ZD160 - Shopmanual

ZOOMLION
Maintenance Manual for ZD160T

ZD160T
Series Crawler Bulldozer
First Edition of June 2012

Crawler Bulldozer Maintenance Manual
To Users
Dear users, thank you for choosing Zoomlion crawler bulldozer. Before maintain this machine, please
read and fully understand this manual and strictly comply with the relevant provisions in it.
Regular inspection, maintenance and repair on the machines are the essential means to ensure that the
machines can give full play to their excellent performance, work safely and reliably and have their service
lives prolonged. In order to make it convenient for you to do inspection, maintenance and repair for the
machines, we provide this Maintenance Manual for you.
The maintenance manual gives you a detailed introduction on the rules and explanations about the
inspection, maintenance and repair of crawler bulldozer s and also introduces methods of troubleshooting for
common faults.
In order to make the machines work normally and to ensure you and other people’s personal safety,
make sure that you have read the manual and other attached documents carefully and thoroughly before
maintaining and repairing the machines. If you have any doubts or questions, please contact the local service
engineers and we will provide technical support for you timely and effectively. The company will not bear
any undesirable consequences resulted in disobeying the rules of this maintenance manual.
In the process of maintaining the machines, any person without authorization cannot dismantle or adjust
the hydraulic components. When any hydraulic components are broken down or any parts are damaged,
please call our local service engineers.
Because of the constant improvement and upgrades of product design as well as differences in the
product specifications and models, the details of some pictures and text content in the manual may be a little
different from the products that you possess. The company reserves the right to revise the content of this
Maintenance Manual due to technical improvement. We are subject to change without prior notice and we
hope that all users can understand.
Applicable models of this manual: ZD160 T-3, ZD160TS-3, ZD160TSH-3 and ZD160TCS-3.
Thank you very much for your trust and support for Zoomlion products and we sincerely wish you all
the best.
I
Safety Information
The manual involves the following safety and warning signs:
Danger
High risk of danger: there is risk of death or serious injuries.
Warning
Middle risk of danger: there is risk of serious injuries.
Attention
Slight risk of danger: there is risk of minor injuries or moderate injuries.
Caution
Safety sign: there is risk of property loss.
Prompt
This icon marks instructions for particular information.
Important
The icon is for showing the importance of particular information.
It shows that this operation does not conform to the safety specification and easily
causes death and injuries, so it is forbidden.
II
Contents
To U sers................................................................................................................................................................................
sers................................................................................................................................................................................ I
Safety Information ...........................................................................................................................................................

Information........................................................................................................................................................... II
Chapter One: Safety Criterion for Bulldozer Maintenance ..............................................................................

Maintenance.............................................................................. 1-11
1-
1.1 Basic Safety Requirements for Maintenance.............................................................................................. 1-1
1.2 Precautions for Maintenance.......................................................................................................................... 1-2
Chapter Two: General Drawing and Main Parameters of Bulldozer .............................................................

Bulldozer............................................................. 2-
2-11
2.1 Outline Drawing of Bulldozer....................................................................................................................... 2-1
2.2 Main Technical Parameters of Bulldozer.................................................................................................... 2-1
Chapter Three: Structure and Principle for Various Parts of Bulldozer .......................................................
Bulldozer....................................................... 3-11
3-
3.1 Structure and Principle of Various Parts...................................................................................................... 3-1
3.2 Hydraulic System.......................................................................................................................................... 3-13
3.3 Electrical System........................................................................................................................................... 3-68
3.4 Working Device............................................................................................................................................. 3-69
Chapter Four: Maintenance of Bulldozer ...............................................................................................................

Bulldozer............................................................................................................... 4-11
4-
4.1 Maintenance Information of Bulldozer........................................................................................................ 4-1
4.2 Maintenance of Electrical System................................................................................................................. 4-2
4.3 Maintenance of Hydraulic System................................................................................................................ 4-3
4.4 Maintenance of Various Parts........................................................................................................................ 4-3
4.5 Oil for Various Parts and Coolant............................................................................................................... 4-11
4.6 Wearing Parts................................................................................................................................................. 4-15
4.7 Tightening Torque Table.............................................................................................................................. 4-16
Five:: Maintenance Schedule of Bulldozer

Chapter Five ..............................................................................................
Bulldozer.............................................................................................. 5-11
5-
5.1 Daily Maintenance........................................................................................................................................... 5-2
5.2 Initial 100 Hours.............................................................................................................................................. 5-7
III
5.3 Every 250 Hours.............................................................................................................................................. 5-7
5.4 Every 500 Hours............................................................................................................................................ 5-12
5.5 Every 1000 Hours.......................................................................................................................................... 5-12
5.6 Every 2000 Hours.......................................................................................................................................... 5-16
5.7 Every 4000 Hours.......................................................................................................................................... 5-17
5.8 Maintenance When in Need ......................................................................................................................... 5-17
5.9 Maintenance Table........................................................................................................................................ 5-22
Chapter Six
Six:: Troubleshootingof Common Faults .................................................................................................
Faults................................................................................................. 6-
6-11
6.1 Engine................................................................................................................................................................ 6-1
6.2 Electrical system.............................................................................................................................................. 6-2
6.3 Chassis............................................................................................................................................................... 6-3
IV
Maintenance Manual for C rawler Bulldozer
Chapter One: Safety Criterion for Bulldozer Maintenance

Maintenance Safety Criterion

Chapter One: Safety Criterion for Bulldozer Maintenance
for Bulldozer
1.1 Basic S afety Requirements for Maintenance
It is of great significance to carry out maintenance and repair for the bulldozers, for this can extend the
machines’ service lives, ensure the personnel and machine’ s safety, improve work efficiency and increase
economic benefits. Except reading the “Safety Tips”, maintenance staff should comply with the following
regulations:
a) The staff in charge of maintenance should not perform the maintenance work unless they have fully
understand the structure, performance, assembly and disassembly procedures, technical requirements and
precautions of the complete vehicle.
b) For difficult maintenance items, you'd better consult the manufacturer.
c) Routine maintenance is usually carried out before starting the vehicle and after completing the work
every day. Park the vehicle on level ground, lock the locking mechanism, and then carry out maintenance.
d) Before maintenance, the surrounding area of the parts to be maintained should be cleaned and
scrubbed thoroughly, especially the surrounding area of oil filling port, filter, fuel injectors and box cover, so
as to prevent dust from entering into the oil.
e) Always remember that there is high pressure in the hydraulic circuit and release the pressure first
before refueling, fuel discharging or inspection and maintenance.
f) Before changing engine oil, start the vehicle and let the oil temperature rise to 30 ℃～ 40 ℃ before
draining the old oil.
g) Use clean oil and grease. The inspection or change of oil should not be performed at dusty place,
otherwise the dust will enter into the oil.
h) The electrical system can not be handled in the rain.
i) When checking or adding coolant, take care not to let the hot water spray out and hurt people.
j) After the replacement of engine oil filter element or coarse strainer, air in the oil circuit should be
discharged.
k) It is prohibited to refuel with the filter screen on the oil filling port being removed.
l) Before overhauling the gearbox, empty the pockets. Take care not to let wrenches, nuts and other
things fall into the cabinets, resulting in unnecessary troubles.
m) Keep oil far away from fire and do not use a torch instead of lighting.
n) When replacing O-rings, gaskets or other seals, the parts surface should be cleaned and installed
carefully.
o) When doing maintenance with the engine cover and the left and right doors open, use the locking
lever to lock the engine cover and the left and right doors firmly. If inspection or maintenance is done they
are open but not locked, there is risk of their being closed suddenly by blowing wind and causing personal
injury.
p) Avoid dropping things into the interior of the machine.
1) When opening the inspection window or the oil filling port of the oil tank, pay attention not to drop
any nuts, bolts or tools into the interior of the machine. If these things fall into the machine, machine damage
or fault may occur, resulting in accidents. If something falls into the machine, take out it at once.
2) Don’t put unessential things in your pockets, just necessary things for inspection.
1-1
1.2 Precautions for Maintenance

Maintenance Safety Criterion
Carry out technical maintenance correctly and timely, that is, perform such technical maintenance works
for Bulldozer
as inspection, cleaning, lubrication, adjustment and fastening etc. for the machines frequently and regularly.
This will not only increase the production efficiency, reduce wear and avoid unexpected failures, but also
improve bulldozers’ working efficiency, extend machines’ service lives and reduce maintenance costs.
The machine’s maintenance period is recorded by the hour meter.
Under poor operating conditions, maintenance should be done earlier than the required time.
Attention
1. Comply with relevant provisions of the "Safety Criterion for Bulldozer Maintenance" during
maintenance.
2. When maintenance is performed under the vehicle, you should put up signs at the driver's seat
or around the vehicle when necessary.
3. When the blade needs to be lifted up as required by the maintenance item, the blade should be
supported at the bottom to avoid it from droppi ng down .
4. When the blade is used to lift the machine body, the control lever should be locked tightly and
the under part of the track should be tamped to prevent the complete machine from droppi ng down.
5 . Before cleaning or refueling the machine, checking the tension of the fan belt or inspecting the
movi ng parts and their nearby parts, shut down the engine.
6 . Before maintaining, inspecting or charging the batteries, shut down the engine and remove the
battery clips at the same time. Before dismantling the connector between the batteries and the charger,
switch off the charger switch.
7. Keep away from open fire during maintenance (no smoking and no electrical sparks).
box..
8. Pay attention no things drop down when opening the gear box
9. Before carrying out oil feeding, oil draining or other inspections and maintenance for the
hydraulic system, release the pressure first. The method is: lower the blade to the ground, shut down
the engine and loosen each cover after operating each operating levers for two to three times.
10.. Special adjusting tools should be used when adjusting oil pressure, or else failures will occur
10
when performing difficult maintenance items.
11
11.. During inspection and maintenance, only essential personnel can approach.
12
12.. All oil filling ports, surface of oil dipstick and all fuel containers should be kept clean; use
clean oil and grease; the inspection and replacement of various oils should be performed in
environments with few dusts, so as to prevent foreign matters from entering in the oil.
Don’’ t mix oils of different brands together. If you need to add oils of different brands, please
13. Don
brand..
discharge all the old oil and add oil of new brand
14. After maintenance of oil filter
filter,, the engine should be operated at intermediate speed for 5 to 10
oil-way..
minutes to exhaust the air in the oil-way
1-2
Chapter Two: General Drawing and Main

Parameters of Bulldozer
Chapter Two: General Drawing and Main Parameters of
Bulldozer
2.1 Outline Drawing of Bulldozer
See Figure 2-1 for the outline drawing of Zoomlion ZD160-3.
General Drawing and Main

1. Front hood 2. Lifting oil cylinder 3. Cab
4. Fuel tank 5. Track 7. Sprocket
8. Track frame 9. Pushing frame 10. Idler
11.Tilting oil cylinder 12. Blade
Figure 2-1 Outline drawing of ZD160T series bulldozer
2.2 Main Technical Parameters of Bulldozer
See Table 2-1 for the main technical parameters of ZD160T series bulldozer and the outline dimension
is shown in Figure 2-2.
2-1
Table 2-1 Main technical parameters of Z D160T-3 series bulldozer

Total weight Working weight (kg) 15920 (Straight-tilt blade)
(Regular cab) Ground pressure (KPa) 64.9
Model WD10G178E25
In-line, water-cooled, 4 stroke, direct injection
Type
turbo-charged diesel engine
Engine Rated speed (r/min) 1850
Maximum torque (Nmr/min) 830/1100～1200

Number of cylinders － cylinder
6－126mm ×130mm
bore × travel distance
Setting pressure of speed change
2.0
(MPa)
Hydraulic system of
Setting pressure of steering (MPa) 2.0
Chassis
Settling pressure of braking
2.0
(MPa)
Settling pressure (MPa) 14.0
working oil cylinder bore
Hydraulic system of 110mm ×1026mm ×2
× stroke× number
working device
tilting oil cylinder bore ×stroke
160mm ×140mm×1
× number
Ⅰ 0~2.7
Ⅱ 0~3.7
Froward Ⅲ 0~5.4
Ⅳ 0~7.6
Driving speed (km/ h) Ⅴ 0~11
Ⅰ 0~3.5
Ⅱ 0~4.9
Backward
Ⅲ 0~7.0
Ⅳ 0~9.8
Main clutch
Gear box Mechanical constant-mesh type
Spiral bevel gear, single-stage reduction and
Main drive
splash lubrication
Transmission system Wet-type, multi-disc, spring compression,
Steering clutch separated hydraulics and manual hydraulic
control
Wet-type, floating braking and hydraulic
Steering brake
boosted
2-2
Two-stage reduction cylindrical straight gear

Final drive
reducer and splash lubrication
continued))
Table 2-1 ( continued
Sprayed beam, semi-rigid, suspended structure

Type
of equalizer
Number of carrier rollers (pcs) 2/each side
6 (2 pairs and 4 singles)/each side (ZD160T-3)

7 (3 pairs and 4 singles)/each side (ZD160TS-3,
Number of track roller (pcs) ZD160TSH-3)
8 (3 pairs and 5 singles)/each side
(ZD160TCS-3)
Travel system
37 pieces/each side (ZD160T-3),
42 pieces/each side (ZD160TS-3,
Number of track shoe
ZD160TSH-3)
44 pieces/each side (ZD160TCS-3)
510 (ZD160T-3)
Width of track shoe (mm) 950 (ZD160TS-3, ZD160TSH-3)
1100 (ZD160TCS-3)
Pitch (mm) 203.2
Table 2-2 Overall dimension of ZD160T-3 series bulldozer (Straight blade)
ZD160T-3 ZD160TS-3 ZD160TSH-3 ZD160TCS-3

A (Overall length mm) 5025 5305 5305 5583
B (Overall width mm) 3416 4150 4150 4150
C (Overall height mm) 3025 3025 3025 3025
D (Height from exhaust
2783 2892 2892 2892
Outline dimension pipe to ground mm)
E (Track contact length
2430 2935 2935 3240
mm)
F (Height of blade mm) 1160 1039 1595 1039
G (The center distance of
1880 2300 2300 2300
track mm)
H (Maximum lifting height
1095 1052 1052 1155
of blade mm)
K (Maximum cutting depth
Working range 545 434 434 445
of blade mm)
L (Maximum tilting height
860 700 700 700
of blade mm)
2-3
Figure 2-2 Outline dimension of the ZD160T-3 series bulldozer
2-4
Chapter Three: Structure and Principle for

Various Parts of Bulldozer
1
Chapter Three: Structure and Principle for Various Parts of

Bulldozer
The bulldozer consists of engine assembly, chassis (power transmission system, control system,
hydraulic system, travel system, frame, cab, electrical system and so on) and working device etc.
3.1 Structure and p rinciple of v arious parts

3.1.1 Radiator
3.1.1.1 Radiator composition
Radiator mainly cocnsists of water filling chamber (1), radiator (9), water drain chamber (8) and related
accessories (see Figure 3-1).
3.11 .1.2 Working principle of radiator
3.
The cooling water flows through the thermostat to enter into water filling chamber (1) to exhaust the air
in water and then flows through the radiator core (9) to enter into water drain chamber (8). When the cooling
Structure and Principle for Various

water flows through the radiator core (9), the water in it will cool down because of the fan function at the rear
Parts of Bulldozer
end of the radiator. The cold cooling water will then be pumped by water pump to the engine cylinder body
through water drain chamber.
The cooling system is a closed system. The pressure valve install on the water tank keeps the pressure of
the water tank be lower than the manometer pressure of no more than 0.075 MPa, so that the evaporating
temperature of the cooling water is increased to reduce water loss and improve cooling efficiency. The power
of the fan is transmit ted by the belt pulley in front of the engine through the V-shape belt. The cooling
efficiency can be improved through the forced air supply of the fan.
3-1
1.Water filling chamber 2. Water inlet tube 3.Ventilation hose 4.Fan shroud 5.Water pipe clamp
6.Drain plug 7.Water outlet tube 8.Water drain chamber 9.Radiator core 10.Oil cooler of gear box
Figure 3-1 Radiator
3.1.2 Power take-off
3.1.2.1 The main function of the flywheel housing is to achieve power take-off, and its assembly structure
can be seen in Figure 3-2; the transfer case is installed on the upper part of the flywheel housing and the
assembly structure can be seen in Figure 3-3.
3.1.2.2 Working principle
a) The gear on the upper part of the flywheel housing can drive the main shaft and the drive wheel to
rotate and then make the driven wheel to rotate. The driven wheel can drive the transmition oil pump . The
steering oil pump should be installed in the front of the flywheel housing and dismantle the cover to install
the working oil pump.
b) The lubricant oil of the transfer case gear and bearing is from the oil-return hose of the engine oil
cooler and divided by the distributor, and then drops into various related parts through the lubricating pipe.
Parts of Bulldozer
Centre line of
Installation support of
crank shaft
transmission pump
Centre line of
crank shaft
(Main clutch or hydraulic torque

converter)
Figure 3-2 Flywheel housing assembly
3-2
3.1.3 Main clutch (see Figure 3-3)

The machine adopts wet-type, multi-disc brake with inertia and hydraulic power clutch of manual
operation.
Section A-A

Parts of Bulldozer
Section B-B
1. Friction plate 2. Gear blade 3. Pressing plate 4. Clutch bracket 5. Lock

6. Plate 7.Separation sleeve 8. Spring 9. Axle 10.Separation seat baffle
11. Inertial brake drum 12. Positioning plate 13. Clutch housing 14. Flange 15. Coarse filter
16. Return spring 17. Weight block 18. Clutch hub 19. Lantern ring 20. Axle
21. Clutch hub 22. Spacer ring 23. Adjusting ring 24. Connecting rod 25. Rod
26. Fork 27. Tube 28. Axle 29. Rod 30. Cover
31. Gasket 32. Inertial brake belt
Figure 3-3 Main clutch
3-3
From main
clutch pump
To every main
Parts of Bulldozer
clutch
Figure 3-3 (continued)

The machine adopts wet-type and multi-disc friction clutch, which is used to transmit and cut off the
engine power.
The friction between the driving gear blade with external teeth in the outer circumference and the driven
gear blade with internal teeth in the inner circumference should be used by the disc friction clutch to switch
on or cut off the power which is transmitted to the transmission devices after leading to the main clutch.
The external teeth of the driving gear blade meshes with the internal teeth of the engine flywheel, so
they always rotate with the engine together.
The internal teeth of the driven gear blade meshes with the gear (21), the gear is connected to the main
clutch shaft (20) with the spline, so when the main clutch is separated, the main clutch shaft do not rotate,
that is it do not transmit the power.
When pressing the driving gear blade and driven gear blade tightly, the torque of the driving gear blade
will transmit to the driven gear blade, main clutch is connected to eliminate the pressing force, so the main
clutch is separated.
The driven gear blade consists of the powder metallurgy with high friction coefficient and has the forced
lubrication friction surface to ensure the service lift and overheating of the main clutch.
3-4
On the other hand, in order to press the driven blade and the driving blade tightly, the pressing force
should be increased to prevent slipping.
The crank lever mechanism and the centrifugal force are used by the eccentric bias system to supply
enough pressure so as to prevent the slipping of the friction surface under the condition of not increasing of
the main clutch control force.

