the arrow in Figure 4-27) to drain the oil, and tighten the drain plug again after draining the oil.

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Figure 4-24

Figure 4-25

Figure 4-26

154

Figure 4-27

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• Remove the left floor, the bolt, the cap, the steering clutch’s strainer and the magnet; Loosen the bolt, and remove the torque converter’s strainer and cover altogether. After cleaning the inside of the housing, the strainer and other parts removed, re-install them back to their appropriate positions.

• If the strainer is damaged, change a new strainer.

• After replacing the gearshift and steering oil filter’s element

(See “EVERY 250 HOURS SERVICE”), add the required amount of engine oil through the oil injection port. (Figure

4-28).The amount of oil added: 136L. The lubricant type used depends on the ambient temperature. See the “USE

OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO

AMBIENT TEMPERATURE” for reference.

6. Final drive case (Figure 4-29 and Figure 4-30)

• Remove the oil filler plug from two sides of the body, and then remove the drain plug to drain the oil. After the draining, tighten the drain plug.

• Inject the required amount of the engine oil through the oil filler plug (See “EVERY 250 HOURS SERVICE”). The lubricant type used depends on the ambient temperature. See the “USE OF FUEL, COOLANT AND LUBRICANTS AC-

CORDING TO AMBIENT TEMPERATURE” for reference.

Amount of oil added on each side: SD32, SD32D and

SD32R: 55L

7. Hydraulic tank and filter(Figure 4-31-Figure 4-33)

• Remove the drain plug on the bottom of the oil tank, and loosen the drain valve. After draining, tighten the valve and drain plug. Remove the bolt, cap and filter element. Clean the removed parts and filter’s inside, and install the new filter element. Inject the required amount of the hydraulic oil through the oil injection port (F) (See the “EVERY 250

HOURS SERVICE”). Amount of oil added: 58L. The lubricant type used depends on the ambient temperature. See the “USE OF FUEL, COOLANT AND LUBRICANTS AC-

CORDING TO AMBIENT TEMPERATURE” for reference.

Always use Shantui genuine filters.

Figure 4-28

Figure 4-29

Figure 4-30

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Figure 4-31

155

8. Walking parts

• Stop the vehicle on a level ground, and check the oil consumption in the track roller, carrier roller, and idler one by one. (Figure 4-34)

• Slowly screw loose the seal bolt (Figure 4-35) to see if there is oil seeping out from the threads. If yes, it means that there is enough oil, and you should tighten the bolt immediately. If there is still no oil flowing out after the seal bolt is completely removed, it means that there isn’t enough oil.

In this case, you should require your local Shantui distributor to make necessary repair.

9. The roller of the tubocharger has clearance

• Contact your local Shantui distributor for necessary check or repair.

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Figure 4-32

10. Corrosion resistor (water filter)

• Shut down the corrosion resistor’s valves for water to get in and out. Use the filter’s wrench to turn the corrosion resistor’s filter element counterclockwise to remove it. Apply a small amount of oil on the sealing surface and install a new element. During installation, tighten 1/2-3/4 turns after the sealing surface is in contact with the cap. (Don’t turn it too tight.) After the replacement, open the valves.

Always use Shantui genuine filters.

Figure 4-33

Figure 4-34

156

Figure 4-35

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4.1.6 EVERY 2000 HOURS SERVICE

Maintenance for every 250, 500, and 1000 hours service should be carried out at the same time.

Lubricating, Inject grease to the grease nozzle shown in the figure.

1. Equalizer bar’s shaft (1 place)

2. Brake pedal’s axle (Figure 4-36) (5 places)

3. Tubocharger

• The excessive carbon black or grease adhered to the tubocharger pump impeller may influence the normal performance of the tubocharger, and sometimes may damage the tubocharger. Contact your local Shantui distributor for necessary check or cleaning. Do not use steel brush or similar things to do that, to avoid the pump impeller’s surface from being damaged.

4. Valve clearance

• Contact your local Shantui distributor to check the valve clearance, because this requires special tools.

4.1.7 EVERY 4000 HOURS SERVICE

Maintenance for every 250, 500, 1000, and 2000 hours service should be carried out at the same time.

1. Water pump

• Check pulley to see if it’s loose or if there is leakage of grease or water. If yes, contact your local Shantui distributor to repair or replace the water pump.

2. Fan pulley and tension wheel

• Check the wheels to see if they are loose or if there is leakage of grease. If yes, contact your local Shantui distributor to repair or replace the wheel assembly.

Figure 4-36

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4.1.8 MAINTENCE WHEN NEEDED

The following items should be checked and serviced when required depending on the result of visual inspection.

Air cleaner

1. Inspection:

• If the monitor lamp of the monitor’s air filter blinks, you should clean the air cleaner’s filter element. Stop the engine when doing the cleaning.

2. Clean or replace the outer filter element:

• Remove the butterfly-shaped nut (1) and the outer filter element (Figures 4-37 and 4-38), and clean the inside of the air cleaner’s housing. Clean and check the outer filter element (For the cleaning method, See the “Outer filter element cleaning method”). For every time the outer filter element is cleaned, tear off one letter sticker on the inner element’s label plate (Figure 4-39), and install the cleaned outer filter element.

• When the sealing gasket (2) or the butterfly-shaped nut (1) is damaged, they should be replaced. (Figure 4-38)

• Check the inner filter element’s mounting nut to see if it’s loose. If yes, tighten it.

3. Replace the inner filter element (when the outer filter element has been cleaned for 6 times or when the inner filter element is damaged)

• Remove the outer filter element first, and then remove the inner filter element. Cover the air intake. Clean the inside of the air cleaner’s housing, and remove the air intake’s cap.

• Install the new inner filter element to the connector, and then tighten it with nut. Install the outer filter element.

Figure 4-37

Label plate

Figure 4-38

Letter sticker

Figure 4-39

158

Figure 4-40

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CAUTION

• An outer filter element that has been cleaned for 6 times and has been used for 1 year should be replaced, and the inner filter element should also be replaced at the same time.

• Do not clean or replace the air cleaner’s element when the engine is running.

• Do not attempt to clean the inner filter element and use it again.

4. Outer filter element cleaning method a .Cleaning using the compressed air

• Use dry compressed air (less than 0.7Mpa) to blow the inside of the filter element directly along the pleat. Continue to directly blow it along the outer pleat, and then repeatedly blow the inner side. Finally check if the filter element is already clean.

b. Washing with water

• Use tap water (less than 0.3Mpa) to flush along the inner pleat of the filter element, and then flush along the outer pleat. Repeat this, and check after it is dry.

c. Using a cleaning agent

• In order to remove the grease and carbon black on the filter element, you can dip it in the lukewarm water containing a neutral cleaning agent to clean it, and then use clean water to rinse it.

Check after it is dry.

• Using dry compressed air (less than 0.7Mpa) to repeatedly blow it inside out can dry it more quickly.

• Do not heat it to dry it.

• Using lukewarm water (about 40°C) to replace soap water is also very effective.

• After cleaning and drying it, when checking it by dropping a lamp into the outer filter element, if you find that there are small holes or there are already some very thin parts, replace the outer filter element. (Figure 4-40)

• If the outer filter element can still be used, after dusting, keep it in a dry location.