Parts of Bulldozer
Main clutch is engaged→the main clutch is located at the dead point→the main clutch is separated
Figure 3-4 Connection condition of the main clutch
Pull the shifting fork (3) to make the moving sleeve (1) slip on the main clutch. Roller (6) and
connecting rod (4) are connected with the heavy hammer lever (5) at point B, and roller is pressed to the
pressing plate (7) after pressing tightly.
Heavy hammer lever (5) is hinged with the adjusting plate at point C. Bolts of the clutch bracket (8) are
installed on the flywheel, so parts of (1) and (4) to (8) all rotate with the engine.
• The connection of the main clutch (see Figure 5-9)
Pull the shifting fork (3) to push the moving sleeve (1) to the left side (to the direction of engine
flywheel) and the hinge point of the moving sleeve and the connecting rod (4) will move to the left side and
the hinge point of the connecting rod and heavy hammer lever (5) deviates from the central line direction of
the main clutch shaft (2).
On the contrary , the non-heavy hammer end of the heavy hammer lever (5) will move in the direction of
the central line of the main clutch shaft while the hinge point (C) is as the central point. After the connection
of the main clutch, pars of (1), (2) and (4) to (8) rotate; under the function of centrifugal force (W), the heave
hammer end of the heavy hammer lever is pushed to the direction of “↓” and the hinge point (B) is close to
the central line of the main clutch shaft. So, if the hinge point (A) is close to the flywheel, force (F) will act
on the pressing plate in the direction of arrow “←” to press the driving gear blade and the driven gear blade,
and the main clutch is connected under this case.
3-5
• The main clutch is located at the dead point (as shown in Figure 5-9)
When the connecting rod (4) is vertical with the main clutch shaft (2), because the direction of the
centrifugal force (W) produced by the rotation of (1), (2) and (4) to (8) is “ ↓ ” direction for the heavy
hammer lever (5), but the connecting line of (A) and (B) two hinge points is vertical with the main clutch
shaft, so the force (N) pushes the moving sleeve (1) in the direction of “↑” and this state is called the dead
point. 3. The main clutch separation (as shown in Figure 5-9)
Pull the shifting fork (3) to push the moving sleeve (1) to the right side (the direction to universal joint),
the hinge point of the moving sleeve (1) and the connecting rod (4) moves to the right side and the hinge
point (B) of the connecting rod and the heavy hammer lever is pulled to the direction of the central line of the
main clutch shaft (2).
On the contrary, heavy hammer lever rotates in the direction of deviating from the central line of the
main clutch shaft in which the hinge point (C) is as the central point. If the main clutch under this condition,
(1), (2) and (4) move to (8), the heavy hammer lever is pushed in the direction of “↓” under the function of
the centrifugal force (W), and the hinge point (B) is closer to the central line of the main clutch shaft. So,
hinge point (A) moves to right, force acts in the direction of “ → ” , which make no friction between the
driving gear blade and the driven gear blade, and the main clutch is separated.
Parts of Bulldozer
3.1.3.1 Adjustment for the main clutch

With the wear increasing of the driving gear blade and the driven gear blade, main clutch begins to slip,
which indicates the pressing force reducing between the driving gear blade and the driven gear blade, so,
adopt the method of making the hinge point (C) of the heavy hammer lever (5) be close to the pressing plate
(7) to recover the large enough pressure, remove the locknut and the lock plate and tighten the adjusting plate
installed on the main clutch bracket (8) in the direction of the flywheel.
3.1.3.2 Inertia brake
The bulldozer has large driving resistance, and the vehicle will stop immediately once the main clutch is
separated and the gear lever is in the neutral gear position and the output shaft will stop at the same time.
However, the main clutch rotates continuously due to inertia even if the power is cut off, the input shaft of
the speed changer connected to the universal joint will rotate also.
If the speed is changed depending on the sliding gear installed on the rotation input shaft and fixed
output shaft, the gear noise and gear wear will occur.
In order to prevent these faults, the inertia brake with the contraction brake belt should be equipped at
the back of the main clutch.
3-6

Parts of Bulldozer
Figure 3-5 Inertia brake
The inertia brake is interlocked with the handle of the main clutch in structure; if the handle of the main
clutch is pushed down, the main clutch is separated first; if the handle of the main clutch is pushed down
further, the brake drum (11) and the brake belt (32) installed on the main clutch (20) will be connected at
once to avoid the inertial rotation of the main clutch and ensure the stable shift of the gear box gears.
3.1.3.3 Control lever system of the main clutch (see Figure 3-6)
3-7
Main clutch
Connection
Separation
Gear lever
Close Open
Parts of Bulldozer
Mutual interlock lever
Main clutch box
Inertia brake
Main clutch booster
Gear box housing
Main clutch booster
Figure 3-6 Control lever of the main clutch

In the above drawing, the connection among the main clutch booster, the main clutch lever and the gear
box.
When the main clutch is moved to the separation position, each connecting rod and handle will move in
the direction of the arrow to make the main clutch separate and the inertia brake is applied and under this
condition the interlock mechanism of the gear box has no effect, shifting gears can be conducted.
3.1.3.4 Hydraulic power unit of the main clutch (see Figure 3-7)
3-8
From the main clutch pump

From the main
clutch pump
Parts of Bulldozer
To main clutch
Detailed drawing of safety valve
1. Connecting rod 2. Bush 3. Support 4. Spring (large) 5. Spring (small) 6. Piston

7. Valve 8. Housing 9. Nut 10. Joint 11. Plug 12. Valve seat
13. Spring 14. Spool A: Connection position B: Separation position
Figure 3-7 Main clutch booster
The function and principle of the main clutch booster are shown in Figure 3-8.
The booster is used to reduce the control force of the main clutch.
a) When the joy stick of the main clutch moves from “separation” position to “connection” position:
If the joy stick of the main clutch is pulled from separation position to the connection position lightly,
the valve rod (7) will be pulled up lightly, so the drain circuit of the engine oil from the main clutch pump is
cut off, and the oil pressure will be increased. The engine oil from the oil pump enters into (F) chamber
through (3), (D) chamber and the hydraulic pressure will push the piston (6) upward (as shown in Figure 3-8
on the left).
When the piston (6) moves upward, the main clutch enters into the connection position. A channel will
be formed between the piston (6) and valve rod (7); the pressure oil from the oil pump will be drained. The
oil pressure drops and piston (6) stops to move (as shown in Figure 3-8 on the right).
3-9
Separation
From pump
From pump
To main clutch
to lubricate
To main clutch
Separation to lubricate
Parts of Bulldozer
Figure 3-8 Function and principle of the main clutch booster

Then, the control lever of the main clutch is pulled backward further lightly, the valve rod (7) moves
upward continuously and close to the channel between piston (6) and valve rod (7) again, and the oil pressure
will raise and this pressure will push the piston (6) upward. The motion between the piston (6) and valve rod
(7) will repeat in a short time, so piston (6) will move upward gradually . Piston (6) moves with the valve rod
(7). So, the main clutch can be controlled with a light control force (see Figure 3-9 on the left).
Separation Connection
Separation
From pump From pump

To main clutch
To main clutch
to lubricate
to lubricate
Separation Separation
Figure 3-9 Function and principle of the main clutch booster

b) When the control lever of the main clutch moves from “connection” position to “separation” position:
3-10
When the valve rod (7) moves downward, the hydraulic oil circuit from the main clutch pump will be
cut off and the oil pressure will be raised.
Pressure oil enters into (E) chamber to push the piston (6) to move downward through (C) chamber.
Piston (6) and valve rod (7) will act in the opposition direction to the above-mentioned direction and push the
main clutch to the separation position (as shown in Figure 3-9).
3.1.3.5 Main safety valve (see Figure 3-10)
The installation of the main safety valve is to
From pump
prevent the pipeline pressure from exceeding the rated
pressure; if the oil from the main clutch pump fills into
the oil filling port to make the engine oil pressure in the
pipeline exceed 3MPa, the check valve (14) will be
pushed open. The main clutch box will overflow through
the oil filling port (G).
In this way, the engine oil pressure in the pipeline

From pump
can be kept in 3MPa.
Parts of Bulldozer
Figure 3-10 Main safety valve
3.1.3.6 Lubrication for main clutch (see Figure 3-11)
Bearing and driven gear blade is lubricated and cooled by the pressure oil from the gear pump. The gear
pump is installed on the power output box and driven by the engine and rotated with the engine. Oil pump
sucks the engine oil from the filter cartridge at the bottom of the main clutch housing, transmit the oil
pressure to booster and lubricate bearing, spring and axle sleeve through the oil duct of the main clutch
housing and the oil duct in the center of the main clutch shaft and flow through the oil groove of the driven
gear blade. After the lubricating of flywheel and power output box, oil flows through the oil hole of the
flywheel and is scattered the internal wall of the main clutch housing due to the centrifugal force and then
gathers in the bottom.
3-11
From the main

clutch booster
Parts of Bulldozer
To pump
Figure 3-11 Schematic diagram of Lubrication for main clutch

3.1.4 Universal joint (see Figure 3-12)
The function of the universal joint is to finish the power transmission between the main clutch and the gear
box, It can ensure steady transmission of motion when the coaxiality between the center lines of the turbine
output shaft and the main shaft of the transmission case is within the allowable range.
1. Oldham's coupling 2. Connecting plate 3. Bolt 4. Bolt

Figure 3-12 Universal joint
3-12
3.1.5 Gear box (see Figure 3-13)

Function of the gear box: 1. To realize the forward and backward traveling of bulldozer; 2. To obtain
different output transmission ratio.
From engine oil cooler

(used for lubrication)
Interme diate shaft
Interme diate shaft

Main
shaft

Parts of Bulldozer
Section B-B
View Z
View Y
Figure 3-13 Gear box
3-13
Gear 5
SectionA-A
Parts of Bulldozer
For Back Gear 4 gear 3 Gear 2 gear 1

ward ward
1. Gear box housing 2. Sleeve 3. Lubricating pipe 4. No.5 gear shift sleeve 5. Sleeve 6. Intermediate
shaft (P.T.O. shaft) 7. Sleeve 8. Bearing seat 9. Main shaft 10. Cover 11. Clamp plate 12.
Intermediate shaft 13. No.1 and No.2 gear sliding sleeve 14. No.3 and No.4 gear sliding sleeve 15.
Sleeve 16. Forward and reverse sliding sleeve 17. Cover 18. Clamp plate 19. Input shaft 20. Clamp
plate 21. Connecting plate 22. Cover 23. Bearing seat 25. Clamp plate 26. Cover
Table 3-1 Gear lever position and transmission system
Gear Gear transmission system (gear box)
Gear 1 A→H→M→G
Gear 2 A→H→L→F
Forward Gear 3 A→H→K→E
Gear 4 A→H→J→C
Gear 5 B→N→P→D
Gear 1 B→N→O→I→M→G
Gear 2 B→N→O→I→L→F
Backward
Gear 3 B→N→O→I→K→E
Gear 4 B→N→O→I→J→C
3-14
3.1.5.1 Shift gear box (see Figure 3-14)
Fork
shaft of
front and
rear gear
Section Z Front

Parts of Bulldozer
1. Shift gear box 2. Adapter 3. Seat 4. Gear pin
5. Interlocking shaft 6. Shifting fork shift 7. No.5 gear shifting fork 8. Gear lever
Figure 3-14 Shift gear box
3-15
No.5
Forward Backward No.4 No.2
No.3 No.1
Parts of Bulldozer
Section A-A
Section C-C
Gear 5 mobile
for shaft
Gear 3-gear 4 Gear 1-gear 2 Forward-reverse gear
3. Seat 5. Interlocking shaft 6. Shifting for shaft (gear 5) 7. Gear 5 shifting fork 8. Shaft 9. Gear
lever 10. Forward and backward gear lever 11. Interlocking plunger 12. Interlocking plunger (gear 5)
13. Shifting fork of gear 1 to gear 2 14. Shifting fork of gear 3 to gear 4 15. Shifting fork of gear for
forward and backward traveling
3-16
3.1.5.2 Drive system (see Figure 3-15, 3-16, 3-17)

The gearbox of the machine is a mechanical constant mesh type, which has five gears for forward
traveling and four gears for reverse traveling
3.1.5.2.1 First gear for forward traveling (A→H→M→G)
(A→
No.5

Parts of Bulldozer
Power Power transmitted
transmitted from from the bevel gear
the engine to the shaft to the final
main clutch drive
Forward Reverse No.4 No.3 No.2 No.1
Figure 3-15 First gear for forward traveling

The input shaft (17) forward gear (A) installed on the input shaft spline is constantly meshed with the
forward shaft (H). Gear (B) integrated with the gear for forward traveling (A) is constantly meshed with the
reverse driven gear (N) on the intermediate shaft.
When the power from the coupling (21) is rotating the input shaft, the gear for forward traveling (H)
will make the driven gear (N) and driving gear (O) rotate reversely. Operate the forward-reverse control lever
in “Forward” to place the gear lever in “First gear”, then the sliding sleeve (16) on the intermediate shaft is
move to the left (forward position) by the gear shift fork to mesh the outer teeth of gear for forward traveling
(H) with the inner teeth of the sliding sleeve.
Gear for forward traveling (H) is installed on the intermediate shaft spline, and the rotary motion of the
input shaft is transmitted into the intermediate shaft.
3-17
On the other hand, the sliding sleeve (12) on the intermediate shaft is moved to the right (first position)
by the gear shift fork, while the inner teeth of the sliding sleeve (12) mesh with the outer teeth of the first
gear (M). First gear (M) is firmly connected with the sliding sleeve (12), so the intermediate shaft can rotate,
and be transmitted into the first gear (G) of the main shaft. When the input shaft is driven by the engine, the
intermediate shaft will rotate in reverse direction, then the gear (M) on the intermediate shaft makes the first
shift gear (G) of the main shaft rotate in the same direction of the input shaft, and transmit power to the small
bevel gear Q.
3.1.5.2.2 First gear for reverse traveling (B→N→O→I→M→G)
(B→
No.5
Parts of Bulldozer

the engine to the shaft to the final
main clutch drive
Figure 3-16 First gear for reverse traveling

Gear for reverse traveling (B) of the input shaft is constantly meshed with the reverse driven gear of the
intermediate shaft. When the power from the coupling (21) is transmitted into the input shaft, gear (H) will
rotate reversely. Driving gear (N) and driven gear (O) of the intermediate shaft also rotate reversely. Pull the
forward-reverse control lever to “Reverse” gear, and place the shift lever in the “First” position near the
driver’s seat, the sliding sleeve (16) of the intermediate shaft is moved to the right (reverse gear) by the gear
shift fork, while the outer teeth of the reverse gear (1) shaft sleeve is meshed with the inner teeth of the
sliding sleeve (16).
3-18
On the other hand, sliding sleeve (12) of the intermediate shaft is moved to the right (first position) by
the gear shift fork, while the inner teeth of the sliding sleeve (12) is meshed with the outer teeth of the first
gear (M) shaft sleeve. First gear (M) is firmly connected with the sliding sleeve (12), thus the rotary power of
the intermediate shaft is transmitted into the first gear (G) of the main shaft. When the input shaft (A) is
rotating with the engine, the intermediate shaft will rotate in the same direction of the input shaft, gear (M)
will make the first shift gear (G) of the main shaft rotate in reverse direction, and transmit the power to the
small bevel gear (Q).
3.1.5.2.3 No.2-No.4 transmission line
Second gear for forward traveling A→H→L→F, second gear for reverse traveling B→N→O→I→L→F
Third gear for forward traveling A→H→K→E, third gear for reverse traveling B→N→O→I→K→E
Fourth gear for forward traveling A→H→J→C, fourth gear for reverse traveling B→N→O→I→J→C
Fifth gear for forward traveling B→N→P→D
No.5

Parts of Bulldozer
the engine to the shaft to the final drive
main clutch
Figure 3-17 No.2-No.4 transmission line

Pull the gear shift lever near the driver’s seat to “Fifth” gear, and slip the sliding sleeve (4) to the left to
make it mesh with the fifth forward gear (P) on the intermediate shaft.
Fifth forward gear (P) of the intermediate shaft is constantly meshed with the fifth forward gear (D) of
the main shaft. When the input shaft is rotated by the engine power, the intermediate shaft will rotate in the
reverse direction. Gear (P) rotates the fifth gear (D) of the main shaft in the same direction of the input shaft,
3-19
and transmits the power to the small bevel gear (Q).

3.1.5.2.4 Interlocking mechanism (see Figure 3-19)
The function of the interlocking mechanism of the gear box is to prevent the slipping off the gear due to
various reasons, such as the change of angles and the machine load as well as the uneven wear of the gear
and so on. It also can prevent the non-meshing of each gear and two sets of gears cannot connect at the same
time for above-mentioned reasons. In other words, the interlocking mechanism has two functions: prevent the
gear slipping off and the double connection of gears.
a) Prevent the gear from slipping off
Gear lever
Machinery 160 for preventing the gear slipping off
should be used the connecting rod to connect the main Front
Middle
clutch rod, forward and backward rods and gear lever. In
Rear Forward -backward rod
other words, if the main clutch rod moves, the machinery Connection
will move also. When the main clutch rod locates at the Separation
“separation” position, the control rod of the gear box

moves, but at any other positions, interlocking

Parts of Bulldozer
Main clutch
mechanism will prevent them from moving. control rod
Interlocking
When the gear lever locating at “neutral” → “gear Interlocking shaft
connection part
1”, the main clutch locates at “separation” position.
If the gear lever locates at the “neutral” position, the
plunger (2) will be pressed to the “neutral” position of
the fork shaft (4). When the main clutch is at
“separation” position, the interlocking shaft groove Main clutch
booster
connected to the main clutch and the rear-end of the
plunger (2) will be formed a straight line.
If the gear lever is tried to be moved from “neutral”
Figure 3-18 Interlocking mechanism f the gear
to gear 1, the plunger (2) will be pushed by the fork shaft
box
upward, however, the plunger (2) can be lifted to the
groove part of the interlocking shaft (1), which can make the gear shift move from “neutral” to “gear 1”.
• The gear lever locates at the “neutral” →“gear 1”, and the main clutch locates at the “connection”
position.
If the gear lever locates at the “neutral” position, the plunger (2) will be pressed to the “neutral” position
of the fork shaft (4). When the main clutch is at “connection”, the interlocking shaft groove connected to the
main clutch and the rear-end of the plunger (2) will be formed a straight line.
At this time, move the gear lever from “neutral” to “gear 1” in the drawing, the plunger (2) will be
pushed upward due to the force of the fork shaft. But there is no groove port on the interlocking shaft (1), the
mobile fork shaft (4) cannot be moved from “neutral” to “gear 1”. So the gear shift is impossible, unless the
main clutch rod is at the “separation” position.
3-20
Main clutch handle

locates at the
Main clutch rod “separation” position
Main clutch rod can

move to the
connection position
Push upward
No.1 No.2 No.1 No.2 No.1 Neutral No.2

Neutral Neutral
Figure 3-19 Location schematic diagram for the gear lever and the main clutch
• The gear lever locates between two gears, and the main clutch is from “separation” to →

“connection”.
If the variable speed locates between “gear 1 and gear 2” (gear 1 and gear 2 are in semi-meshing
Parts of Bulldozer
condition), the plunger (2) is not at the forced position of the shifting fork shaft (4), nut it locates at the lifting
position. When the main clutch is at “separation” position, the interlocking shaft groove connected to the
main clutch rod and rear-end of the plunger (2) will be formed a straight line to align. If the clutch rod is tried
to move from “separation” to “connection”, the plunger (2) will impact with the interlocking shaft groove to
make the interlocking shaft (1) cannot rotate, so the main clutch cannot be moved from “separation” to
“connection”. At this time, when the gear lever is under semi-meshing condition, the interlocking device will
prevent the main clutch from connecting to avoid damaging the shift gear.
As above, in order to prevent the fork shaft from separating in moving, the gears which have been
finished the shift gear are locked with the interlocking shaft (1) and the plunger (2) together. Besides, when
the main clutch locates at the “separation” position completely, the shift gear of the gear box can be possible.
Main clutch locates at the

“connection” position
Main clutch rod cannot be

moved to the “connection”
position
Cannot be lifted Cannot be lifted
Impact
No.1 Neutral No.2 No.1 Neutral No.2 No.1 No.2

Neutral
Figure 3-20 Main clutch locates at the “connection” position
3-21
b) Preventing device of the double connection (as shown in Figure 3-21)

Preventing device of the double connection is used to prevent the movement of other gear when the
gear lever (29) moves to any gear position.
Preventing device of the double connection includes seat (28), four moving forks (34), (35), (36),
(37) and several plungers.
When the gear lever (29) is moved to left or right (in the direction A), select a shifting fork (moving
fork from gear 1 to gear 2 (34), moving fork from gear 3 to gear 4 (36) or moving fork of gear 5 (35)).
If the gear lever has been moved forward or backward (in the direction B), select one gear (gear 1
or gear 2, gear 3 or gear 4, or gear 5).
When the gear lever is moved to left or right, seat (28) will be moved to left or right as well and
supported by the pin (47). There is a extension on the seat (28) and the extension has the groove, and
there are only the bayonet locks of two mobile fork for the extension and the groove, they should not
enter into the bayonet locks of the left mobile forks. For example, when the gear lever locates at hear 1
and gear 2, the extension part of the seat (28) will enter into the bayonet locks of the mobile fork of gear
3-gear 4 (36) and the mobile fork of gear 5 (35), which can make the forward or backward forks stop.
However, the bayonet lock of the mobile fork of gear 1 and gear 2 forms a straight line with the groove
Parts of Bulldozer
of the seat (28) to align, so it can move forward or backward. If the gear lever is moves to gear 1 later,
the mobile fork (34) will be moved to the right (gear 1) and make the pin (47) as the pivot. In other
words, when the gear 1 and gear 2 are selected, the extension part of the seat will brake the mobile fork
to prevent the slipping of the mobile fork in gear 3, gear 4 and gear 5.
When the forward-backward control rod (46) locates at the “backward” position, No.5 rod (48) will
push the plunger, so the mobile fork shaft (45) of gear 5 cannot move. So, the gear lever (29) cannot
enter into gear 5.
If the gear lever (29) locates at the gear 5 and operator tries to move the forward-backward control
rod (46), No.5 rod will impact the upper part of the plunger, so the forward-backward control rod (46)
cannot be moved. If the forward gear 5 is selected, put the forward-backward control rod (46) on the
“forward” position and then pull the gear lever (29) to gear 5.
3-22
Forward
Neut
ral
Back
ward

Parts of Bulldozer
No.1
No.2
Back No.3
ward
No.4
Forward No.5
28. Seat 29. Gear lever 32. Interlocking shaft 33. Interlocking plunger 34. Mobile fork of gear
1-gear 2 35. Shifting fork o gear 5 36. Mobile fork of gear 3-gear 4 37. Forward-backward shifting
fork 42. Forward-backward fork shaft 43. Mobile fork shaft of gear 1-gear 2 44. Mobile fork shaft
of gear 3-gear 4 45. Mobile fork shaft of gear 5 46. Forward-backward fork shaft 47. Shifting
lifting lever pin 48. No.5 rod
Figure 3-21 Gear lever control
3.1.6 Main drive
Main drive, steering clutch and steering brake are all installed in the rear axle housing.
Main drive consists of large bevel gear wheel (3) (which is meshed with the output gear Q of the gear box),
main drive shaft (9), bearing seat (2) and bearing (see Figure 3-22).
3-23
Parts of Bulldozer
1. Bevel gear hub 2. Bearing seat 3. Bevel gear 4. Flange 5. Adjusting nut 6. Cap 7. Sealing
ring 8. Conical rolling bearing 9. Conical rolling bearing 10. Bush 11. Nut 12. Locking spacer
13. Nut 14. Brake drum 15. Pressing plate 16. Friction plate 17. Gear blade 18. Internal drum
19. Piston 20. Sealing ring 21. Spring 22. Flange 23. Bolt 24. Nut 25. Locking spacer
Figure 3-22 Main drive
The main functions of main drive: a) to change the transmitting direction of power (from
longitudinal direction to transverse direction); b) to achieve one-stage reduction and increase the torque.
The power from the engine is transmitted to the left and right steering clutches through the meshing
between the small spiral bevel gear and the large spiral bevel gear on the output shaft at the rear end of
the transmission. The large spiral bevel gear is installed on the bevel gear shaft with 8 refined bolts, and
the bevel gear shaft is supported on the steering box through two tapered roller bearings and bearing
seat.
The correct meshing of a pair of bevel gears can be achieved by adjusting the nut (5) and the adjusting spacer
between the small bevel gear assembly of the gear box and the housing. You can judge whether the meshing
is correct by inspecting the tooth side clearance and the meshing imprint .
The standard clearance of a pair of spiral bevel gears is 0.25-0.33mm. The meshing imprint along
the tooth length should not be less than a half of the tooth length, and should be near to the small end in
the direction of teeth length (30% of small end). The height is a half of the teeth height, as shown in
Figure 3-23. If the meshing is abnormal, it should be adjusted according to the methods shown in Table
3-2.
3-24
Figure 3-23 Meshing imprint of gears

Table 3-2 Position of gear meshing imprint and its adjustment
Position of imprint on the surface of driven M ovi ng direction of
A djusting method
gear gear
Move the driven gear to
to the driving gear, and if the
gear clearance is then too

small, the driving gear
Parts of Bulldozer
should be moved outward.
Forward
get away from the driving
gear; if the gear clearance is
then too large, the driving
gear should be moved
inward.
Move the driving gear

to get close to the driven
then too small, the driven
outward.
Reverse Move the driving gear

to get away from the driven
then too large, the driven
inward.
3-25
continued))
Table 3-2 ( continued
Position of imprint on the surface of driven M oving direction of
A djusting method
gear gear
Move the driving gear to
get close to the driven
gear; if the gear clearance
is then too small, the
driven gear should be
moved outward.
Move the driving gear to

Forward
get away from the driven
is then too large, the driven
inward.
Parts of Bulldozer

get away from the driving
is then too large, the
driving gear should be
moved inward.
Reverse
get close to the driving
is then too small, the
driving gear should be
moved outward.
3-26
3.1.7 Steering clutch

Steering clutch should be installed on both ends of the bevel gear to control the driving direction of
vehicles. These clutches can cut off the power transmission from the bevel gear to the final drive, and
then change the driving direction.
The type of clutch: wet-type, multi-disc, spring compression, separated hydraulics and normally
engaged structure.
The structure of the steering clutch consists of the internal and external drums, pressing plate,
internal and external friction plates and butterfly spring.
Under the normal conditions, the internal and external friction plates are connected under the action
of the disc spring and the power from the transverse shaft transmits to the drive plate of the final drive
through hub (1) → internal drum (18) →internal tooth (17) → external friction plate (16) → external
drum (14).
When you pull the steering lever the pressure oil from steering control valve will enter into the
internal chamber of internal drum (18) (see Figure 3-24), push the piston (19) to move leftward to

compress the disc spring (21), as a result, the friction connection between the internal tooth blade (17)
and friction plate (16) will be released the external drum (14) will stop rotating and the power
Parts of Bulldozer
transmission will be cut off.
When you let go of the steering lever, the pressure oil will be cut off and the pressure plate (15) will be
pressed to return to its original position by the disc spring. As a result, the friction plate (16) and the tooth (17)
will connect with each other to realize power transmission (see Figure 3-25).
Figure 3-24 Oil in the clutch during steering
3-27
Figure 3-25 Oil in the clutch during power transmission

Parts of Bulldozer
3-28
3.1.8 Steering brake

The type of brake: wet-type, belt-type, floating braking and hydraulic boosted (see Figure 3-26).
Forward
Center of bevel

gear shaft
Parts of Bulldozer
Oil level
Parking brake groove
To steering brake pedal
Direction Z
1. Shell of brake booster 2. Adjusting bolt 3. Rocker arm 4. Rocker arm 5. Piston 6. Spool 7. Bushing
8. Spring 9. Rod 10. Cover 11. Connecting plate 12. Brake belt 13. Friction lining of brake 14. Support
15. Rocker arm 16. Tail-end tip end 17. Adjusting nut 18. Pin 19. Rod 20. Pin 21. Pin
Figure 3-26 Brake
3-29
The main function of the brake is to make the final drive gear stop transmitting power through
holding the external drum of the steering clutch tightly and t realize the turning and parking of vehicles.
3.1.8.1 Working principle of steering brake
When the vehicle is traveling forward (see the left part of Figure 3-27) fully pull the pull rod to
control the brake, then the brake booster piston will move to the left, the rocker ram (3) will rotate and
the rocker arm (15) will move upward. The brake belt will be pulled in anti-clockwise direction, so the
rod (19) will be pulled to the left and the pin (18) pushes the support (14). As a result, the rocker arm (15)
will rotate clockwise direction, the point B will be the base and the tail-end (16) will move in the
direction indicated by arrow Q to make the brake belt hold the brake drum to realize braking.
When the vehicle is reversing (see the right part of Figure 3-27), the brake drum rotates clockwise.
The brake belt (12) is pulled in the clockwise direction so the tail-end (16) is pushed to the right
accordingly and the pin (21) pushes the support (14). As a result, rocker arm (15) will rotate clockwise,
point A will be the base and the pin (20) will move in the direction indicated by arrow (R) to make the
brake belt hold the brake drum.
Parts of Bulldozer
Tothe brake pedal
Braking force
Reverse
Forward
Figure 3-27 Working principle of brake
3-30
3.1.8.2 Working principle of steering boosting valve

As shown by the arrow in the left part of Figure 3-28, when the brake pedal is depressed, the rod (9) will
push the slide valve (6) to move to the left, the oil port will be connected and then the hydraulic oil from the
pump will push the piston (5) to move to the left to operate the rocker arm (3) to achieve braking.
As shown by the arrow in the right part of Figure 3-28, when the steering rod is fully pulled, the
adjusting bolt (8) will push the shaft (17) and the brake valve (20) to move to the right, the oil circuit will be
connected and then the hydraulic oil from the pump will push the piston (5) to move to the left to operate the
rocker arm (3) to achieve braking.
From the steering valve

Parts of Bulldozer
Figure 3-28 Working principle of the boosting valve
3.1.9 Final drive
3.1.9.1 Structure of final drive used on dry lan
landd (see Figure 3-29)
The function of the final drive is to increase the output torque through the two-stage reduction and to
transmit power to the traveling mechanism through the sprocket.
3-31
Parts of Bulldozer
1. Driver plate 2. Bearing seat 3. First small gear (11 teeth) 4. First large gear (48 teeth) 5. Second
small gear (11 teeth) 6. Gear cover 7. Floating oil seal 8. Sprocket hub 9. Locking device 10.
Sprocket nut 11. Floating seal 12. Support 13. Cover 14. Nut 15. Retaining ring 16. Dust ring 17.
Half shaft 18. Nut 19. Gear ring hub 20. Second large gear (42 teeth) 21. Nut 22. Bearing 23.
Sprocket wheel
Figure 3-29 Final drive (used on dry land)
3.1.9.2 Structure
tructure of final drive used on wet land (see Figure 3-30)
3-32

Parts of Bulldozer
1. Driver plate 2. Bearing seat 3. First small gear (11 teeth) 4. First large gear (48 teeth) 5. Second
small gear (11 teeth) 6. Gear cover 7. Floating seal 8. Sprocket hub 9. Locking device 10. Sprocket
nut 11. Floating seal 12. Support 13. Cover 14. Nut 15. Retaining ring 16. Dust cover 17. Half
shaft 18. Nut 19. Ring gear hub 20. Second large gear (42 teeth) 21. Nut 22. Lengthened sleeve 23.
Sprocket wheel
Figure 3-30 Final drive (used on wet land)
3.1.9.3 Power transmission of the final drive (see Figure 3-31)
Spur gear two-stage reduction, splash lubrication and floating oil seal are adopted for the final drive.
The driving force from the bevel gear shaft and steering clutch is transmitted to the final drive plate (1)
through the brake drum and drive the first driving gear (3) on the drive plate to rotate.
The first driving gear is meshed with the first driven gear (4), thus driving the second the driving gear (5)
to rotate. The power is further transmitted to the second driven gear that is meshed with the second driving
gear from the second driving gear, thus achieving the purpose of deceleration.
Due to that the structure of the second driven gear is fixed on the final drive hub (19) with bolts and the
sprocket hub (8) is press-fitted on the final drive hub (19), the power is finally transmitted to the sprocket.
Gear cover plays a role of an oil tank for storing gear lubricants. The rotary sliding parts of the sprocket
is installed with floating oil seal (7) and (15) to prevent the sand lime sand and mud from entering the
cabinets and avoid lubricants leakage.
3-33
Forward Backward
Forward Backward
Parts of Bulldozer
Figure 3-31 Final drive

3.1.10 Operation of transmission system
3.1.10.1 Shifting operation (see Figure 3-32)
3-34

Parts of Bulldozer
Figure 3-32 Shifting operation
3.1.10.2 Steering operation (see Figure 3-33)
Figure 3-33 Steering operation
3-35
3.1.11 Traveling mechanism (see Figure 3-34, 3-35, 3-36)

The trolley plays a role of supporting the weight of the machine and distributing the weight on the
ground as well as converting the driving force transmitted from the sprocket into the traction force. The
trolley assembly consists of the trolley frames (8), idler (1), carrier rollers (3) and track rollers (5) and (6)
installed on the left and right in pairs. The track shoe (2) that surrounds each trolley frame is driven by the
sprocket and is guided by the front idler, carrier roller and track roller. The guard plate (7) for the track roller
attached on the bottom of the track frame can prevent the track from derailing when any rocks are embed in
the track (see Figure 3-28).
Parts of Bulldozer
1. Idler 2. Track 3. Carrier roller 4. Sprocket cover 5. Track roller (single side) 6. Track roller (both
sides) 7. guard plate for track roller 8. Trolley frame 9. strut 10. Pin
Figure 3-34 Traveling mechanism (used for dry land)
3-36