• When cleaning the outer filter element, do not use other objects to knock or impact it.

• An outer filter element with an unevenly or deformed pleat or a damaged gasket cannot continue to be used.

CAUTION

• When using the compressed air, wear the safety glasses and other objects that can ensure safety.

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Clean the inside of the cooling system

1. Replace coolant, corrosion resistor and clean the inside of the cooling system according to the table below.

Kind of coolant

Permanent type antifreeze (All season type)

Non permanent type antifreeze containing ethylene glycol (winter, one season type)

Not using antifreeze

Cleaning inside of cooling system and changing coolant

Every year (autumn) or every

2000 hours, whichever comes first

Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn)

Every 6 months or every 1000 hours, whichever comes first

Replacing corrosion resistor

Every 1000 hours and when cleaning the inside of the cooling system or when changing coolant

• Stop the machine on level ground when cleaning or changing the coolant.

• Use a permanent type of antifreeze. If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.

• The corrosion resistor (water filter) must be replaced.

• The cooling water has to be the tap water used in cities. When diluting the coolant, use distilled water or tap water (soft water). Natural water, such as river water or underground water (hard water), contains a large amount of minerals (calcium, magnesium etc), and is easy to form water scale inside the engine or the radiator. Once scale accumulates in the engine or the radiator, it’s very hard to be removed. We recommend you to use water less than 100PPM.

• The ratio of antifreeze to water depends on the ambient temperature. When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below.

• It is actually better to estimate a temperature about 10°C lower when deciding the mixing rate.

• The ratio of antifreeze to water during the transportation of the machine should be determined according to a temperature about 20°C lower than the expected lowest temperature during the transportation. (If you cannot make an estimate, please mix them at the biggest ratio, or if the conditions cannot be met, drain all the coolant, and re-add it as required before operation).

The blending ratios of water and antifreeze are shown in the table below:

Min. atmospheric temperature °C

Amount of antifreeze %

Amount of water

%

Above

-10

30

70

-15

36

64

-20

41

59

-25

46

54

-30

50

50

-35

54

46

-40

58

42

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2. Clean the cooling system

• Turn off the engine, and shut down the corrosion resistor’s valves for water to get in and out.

• Slowly rotate the radiator’s cap until it is open. (Figure 4-41)

• When removing the radiator’s cap, you must slowly rotate the cap, to release the pressure.

• Loose the water drain valve on the bottom of the water tank and the water drain valve on the two ends of the oil cooler, to drain the cooling water. (Figure 4-42)

• Close the water tank’s water drain valve and the water drain valve on the two ends of the oil cooler, and add clean water (tap water used in cities), until the water is added to the water intake’s edge. When the water reaches the water intake’s edge, let the engine idle, open the water tank’s water drain valve and the water drain valve on the two ends of the oil cooler, and continue to add clean water to the water tank, until the clean water continuously flows out from the water drain valve for 10min.

• When draining the water, adjust water flow, to ensure that the water added is equivalent to the water drained, and to keep the water tank full of water all the time. When the water becomes completely clean, stop the engine. Open the water drain valve and the water drain valve on the two ends of the oil cooler to drain the water, and then close the water drain valve and the water drain valve on the two ends of the oil cooler.

• Use the cleaning agent bought in the market to clean the cooling system. Follow the instructions of the cleaning agent.

CAUTION

• Antifreeze is flammable, so keep it away from flame.

• If the water temperature is high, don’t remove the cap, as hot water may spurt out.

Figure 4-41

Figure 4-42

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3. Add the coolant

• After washing the cooling system, drain the water completely, and then turn on the water drain valve, and slowly inject the tap water until there is water at the edge of the water intake. When water reaches the edge of the water intake, let the engine idle and turn on the water drain valve while continuing to inject clear water into the radiator until clear water flows out from the water drain valve.

• When draining the water, adjust water flow, to ensure that the water added is equivalent to the water drained, and to keep the water tank full of water all the time. When the water becomes completely clean, stop the engine, turn off all water drain valves. Replace corrosion resistor’s filter and open its water inlet/outlet valve.

• Add water, until water overflows from the water intake.

• Let the engine idle for 5min, and then run at an intermediate speed for 5min, to exhaust the air accumulated in the cooling system. (During operation, open the radiator’s cap).

After the engine has stopped running, wait for 3min, add coolant, until it reaches the required level, and then tighten the cap.

► For the replacing corrosion resistor, see “Maintenance for

Every 1000 Hours”.

Track tension

1. Inspection

• Stop the machine on level ground (stop with the transmission in FORWARD without applying the brake). Then place a straight bar on the track shoes between the carrier roller and the idler (Figure 4-43), and measure the clearance between the bar and the grouser at the midpoint. If the clearance is 30 to 40mm, the tension is standard.

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Figure 4-43

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2. Adjustment

• In order to increase tension, pump in grease through the grease fitting with a grease pump (Figure 4-44). On the other hand, in order to loosen tension, slowly rotate the plug in the opposite direction for one turn, to squeeze out the grease. If pump in the grease until S is 0mm (Figure 4-45), and the tension is still loose, this shows that the bushing is seriously worn and thinned. Contact your local Shantui distributor to repair or replace the track.

• If the plug or other parts are made too loose, due to the high pressure from pumping in the grease, the parts are easy to fly out. If the grease cannot be pumped in smoothly, move the vehicle forward and backward for a distance.

CAUTION

• When loosening the plug, do not do it by more than an entire turn. Also, do not loosen any other parts except for the plug.

Check and tighten track shoe bolts

• If the machine is used with track shoe bolts being loose, they will break, so tighten any loose bolts immediately.

Tighten to a tightening torque of 1078±98N•m

Turn or Replace the end bit and the cutting edge (Figure

4-46)

• Before the end bit and the cutting edge is worn to the edge of the blade, turn the cutting edge over and replace the end bit. If both sides of the cutting edge are worn, replace the cutting edge. Raise the blade to a suitable height, put the block beneath the push rod, to prevent the blade from falling down. Remove the end bit and the cutting edge, and clean the mounting face. Replace the new end bit, turn over the cutting edge (or change a new one), and tighten with nuts.

• Tightening torque: 859±139N•m. After operating for a few hours, tighten the nuts.

Figure 4-44

Figure 4-45 s

Figure 4-46

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4.1.9 LUBRICATION DIAGRAM AND LUBRICATION TABLE

THE SD32 BULLDOZER’S LUBRICATION DIAGRAM:

MAINTENANCE | MAINTENNANCE

24

10

9

3 11

2

25

15 14

16

23

18

22

17

4

3

20

21

1

19

6

12

7

8

5

164

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

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LUBRICATION TABLE (THE SD32 SERIES BULLDOZERS)

No.