Parts of Bulldozer
1. Idler 2. Track 3. Carrier roller 4. Sprocket cover 5. One-side track roller (4 each side) 6. Two-side
track roller (3 each side) 7. Guard plate for track roller 8. Trolley frame 9. Strut 10. Pin
Figure 3-35 Traveling mechanism (used for wet land)
3-37
1. Idler 2. Track 3. Carrier roller 4. Sprocket cover 5. Sing-side track roller (5 each side) 6.
Two-side track roller (3 each side) 7. Guard plate for track roller 8. Trolley frame 9. Strut 10. Pin
Figure 3-36 Traveling mechanism (used for super-wet land)
3.1.11.1 Track tensioning device (see Figure 3-37)
The tensioning and cushioning device of the idler is installed on the track frame between the idler and
the sprocket. Its functions are:
(1) To keep proper track tension;
(2) To absorb the vibration of experienced by the idler during driving.
One end of the tension rod (2) is connected with the idler support (1), and the other end is connected
with the cylinder (3) that is filled with lubricating grease which is pressed by the piston. The front guide of
the tension spring (6) and the piston (4) are always pushed to the front direction of the machine by the tension
spring (7). Meanwhile the tension rod is also pushed to the front by the lubricating grease inside the cylinder
under the force of the piston.
When the idler that connects to the cushioning spring through the cylinder (3) withstands an impact
force that exceeds the initial pre-load of tension spring, the tension spring will retract to absorb vibration. In
Parts of Bulldozer
addition, when any earth, rock or snow are clogged between the track and sprocket, the tension spring will
absorb the vibration caused by the sudden increases of track tension, so as to prevent the track, sprocket or
other carrier rollers from being damaged.
Cylinder (3) is installed with lubricator fitting for supplying lubricating grease to impel the cylinder
piston to move the idler forward and thus increase the track tension. On the other hand, you can unscrew the
lubricator fitting to discharge the lubricating grease, so that the track tension can reduce.
To reduce the track tension, you can screw the lubricator out for one round. If the grease is difficult to
discharge, you can try to drive the machine forward and backward for a short distance. Do not screw the
lubricator out for more than one round, so as to prevent the lubricating grease from spraying under high
pressure. Although the protective device has been installed to prevent the lubricator fitting from flying out,
you still need to keep the protective measures in mind to ensure safety.
3-38

Parts of Bulldozer
1. Support 2. Tension rod 3. Cylinder 4. Piston 5. End cover 6. Front guide 7. Tension spring 8.
Rear guide 9. Nut 10. Cover 11. Sleeve 12. Wear ring 13. Lubricator fitting
Figure 3-37 Track tensioning device
3.1.11.2 Idler (see Figure 3-38)
The idler (1) installed in the front of each side trolley frame at each side is supported on the idler shaft (3) by
the bracket (6) and the bushing (2).
The idler assembly that includes the support (the support is connected with the bracket (6)) can slide back
and force along the trolley frame with the guide plate attached on the trolley frame through the bracket and
the cover (4), so as to keep the smooth rotation of the track.
Lubricant enters into the bushing through the oil hole in the shaft to lubricate the sliding surface of the
bushing. Each end of the bushing is installed with floating oil seal to prevent oil leakage and to prevent mud
and water from entering.
In order to improve the wear resistance, the idler is made of silico-manganese alloy steel castings, and
the idler that contacts with the track links has gone through high-frequency hardening.
3-39
thickness of standard adjusting spacer:

4mm. Adjustment range: 0~6mm
Parts of Bulldozer
1. Idler 2. Sleeve 3. Shaft 4. Cover 5. Floating oil seal 6. Guide plate

Figure 3-38 Idler
3.1.11.3 Track roller (see Figure 3-39)
The track roller is used to support the weight of the bulldozer and to prevent the horizontal derailment of
track.
Track roller is installed on the bottom of the both sides track frame, through which evenly distributes the
weight of the machine to the crawler. The track roller assembly consists of track roller (1), bushing (2),
floating oil seal (4), shaft (5) and cover (3). The track roller is made of special alloy steel and has gone
through quenching and tempering treatment.
There are two kinds of track rollers: for one kind there is only a flange at the outer side; for the other
kind, there are flanges at both the inner and the outer side. Track roller withstands the thrust load (axial load),
and the single-sided and two-sided track rollers are arranged alternately. There are oil holes on the track roller
for injecting the grease to lubricate the sliding surface of the bushing. Both ends of the bushings are installed
floating oil seal to prevent oil leakage and prevent mud and water from entering.
Track roller can be divided into single-sided and two-sided structure, this figure shows the single-sided
track roller structure. Except that the shapes of the track roller hubs (1) are different, other structures of the
single-sided and two-sided track roller are the same.
3-40

Parts of Bulldozer
1. Track roller 2. Sleeve 3. Cover ring 4. Floating oil seal 5. Shaft
Figure 3-39 Track roller
3.1.11.4 Carrier roller (see Figure 3-40)
Carrier roller is arranged on the top of the trolley frame at both sides. The role is to support the upper half of
the entire track when the machine is traveling to prevent the track from swinging or shaking under its own
weight. The carrier roller, raceway and flange part made of special alloy steel are all hardened by heat
treatment. The flange part is used to withstands the thrust load (axial load), so as to prevent the track from
slipping from the carrier roller.
Oil holes are drilled on the shaft to supply lubricant (engine oil) to the sliding surface of the bushing.
One end of the bearing is fitted with a floating seal to prevent oil leakage and prevent mud and water from
entering.
3-41
1. Support 2. Shaft 3. Inner cover 4. Floating oil seal 5. Seal 6. Carrier roller 7. Cover 8. Nut
Parts of Bulldozer
Figure 3-40 Carrier roller

3.1.11.5 Track
The role of the track is to distribute the bulldozer ’s weight to the ground, so as to ensure the adhesion of
the bulldozer and provide driving force for the track shoe (see Figure 3-41, 3-42).
3.1.11.5.1 Track used for dry land
1. Dust seal ring 2. Pin 3. Main dust seal ring 4. Main pin 5. Link 6. Main pin sleeve 7. Pin sleeve
3-42
8. Single-tooth track shoe 9. Track shoe bolt 10. Track shoe nut
Figure 3-41 Track used for dry land
3.1.11.5.2 Track used for wet land

Parts of Bulldozer
1. Ordinary pin seal ring 2. Ordinary pin 3. Main pin seal ring 4. Main pin 5. Track link 6. Main pin
sleeve 7. Ordinary pin sleeve 8. Track shoe 9. Track bolt 10. Track nut
Figure 3-42 Track used for wet land
3.1.11.6 Suspension device (see Figure 3-43, 3-44)
This machine adopts semi-rigid suspension. As shown in Figure 3-35 and Figure 3-3 6, the equalizing
beam (1) is fitted in the main frame through the center pin (2), and both of its ends are supported on the track
frame. Due to this kind of arrangement, the front half of the mechanism’s weight is passed to the track frame
through the equalizing beam, while the vibration from the trolley frame to the main frame is absorbed by the
equalizing beam. Bracket pin on both the left and right sides of the trolley frame can prevent the front part of
the machine from rising too high during the traveling and operation. In addition, the equalizing beam is also
designed to be able to rotate on the center pin.
In order to lubricate the equalizing beam, the main frame is equipped with a grease cup. The lubricating
grease is transferred to the center pin through the filling tube and the oil hole inside the center pin, to
lubricate the sliding gauge between the pin and its sleeve.
3-43
Section A-A
1. Equalizing beam 2. Pin 3. Retaining pin 4. Sleeve 5. Dust seal

Parts of Bulldozer
Figure 3-43 Suspension device (used on dry land)
Cross section A-A
1.Equalizing beam 2. Pin 3. Retaining pin 4. Sleeve 5. Dust seal

Figure 3-44 Suspension device (used on wet land)
3.2 Hydraulic System
Hydraulic system consists of three parts: hydraulic system of working device and hydraulic system of
main clutch and steering.
3.2.1 Hydraulic system of working device
a) Angle blade bulldozer (without ripper)
When the Engine is running, the bulldozing plate joystick is in the “HOLD ” position (see Figure 3-45
and Figure 3-46).
3-44

Parts of Bulldozer
Figure 3-45 Hydraulic system of the angle blade bulldozer
3-45
Lower Lift
Float Lower Hold Lift
Starting pressure
Parts of Bulldozer
PAR112
227 r/min. (1850rmp)
1. Working oil pump 2. Main safety valve 3. Check valve

4. Blade lift controlFigure 3-46 Hydraulic control
valve stem 5. Liftprinciple
cylinder of the
the angle blade bulldozer
bulldozer 6. Oil filling valve for lifting
7. Oil
b) Angle
filling blade
valve bulldozer
for lowering
(with ripper) 8. Hydraulic oil filter 9. Hydraulic oil tank
When the engine is running, and both joysticks are in the “HOLD” position (see Figure 3-47 and Figure
3-48).
3-46
Lift Lower
Lift
Lower

Parts of Bulldozer
Blade Ripper
① Lift ○
A Lift
② Hold ○
B Hold
③ Lower ○
C Lower
④ Float
Figure 3-47 Hydraulic control system of the angle blade bulldozer (with ripper)
3-47
Lift Lower
Lower Hold Lift
Lower Lift Starting pressure

0.15MPa
Parts of Bulldozer

4. Blade lift control valve stem 5. Lift cylinder of the bulldozer 6. Oil filling valve for lifting
7. Oil filling valve for lowering 8. Check valve 9. Control lever of the ripper
10. Lifting cylinder of the ripper 11. Oil filling valve for lifting 12. Oil filling valve for lowering
13. Overload valve for lifting 14. Overload valve for lowering 15. Hydraulic oil filter
16. Hydraulic oil tank A. Main safety valve pressure tap
Figure 3-48 Hydraulic control principle of the angle blade bulldozer (with ripper)
3-48
c) Straight-tilt blade bulldozer

When Engine is running, the bulldozing plate joystick is in the “HOLD ” position (see Figure 3-49 and
Figure 3-50).
Lift
Lower

Parts of Bulldozer
Blade lift
control valve
Blade tilt
control
valve
① Lift
② Hold
○
A Tilt left
③ Lower
○
B Hold
④ Float
○
C Tilt right
Figure 3-49 Hydraulic control system of the straight-tilt blade bulldozer
3-49
Lower Lift

Starting pressure
Parts of Bulldozer

4. Lift control valve lever of the bulldozer 5.Lifting cylinder of bulldozer 6.Oil filling valve for lifting
7. Oil filling valve for lowering 8. Hydraulic oil filter 9. Hydraulic oil tank
Figure 3-50 Hydraulic control principle of the angle blade bulldozer

d) Straight-tilt blade bulldozer (with ripper)
When the engine is running, and the bulldozing plate joystick is in the “HOLD” position (see Figure
3-51 and Figure 3-52)
3-50
Lift Lower
Lift
Lower

Parts of Bulldozer
Blade lifting Blade tilting Ripper
① Lift ○
A Tilt left ○
D Lift
② Hold ○
B Hold ○
E Hold
③ Lower ○
C Tilt right ○
F Lower
④ Float
Figure 3-51 Hydraulic control system of the straight-tilt blade bulldozer (with ripper)
3-51
Lower Lift

Tilt right Tilt left

Parts of Bulldozer
Tilt right Hold Tilt left
Starting pressure
1. Hydraulic oil pump 2. Main relief valve 3. Flow control valve 4. Tilt control valve lever
5. Tilting cylinder 6. Check valve 7. Blade lifting control 8. Blade lifting cylinder
lever
9. Suction valve of the 10 Suction valve of the 11. Check valve 12. Control valve lever of
lifting cylinder head lifting cylinder end the ripper
13. Ripper cylinder 14. Suction valve of the 15. Suction valve of the 16. Safety valve of the
ripper cylinder head ripper cylinder end ripper cylinder head
17 Safety valve of the 18. Oil filter 19. Hydraulic A. Pressure test connector of the main
ripper cylinder end relief valve
Figure 3-52 Hydraulic control principle of the straight-tiling blade bulldozer (with ripper)
3.2.1.1 Working oil pump (see Figure 3-53)
3-52

1. Driving gear shaft 2. Front cover of the pump 3. Pump body 4. Rear cover of the pump 5.Driven
Parts of Bulldozer
gear Type: Gear pump (PAR112) Flow: 250L/min (1850rmp) Set pressure: 14MPa (140Kgf/cm 2)
Figure 3-53 Gear oil pump
3.2.1.2 Working principle of the working device
Gear pump sucks the working oil out of the working oil tank, and pumps it into the blade lift and tilt
control valve (there is only blade control valve on the angle blade bulldozer). If no working device is
operated, the oil will return to the working oil tank through the blade lift and tilt control valve, ripper control
valve (with ripper) and oil filter. If the oil filter element is clogged, the oil will push the oil filter safety valve
open to return to the working oil tank. If the blade lift and tilt control valve is operated, you can control the
blade cylinder to achieve the lifting, lowering, hold and float operation of the blade and you can also control
the tilt cylinder to achieve the ltyeft tilt, right tilt and hold operation of the blade. If manipulate the ripper
control valve, you can control the ripper cylinder to achieve the lift, lower and hold of the ripper.
The inlet check valve is in front of the reversing valve to overcome the nodding impact that may be
produced during the reversing of each working mechanism.
In order to make the tilting cylinder obtain a desired moving speed, the flow control valve has been
installed.
In order to prevent the system pressure from being too high due to overload during ripper operation,
main safety valve has been installed for protection.
During operation, if the load is too large, the system pressure may exceed the setting pressure of 14MPa
in short term, and then the main safety valve will be activated and the working oil will return to the oil tank
through the relief valve to protect the system.
3.2.1.3 Main safety valve (see Figure 3-54)
3-53
1. Pressure regulating cock 2. Locking nut 3. Cover body 4. Spring 5. Pilot valve 6. Valve seat 7.
Valve body 8. Spring 9. Main safety valve
Figure 3-54 Main safety valve
3.2.1.4 Suction valve (see Figure 3-55)

Parts of Bulldozer
The suction valve has been installed to prevent vacuum phenomenon from occurring in the oil cylinder
when the direction of the external force is the same as the moving direction of the cylinder piston.
Figure 3-55 Suction valve

Above valves are all fitted in the oil tank of the working device.
3.2.1.5 Working oil tank (see Figure 3-56, 3-57)
To prevent dust from polluting the working oil, the oil tank of the working device should be designed of
closed structure.
3-54
To the hydraulic pump
A. To the oil filter B. To the ripper control valve C. From the hydraulic pump D. To the blade lifting
cylinder end E. To the blade lifting cylinder head F. To the ripper cylinder end G. To the ripper cylinder
head
Figure 3-56 Hydraulic oil tank equipped with ripper and angle blade

Parts of Bulldozer
To the hydraulic pump
A. To the ripper control valve B. To the blade lifting cylinder end C. To blade lifting cylinder head D.
From the hydraulic pump E. To the blade tilting cylinder end F. To the blade tilting cylinder head G. To
the ripper cylinder end H. To the ripper cylinder head I. To the oil filter
Figure 3-57 Hydraulic oil tank equipped with ripper and straight-tilt blade
3.2.1.6 Structure of hydraulic cylinder
3.2.1.6.1 Overview
Hydraulic cylinder is a kind of device that converts hydraulic energy into mechanical energy for linear
motion, and there are oil chambers both at the head (piston rod end) and the bottom of the cylinder. If the oil
enters from the head, the piston will move to the bottom and then the oil at the bottom will enter into the oil
tank. Similarly , if the oil enters from the bottom, the piston will move to the head and then the oil at the head
will enter into the oil tank.
Therefore, such type of piston that can move in both directions is referred to double-acting piston.
Oil cylinder is made of steel tube and the bottom is welded with steel plate. The interior of the cylinder
has been honed and processed to prevent piston ring wear or oil leakage.
3.2.1.6.2 Piston valve (see Figure 3-58)
3-55
Piston valve is installed in the piston of the

straight-tilt blade bulldozer ’s blade lift ing cylinder. As Piston Valve
valve seat Low
shown in the right figure, when the piston valve is Valve pressure oil
seat
opened, the oil at the high pressure side will flow to the Piston
rod
low pressure side. Therefore, its role is to reduce the
pressure when the piston is about to arrive at the end of
its stroke. If the blade of the straight-tilt blade bulldozer
is inclined, then the strokes of the pistons of the left and
right lifting cylinders are different.
In this situation, the piston valve of the earlier fully
retracted cylinder will open to release the high pressure
Figure 3-58 Piston valve
oil to the low pressure side. This can prevent the
hydraulic pressure from rising, so that the cylinder at the other side can stop retracting , thus avoiding blade
twist.
In addition, the piston type slide valve has several other roles.
If the piston rod moves quickly and suddenly stops when it reaches its end, then a great pressure impact
Parts of Bulldozer
may be caused within the oil circuit.