Parts to be lubricated

1 Oil pan

2 Steering case

3 Fuel filter

4 Bypass filter

5 Engine’s pulley axle

6 Cooling fan’s axle

7 Engine oil filter

8

Corrosion resistor’s filter element

9 Screw

10 Oil cylinder’s supporting shaft

11 Ball Joint

12 Oblique oil cylinder’s ball joint

13

Ball joint of the Blade’s oil cylinder

14 Gearshift’s oil filter element

15 Steering oil filter element

16 Ripper oil cylinder’s pin

17 Hydraulic tank

18 Final drive case

19

Hydraulic torque converter’s main shaft

20 Universal joint

21

22

The bushing of the Idler’s tensioning oil cylinder

Hydraulic tank’s oil filter element

23 Diagonal brace

24 Equalizer bar’s pin

25 Brake pedal’s shaft

1

2

2

2

8

5

1

2

1

1

1

2

Number of points Lubricants

1

1

2

1

2

1

1

Lubricant

Lubricant

—

—

Lubricating grease

Lubricating grease

—

Lubrication cycles (hours)

Add oil after 10 hours, and replace 23 liters after 250 hours

Add oil after 10 hours, and replace 136 liters after 1000 hours

Replacing it every 250 hours

Replacing it every 250 hours

Add oil after 250 hours

Add oil after 250 hours

Replacing it every 250 hours

12

1

2

1

1

6

—

Lubricating grease

Lubricating grease

Lubricating grease

Lubricating grease

Lubricating grease

—

—

Lubricating grease

Lubricant

Replacing it every 250 hours

Add oil after 250 hours

Add oil after 250 hours

Add oil after 250 hours

Add oil after 250 hours

Add oil after 250 hours

Replacing it every 250 hours

Replacing it every 250 hours

Lubricant

Lubricating grease

Lubricating grease

Lubricating grease

—

Lubricating grease

Lubricating grease

Lubricating grease

Add oil after 250 hours

Add oil after 250 hours, and replace 103 liters after 1000 hours

Add oil after 250 hours, and replace 55 liters after 1000 hours

Add oil after 1000 hours

Add oil after 1000 hours

Add oil after 1000 hours

Replacing it every 1000 hours

Add oil after 1000 hours

Add oil after 1000 hours

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

165

4.1.10 ADJUSTMENT OF VARIOUS PARTS

Adjusting the brake pedal

1. Inspection

• When the brake lining is worn, the stroke of the steering pedal will increase to make steering difficult. When the stroke is over 150mm (when the braking force is reduced), make adjustment as follows: standard stroke: 95-115mm

(when the engine is idling and the operation force is 150N)

Figure 4-47); 66mm (the stroke when the engine is not running).

2. Adjustment

• Remove the rear cover and the inspection cover. Tighten the adjusting bolt until the tightening torque is 50N.m, to make the lining and the braking drum in close contact (step down the braking pedal to confirm the contact condition).

And then, rotate the adjusting bolt for 7/6 turns in the opposite direction. The stroke of the two brake pedals should be made the same, or the brake flexibility of the two sides will not be the same. If the size of the adjusting bolt, is less than 127mm, please contact your local Shantui dealer to get the new brake lining.

Idler

If the idler is forced to rotate for a long time, the guide plates on the side, on the top and on the bottom as well as the directing plate will gradually become worn, causing the idler to swing left and right, or the track’s links will get out of the idler because the idler becomes tilted, or the idler and the links will become unevenly worn. Therefore, you must adjust the idler whenever it’s necessary according to the following procedure, to enable it to be in a good operational state.

1. Adjusting the guide plates on the side(Figures 4-48)

• Drive the machine for 1-2m on a level ground, to tighten the track evenly, and then stop the vehicle. Check the clearance “A” between the side guide plate and the track frame

(the guide plate on each side has 4 clearances: left, right, top, and bottom).

• If any of the clearances is over 4mm, loosen bolt (1), remove certain number of shims (2), and then adjust the clearances to the standard values: 0.5~1.0mm. The shim’s thickness is 0.5~1.0mm.

• When loosening the bolt (1), be sure not to rotate the bolt for more than 3 turns.

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95-1

15mm

Figure 4-47

166

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

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2. Adjusting the directing plates (4) and the top & bottom guide plates (6) (Figures 4-48)

• Measure the clearance “B” between the track frame’s upper wearing plate (3) and the directing plate (4) as well as the clearance “C” between the top & bottom guide plates (6) and the track frame’s wearing plate. If the sum of the two clearances “B” and “C” is over 5mm, reduce it to

2mm. The method is to pull out shim (7), to reduce it to the required thickness, and add a shim of the same thickness to shim (8). Such adjustment can be completed using the following procedure.

• It is normal if clearance “C” is 0mm. Measure clearance “B” and minus 2mm from the value of “B” to get the shim’s thickness (for example, if B=5mm, then the adjusting shim’s thickness should be

5-2=3mm). Shims (7) and (8) can be shims that can be pulled out.

• Loosen bolt (9) (there are a total of 4 bolts inside and outside) until you can’t feel the force of the spring.

• Loosen bolt (1). Be sure not to rotate the bolt for more than 3 turns.

• Use a stick to adjust guide frame (5) upward, to make clearance “C” 0mm. Remove shim (7) according to the required shim’s thickness determined in the first step. Add shim (7) to shim (8)

(you need to complete this process for 8 places: the inside and outside of the left and right guide plates as well as the front and back of each side. Before and after the adjustment, the total thickness of shim (7) and shim (8) combined remains the same. If the total thickness of the two shims is increased or decreased due to carelessness, the preload of the spring installed within the guiding device will become inappropriate. Shim (7) and shim (8) are consisted of several pieces of two types of shims: the 1mm shim and the 2mm shim. Tighten the spring seat’s bolt (9). The tightening torque of bolt (1) is 675~845Nm. The maximum adjustment allowed for the top & bottom guide plate is 6mm.

5

9

7

8

2

1

4

A

C

B

3

6

Figure 4-48

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167

Fan belt

Because fan belt has an automatic tension device, its tension always remains constant and has nothing to do with the V-belt.

The belt does not need to be adjusted until it is damaged. But when replacing the old belt with a new one, you should check if size “A” is 113±5mm (Figure 4-49), and when its value is not within this range, it should be adjusted. When changing the Vbelt, you should change both belts at the same time.

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A

Figure 4-49

Walking parts

The check and adjustment of track tension: For rocky areas, the track should be slightly tighter. For areas with clay and sandy soil, the track should be a little bit loose (See “Maintenance when needed” for check and adjustment methods).

1. Measuring height of grouser

• Take a tight track shoe and measure the height of grouser.

(Figures 4-50 and 4-51)

Standard height (H): 80mm

Repair limits (H):25mm

H

Figure 4-50

Figure 4-51

168

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

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2. Measuring outside diameter of track roller (Figure 4-52)

• Measure the dimensions (size C and B) of link tread as shown. Calculate outside diameter of track roller (Size A):

A=(B-C)X2

Standard size (A): 255mm

Repair limits (A):229mm

Figure 4-52

Adjustment of blade (See “Chapter 3, Bulldozing Operation”)

1. Adjustment of the ripper’s ripping depth (Figure 4-53)

• Use the two pin holes on the ripper shank to make the adjustment, and generally the hole on the bottom is used.

When you need to increase the ripping depth, use the upper hole. You can point an iron rod with a sharp end to pin

(1) and hit it with a hammer, and then pull out pin (2), to change the mounting hole’s position of the tooth angle (top or bottom).

2. The replacement of the ripper tooth tip and the guard plate after being worn (Figure 4-54)

• After the ripper tooth tip and the guard plate ripper are worn, when replacing them, use a hammer to knock out the pins in the figure. You can switch the three tooth tips according to their wear level, to extend their service life.

Figure 4-53

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

Figure 4-54

169

MAINTENANCE | MAINTENNANCE

4.1.11 SERVICE STANDARDS FOR MAIN PARTS

HYDRAULIC TORQUE CONVERTER

15

1

14

11

10

5 6

12

3

4

2

170

7

8

9

13

Figure 4-55

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No.

1

2

3

4

5

6

7

8

9

Items to be checked

Standard size

The outer diameter of the guider’s neck

The outer diameter of the contact surface of the shaft coupling’s oil seal

The inner diameter of the contact surface of the gear sealing ring

The inner diameter of the sealing ring’s contact surface of the guide roller’s axle

The sealing ring of the guide roller’s axle

78

80

150

65

Width: 4.5;

Thickness: 5.5

Width: 2.5;

Thickness: 2.7

The sealing ring of the turbine shaft

The clearance between the oil scavenger pump’s driving gear and pump impeller

Oil scavenger pump’s axial clearance

Oil scavenger pump’s radial clearance

—

—

—

Standard clearance

—

—

—

—

—

—

0.16~0.43

0.13

0.15

Repair limit

77.75

77.9

150.3

65.1

Width: 3.0;

Thickness:

5.0

Width: 2.0;

Thickness:

2.5

0.50

0.25

0.30

Unit: mm

Measures

Chrome plating or replacing

Changing

10 Tightening torque 55±5N. m

11 Tightening torque

12 Tightening torque

70±5N. m

115±10N. m

Adjustment 13 Tightening torque

14 Tightening torque

15 Tightening torque

16

Torque converter’s stalled speed

12±1N. m

115±10N. m

95±5N. m

1600±5rpm

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171

2

3

MAINTENANCE | MAINTENNANCE

TRANSMISSION CASE

4

9

6 8

4

8 6

6

8

4

1 8

6

4 1

10

7

1

5

11

12

13

Figure 4-56

172

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

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No.

1

2

3

4

5

6

7

8

9

10

11

12

13

Items to be checked

The clearance between the

No.1, No.3 and No.4 sun wheels and the planetary gear

The clearance between the

No.2 sun wheel and the planetary gear

The clearance between the

No.2 planetary gear and the planetary gear

The clearance between the gear ring and the planetary gear

The tooth clearance of the output gear

The thickness of the driven plate of clutches numbers 1 through 4

The thickness of the No.5 clutch’s driven plate

The thickness of the drive plate of clutches numbers 1 through 4

Thickness of the No.1 clutch’s plate

The thickness of the No.5 clutch’s drive plate

The spring of the No.1 clutch

The spring of the No.2 clutch

The spring of the No.3 and

No.4 clutches

Basic size

—

—

—

—

—

5.4

5.4

7.0

5.4

5.0

Free length 83.5

Installation load

117N

Free length 66

Installation load

Free length

Installation load

133N

59

130N

Unit: mm

Standard clearance

Application limit

Treatment methods

0.14~0.37

0.13~0.34

0.13~0.34

0.16~0.48

0.21~0.51

—

—

—

—

—

—

—

—

0.75

0.75

0.75

0.75

0.75

4.6

4.6

6.2

4.6

4.2

78.5

105N

62

120N

55.5

120N

Replacing

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173

MAINTENANCE | MAINTENNANCE

TRANSMISSION VALVE

13

1

1

2

3

19

15

14

16

17

5

Profile A-A

8

9

18

7

6

4

Figure 4-57

174

10

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

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No. Items to be checked

1

2

The clearance between the direction valve/the speed value and the valve body

The clearance between the safety valve and valve body

3

4

5

6

7

8

9

10

The clearance between the safety valve and the piston

The clearance between the fast return valve and valve body

The clearance between the pressure relief valve and valve body

The clearance between the pressure relief valve and the piston

The clearance between the pressure-adjusting valve and valve body

The clearance between the pressure-adjusting valve and the pressure relief valve

The clearance between the pressure relief valve and the piston

The clearance between the lubricating valve and valve body

Pressure of the No.1 through

No.4 clutches

11

No.5 clutche’s pressure

12

Transmission case’s lubricating oil pressure

13

14

15

16

Safety valve’s spring

The pressure-adjusting valve’s spring

The pressure-adjusting valve’s spring (big)

The pressure-adjusting valve’s spring (small)

17 Pressure relief valve’s spring

18

19

Slide valve plug’s spring

Lubricating valve’s spring

0.124 MPa

Free length

Installation load

Free length

Installation load

79

14.1N

53

86.5N

Free length 42.4

Installation

35N load

Free length 41.5

Installation load

35N

52 Free length

Installation load

134N

Free length 59.5

Installation load

Free length

Installation load

91N

87

76N

—

—

—

—

—

—

—

Unit: mm

Basic size

28

28

20

12

28

Standard clearance

0.035~

0.058

0.035~

0.058

0.020~

0.051

0.035~

0.056

0.035~

0.058

Application limit

Treatment methods

0.064

0.064

0.056

0.062

0.064

15

0.035~

0.048

0.053

35

25

0.035~

0.058

0.035~

0.058

0.064

0.064

15

28

0.020~

0.048

0.035~

0.058

Engine’s low idle 1.6-2 MPa

Engine’s high idle 2-2.5 MPa

0.053

0.01

Replacing

1.25 MPa

75.8

13.4N

51.2

77.9N

42.1

31.5N

41.4

31.5N

51.2

121N

59.8

82N

84.5

68N

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

175

CENTRAL DRIVE

MAINTENANCE | MAINTENNANCE

4

3

1

2

5

9

Figure 4-58

6

7

8

176

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No.

1

2

Items to be checked

Bevel gear’s back jump

Preload of the tapered roller bearing

3 Bevel gear’s side clearance

4 The match of bevel gear’s bolt

5

The inner diameter of the contact surface of the bearing support’s sealing ring

The width of the sealing ring

6

The width of the sealing trough

Unit: mm

Basic size

Standard clearance Application limit

— —

0.05 (Measured by being installed behind the cross shaft)

2-6kg

(Measuring at the end based on the big bevel gear)

Treatment methods

Replacing

Adjustment

— 0.25~0.33

0.75

Adjust and replace

0~0.045

145

4.5

4.5

—

—

145.3

4.0

5.0

Replacing

7

8

The press-in force of the coned splint

300~400KN

(30~40T)

The size of the central drive shaft after being pressed in

5-6.5

9 Tightening torque 700±50N.m

—

—

—

—

—

—

Adjustment

10

The perpendicularity of the hub to the cross shaft

11 The hub-hub coaxiality

—

—

—

—

0.15

0.15

12

Oil drain plug’s tightening torque

130-180 N.m

—

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177

STEERING CLUTCH

1

2

5

6

MAINTENANCE | MAINTENNANCE

9

7

8

6

3

4

Figure 4-59

178

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No.