If too much oil enters into the oil cylinder, the
Piston Piston Piston
pressure inside the oil circuit will rise sharply and the oil rod valve
will be discharged through the main safety valve of the

control valve.
As a result, each time when the piston reaches to its
end of stroke, the working principle of the piston valve is
as follows:
a) When the piston is moving.
the oil from the working pump will push the piston Valve seat
Valve seat
and piston valve move to the right. (See Figure 3-59)
Figure 3-59 Piston moves
The piston valve is pushed to the right, so its
Piston valve
tapered portion will in contact with the piston valve seat,
and thus the hydraulic oil cannot pass. As a result, the
pressure within the cylinder will rise and push the piston
rod to move to the right.
b) When the piston valve is working (See Figure
3-60) Valve seat Valve seat
Before the piston is about to reach its end of stroke, the end point of piston valve will contact with the
cylinder end (or cylinder head). The piston valve will stop at this location and no longer moves, but the
piston rod will continue to move to the right. Therefore, a Figure 3-60 Piston valve works
clearance will form between the tapered portion and the
valve seat of the piston valve. The high pressure oil within the oil cylinder will overflow through this
clearance, so that the hydraulic pressure will no longer rise.
3-56
Thus, the piston valve prevents the generation of the impact pressure, and thereby also prevents oil
discharge through the safety valve. Oil just flows to the low pressure side of the oil circuit just through the
piston valve. The occurrence of both pressure impact and oil discharge is undesirable. Therefore, in order to
prevent this phenomenon, the piston valve should be activated before the piston is about to reach its end of
stroke. Then the oil can be discharged to the low pressure side and thus impact pressure and pressure
reduction of oil circuit can be prevented. Meanwhile vibration generated when the piston impacts the cylinder
head or end can be reduced.
3.2.1.6.3 Oil cylinder cover (see Figure 3-61)
Sealing
There are two types of oil cylinder covers, one is Dust ring
ring
mounted in the cylinder with bolts, as shown in the figure.
The other type is threaded and can be directly screwed Piston
rod
into the oil cylinder. Bushing (bronze) is mounted in the
center hole of the cylinder cover, so that the piston rod
does not slide directly with the cylinder cover.

In addition, sealing ring has also been fitted to
Parts of Bulldozer
prevent oil in the cylinder from leaking from the Bushing sleeve
clearance between the cylinder cover and the piston rod.
Figure 3-61 Cylinder cover
Furthermore, dust ring can prevent the dust on the
piston rod from entering the oil cylinder when the piston
rod is retracting.
3.2.1.6.4 Piston (see Figure 3-62)
Piston ring has been equipped for the piston slipping in the internal cylinder (Figure 3-62 left), so as to
prevent the oil from flowing from the high pressure side into the low pressure side through the piston.
If the hydraulic pressure is applied from the other side, back up ring will change its shape and the slip
ring seal will be pushed to the cylinder to prevent oil leakage.
Furthermore, the piston and cylinder are all made of steel. Therefore, mutual abrasions are bound to
occur in case of direct sliding contact. In order to prevent this phenomenon, the piston is equipped with
antifriction ring which is made of bakelite and with filler.
3-57
Cylinder Back-up ring

Slip ring
Upper back-up ring
Piston rod
Antifriction ring
Piston ring
Piston
1. Ear ball piston 2. Seal cover 3. Oil cylinder cover 4. Cylinder body 5. Piston rod 6. Nut 7.
Bushing 8. Sealing ring 9. Bushing 10. Dust ring
Figure 3-62 Piston

Parts of Bulldozer
3.2.1.6.1 Blade lifting cylinder (see Figure 3-63)
1. Ear ball piston 2. Seal cover 3. Oil cylinder cover 4. Cylinder body 5. Piston rod 6. Bushing 7.
Nut 8. Bushing 9. Sealing ring 10. Bushing 11. Dust ring 12. Baffle 13. Upper back-up ring 14.
Slipping ring seal 15. Back-up ring 16. Antifriction ring 17. Piston 18. Valve seat 19. Piston valve
20. Ear ball cover
Figure 3-63 Lifting cylinder
The outer diameter of the piston rod of blade lifting cylinder is 65mm, the inner diameter of cylinder is
110mm, the effective stroke of piston is 1026mm, the maximum length of cylinder is 1744mm, the minimu m
length of cylinder is 708mm and the caliber of piston nut wrench is 55mm.
3.2.1.6.2 Blade tilting cylinder (see Figure 3-64)
3-58
Bushing 8. Piston 9. Antifriction ring 10. Upper back-up ring 11. Bushing 12. Sealing ring 13.
Bushing 14. Dust ring
Figure 3-64 Blade tilting cylinder of the straight-tilt blade bulldozer

The outer diameter of the piston rod of tilting cylinder is 70mm, the inner diameter of cylinder is
Parts of Bulldozer
160mm, the stroke of piston is 140 mm, the maximum length of cylinder is 1236 mm, the minimum length of
cylinder is 1096mm and the caliber of piston nut wrench is 80mm.
3.2.1.6.3 Ripper cylinder (see Figure 3-65)
Bushing 8. Sealing ring 9. Bushing 10. Dust ring 11. Upper back-up ring 12. Slip ring seal 13.
Bushing 14. Antifriction ring 15. Piston
Figure 3-65 Ripper cylinder
The outer diameter of piston rod is 75mm, the inner diameter of cylinder is 160mm, the stroke of piston
is 350mm, the maximum length of cylinder is 1080mm, the minimum length of cylinder is 730mm and the
caliber of piston nut wrench is 80mm.
3.2.2 Hydraulic system of main clutch
Main clutch hydraulic system consists of coarse filter, main clutch pump (1), main clutch booster (2)
and main safety valve. (See Figure 3-66)
3-59
1. Main clutch pump 2. Main clutch booster

Figure 3-66 Main clutch hydraulic system
Parts of Bulldozer
The engine oil of the main clutch housing that is filtered by the coarse filter is sucked into the main
clutch pump (1) and sent to the main clutch booster (2) which is controlled by the main clutch lever.
When the main clutch handle is placed in the “Engage” or “Separate” position, the engine oil pressure of
the pipe will rise. When the oil pressure is 3MPa, the main safety valve will overflow oil which flows to the
main clutch and PTO box from the booster to lubricate.
3.2.2.1 Hydraulic control of the main clutch (see Figure 3-67)
When the engine is running, the main clutch is in “Engage” state.
3-60
Engage
Separate
Separate
Engage
Set pressure
Separate

Parts of Bulldozer
Engage
Separat
e
Engage
1. Main clutch pump 2. Main clutch booster 3. Main safety valve 4. Main clutch 5. PTO box 6.
Main clutch housing A. Pressure testing connector of the main clutch booster (1/8 pipe thread)
Figure 3-67 Hydraulic control of the main clutch
3.2.2.2 Main clutch pump (double-pump) (See Figure 3-68)
Outlet Inlet
Main clutch pump (steering pump)
1. Driving gear 2. Bracket 3. Housing 4. Middle box 5. Bracket 6. Housing 7. Driving gear 8.
Side plate 9. Cover 10. Driven gear 11. Sealing ring 12. Driven gear Type: Gear Pump
displacement: 57.9 L/min. (1850rpm) Setting pressure: 3MP
Figure 3-68 Main clutch pump
3.2.3 Steering brake oil circuit
Steering hydraulic system is mainly composed of coarse filter (1), steering pump (2), steering fine filter
3-61
(3), steering control valve (4), brake booster, safety valve and oil cooler (5) (see Figure 3-69).
Parts of Bulldozer
1. Steering coarse filter 2. Steering pump 3. Steering fine filter 4. Steering control valve 5. Oil cooler
Figure 3-69 Steering clutch and brake pipeline
The hydraulic oil in the steering clutch box is sucked through the magnetism coarse filter (1), steering
pump (2), then is pumped to the steering fine filter (3), and will flow to the steering control valve (4), brake
booster and safety valve.
Hydraulic oil released by the safety valve [setting pressure of 2MPa (20kgf/cm2)] flows into oil cooler
bypass valve.
For reasons such as an oil cooler (5) or lubrication system is clogged, when the oil pressure of the cooler
bypass valve exceeds the set pressure of 1.2MPa (12kgf/cm), the hydraulic oil should be discharged into the
steering clutch box.
When the steering rod is pulled to a half, the hydraulic oil flowing to the steering control valve (4) will
flow into the steering clutch. When the steering rod is pulled to the end, the hydraulic not only continues to
flow to the steering clutch to separate the steering clutch, but at the same time flows into the brake booster to
make the brake work.
3.2.3.1 Schematic and structure diagram of Steering brake oil circuit (see Figure 3-70, 3-71)
3-62
ON
OFF
Separate Engage
Separate Engage

Parts of Bulldozer
ON
Setting pressure Settingpressure OFF
Opening
pressure
FAR 032
57.9 L/min.
(1850 rpm)
1. Steering coarse filter (magnet type) 2. Steering pump 3. Steering fine filter 4. Safety valve 5. Oil
cooler bypass valve 6. Oil cooler 7. Steering control valve 8. Brake valve 9. Brake booster 10. Left
steering clutch 11. Right steering clutch 12. Steering clutch box
A. Pressure tap of the safety valve (ZG1/8) B. Pressure tap of the left steering clutch (ZG1/8)
C. Pressure tap of the right steering clutch (ZG1/8) D. Pressure tap of the left brake booster (ZG1/8)
E. Pressure tap of the right brake booster (ZG1/8) F. Pressure tap of the bypass valve (ZG1/8)
Figure 3-70 Schematic diagram of steering brake system
3-63
To the right
control
steering
mechanism
To the right
Parts of Bulldozer
brake booster
From the right steering valve
Figure 3-71 Schematic diagram of steering brake system

3.2.3.3 Steering control valve
Steering control valve consists of two steering valves (12) to control the oil circuit flowing into the left
and right steering clutches, and two brake valves (20) on the left and right to control the oil circuit flowing
into the left and right brake boosters.
3.2.3.3.1 Structure (see Figure 3-72)
3-64
From the oil pump

To the steering clutch
Parts of Bulldozer
To the brake booster
Pressure port of the From the steering Pressure port of the

right brake booster oil pump left steering clutch
Pressure port of the left Pressure port of the

brake booster left steering clutch
1. Steering valve body 7. Lever 8. Adjusting bolt 9. Shaft 10. Spring 11. Guide sleeve 12. Steering
valve stem 13. Spring 14. Piston 15. Cock 16. Guide seat 17. Shaft 18. Spring 19. Spring 20.
Brake valve stem 21. Spring 22. Piston 23. Cock
Figure 3-72 Steering control valve
3-65
From the steering oil pump
To the brake valve

Parts of Bulldozer
To the pressure port of To the pressure port of

the left brake booster the right brake booster
From the steering
oil pump
To the left brake To the right
booster brake
booster
2. Tube 3. Brake valve body 4. Bolt 5. Washer 6. Lever

3-66
3.2.3.3.2 Working principle of the steering control

valve To the oil cooler
a) When the steering rod has not been pulled:
(steering clutch is engaged; the brake will not work)
Hydraulic oil flows to the safety valve (24), steering
control valve chamber (A) and brake booster from the
steering pump. But the oil circuit of the steering valve and
brake booster is cut off, so the oil pressure in the circuit
From the
will rise. When the pressure exceeds the setting pressure steering oil
pump To the brake booster
of the safety valve (24) of 2MPa (20Kgf/cm2), then the
hydraulic oil will be discharged and sent to the oil cooler.
b) When slightly pulling the steering rod: (steering
clutch is half engaged, without applying brake)
When pulling the steering rod, lever (7) pushes the

compression spring (10) along the direction indicated by
Parts of Bulldozer
the arrow and the spring pushes the steering valve stem Tothe brake booster
(12) along the direction indicated by the arrow. As a result,

the chamber (B) and chamber (G) will be closed and the From the steering oil pump
chamber (A) and chamber (B) will be opened. Then the

hydraulic oil will inject into the steering clutch. Oil
pressure will start to rise after the steering clutch is filled
with hydraulic oil.
The hydraulic oil flowing to the chamber (c) through
the orifice (a) pushes the piston (14), and its reaction force
will push the steering valve stem (12) along the direction
indicated by the arrow, and compress the spring (10).
Steering valve stem (12) will close the chamber (A) and
chamber (B) to cut off the hydraulic oil flowing to the
chamber (B) At this time the oil pressure within the valve
is in equilibrium with the spring. If further pulling the
steering rod, spring (10) is further compressed, which can
also pull the steering valve stem to the right to repeat the
above actions, then the oil pressure will further rise, the oil To the steering clutch
pressure is in a new equilibrium with the spring after the To the brake booster
oil pressure rising, and the steering clutch is partly
separated.
c) When the steering rod is pulled to the blocked position Figure 3-73 Steering control valve action
(When the steering rod is further pulled after being pulled to this stroke position, you feel that larger
pulling force is needed): (the steering clutch will be disengaged and the brake will not work)
3-67
When pulling the steering rod to the blocked position,

shaft (9) move along the direction indicated by the arrow,
and contact with the guide sleeve (11). Shaft (9) will push
guide sleeve (11), and then the guide sleeve will push the
steering valve stem (12), so even the pressure in the
chamber (B) rises, the steering valve stem (12) will not
move to the left. Spring (10) will be fully compressed and
the hydraulic pressure will reach 1.89MPa (18.9Kgf/cm2 ) To the steering clutch
(regulating process is completed). Hydraulic pressure will
continue to rise to 2MPa (20Kgf/cm2), i.e. setting pressure
of the safety valve, and then the steering clutch will be From the steering oil pump
completely disengaged.
d) When further pulling the steering rod: (steering
clutch will be disengaged, and oil pressure of brake circuit
will starts to rise)

Parts of Bulldozer
Since the shaft (9) contacts with the sleeve (11), the To the steering clutch
opening width of the chamber (A) and chamber (B) is the To the brake booster
same as that of the moving distance of the shaft (9).
Due to the role of the adjusting bolt (8), shaft (17)
will move to the right and push the brake valve stem (20).
Therefore, chamber (E) and chamber (H) are cut off, and
the chamber (D) and chamber (E) are connected at the
same time, then the hydraulic oil will flow to the brake
booster through the chamber (E). To the brake booster
Pressure oil flowing to the chamber (F) through the
orifice (b) pushes the piston (22), and its reaction force
will push the brake valve stem (20) to the left, and
compresses the spring (18). Brake valve stem (20) will cut
off the oil circuit from the chamber (D) to the chamber (E),
and then the system pressure will be balanced with the
force of the spring (18).
If further pulling the steering rod, the spring (18) will
be further compressed and the spring force will increase,
As a result, the oil pressure in equilibrium will rise with Figure 3-74 Steering control valve action
the increase of the spring compression force, thus making
the brake start to work.
e) When the steering rod is pulled to the end: (steering clutch will be disengaged; applying brake)
Shaft (9) will move to the right until the sleeve (G) and (H) connect with each other. Then shaft (9)
cannot move to the right any more, and the steering valve stem (12) cannot further move either like shaft (9).
Shaft (17) can still push the brake valve stem (20) to the right due to the pushing of the adjusting bolt (8).
3-68
But even when the shaft (9) reaches the end of the stroke,
the shaft (17) does not reach the end of stroke. Therefore,
the pressure oil flowing to the chamber (F) from the
orifice (b) will push the piston (22), and its reaction force
will push the brake valve stem (20) to the left and
compress spring (18). Brake valve stem (20) will cut off
the pressure oil circuit from the chamber (D) to the
chamber (E). System pressure and spring (18) force can
reach a balance. When the steering rod is pulled the end,
spring (18) force reaches the maximum. The circuit Tothe brake booster
pressure in equilibrium with the spring (18) force also

reaches the maximum valve of 1.67 MPa (16.7 Kgf/cm 2),
and thus the brake band clasps with the brake drum to
complete the braking process.

f) When putting back the steering rod back: (the
Parts of Bulldozer
steering clutch will be engaged and the brake will not
work)
Shaft (9), shaft (17), brake valve stem (20) and
steering valve stem (12) are all return to their original
positions due to corresponding spring force. In this
situation, steering valve stem (12) will cut off the oil
circuit from the chamber (A) to chamber (B) and connect
the chamber (B) and chamber (G) at the same time, and
then the hydraulic oil in the steering clutch will be
discharged into the clutch box through the chamber (B)
and chamber (G).
In addition, brake valve stem (20) will cut off the oil
To the steering clutch box
circuit from chamber (D) and chamber (E) (Figure 3-76),
Form the steering clutch
connect the chamber (E) and chamber (H) at the same
From the brake booster
time, and then the hydraulic oil will be discharged into the steering clutch box through the chamber (E) and
To the steering clutch box
chamber (H).
The oil is discharged into the rear axle box through Figure 3-75 Steering control valve action
the oil inlet G. Brake valve (15) closes the pathway
between the oil inlet D and E and the pathway between the oil inlet E and F will open, so that the oil in the
brake booster can be discharged into the rear axle box through the oil inlet H.
3-69
3.3 Electrical system

Bulldozer electrical system which consists of starting motor, silicon rectification generator, magnetic
switch, voltage regulator and two batteries (12V) is mainly used for starting the diesel engine and lighting.
Schematic diagram of electrical system(see Figure 3-76).
Wiper
Safety relay
Start er relay
Fuel relay
Fan
lamp
Cab
Fus ebox
Cab
Batteryrelay
Rear lamp
Parts of Bulldozer
Battery
Neutral
s witch
Pres s ure s witch
Water temperature s ensor

Starter
Buzzer
Trans former temperature s ens or

Horn s witch
Generator 24V
Front lamp
Horn
Rearlamp s witch
Front lamp s witch
Standby s witch
Figure 3-76 Schematic diagram of electrical system
3-70
3.4 Working Devices

Working devices mainly refer to dozer blade and ripper, namely devices for completing various
operations of bulldozer.
3.4.1 Dozer blade
There are straight-tilt blade, angle blade, U-shape blade and other blades, among which straight-tilt
blade is included in standard configuration, while angle blade, U-shape blade and other blades can be freely
selected by user.
3.4.1.1 Straight-tilt blade (see Figure 3-77)

Parts of Bulldozer
Profile B-B Profile C-C Profile D-D
Profile A-A Profile E-E Profile F-F Profile G-G
1. Dozer plate 2. Blade 3. Blade angle 4. Brace 5. Tilting cylinder (left side) Brace (right side) 6.
Direct pushing beam 7. Ear shaft 8. Yoke
Figure 3-77 Straight-tilt blade
3-71
The push rod of straight-tilt blade is of box structure. Its bending strength, pressure resistance stability
and rigidity are superior. Its front end with cruciform joint is connected with blade and its trailing end is
hinged with the trunnion (7) fixed on frames.
Under the action of blade cylinder, both the push rod and cutting head swing with the trunnion (7) as the
center, thus realizing lifting and lowering of blade.
Tilting oil cylinder (5) may make blade tilt left and right at a direction vertical to the ground.
The blade (2) can be turned over and reused after the use for a period.
3.4.1.2 Angle blade (see Figure 3-78)
Profile A-A
Parts of Bulldozer
Profile B-B
Profile C-C
Profile E-E Profile F-F Profile G-G Profile H-H Profile D-D
1. Blade 2. Blade 3. Blade angle 4. Upper support 5. Arch frame 6. Ear shaft 7. Arm 8. Fork arm
9. Central shaft 10. Link block
Figure 3-78 Angle blade
The dozer blade (1) made of high strength steel plate is firm and tenacious enough to withstand the
heavy-duty works. The blade (2) is made of carbon steel and there are cutting edges on both of its sides, so it
can be used with both edges. Side blade (3) is a steel casting with good wear-resistance and high strength.
Arch frame (5) is of box structure and is also made of steel with high tensile strength. Moreover, its front part
is connected to the blade by joint, while its rear part is hinged on the track frame with the help of trunnion (6).
3-72
Arch frame can move up and down under the action of blade lifting cylinder. The blade is supported on the
arch frame by the center shaft (9), lower support (7) and upper support (4).
3.4.2 Ripper (See Figure 3-79)
The upper connecting rod (3) and lower connecting rod (7) are fixed on the ripper support by using pin
A and pin D, and the support is installed on the surface of the steering clutch box’s rear part by using nuts.
Beam (4) is installed on the opposite ends of the upper connecting rod and lower connecting rod by pin B and
pin C.