Items to be checked Basic size

Unit: mm

Standard clearance

Application limit

Treatment methods

The thickness of the drive tooth piece

2.9

—

1

The unevenness of the drive tooth piece

Below 0.20

—

The thickness of the driven tooth piece

4.7

2

3

4

5

6

7

8

9

The unevenness of the driven tooth piece

The thickness of the assembly of the drive tooth piece and the driven tooth piece

The tooth clearance between the drive tooth piece and the inner hub

The tooth clearance between the driven tooth piece and the outer hub

The inner diameter of the inner hub and the sealing ring’s contact

The clearance between the sealing ring’s groove and sealing ring

Spring (big)

Spring (small)

The diameter of the outer hub

Below 0.20

88.3

—

—

245

—

Free length 145.15

Installation load

2430N

Free length 137.83

Installation load

1388N

450

—

—

—

0.3~0.4

0.3~0.4

0.07~0.18

—

—

—

2.0

0.3

3.7

0.3

81.6

1.0

1.0

245.5

0.4

141

2291N

134

1320N

445

Replacing

10 The brake drum’s end jump Below 0.30

— 0.5

11 The brake drum’s coaxiality Below 0.15

— 0.3

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STEERING CONTROL VALVE

MAINTENANCE | MAINTENNANCE

20

Profile B-B

19

Figure 4-60

17

Profile A-A

17

18

16

180

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No.

Items to be checked Specifications

1

2

3

4

5

6

7

8

The clearance between valve body and valve core

Standard size

26

The clearance between the valve core and the piston

The clearance between valve stem and valve body

The clearance between brake valve and valve body

The clearance between brake valve and piston

The clearance between the control lever and the bushing

The clearance between the control lever and the bushing

10

26

16

9

22

18

Axle reset spring

Tolerance

Shaft

-0.035

-0.045

-0.030

-0.040

-0.035

-0.045

-0.030

-0.035

-0.030

-0.040

+0.023

+0.002

+0.019

+0.001

Hole

+0.013

0

+0.015

0

+0.013

0

+0.018

0

+0.015

0

+0.170

+0.086

+0.156

+0.086

Free length

36

Standard size

Installation length

27.2

Installation load

6.02kg

Standard clearance

0.035~

0.058

0.030~

0.055

0.035~

0.058

0.030~

0.053

0.030~

0.055

0.068~

0.168

0.067~

0.155

Allowable limit

0.08

0.08

0.08

0.08

0.08

0.2

0.2

Repair limit

Free length

Load

35.3

5.7kg

9 Steering valve spring 62 15.3

3.5kg

60.9

3.2kg

10

Steering valve reset spring

11 Steering valve spring

12

13

14

15

Brake adjusting spring

Brake valve reset spring

Brake valve reset spring

Brake valve’s action trip

91.6

55

28.5

50.5

90

25

20.0

25.5

14

27

4.53kg

3.61kg

3.0kg

2.36kg

4.48kg

15.8

90.6

54

27.4

49.5

88.5

4.3kg

3.3kg

2.8kg

2.2kg

4.15kg

Unit: mm

Measures

Replacing

Adjustment

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181

MAINTENANCE | MAINTENNANCE

BRAKE

182

118±7N·m

9

118±7N·m

7

4

6

5

2

3

1

Figure 4-61

118±7N·m

8

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No.

1

2

3

Items to be checked

The thickness of the brake lining and the brake band

The thickness of the brake lining

The clearance between brake band and brake drum

4 Brake band’s adjusting bolt

5

6

7

8

9

The clearance between the valve body and the piston

The clearance between the shaft and the sleeve

Safety valve’s spring

The pressure-adjusting valve’s spring

Servo motor valve’s reset spring

Basic size

15.5

9.5

Tighten it to 50N.m, and then turn it back 7/6 circles

80 0.03-0.079

0.2

25

Free length 78.3

Installation load

200N

Free length 42.4

Installation load

45.4N

Free length

Installation load

89

100N

Unit: mm

Standard clearance

Application limit

Treatment methods

0.3

—

—

0.048-

0.017

—

—

—

—

—

—

11.5

4.7

0.1

82

160N

43.4

36N

85.9

90N

Replacing

Adjustment

Replacing

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183

MAINTENANCE | MAINTENNANCE

STEERING MAIN RELIEF VALVE

3

1 2

A

A

Profile A-A

Figure 4-62

No.

Items to be checked Basic size

Standard clearance

Unit: mm

Application limit

Treatment methods

1

2

3

The clearance between the valve and the valve body

The clearance between the valve and the piston

Main relief valve’s spring

28

15

Free length 48.9

Installation load

192N

0.014-0.036

0.020-0.048

—

—

0.08

0.08

48

182N

Replacing

184

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SAFETY VALVE, PRESSURE-ADJUSTING VALVE

1

2

1

3

Figure 4-63

No.

1

Items to be checked

The clearance between valve body and slide valve

Safety valve’s spring

2

3

Safety valve’s set value

The pressure-adjusting valve’s spring

Pressure-adjusting valve’ set value

Basic size

Standard clearance

Application limit

3.2

0.05~0.091

0.20

Free length 137.7

Installation load

635N

—

134.2

579N

0.84-0.86MPa Oil temperature 75±5°C

Free length 126.6

Installation load

209N

—

120

140N

0.2-0.55MPa Oil temperature 75±5°C

Unit: mm

Treatment methods

Replacing

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185

MAINTENANCE | MAINTENNANCE

FINAL DRIVE

17

18

1200±100N·m

16

11

15

283±32N·m

1750±250N·m

12

2

180±20N·m

19

14

900±50N·m

4 10

285±30N·m

3

6

393±42N·m

7

700±50N·m

13

8

9 5

113±12N·m

113±12N·m

1

560±60N·m

945±105N·m

Figure 4-64

186

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | MAINTENANCE

No.

1

2

3

4

5

Items to be checked

The clearance between the half shaft and the bushing

The clearance between the half shafts out bushing and spacer

Primary gear’s engagement backlash

Secondary gear’s engagement backlash

The outer diameter of the flange at the oil seal’s contact

6 Press-in force

7

Sizes of the primary gear’s shaft shoulder and steps within the flange

8 The flange’s end jump

Basic size

90

140

—

—

120

Standard clearance

0.036~0.106

0.105~0.288

0.27~0.68

0.31~0.82

—

Application limit

Unit: mm

Treatment methods

0.5

Replacing

Bushing

0.5

300 ~ 400KN (30 ~ 40t)

1.5

1.5

119.9

-0.5-+1.0 (+ indicates that the shaft shoulder protrudes)

0.08 (Max.)

9 The flange’s radial jump

10

11

12

The press-fit force of the primary big gear

The press-fit force of the sprocket hub

Size of the sprocket hub after being pressed in

13 The press-fit force of the half shaft

0.08 (Max.)

70 ~ 210KN (7 ~ 21t)

700 ~ 800KN (70 ~ 80t)

39~41

14 Dust cover clearance

15

The clearance between the sprocket hub’s nut and the support

16 Diameter of the sprocket’s tooth top

17

Diameter of the sprocket’s tooth bottom

18 Width of the sprocket’s tooth top

1011

912.15

83

150 ~ 410KN (15 ~ 41t)

4.3±1.0

3.4±1.2

—

—

—

—

—

75

19 Width of the sprocket’s tooth bottom 103 — 95

Replacing

Adjustment

Repairing and changing

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187

TRACK

1. TRACK FRAME

MAINTENANCE | MAINTENNANCE

3

5

4

Figure 4-65

3

4

5

No.

1

2

Items to be checked

Horizontal deformation

Deformation of track frame

Twisted

The place where the idler is installed is outwardly opened

The distance between the center of the left track frame and the center of the right track frame

The clearance between the half shaft and the bushing

The tightening torque of the bolt of the track roller’s guard plate

The tightening torque of the spacer sleeve’s bolt

188

Basic size

—

—

—

2000

90

Standard clearance

—

—

Application limit

7/300

3/300

—

—

0.036~0.106

840-1050N. m

5

The front and back difference is smaller than

15

0.5

840-1050N. m

Unit: mm

Treatment methods

Repairing and changing

Adjustment

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MAINTENNANCE | MAINTENANCE

2. TRACK TENSION DEVICE

A

2

1

1

4

3

5

Profile A-A

Figure 4-66

3

4

No.

1

2

5

Items to be checked

Buffering spring (big)

Buffering spring (small)

The clearance between oil cylinder and bushing

Tension rod assembly’s press-in force

The clearance between control seat and nut

Oil nozzle’s tightening torque

Basic size

Free length

Installation load

Free length

Installation load

130

1008

222000N

693.5

70000N

Standard clearance

—

—

0.036~0.160

Unit: mm

Application limit

985

Treatment methods

200000N

675

62600N

Replacing

0.5

400KN (40t)

10

50±2.5 N. m

Adjustment

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

189

3. IDLER

MAINTENANCE | MAINTENNANCE

190

Figure 4-67

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | MAINTENANCE

No.

Items to be checked

1 Idler’s outer diameter

2

Roller track surface’s outer diameter

3 Width of the raised part

Basic size

850

Standard clearance

Application limit

Unit: mm

Treatment methods

— —

800

120

—

—

781

Repairing through overlay welding or replacing

4 Width of the roller track 60 — 69

240

20

—

—

5 Overall width

6 Shaft collar’s width

7

8

9

10

11

The clearance between the shaft and the dual-metal bushing

The interference between the idler and the bushing

The axial clearance of the idler’s axle

The clearance between the sliding plate and the bracket

The clearance between the side guide and the bracket

12 Tightening torque

13 Amount of oil added

85

135

—

—

—

0.43~0.51

-0.02~-

0.180

0.51~0.74

2

0.5~1.0

210±5N.m

-0.30

390-450ml (SAE85W-140)

19

1.5

1.5

3

Replacing

Adjustment

Add oil

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

191

MAINTENANCE | MAINTENNANCE

4. SINGLE FLANGE TRACK ROLLER, DOUBLE FLANGE TRACK ROLLER

15

12

192

3 2 1

Figure 4-68

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | MAINTENANCE

No.

1

2

Items to be checked

The outer diameter of the track roller

The outer diameter of the track roller

3 Roller track surface’s diameter

4 Overall width

5

6

7

8

9

The width of the roller track of the single flange track roller

The width of the roller track of the double flange track roller

The width of the raised shoulder of the single flange track roller

The width of the raised shoulder of the double flange track roller

The width of the raised shoulder of the double flange track roller

10 Shaft collar’s width

11

12

13

The clearance between the shaft and the dual-metal bushing

The interference between the bushing and the track roller

The axial clearance of the track roller’s axle

14 Track roller’s mounting bolt

Basic size

298

Standard clearance

Application limit

Unit: mm

Treatment methods

— —

282

255

292

65

62

24

24

22

20

85

135

—

—

—

—

—

—

—

—

—

0.43~0.515

-0.017~-

0.130

0.50~0.76

—

230

74

80

15

15

13

19

1.0

-0.30

1.5

Repairing through overlay welding or replacing

Replacing

840-1040N.m

210±5N.m

Adjustment

15 Oil filler plug’s tightening torque

16 Amount of oil added 390-450ml (SAE85W-140) Add oil

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

193

5. CARRIER ROLLER

MAINTENANCE | MAINTENNANCE

Figure 4-69

No.

1

2

Items to be checked

The outer diameter of the carrier roller

The outer diameter of the roller track

3 The width of the raised shoulder

4 The width of the roller track

5

The axial clearance of the carrier roller

6 Tightening torque

7 Tightening torque

8 Amount of oil added

Basic size

220

190

21

63

Standard clearance

—

—

—

Application

—

0.10~0.13

560±60N.m

210±50N.m

630-720ml (SAE85W-140)

limit

—

171

14

72

0.2

Unit: mm

Treatment methods

Repairing through overlay welding or replacing

Adjusting or

Replacing

Adjustment

194

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6. END BIT AND CUTTING EDGE

Figure 4-70

No.

Items to be checked

1 The cutting edge’s height

2 The height of end bit’s outer side

3 The height of end bit’s inner side

4 End bit’s width

5 Tightening torque

Basic size

254

315

254

540

Standard clearance

—

—

—

Application limit

213 (After rotation:175)

235

Unit: mm

Treatment methods

Replacing

215

— 440

753-1019N.m

Adjustment

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

195

7. TRACK

MAINTENANCE | MAINTENNANCE

Figure 4-71

196

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | MAINTENANCE

No.

1

2

3

Items to be checked

Track link

Grouser’s height

Track link’s height

Basic size

228.6

80

138

Standard clearance

—

—

—

Unit: mm

Application limit

Treatment methods

233.85

Inverting or

Replacing

30

125

Repair through build-up soldering or replace

4 Bushing’s outer diameter

5

6

7

8

The clearance between the pin and the bushing

The clearance between the master pin and the bushing

The interference between the bushing and the track link

The interference between the pin and the track link

9

The interference between the master pin and the track link

10

The clearance of the track link’s joint surface

11 Tightening torque

79

—

—

77

48.5

48.5

—

—

0.230~0.830

0.430~0.930

-0.230~-0.344

-0.272~-0.434

-0.138~-0.230

One-sided 0~1.4

Two-sided 0~2.8

1000-1200N.m

74

—

—

-0.1

-0.14

-0.08

8

Replacing

Adjustment

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197

MAINTENANCE | MAINTENNANCE

STRAIGHT TILT BLADE

1. BLADE

G

F

E

D

C

A

B

H

8

9

11

12

13

198

Detail A

Detail E

10

Detail B Detail C

6

5

Detail D

7

2

1

4

Detail H

Detail F

Figure 4-72

3

Detail G

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MAINTENNANCE | MAINTENANCE

No.

Items to be checked

1

2

3

4

5

6

7

The clearance between the seat and the spherical head

The clearance between the pin and the blade rack’s connector

The clearance between the push rod’s pin and the connector

The clearance between the connector and the blade rack

The clearance between the pin and the seat

The clearance between the pin and the screw

The clearance between the spherical head and the seat

8

9

The clearance between the arm’s pin and the blade’s bracket

The clearance between arm pin and arm rod

10

The clearance between the lift cylinder’s pin and the bracket

11

The clearance between the lift cylinder yoke and the bushing

12

12

The clearance between the lift cylinder yoke and the bushing

The clearance between the lift cylinder’s supporting shaft and the bushing

Basic size

Standard clearance

Application limit

Unit: mm

Treatment methods

160

70

70

140

60

60

115

60

60

50

125

100

85

0.5~0.15

0.5~0.9

0.5~0.9

0.5~1.5

0.5~1.0

0.6~1.0

0.2~0.6

0.5~1.0

0.6~1.0

0.3~0.8

10

3

3

3

2

2

1

2

2

2

0.5

0.5

0.5

Replacing

Adjustment

Replacing

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199

MAINTENANCE | MAINTENNANCE

2. TRIPLE-SHANK RIPPER

2

2

2

3 4

2

1

4

1

2

6

5 6 7

8

5

7

Figure 4-73

No.