Parts of Bulldozer
Profile A-A
Profile B-B
Profile C-C
Profile D-D
View Z
1. Ripper bracket 2. Ripper cylinder 3. Upper connecting rod 4. Beam 5. Gear rack 6. Tooth tip 7.
Lower connecting rod
Figure 3-79 Ripper
Ripper rack (5) is installed on the beam (4) by using pin, while its tooth tip (6) is fixed on the rack with
3-73
pin to lift and lower the ripper oil cylinder of rack. The bottom of cylinder is fixed on the support (1), while
the piston rod is fixed on the beam (4). To realize digging of the tooth tip , four-link mechanism (a
parallelogram mechanism consisting of pin A, pin B, pin C and pin D) is used. Extension or retraction of
ripper oil cylinder may drive the rack to go up and down. When cutting soil, the tooth tips can maintain the
optimal cutting angle.
In view of the soil texture and hardness, one tooth or two teeth may be removed to make the ripper work
under double teeth or single tooth state.
Parts of Bulldozer
3-74
Chapter Four: Maintenance of Bulldozer

Chapter Four: Maintenance of Bulldozer

4.1 Maintenance Information of Bulldozer
When operating or steering the machines, users must carry out regular maintenance and repair work for
them, so as to guarantee safety. In addition, to further improve safety, users should also replace the key parts
regularly, because the materials of these parts will change as time passes by and these parts are prone to wear
down or deteriorate. Since it is hard to determine the conditions of parts through regular maintenance, you
should change the parts when the prescribed time for replacement arrives, which is essential to guarantee that
these parts are in good condition all the time. These parts are closely related to safety and fire prevention.
If these parts are abnormal before the replacement cycle arrives, they must be repaired or changed
instantly. Please contact Zoomlion or Zoomlion dealers to replace the key safety parts. Before maintaining
and repairing excavators, please read the “Operation Manual” and the following maintenance guidelines first.
Prompt
Don’’ t carry out any inspection and maintenance not described in this manual.
1. Don
2. Maintenance and repairs should be done on flat and firm ground.
Meter’’s Readings
4.1.1 Hour Meter
Check the readings of the hour meter every day and see whether they have arrived the required time to
carry out maintenance.
4.1.2 Genuine Wearing Parts of Zoomlion
Maintenance of Bulldozer
Use the genuine parts of Zoomlion specified in the “Parts Catalogue” for replacement.
4.1.3 Lubricating Oil
Use the engine oil and lubricating oil designated by Zoomlion. Choose the engine oil and lubricating oil
with suitable viscosity according to ambient temperature. Keep the oil or the grease container clean. Don’t let
any impurities mix into the oil and the grease.
4.1.4 Check the Discharged Oil and the Used Filter Cartridge
After changing the oil or the filter cartridge, check if there is metal debris or impurities in the old oil and
the filter cartridge. If a mass of metal debris and impurities are found, report to the executive stuff and take
proper measures.
4.1.5 Coarse Fuel Filter Cartridge
If the machine is assembled with coarse fuel filter cartridge, don’t remove the filter cartridge when
adding fuel.
4.1.6 Notes for Welding
a) Disconnect the starter switch of the engine and disconnect the battery cathode.
b) Don’t use a voltage over 220V continuously.
c) Connect grounding cables within 1m from the welding location. If the grounding cables are close to
the apparatus or connectors etc., failures may occur.
d) Avoid sealing elements or bearings between the welding location and the ground point.
e) Don’t use the surrounding regions of the working device’s pin or the hydraulic cylinder as the ground
4-1
point.
4.1.7 Working Sites with Much Dirt
When working at places with much dirt, please do as the following procedures:
a) The dirt indicator should be used frequently to check whether the air filter is blocked and clean the
filter cartridge more frequently.
b) Clean the radiator filter frequently to prevent it from being clogged.
c) Clean and replace the fuel filter cartridge regularly.
d) Clean the electrical parts, especially the starter motor and the alternator to avoid dirt accumulation.
e) When checking or changing oil, move the machine to a place without dirt, so as to prevent the dirt
from entering the oil.
4.1.8 Hydraulic System—Exhausting
System—
When the hydraulic system is repaired or changed or the hydraulic pipeline is dismantled or installed, air
must be discharged from the oil circuit.
4.1.9 Installation of the Hydraulic Hose
a) When dismantling parts at positions with O-rings or sealed with sealing gaskets, please clean the
installing surface and replace them with new parts. Do not forget to install the O-rings and sealing gaskets.
b) When installing the hoses, don’t twist the hoses or bend them into circles with minor diameters,
because this will damage the hoses and shorten the hoses’ service life significantly.
4.1.10 Checks after Maintenance and Inspection
If no checks are done after inspection and maintenance, accidental faults may occur and cause severe
injuries or damage. You must do as the following procedures:

a) Inspections after shutting down the machine (after shutting down the engine)
1) Whether the maintained parts have been checked;
2) Whether the inspection and maintenance of all items have been done correctly;
3) Whether there are tools or parts falling into the interior of the machines;
4) Whether there is water leak or oil leak;
5) Whether all the bolts are fastened.
b) Inspections when operating the engine
The inspection details about operating the engines can be seen in relevant chapter of the “Operation
Manual”, and pay attention to safety.
1) Whether the inspection and maintenance items have been done normally;
2) Whether there is oil leak when the engine speed rises and load is imposed.
4.2 Maintenance of Electrical System
a) It is very dangerous if the electrical devices are damp or the wire insulation layers are damaged,
because this will result in electricity leak and machine faults. Don’t use water to wash the interior of the cab.
When washing the machines, pay attention to prevent water from entering the electrical parts.
b) For the maintenance of electrical system, check the tension of the fan belt and check whether the fan
belt is damaged or worn down.
c) Don’t install any electrical elements which are not specified by Zoomlion to install.
4-2
d) The disturbance of the external signals will cause fault of controller in the control system. When
installing radio receiver or other wireless devices, please contact Zoomlion or Zoomlion dealers.
e) When working in the beach, clean the electrical system carefully to prevent corrosion.
f) When installing air cooler or other electrical devices in the cab, connect it to the specialized power
connector, and the selected power can’t be connected to the fuse, the starter switch or the electrical relay of
the storage battery.
4.3 Maintenance of Hydraulic System
The hydraulic system is at high temperature during and after work. During operation, there is also high
pressure in it. Therefore, when doing inspection and maintenance to the hydraulic system, comply with the
following procedures:
a) Park the machine on flat ground, lower the bucket down to the ground and release the pressure in the
hydraulic cylinder and pipeline.
b) Shut down the engine.
c) Before starting maintenance, please wait for the system to cool down.
d) Even if the temperature decreases, there is still pressure in the interior. When loosening the plug
screws, screws or hose connectors, don’t stand in front of the parts. Before dismantling the parts, loosen them
gradually to release the internal pressure.
e) When doing inspection and maintenance to the hydraulic oil pipeline, the internal pressure must be
discharged.
f) The inspection or maintenance items include: check the oil level of the hydraulic oil, replace the filter
cartridge and add hydraulic oil.
g) When dismantling the high-pressure hose, check whether the O-ring is damaged. If it is damaged,
replace it.
4.4 Maintenance of various parts
4.4.1 Check and Adjustment for track tension
tension
Track tension should be detected at any time as the abrasion condition changes on account of different
operating conditions and soil textures, so as to keep the track properly tensioned.
Overhaul and adjustment should be conducted under the same working state.
4.4.1.1 Check of track tension
4-3
Figure 4-1 Overhaul of track tension

The vehicle should be parked on even road surface (stop the vehicle without braking under forward
traveling state), and a rod should be placed between the carrier roller and the idler as shown in Figure 4-1. If
the distance between the rod and the grouser is at 20 ~ 30mm, the tension meets the standards. Otherwise, the
following adjustments must be conducted.
4.4.1.2 Adjustment for track tension
To increase the tension, you can fill lubricating grease through the lubricator (1). To decrease the tension,
you can unscrew the lubricator for one round to let lubricating grease out, as shown in Figure 4-2 and 4-3.
Figure 4-2 Adjustment for track tension Figure 4-3 Adjustment for track tension (continued)
If the track is still loose after filling lubricating grease, it means that pin bush has been seriously worn .
At this time, the pin bush should be reversed or changed.
Danger
There is a risk that the high pressure lubricating grease in the tensioning cylinder may splash out, so the
lubricator (1) shall not be unscrewed for more than one round. At this time, other components except for the
lubricator should be loosened. In case the lubricating grease can not outflow smoothly, you can move the
vehicle forward and backward for a short distance.
4.4.2 Adjustment of idler clearance
Side plate is tightly pressed on the track frame to force the idler to move forward and backward along
4-4
the guide plate of track frame. Therefore, when the idler

moves, the side plate will be subject to wear and this
situation will make the idler swing or tilt, resulting in
that the idler leaves the track or there is uneven
abrasion for track link and idler. The following
adjustment methods can be seen in Figure 4-4:
a) Let the vehicle travel for 1-2 meters on flat
ground, and measure the clearance “A” between the
idler and the track frame (measure at four points: left,
right, inside and outside). Clearance A
b) If clearance “A” exceeds 4mm, unscrew bolt (1),

demount guide plate, take out washer (a) and adjust
Figure 4-4Adjustment for idler clearance
clearance at each side to reach 0.5~1.0mm (the
thickness of each washer (a) is 1.0mm).
Figure 4-5 Adjustment for idler clearance (continued)
brakee pedal travel
4.4.3 Adjustment for brak
The brake pedal travel will increase after the friction
plates have worn down, so the clearance between brake
band and brake drum must be adjusted.
4.4.3.1 Inspection
Braking pedal travel is shown in Figure 4-6. The
travel distance of the pedal top should be 95~115mm . If it
exceeds 125mm, adjustment should be conducted
according to the following methods. The standard
clearance between friction plate and brake drum is 0.3mm
(pedal travel with standard clearance is 95~115mm).
Figure 4-6 Inspection of brake pedal travel
4-5
4.4.3.2 Adjustment
Figure 4-7 Adjustment for brake pedal travel Figure 4-8 Adjustment for brake pedal travel (continued)
Remove the cover (1) at the rear part, and then take down the braking access cover (2). As shown in
Figure 4-7 and Figure 4-8, screw the adjusting nut up (torque tightening: 88N.m) to make friction plates
connect with each other tightly.
Turn the adjusting nut for about 1-5/6 round and then confirm standard clearance and travel.
a) If some problems are found in braking mechanism after adjusting, the repair must be conducted by
customer service department of Zoomlion.
b) Travel distances of the left or right pedals should be the same after adjusting; If any difference is
found, adjustment should be conducted at one side.
c) Travel measurement should be conducted when the engine has been shut down and by applying a leg
power of 147N to depress the pedal.

4.4.4 Adjustment for main clutch
4.4.4.1 Inspection for main clutch
Start the engine to make it high-speed operation,
place the gear lever at forward gear 3, and floor the
brake pedal.
Determine the main clutch required time from
combination to engine stalling.
Standard time: 0.8 to 1.3 seconds
Figure 4-9 Adjustment for main clutch

4.4.4.2 Adjustment for main clutch
It can be seen in Figure 4-9 and Figure 4-10.
a) Remove the inspection cover of main clutch, move the flywheel to adjust the locking mut (1) to
upward side.
Unscrew the locking nut, and pry the locking plate (2) to make it become loose.
There are two locking plates at relative location.
4-6
b) Trigger the heavy hammer lever (4) to make

the adjusting plate (5) run and carry out adjustment.
Opposite side width:of spanner: 50mm.
Engine stops the time-taken and it can be
adjusted as per the following methods:
To reduce time, it is necessary to clockwise
rotate and adjust the plate.
To increase time, it is necessary to anticlockwise
rotate and adjust the plate.
c) Tighten the locking nut after it adjusting.
The locking nut: 90 ±1N•m.
Figure 4-10 Adjustment for main clutch

(continued.)
4.4.4.3 Inspection for inertia brake
Remove the floor, and then start the engine to make it do a high-speed operation.
Forward push the main clutch lever to bottom, test the main clutch axis and stop it time-taken (neutral
position for variable speed device).
Standard time: 2.5~3.5 seconds.
4.4.4.4 Adjustment for inertia brake
a) Start the engine after adjusting the main clutch. Lock the brake pedal, push the main clutch lever to
“splice”, and stop the engine.
b) Unscrew the locking nut (6), as well as spin and adjust the mut (7), tighten the brake (5), and adjust
clearance "b".
The adjustment of clearance "b" can be shown as follows:
Screw in the nut, and reduce clearance.
Screw out nut, and increase clearance.
1) Standard distance “a”: 20mm;
2) Standard distance “b”: 2mm;
3) Inertia brake should be adjusted after assembling.
4.4.5 Adjustment for working device
4.4.5.1 Adjustment for the tilt amount and cutting angle of straight-tilt dozer blade
a) The maximum tilt amount of using the tilting cylinder to adjust the dozer blade is:
Right side: 427mm
Left side: 415mm
For greater tilt amount, you can adjust according to the following methods as shown in Figure 4-6.
4-7
Figure 4-11 Adjustment for blade tilt Figure 4-11 Adjustment for blade tilt (continued.)
Rotate the right strut (1) by pulling the adjusting rod (2). According to the change of the strut length, the
maximum tilt amount can be adjusted to 860mm.
Prompt
1. The maximum tilt amount should not exceed 860mm.

b) Adjustment for the cutting angle
The cutting angle (θ) can be adjusted to the optimum angle for various soils. The rod (1) is used to
adjusting the angle. The cutting angle of the blade will increase when increasing the length of the strut (1)
and the angle (θ) will become smaller when the length of the strut is shortened.
The standard cutting angle of the dozer blade (θ) is 55 o.
4.4.5.2 Adjustment for the inclination angle of

angle blade
The blade can be adjusted to 25° position when you
need to do bulldozing operation at one side. See Figure
4-12 .
Figure 4-12 Adjustment for horizontal angle of

angle blade
a) Raise the bulldozing board for 400～500mm and put a cushion block under the arch frame.
b) Pull out the pins (1) at both sides and dismantle the support arm from the arch frame. See Figure
4-13 .
4-8
Figure 4-13 Angle adjustment of dozer with angling blade of angle shovel
Attention
1. The bulldozing plate can swing freely after the support boom is removed, so pay attention to it.
c) Change the angle of blade, install the support arm (2) to the required position (three positions
indicated by arrows (see Figure 4-14) are available), and lock it with support arm pin (1). See Figure 4-14.
Figure 4-14 Adjustment for the inclination angle of angle blade (continued)
4.4.5.3 Adjustment method for horizontal angle of angle blade
See Figure 4-15
Figure 4-15 Adjustment for horizontal angle of angle blade
4-9
a) Raise the bulldozing board for 400 ～500mm and

put a cushion block under the arch fram e.
b) Loosen the fixing bolt (1) of the supporting
carrier rod and insert the adjusting rod into the hole (2) of
the carrier rod;
Tilt to the right: the right part is shortened and the
left part is extended.
Tilt to the left: the left part is shortened and the right
part is extended.
c) Tighten the fixing bolt (1).
Figure 4-16 Adjustment for horizontal angle

of angle blade (continued)
Attention
1. The maximum tilt amount can be adjusted to 860mm

2. The maximum tilt shall not exceed 400mm.
4-10
4.4.6 Compensation adjustment for ball joint part

There are six ball joint parts on the blade and
compensation adjustments must be conducted for them to
ensure that the axial clearance is within 1 mm. See the
directions indicated by arrows in Figure 4-17.
a) Unscrew the bolt, remove the washer (1) and then
fasten the bolt (2), so that there is no clearance at the ball
joint part.
b) Measure the size of clearance A and then unscrew
the bolt (2).
c) Adjust the thickness of washer (1) to obtain an
axial clearance of within 1mm.
Figure 4-17 Compensation adjustment
d) All the bolts must be tightened after adjustment,
schematic diagram of ball joint part
but the tightening should ensure that the ball joint part can
rotate flexibly.
4.5 Oil for Various Parts and Cooling Liquid
4.5.1 Deal with Lubricating Oil, Fuel and Coolant and Analyze the Oil Quality
4.5.1.1 Lubricating oil
The lubricating oil used under poor working conditions (high temperature and high pressure) will
deteriorate in use. Use the oil brand specified in Table 4-1.
a) When the specified time arrives, even if the oil is not dirty, it should be changed.
b) The lubricating oil is like the blood in human body, so pay attention to prevent any impurities (water,
metal particles and dust etc.) from entering it when dealing with it. Most of machine’s problems are caused
by impurities, so please pay special attention to prevent any impurities from entering the oil when it is stored
or refueled.
c) Do not mix lubricating oils of different grades or brands.
d) Add oil according to the specified oil mass. Too much or too little oil will both cause faults.
e) If the oil in the working device is not clean, some water or air must have entered the oil circuit. In this
case, please contact Zoomlion or Zoomlion dealers.
f) When changing oil, change relevant filter cartridge. Especially when changing the engine oil filter
cartridge, add fresh, clean and specified engine oil into the new filter cartridge before the installation.
g) It is recommended to make regular analysis for oil quality, so as to check the machines’ conditions.
Please contact Zoomlion or Zoomlion dealers for to apply for this service.
Prompt
1. When replacing hydraulic oil, please clear away the remaining oil in the pipeline and the oil
cylinder.
4.5.1.2 Fuel
a) The injection pump is a precision component which cannot work properly if the fuel used contains
4-11
water or contaminations.
b) When storing or adding the fuel, pay special attention not to let impurities mix into it.
c) Be sure to use the fuel specified in Table 4-1.
When using the fuel, select it according to the ambient temperature. Otherwise, the fuel is easy to
solidify in a low temperature (especially lower than -15 ℃ (5℉)).
d) To avoid condensation and water formation of moisture in the air inside the fuel tank, fully refuel the
fuel tank after the finishing works every day.
e) Before starting the engine or in the ten minutes after refueling, discharge the sediments and water in
the fuel tank.
f) If the fuel in the engine is used up or the filter cartridge is changed, discharge the air in the oil circuit.
4.5.1.3 Coolant
a) There is a large amount of calcium and other matters in the river water. If this water is used, the scale
will affix on the engine and the radiator, which causes fault of heat exchange and overheating. Don’t use any
water unfitted to drink.
b) Zoomlion uses specified antifreeze in the coolant. This kind of antifreeze can effectively prevent the
cooling system from corrosion and it can be used continuously for 2 years or 4000 hours. Besides, this
antifreeze can be used even in hot areas.
c) The antifreeze is flammable, so it should be kept away from open fire.
d) The mixture ratio of the water and the antifreeze varies with the ambient temperature.
e) If engine overheating occurs, please wait for the engine to cool down before adding coolant.
f) Apart from resulting in engine overheating, shortage of coolant will also cause corrosion of the
cooling system due to the incoming air.
4.5.1.4 Lubricating Grease
The grease is used for preventing the joint from being twisted and for preventing noise. After a long
time’s use, grease should be added to parts which are not flexible or make noise.
Attention
1. Pay special attention to wipe off the old grease squeezed out when adding new grease. The sand
or dirt which affixes on the grease will cause abrasion of the rotating parts.
4.5.1.5 Storage of the Lubricating Oil and the Fuel
a) Put them indoors to avoid water, dirt or other foreign matters from entering into them.
b) If an oil drum is to be stored for a long time, you should lay it on its side with the oil filling port on
the side, so as to avoid sucking moisture. If the oil drum has to be put outdoors, the waterproof cloth should
be used to cover it or take other protecting measures.
c) In order to prevent the oil from deteriorating in the long process of storage, first-come-first-go
principle must be adopted (the lubricating oil or the fuel with the longest storage time should be used first).
4.5.1.6 Filter Cartridge
4-12
a) The filter cartridges are very important safety components which can prevent impurities in the oil
pipeline and the air pipeline from entering the important devices and cause faults. Replace all the filter
cartridges regularly.
b) Don’t use the cleaned filter cartridge again (filter cartridge type). Replace it with a new one.
c) When changing the filter cartridge, check whether there are metal particles on the old filter cartridge.
If any metal particles are found, please contact Zoomlion or Zoomlion dealers.
d) Before use, don’t open the package of spare filter cartridges.
e) Use the filter cartridges specified by Zoomlion.
4.5.2 Choose Suitable Lubricating Grease, Fuel and Coolant
Important
1. Please choose the oil specially used for Zoomlion bulldozers at the designated place.
2. When starting the engine in a temperature below 0 °C, make sure to use the multi-level oil
recommended by Zoomlion as the engine oil even if the temperature may rise to above 10
10°°C in the
You’’ d better limit your use of low-viscosity lubricating oil, because though it can improve the
daytime. You
engine’’s service life if used for a long time.
cold-start performance, it will shorten the engine
coolant’’s freezing
3. The coolant is essential in whatever climate. The antifreeze can reduce the coolant
point and increase the coolant
coolant’’s boiling point. Even in warm regions, we still recommend you to choose
antifreeze coolant specified by Zoomlion, because it not only has the antifreeze function, but also
parts’’ life.
prevents the cooling system from corrosion and prolongs the parts
4. If you have any questions on the selection of oil, please consult Zoomlion or Zoomlion dealers.
4.5.3 Brand and Usage of Oil and Coolant Used for Main Parts of Bulldozer (Table 4-1)
4-13
Table 4-1 Technical Specifications of Lubricating Grease, Fuel and Coolant Used for Bulldozer
Kinds Ambient temperature (°C)
Part
of Qty (L)
name -40 -30 -20 -10 0 10 20 30 40
liquid
SAE 15W-40
Diesel
Engine engine SAE 10W-30 26
oil pan oil
SAE 5W-40
No.0
No.1
Engine Light 0
fuel diesel 290
tank oil No.2
0
No.35
Workin
SAE 15W-40 108
g tank Diesel
engine
SAE 5W-40
Final oil
31 ×2
drive
SAE 10W-30
Track 0.25(each
roller SAE 85W-140 one)
Carrier 0.25(each
Gear
roller SAE 80W-90 one)

oil
0.25(each
Idler SAE 80W-140
one)
Soft water
Antifr
Cooling
eeze 79
system Soft water and antifreeze liquid
liquid
Rear Hydro 6# hydrodynamic drive oil or SAE 15W-40 80

axle dynam
box ic 8# hydrodynamic drive oil or SAE 10W-30
drive 20
Main oil or ATF-III transmission oil or SAE 5W-40
clutch diesel
engine
case
oil
Bearing
and Lubric
hinged ating No. 2 or No. 3 General lithium lubricating grease (GB7423-1994)
connect grease
ion
Notes: a) Lubricating oil quality grade shall be CF-4.
b) For oil used for gear box, torque converter and rear axle box, 6# hydrodynamic drive oil shall be used
when the temperature is above -20 ℃and 8# hydrodynamic drive oil shall be used when the temperature is
4-14
below -20℃ in China. However, if the machine is used in foreign countries, please select oil of similar
performance and index grade for various parts according to different temperatures.
c) Before adding oil, the filter screen should be drawn out from the oil filler first and cleaned with clean
diesel oil before being put back. Then you can add the new oil in which the grounds have completely settled.
d) The quantity of oil and grease added shall meet specific requirements. You should not add too much
or too few oil.
e) The tools used for filling oil and water should be clean and they shall be stored in case or cabinet
which is covered tightly when not used.
f) When discharging oil, it is suggested to preheat the oil to 30 ～40 ℃. SAE oil grade is international
general oil grade.
4.5.4 Filling oil and cooling liquid of new machine leave factory (Table 4-2)
Table 4-2 Filling oil and cooling liquid of new machine leave factory
Part name technical specification of oil quality
Engine oil pan SAE15W-40
Fuel tank No. 0 diesel oil
Working oil tank SAE15W-40
Main clutch No.6 hydrodynamic
drive oil
Rear axle box
Final drive SAE15W-40
Cooling system Soft water

Parts of bearing and hinged connection No. 2 or No. 3 General lithium lubricating grease
4.6 Wearing Parts
The wearing parts, such as the filter cartridge and the dozer blade, should be replaced during unscheduled
maintenance or before reaching wearing limits. You should change the wearing parts correctly and select
Zoomlion parts with high quality for replacement.
Common wearing parts are shown in Table 4-3.
4-15
Table 4-3 Detailed List of Wearing Parts

Item No. Name Quantity Replacement time
Steering and 004903049A6620000 Filter cartridge 2 After 250 hours
transmission oil （1081001405） (O-ring) 2 After 250 hours
filter cartridge
Filter of working 004903060A1430000 Filter cartridge 1 After 1000 hours
oil tank （1081001411） (O-ring) 1 After 1000 hours
Air filter 004903002A1000000 Filter cartridge 1
assembly
004902071A0001010 Blade 3
004902071A0001020 Left blade corner 1
004902071A0001030 Right blade corner 1
Blade
004902071A0001140 Bolt 35
004902071A0001150 Nut 35
（1040300960） Washer 35
Note: Parts in the brackets should be replaced at the same time.
4.7 Tightening Torque Table
4.7.1 Table of Tightening Torques for Common Bolts and Nuts (Table 4-4)
Table 4-4 Tightening Torque Table of Common Bolt and Nut
M12 18 131 ~175 110~130 78~104
M14 21 209 ~278 180~205 124~165

M16 24 326 ~434 280~330 193~257
M18 27 448 ~597 380~450 264~354
M20 30 635 ~847 540~650 376~502
M22 34 864 ~1152 740~880 512~683
M24 36 1098 ~1464 940 ~1120 651~868
M27 41 1606 ~2142 1400~1650 952~1269
M30 46 2181 ~2908 1700~2000 1293~1723
M33 50 2968 ~3958 2473~3298 1759~2345
M36 55 3812 ~5082 2800~3350 2259~3012
M39 60 4933 ~6577 4111~5481 2923~3898
4.7.2 Table of Tightening Torques for Metric Thread Fittings of Commonly-used Hydraulic
Hoses (Table 4-5)
4-16
Table 4-5 Table of Tightening Torques for Metric Thread Fittings of Commonly-used Hydraulic Hoses
Thread Tightening torque (N.m)
M14×1.5 20 ~35
M16×1.5 25 ~40
M18×1.5 30 ~45
M20×1.5 35 ~50
M22×1.5 40 ~70
M24×1.5 40 ~70
M26×1.5 60~100
M30×2.0 80~120
M36×2.0 100~150
M42×2.0 150~220
M45×2.0 180~250
4-17
Chapter Five: Maintenance Schedule of Bulldozer

Chapter Five: Maintenance Schedule of Bulldozer

Proper lubrication and maintenance can ensure trouble-free operations and longer service life of
machine. The time and expense for service and maintenance can be compensated by the machine’s extended
service life and reduced operation costs.
The hours mentioned below is based on the readings of the hour meter. You’d better reorder these
numbers for a convenient use of the maintenance schedule. Maintenance interval stated in this manual shall
be shortened when the machine is working on rough road or poor working condition.
The operator of this bulldozer shall know about the followings:
a) Keep the bulldozer clean so as to find any trouble in time; especially the lubricating nozzle and oil
level detection window shall be kept clean, to avoid any dirt from entering.
b) Use lubricant of specified viscosity according to different temperatures. Containers to be used shall
be clean to prevent dust from entering; inspection and replacement of lubricating oil shall be conducted in a
dust-free site.
c) Hang an overhaul board to avoid someone starting or driving the bulldozer in the middle of
overhauling.
d) Do not discharge oil or water or replace filter element immediately after finishing operation. Instead,
you should wait until the machine cools down. If you need to discharge oil in cold weather, the oil should be
heated to a temperature of 20℃~40℃.
e) A strainer screen is set at the oil filling port, which shall not be removed during oil filling.
f) Pay attention to the water on the surface and bottom of the oil drum when adding fuel to prevent it
from entering into the fuel.
g) Release the pressure first before adding or discharging oil when overhauling the oil circuit.
The procedures are as follows:
1) Put the bulldozing plate on the ground;
2) Stop the engine;
3) Pull the joystick to each position for two or three times.
4) Unscrew the cap of the oil filling port; Maintenance Schedule of
5) Finally, make sure there are not too many metallic particles or other foreign matters in the discharged
Bulldozer
oil.
h) After replacing or cleaning the filter element and screen, please exhaust the air in the hydraulic oil
line.
i) The lubricant shall not be too much or too little, so you should keep the oil level at a correct one
during checking and oil filling.
j) After filling the grease, the dirty grease having been squeezed out should be cleared away. For parts
that will wear down quickly when there is any sand or dust on it, you should pay special attention to keep
them clean.
k) The non-flammable cleaning agent or diesel oil shall be used during the parts cleaning. Keep away
from any fire while using the diesel oil.
5-1
l) When removing the parts fitted with O-rings or seals, the mounting surface shall be cleaned and seals
should be replaced.
m) When conducting maintenance for the interior with the cover being opened, pay attention to prevent
tools in the pocket from falling out.
n) Comply with the precautions pasted on the bulldozer.
o) In order to exhaust the air mixt ure after replacing the oil and filter element of the working oil tank or
dismounting the hydraulic cylinder or pipeline of working device, you should put the accelerator control
handle to the low-speed position and operate the control handle to extend and retract the piston rod of
cylinder for 4~5 times (the cylinder piston shall not travel to stroke end at this time; instead, it should stop at
a position that is 100mm away from the stroke end). Then, let the cylinder piston travel to the stroke end and
extend and retract it for 3~4 times.
Prompt
1. If you run the engine at very high speed or fully extend or retract the cylinder at the very beginning,
the seals of the piston will be damaged by the air that has entered into the cylinder.
p) When the bulldozer needs to work in the muddy water, rain, beach or snow, check for any loose or
fallen oil plug or nut before operation. Each part should be lubricated. Especially for the pins of the working
devices that work in the muddy water, daily lubrication should be conducted.
q) When operating the machine at seaside, pay attention to prevent any corrosion of electrical system.
r) When operating the machine at dusty sites, pay attention to the following precautions:
1) pay attention to the dust indicator light which is used to indicate the air cleaner cartridge's blocking
and timly clean the filter cartridge.
2) The radiator fin should be cleaned frequently to prevent clogging.
3) The fuel filter should be cleaned frequently and replaced regularly.
4) The electrical components, the starting motor and generator in particular, should be cleaned
frequently to prevent dust.
s) When operating the machine at rocky sites, always check if there is any damage of the traveling
Maintenance Schedule of
mechanism and check the bolts and nuts for any looseness, crack or damage, etc. The track shall not be too
much tensioned.
Bulldozer
t) When removing the track shoe, do not put your fingers between two track shoes and you must wear
gloves when dismounting the blade.
u) When two or more people work together, they should work under the arrangements of the person in
charge. Anything unplanned shall not be done.
v) The fuel, engine oil, grease or clothes with oil dirt shall be disposed at a place far away from the fire
source. To prevent fire, you must understand the storage location and usage of the fire hydrant and other
fire-fighting equipment.
5.1 Daily Maintenance
5.1.1 Leakage check
Check around the bulldozer for any oil leakage or water leakage.
5-2
Pay special attention to:

a) Connection part of the high-pressure hose and pipeline.
b) Hydraulic cylinder.
c) Final transmission case.
d) Floating oil seal of the traveling device.
e) Surrounding area of the water tank.
Prompt
1. In case of any leakage, effective measures should be taken.