1

2

3

4

5

Items to be checked

The clearance between the mounting pin and the bushing

The clearance between hydraulic cylinder and mounting pin

The clearance between shank and mounting pin

The clearance between connecting frame and mounting pin

The clearance between guard plate and mounting pin

6 The wearing of the tooth tip

Basic size

110

Standard clearance

0.156-0.297

Application limit

1.5

Unit: mm

Treatment methods

110

—

—

—

335

0.156-0.297

3.7-6.3

0.4-1.6

0.3-0.85

—

1.5

15

10

225

Replacing

7 The wearing of the guard plate

8 Tighten the ripper’s mounting bolt

115 —

3600-4400N. m

90

Adjustment

200

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MAINTENNANCE | MAINTENANCE

3. SINGLE-SHANK RIPPER

2

2

2

2

3

4

3 4

1

1

1

5 6 7

6

8

5

7

Figure 4-74

No.

1

2

3

4

5

Items to be checked

The clearance between the mounting pin and the bushing

The clearance between hydraulic cylinder and mounting pin

The clearance between shank and mounting pin

The clearance between connecting frame and mounting pin

The clearance between guard plate and mounting pin

Basic size

110

110

—

—

—

Standard clearance

0.156-0.297

0.156-0.297

6.7-9.3

1.4-2.6

0.3-0.85

Application limit

Unit: mm

Treatment methods

1.5

1.5

15

10 Replacing

6 The wearing of the tooth tip 335 — 225

115 90 7 The wearing of the guard plate

8 Tighten the ripper’s mounting bolt

—

3600-4400N. m Adjustment

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

201

MAINTENANCE | MAINTENNANCE

4.1.12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

CAUTION

• If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation.

• Always pay careful attention when tightening parts.

TORQUE LIST

1. Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.

• If it is necessary to replace any nut or bolt, always use a Shantui genuine part of the same size as the part that was replaced.

Width across flats (b)

(mm)

36

41

46

50

24

27

30

32

55

60

10

13

17

19

22

Thread diameter of bolt (a)

(mm)

24

27

30

33

16

18

20

22

36

39

10

12

14

6

8

260

360

510

688

Target value

N.m

kgf.m

ibft

13.2

1.35

9.8

31

66

113

172

3.2

6.7

11.5

17.5

23.1

48.5

83.2

126.6

26.5

37

52.3

70.3

191.7

267.6

378.3

508.5

Specifications

N.m

11.8-14.7

Torque range kgf.m

1.2-1.5

27-34

59-74

98-123

153-190

2.8-3.5

6.0-7.5

10.0-12.5

15.5-19.5

235-258

320-400

455-565

610-765

23.5-29.5

33.0-41.0

46.5-58.5

62.5-78.0

ibft

8.7-10.8

20.3-25.3

43.4-54.2

72.3-90.4

112.1-141

170.0-213.4

238.7-296.6

336.3-419.5

452.1-564.2

883 90 651 785-980 80.0-100.0

578.6-723.3

1295 132.5

958.4

1150-1440 118.0-147.0

853.5-1063.3

1720 175.0

1265.8

1520-1910 155.0-195.0 1121.1-1410.4

2210 225.0

1627.4

1960-2450 200.0-250.0 1446.6-1808.3

2750 280.0

2025.2

2450-3040 250.0-310.0 1808.3-3242.2

3280 335.0

2423.1

2890-3630 295.0-370.0 2133.7-2676.2

202

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | MAINTENANCE

1. Tighten the hydraulic hoses according to the tightening torque in the table below

Thread diameter of bolt (a)(mm)

Width across flats

(b)(mm)

9/16-18UNF

11/16-16UN

13/16-16UN

1-14UNS

13/16-12UN

19

22

27

32

36

Target value

N.m

kgf.m

ibft

44 4.5

32.5

74

103

7.5

10.5

54.2

75.9

157

216

16

22

Specifications

N.m

35-63

54-93

84-132

Torque range kgf.m

3.5-6.5

5.5-9.5

8.5-13.5

ibft

25.3-47.0

39.8-68.7

61.5-97.6

115.7

128-186 13.0-19.0

94.0-137.4

159.1

177-245 18.0-25.0

130.2-180.8

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

203

TROUBLESHOOTING | MAINTENNANCE

4.2 TROUBLESHOOTING

Although not all the faults are included in this chapter, most common faults are included.

4.2.1 ENGINE

Engine oil pressure monitor flashes when engine speed is raised after completion of warm-up.

1. Add oil to specified level;

2. Replace engine oil filter element;

3. Check the tubes and connectors for oil leakage.

Steam is emitted from top part of radiator

(pressure valve).

1. Add cooling water, and check for water leakage;

2. Adjust fan belt’s tension;

3. Clean inside of cooling system;

4. Clean or repair the water tank’s radiation fin;

5. Replace thermostat.

6. Tighten radiator cap or replace its gasket.

Water temperature is higher than 100°C.

1. Replace thermostat;

2. Check water temperature sensor ;

3. Check water temperature gauge and water temperature sensor.

Engine does not start when starting motor is turned

1. Add fuel;

2. Check if air has entered the fuel system;

3. Calibrate or replace oil pump and oil nozzle;

4. Check valve clearance;

5. Run the starting motor at a low speed (See

ELECTRIC SYSTEM).

Exhaust gas is white or blue

1. Add oil to specified level;

2. Change to specified fuel;

3. Check supercharger for leakage.

Exhaust gas turns black

1. Clean or replace air filter;

2. Replace oil nozzle;

3. Clean or replace supercharger.

Abnormal noise generated (combustion or mechanical)

1. Change to specified fuel;

2. Check if the engine is overheated;

3. Replace muffler;

4. Adjust valve clearance.

204

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MAINTENNANCE | TROUBLESHOOTING

4.2.2 ELECTRIC SYSTEM

Lamp does not glow brightly even when the engine runs at high speed.

1. Check, repair loose terminals, disconnections;

2. Adjust engine belt tension.

When the engine runs at a high speed, voltmeter indicates not charging (not within the green zone)

1. Check generator;

2. Check and repair circuit.

Abnormal noise is generated from alternator

Replace generator.

Starting motor does not crank when ignition switch is turned ON.

1. Check and repair circuit and relay;

2. Charge the battery;

3. Replace starting motor.

Pinion of starting motor keeps going in and out

1. Charge the battery;

2. Replace starting motor.

Starting motor disengages before engine starts

1. Check and repair circuit ;

2. Charge the battery.

When the engine stops (starting switch is in the “ON” position, engine oil pressure gauge is 0.

1. Replace engine oil pressure sensor;

2. Check and repair circuit.

4.2.3 CHASSIS

Oil pressure in torque converter fails to rise

(the vehicle cannot start to move)

1. Check and repair oil pipes or connectors for air leakage;

2. Check or replace gear pump;

3. Add oil to transmission case;

4. Clean and replace transmission case’s filter.

The hydraulic torque converter is overheated

1. Tighten or replace fan belt.

2. See the ENGINE part.

3. Clean or replace oil cooler.

4. See the “Oil pressure in torque converter fails to rise” part.

The vehicle does not move when gear shift lever in any position

1. Add oil to the steering clutch case.

2. See the “Oil pressure in torque converter fails to rise” part.

3. Check or replace gear pump.

4. Clean oil filter.

When pull the steering lever on one side, the vehicle continues to move forward without steering.

• Adjust brake.

Machine doesn’t stop when brake pedal are depressed.

• Adjust brake.

Track comes off

• Sprocket is abnormally worn

• Adjust track tension

Blade rises too slowly or does not rise at all

• Add oil to the hydraulic tank

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

205

PRECAUT. FOR DISASSEMBLY & ASSEMBLY | MAINTENNANCE

4.3 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

4.3.1 DISASSEMBLY

1. Before disassembling bulldozer’s any part, read the manual carefully, so that you have a thorough understanding of the parts to be disassembled. Knowing the structure and role of various parts is an important factor in successfully performing the servicing.

2. During disassembly, pay adequate attention to the direction and position of every part. If necessary, make the identification marks. Meanwhile, pay attention to the sequence of removing various parts from the bulldozer, to ensure the correct installation of the parts.

3. Use special tools required. If you don’t have special tools, use similar ones. When ordinary tools can damage related parts in one way or another, you must use special tools.

4. Tapered or closely matched parts should be closely installed in their original places. If these parts are already loose, check their wear.

5. The removed parts should be cleaned and orderly put together. Measures should be taken so that they will not be covered by dust. Two types of cleaning liquids should be used: one for washing away the dirty things, and another for rinsing.

CAUTION

Filters, magnetic plugs and breather covers are all parts that you should pay special attention to when washing and cleaning them

206

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MAINTENNANCE | PRECAUT. FOR DISASSEMBLY & ASSEMBLY

4.3.2 ASSEMBLY

1. All the parts should be clean before being assembled. Replacement parts are usually covered with anti-rust agent, and you should wipe off the anti-rust agent first.

2. In most cases, the installation of bearings, bushing, oil seals and other similar parts should use the special installation tools. Using a hammer to directly knock a part into place is a bad habit.

Usually, you need to put a wood block or soft metal part beneath the part to be installed to transmit the impact from the hammer.

3. Spring washers, flat washers, tongue washers and cotter pins are all very important parts. But because of their small size, they are easy to be missed out during assembly. When installing fasteners such as bolts and nuts, check the tightening methods of these parts for compliance.

4. A torque wrench should be used in places where the torque limit is specified. When fixing covers or similar parts with many bolts (such as valve body etc), tighten the bolt symmetrically and gradually, to let the pressure be evenly distributed.

5. The matching markings are not the identification markings for parts that go with each other, and instead they represent a way to show that you should align them as much as possible. Never misunderstand them.

4.3.3 ASSEMBLY AND DISASSEMBLY OF BEARINGS

1. Dust is harmful to all the bearings. Dust is often the cause of the noise from bearings and the cause for the accelerated deterioration of lubricant. When replacing bearings, you can only open the package of the bearings after all the other installation work has been completed.

2. Use gasoline as the cleansing liquid for bearings. If you have access to the compressed air, you can also use kerosene and diesel for cleaning, and then use the compressed air to blow away the dust.

3. When installing the bearings, the position should be correct. Let the bearings closely contact the raised shoulder or the bearing support’s ring, to reduce the excessive clearance on both ends.

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

207

PRECAUT. FOR DISASSEMBLY & ASSEMBLY | MAINTENNANCE

4.3.4 OIL SEAL INSTALLATION

1. When installing the oil seal, the oil seal’s labial margin sealing engine oil or gear oil should face inward (the side used to seal the oil), to improve the oil sealing performance; the oil seal’s labial margin sealing the lubricating grease should face outward, and when sufficient new lubricating grease is pumped in, the old lubricating grease is easy to be squeezed out.

2. The oil seal should closely contact the raised shoulder or the oil seal’s seat ring.

3. Before installing the oil seal, apply a layer of lithium-based lubricating grease on the labial margin, or the oil seal may be scratched due to the friction from the dry friction surface during the initial period of operation.

4. When installing the oil seal, you can use a conduit to let the oil seal slip into the seat (See Figure 4-75A). If you don’t have such as conduit, you can use a brass sheet to produce a makeshift conduit (See Figure 4-75B).

5. When pressing the oil seal into the seat (See Figure 4-75C), you must use a suitable tool, to make the pressure applied on the end surface of the oil seal even. The diameter of the tool should be 0.5-1mm smaller than the seat hole, and its free end should have a shape suitable for being hammered.

208

Figure 4-75: Oil seal installation of the A, B and C

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

MAINTENNANCE | ADDITIONAL TABLE

4.4 ADDITIONAL TABLE: USE OF FUEL, COOLANT AND LUBRICANTS AC-

CORDING TO AMBIENT TEMPERATURE

Locations

Ambient temperature and suitable oil

-30 -20 -10 0 5 10 15 20 25 30 35 40 45°C

Rated usage

(liter)

Engine

Fuel tank

-10~-30 light diesel

640

Engine

Oil pan

Torque converter

Transmission case

Steering case

Hydraulic oil tank

Final drive case

Track roller

Carrier roller

Idler

The remaining lubricating locations

Engine

Coolant

SAE10W-30

*SAE15W-40

SAE10W-30

*SAE15W-40

SAE30

SAE10W-30

*SAE15W-40

SAE10W-30

*SAE15W-40

SAE85W-140

No.2 and No.3 lithium-based lubricating grease

Soft water + antifreeze

Soft water

SHANTUI CONSTRUCTION MACHINERY CO., LTD.

47

185

164

55 each left and right

0.39~0.45

0.63~0.72

0.39~0.45

Suitable amount

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ADDITIONAL TABLE | MAINTENNANCE

Note:

1. Oil marked with “*” is the alternative to the oil in the column, and when the oil in the above line is not available, the oil with * can be used as the alternative.

2. All the lubricant brands are the CF Class. If the CD Class is used, the oil change time should be

1/2 of the required time.

3. When ambient temperature is lower than -20°C, the oil in the engine oil pan should be changed to SAE5W-20.

4. When adding oil, pull out the filter screen from the oil injection port first, use clean diesel to wash it clean, and then put it back to the oil injection port before going ahead to add oil. Oil that has been fully sedimented should be used.

5. The amount of oil or grease added should meet the requirement, not too much or too less.

6. The tools for adding oil or water must be clean, and they should be put in covered boxes or cabinets after use.

7. Before draining oil, preheat the oil to 30-40°C.

SAE is the internationally accepted oil numbering system.

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SHANTUI CONSTRUCTION MACHINERY CO., LTD.

NOTE PAPER

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