5.1.2 Check for any loose bolts and nuts on various parts
Check if bolts and nuts on various parts are properly tightened. In case any loose bolts or nuts are found,
tighten them immediately, especially the bolts of the air filter, silencer, track roller and track shoe etc.
a) Air filter.
b) Air intake and exhaust pipes.
c) Mounting part of silencer.
d) Bearing of carrier roller.
5.1.3 Check of electrical circuit
Check each electrical component to see if all circuits are normal.
waterr
5.1.4 Check and supplement of cooling wate
Remove the cover (1) of water tank to check if the

cooling water is adequate. If not, add cooling water. See
Figure 5-1.
Bulldozer
Attention Figure 5-1 Supplement of cooling water
1. If you have to add large quantity of water frequently, there may be water leakage that needs repairs.
2. If the water temperature is high, do not remove the cap of water tank, for hot water may spray out.
After the water cools down, loose the cap gently to release the internal pressure before removing it.
5.1.55 Check of fuel (see figure 5-2)
5.1.
a) Remove the cap of fuel tank and check the fuel quantity with oil dipstick (F) .
b) Add fuel from the oil filler after operation (G).
5-3
Figure 5-2 Check of fuel Figure 5-2 Check of fuel (continued)
Prompt
1. If the air vent on the cap of fuel tank is blocked, the internal pressure of the fuel tank will drop, which
may cause disruption of fuel supply. Pay attention to clean it frequently.
2. The fuel tank capacity is 290L.
5.1.6 Check of oil volume of engine sump
As shown in Figure 5-3 and Figure 5-4, open the side plate of engine, take out the oil dipstick F and
check the oil volume.
If the oil level is lower than L, fill the diesel engine oil from the oil filler (G). Use diesel engine oil that
is suitable for the ambient temperature (refer to Table 4-1).
Prompt
1. Before checking the oil volume, the bulldozer shall be parked horizontally and you need to wait for
15 minutes after the engine has been shut down.
2. The oil level shall not exceed the “H” mark on the oil dipstick when adding oil.
Bulldozer
Figure 5-3 Supplement of oil volume of engine sump Figure 5-4 Check of oil volume of engine sump
5-4
5.1.7 Check and supply of oil volume of main

clutch
a) After shutting down the engine, wait for 5
minutes and then check oil level with oil dipstick (F) .
See figure 5-5.
b) If the oil is insufficient, supplement the diesel
engine oil from the inserting port of oil dipstick. Use
diesel engine oil that is suitable for the ambient
temperature (refer to Table 4-1).
Figure 5-5 Check of oil quantity of main clutch
5.1.8 Check of oil volume in steering clutch box
Figure 5-6 Check of oil volume of steering clutch
As shown in Figure 5-6, check the oil level with oil dipstick (F). If the oil is insufficient, supplement the
diesel engine oil from the inserting port of oil dipstick. Use diesel engine oil that is suitable for the ambient
temperature (refer to Table 4-1).
When the bulldozer is working on a slope of 25 °, add oil to the level of “H” mark on the dipstick.
5.1.9 Discharge of water and sediments in fuel tank
Bulldozer
Loosen the cock at the bottom of fuel tank to

discharge the water and sediments on the bottom, as
shown in Figure 5-7.
Figure 5-7 Discharge of water in fuel tank
5-5
5.1.10 Check of monitoring device of electronic instrument

As shown in Table 5-1
Table 5-1 Monitoring items of electronic instrument
No. Monitoring items Unit Alarm value Alarm level Remarks
Analog
Total operating
1 h quantity
hours of machine
Analog
2 Voltage of vehicle V
quantity
Analog
3 Engine oil pressure Mpa < 0.08 2
quantity
Cooling water Analog
4 ℃ > 102 2
temperature quantity
5.1.11 Alarm indication of air filter
As shown in Figure 5-8, when the window pointed

by the arrow turns red, you need to maintain the air filter
and reset it by pressing the button on the top.
5.1.12 Check of brake pedal travel Figure 5-8 Air filter

As shown in Figure 5-9, the travel distance of the

Bulldozer
top of brake pedal shall be 95 ~ 115mm, If the braking

function is unsatisfactory, please carry out debugging by
referring to the adjustment for various parts.
Travel measurement is conducted when the engine
has been shut down and by depressing one brake pedal
with a foot power of 15kg (147N).
Figure 5-9 Check of brake pedal travel
5-6
5.2 I nitial 100 hours

After the machine has been operated for the initial 100 hours, the following items shall be provided to it:
a) Replace the oil of the main clutch, and wash the strainer.
b) Replace the oil of steering clutch housing (Rear axle housing), and clean the strainer.
c) Replace the oil of final drive box.
d) Replace the oil of working oil tank and filter element of oil tank.
e) Check the valve clearance of engine for abnormal.
f) Replace diesel oil filter and engine oil filter within 100hours at first time, replace engine oil.
5.3 E very 250 hours
Please refer to the operation and maintenance manual of diesel engine for the check and maintenance of
diesel engine.
Carry out the following maintenance items after operating the machine for the initial 250 hours::
a) Replace oil for main clutch, and wash the strainer.
b) Replace the oil of steering clutch housing (including the bevel gear housing) and clean the coarse
filter.
c) Replace the oil of final transmission case.
d) Replace the oil of working oil tank and filter element of oil tank.
Maintenance items for every 250 hours:
5.3.1 Add grease
Add grease into the grease nozzles indicated by the arrows.
5.3.1.1 Equalizing beam shaft (Figure 5-10):
1point
Bulldozer
Figure 5-10 Equalizing beam shaft
5-7
5.3.1.2 Cylinder bracket (Figure 5-11): 4 points

5.3.1.3 Cylinder horizontal shaft (Figure 5-12): 2 points
Figure 5-11 Cylinder bracket Figure 5-12 Cylinder horizontal shaft

5.3.1.4 Cylinder knuckle bearing (Figure 5-13):2 points
5.3.1.5 Strut knuckle bearing (Figure 5-14): 2 points
Figure 5-13 Cylinder knuckle bearing Figure 5-14 Strut knuckle bearing
5.3.1.6 Slanted strut (Figure 5-15):2 points
5.3.1.7 Tilt ing cylinder knuckle bearing (Figure 5-16): 1 point
Tilting
Bulldozer
Figure 5-15 Slanted strut Figure 5-16 Tilting cylinder knuckle bearing
5-8
5.3.2 Check and refueling of oil volume

5.3.2.1 Final transmission case
Figure 5-17 Check of oil volume of final transmission case

As shown in Figure 5-17, remove the cock (G) and add oil if the oil does not reach the lower edge of
cock hole. Use diesel engine oil that is suitable for the ambient temperature (refer to Table 4-1).
Prompt
1. The vehicle should be parked on flat ground for oil level check.
5.3.2.2 Check of working oil tank (see Figure 5-18)
Bulldozer
Figure 5-18 Check of working oil tank

a) Place the bulldozing plate on the level ground and check the oil level after the engine has been shut
down for about 5 minutes. Observe the oil dipstick (F) and the oil level in the inspection window is normal if
it is in the middle.
b) When the oil is insufficient, add diesel engine oil from the oil filler (G) . Use diesel engine oil that is
suitable for the ambient temperature (refer to Table 4-1).
Attention
Before removing the cap of oil filter, loosen it gently until the internal pressure has been released.
5-9
5.3.3 Check of the tension of generator drive belt

Check: Push the middle part of fan belt with a force
of about 58N;
If the belt deflection is about 10 mm, the tension is
considered to proper. See Figure 5-19 .
Adjustment: Turn the screw rod to move the tension
pulley to the outside.
Importance
Figure 5-19 Check of belt tension
1. Check the damage of each belt pulley and abrasion of V-groove; pay special attention to the abrasion
of V belt.
2. If the belt is stretched beyond the adjustment range and is with cracks, the two belts should be
replaced at the same time.
5.3.4 Washing and replacement of oil filter parts
5.3.4.1 Replacement of fine cleaner cartridge of the power gearbox
Replacement
As shown in Figure 5-20:
a) Dismantle the bottom plate of cab seat.
b) Unscrew the bolt (2), dismantle the upper cover
(3), and extract the filter cartridge.
c) Wash the interior of housing and the dismantled
parts, replace the filter element and tighten the upper
cover (3) with bolt (2).
d) After the completion of installation, loosen the

ventilation plug. Keep the engine operating until no
Bulldozer
bubble appears and then tighten the ventilation plug.
Prompt Figure 5-20 Replacement of fine filter element
1. Accessories designated by Zoomlion shall be used for the filter element.
5-10
5.3.4.2 Washing of filter screen at the bottom of

fuel tank
a) Tighten the valve (1) and remove the cover (2), as
shown in Figure 5-21 .
b) Remove the dirt adhered to the filter screen, wash
the screen with diesel oil or cleaning oil and finally
reinstall the screen.
The screen and the cover (2) are mounted together,
and they shall be dismantled together.
Figure 5-21 Washing of fuel tank filter
5.3.5 Battery
The battery is with low self-discharge rate, strong
charge acceptance, good large-current discharge, wide
working temperature (it can be used safely within the
range of -40℃ to -65 ℃), very long service life and
excellent shock resistance. Besides, it is completely
maintenance-free and easy to use.
Figure 5-22 Battery
5.3.6 Check of track shoe bolts

As shown in Figure 5-23, the loose bolt (1) of track
shoe will cause fracture of track shoe. So tighten any
loose bolt immediately .
Tightening torque: Bolts located at master pin:
Bulldozer
588 ± 60N • m
Bolts located at standard pin:
686 ± 80N • m
Center holes are punched on both ends of master pin.
Figure 5-23 Check of track shoe bolts
5-11
5.3.7 Cleaning and check of radiator

a) Dismantle the bolt (1) and open the guard board
(2) of water radiator.
b) Blow off the dirt, dust, twigs and leaves on the
radiator fin with compressed air. Steam and water can
also be used.
Check rubber hose and replace it if there is any crack
and aging; check if the clamp is loose.
Figure 5-24 Cleaning and check of radiator

5.
Maintenance items for every 250 hours should also
be carried out.
5.4.1 Washing of ventilation device of main
clutch
Remove ventilation device (1) in Figure 5-25 and
wash out the dirt inside it with clean diesel.
Figure 5-25 Ventilation device of rear axle housing
5.4.2 Washing of ventilation device of steering

clutch
Remove ventilation device (2) in Figure 5-26 and
wash out the dirt inside it with clean diesel
Bulldozer
Figure 5-26 Ventilation device of rear axle housing
5.4.3 Washing of ventilation device of final reduction box

Remove ventilation devices (1) and (3) in Figure 5-2 6 and wash out the dirt inside it with clean diesel or
gasoline
Please refer to the operation and maintenance manual of diesel engine for the check and maintenance of
diesel engine.
5-12
In addition to the maintenance items for every 250 hours and 500 hours, the following items shall also
be carried out.
5.5.1 Add grease
Fill grease to the grease fitting shown by the arrow.
a) Semiaxle bracket bearing (Figure 5-27):2 points
b) Universal joint (Figure 5-28): 8 points
Figure 5-27 Half shaft bracket bearing Figure 5-28 Universal joint
5.5.2 Oil replacement and oil filter washing in rear a xle housing (including the bevel gear
housing)
a) Remove the drain plug at the bottom of the machine to drain oil, and then reinstall it after the oil
drainage, as shown in Figure 5-29.
b) Dismantle the left pedal, remove the bolt (1) of coarse filter housing under the left pedal, remove the
upper cover (2), and finally take out the spring (3) out and cleaner cartridge (4), as shown in Figure 5-30 .
c) Clear off the dirt adhered to the cleaner cartridge (4), and wash the cleaner cartridge with the clean
diesel or gasoline, In addition, other components removed from the interior of the coarse filter should also be
cleaned.
Bulldozer
Figure 5-29 Oil replacement for rear axle box Figure 5-30 Oil filter washing
d) Mount the filter element and spring firstly, and then fasten the upper cover (2) with the bolt (1).
e) Replace the fine filter element of steering clutch box by referring to the maintenance instructions for
every 250 hours.
f) Add specified quantity of diesel engine oil from the oil filling port (G), as shown in Figure 5-31. The
Use diesel engine oil that is suitable for the ambient temperature (refer to Table 4-1).
5-13
Prompt
1. Quantity of oil replacement: 80L

2. Replace the cleaner cartridge if it is damaged
Figure 5-31 Oil replacement for rear axle box

5.5.3 Oil replacement and oil filter washing for working oil tank (see Figure 5-3
5-322 )
a) Place the bulldozing plate on the flat ground, and shut down the engine. Operate the control handle of
bulldozing plate to let the bulldozing plate swing from back to forth and from left to right, loose the cap of oil
filling port (G), open it until the pressure has been released.
b) Unscrew the drain plug (P) on the bottom of oil tank, discharge the oil in the tank, and then screw the
oil plug up after oil drainage.
c) Unscrew the bolt (1), then remove the cap (2) and take out the cleaner cartridge, wash the filter
housing and parts removed, and replace a new cleaner cartridge.
Bulldozer
Figure -32 Oil replacement for working oil tank

d) After replacing the filter element and add specified quantity of diesel engine oil from the oil filling
port (G), Use diesel engine oil that is suitable for the ambient temperature (refer to Table 4-1).
e) Confirm if the oil reaches to the specified oil level by referring to the maintenance instructions for
every 250 hours.
Prompt
Quantity of oil replacement: 108L

Accessories designated by Zoomlion shall be used for the cleaner cartridge.
5-14
5.5.4 Oil replacement of final transmission case ( Figure 5-33)

a) Unscrew the oil plug on both sides of the vehicle.
b) Unscrew the oil plug (P) for oil drainage and then screw the oil plug up after oil drainage.
c) Add specified quantity of diesel engine oil from the oil filling port (G). Use diesel engine oil that is
suitable for the ambient temperature (refer to Table 4-1)..
d)) Confirm if the oil reaches to the specified oil level by referring to the maintenance instructions for
every 250 hours..
Quantity of oil replacement: 31Lfor left and right
Figure -33 Oil replacement for final transmission case

5.5.5 Oil replacement of main clutch box
a) Unscrew the drain plug (P) for oil drainage, screw
the oil plug after the old oil drainage.
b) Fill the engine oil to the specified oil level from
the oil filling port of the main clutch cover.
Quantity of oil replacement: 20L
Figure -34 Oil replacement of main clutch

devicess
5.5.6 Replacement of oil in traveling device
Bulldozer
Check if the quantities in carrier roller, track roller and and idler decrease by referring to the following
steps, as shown in Figure 5-35:
a) Park the vehicle on a flat ground.
5-15
Figure -35 Oil replacement for traveling devices

b) Loosen the sealing bolt: if the oil leaks from the thread, the engine oil has not decreased and the bolt
shall be tightened immediately.
Prompt
If there is no oil leaking from the thread, the oil is insufficient and you should find out the reason and
conduct necessary repairs.
5.66 E very 200
5. 0000 hours
In addition to maintenance items for every 250 hours, 500 hours and 1000 hours, the following items
should also be performed :
5.6.1 Washing of engine ventilation device
Remove the ventilation device and wash the dirt
adhered to its interior with clean diesel oil, as shown in
Figure 5-36.
Dust around the ventilation device shall be wiped
clean before removing it.
Bulldozer
Figure 5-36 Engine ventilation device
5.6.2 Check of alternator and starter motor

Repair the electric brush if it has worn down and dismantle it carefully to prevent damage to the seals.
If the mechine is used at night frequently, an overhaul is required every 1000 hours.
5.6.3 Inspection of engine valve clearance
Use special tools for dismantling and adjustment of these parts
5-16

Maintenance items for every 4000 hours and that for every 250 hours, 500 hours and 2000 hours shall
be performed at the same time.
a) Examine and repair the cooling water pump .
b) Check the belt to see if it is loose and check if there is any oil or water leakage. If the belt is found to
be abnormal, repair or replace it immediately.
5.8 Maintenance When in Need
5.8.1 Lubrication of control handle shaft and pedal shaft
a) Brake pedal shaft of steering clutch. b) Brake locking handle shaft.
c) Control handle shaft of power gearbox. d) Deceleration pedal shaft.
e) Throttle lever shaft. f) Control handle shaft of bulldozing plate.
5.8.2 Replacement of Coolant
Please replace the coolant in spring and autumn. The vehicle should be placed in a level state to change
the water. If you do not use antifreeze, the water shall be changed every 1000 hours, as shown in Figure5-3 7
and Figure5-3 8
Change the water:
a) Shut down the engine, loosen the cover (1) gently and remove it.
Warning
1. When the water temperature in the water tank is very hot, please do not remove the cover of water
tank, because the hot water may spray out.
2. Before removing the cover of water tank, loosen the cover gently and wait until the internal pressure
has been released..
Water drain
valve
Bulldozer
Figure5 -37 Coolant replacement Figure5 -38 Coolant discharge

b) Water drain valves are located at the bottom of water tank and on the oil cooler, which shall be
opened for water drainage.
c) After the water has been drained, wash the water tank with cleaning agent.
5-17
d) After washing, discharge all the water, close the drain valves and add the soft water.
e) When the water reaches to the port, operate the engine with low speed and then open the drain valves
located at the bottom of water tank and on the oil cooler for water drainage until clean water flows out.
f) Shut down the engine, closed the two water drain valves and fill the water to the port.
g) After adding water, idle the engine with low idle speed for 5 minutes and then operate the engine with
high speed for 5 minutes to exhaust the residual air within the cooling system (remove the cover (1) of water
tank before carrying out this operation
h) Stop the engine, and about 3 minutes later, add water until it reaches the port. Then tighten the cover
(1) of water tank.
For the cautions of using antifreeze, please refer to the maintenance items for cold weather.
5.8.3 Check, washing and replacement of air filter
Maintain, clean and replace the air filter of diesel engine.
5.8.3.1 Cleaning and replacement of cleaner cartridge
Figure 5-39 Cleaning and replacement of cleaner cartridge Figure 5-39 Cleaning and replacement of
cleaner cartridge (Cont.)
When the display window of dust indicator (3) turns red, as shown in Figure 5-40, the cleaner cartridge
of air filter should be cleaned.
a) Loosen the bolt (1), remove the cover (2), and take out the filter element.
b) Clean the interior and cover.
Bulldozer
c) Clean and maintain the filter element. If the filter element is damaged, replace it immediately.
d) Install the filter element and cover (2) which have been cleaned, and tighten the bolt (1).
Prompt
1. If the display window of air filter turns red after the filter element is installed, the filter element shall
be replaced.
2. Never install the used inner filter element
3. Do not start the engine during the washing and replacement of the filter.
5-18
5.8.3.2 Cleaning method of outer cleaner cartridge

outer
If compressed air with a pressure of less than 686kPa is used, blow it from the interior of filter element
along the crease, then blow it along the outer crease, and finally blow it on the interior again.
Warning
1. Safety goggles and safety appliances shall be worn when using the compressed air .
2. After cleaning the filter element, check it with lamp and the filter element shall be replaced with a
new one when a hole or thin part is found.
3. Pay attention to prevent any bump when cleaning the filter.
4. If the folded part or gasket and oil seal of filter element are damaged, the filter element should not be
used.
5 You can blow dry air with a pressure of less than 0.7MPa on the air filter from the interior to the
exterior repeatedly to speed up drying. But heat dying is prohibited.
6. Do not use an object to hit the filter element while cleaning it .
5.8.4 Clean the interior of cooling system
Refer to Table 5-2 for cleaning of the interior of cooling system and antifreeze replacement.
Prompt
1. The vehicle should be parked in a level position for the replacement of cooling water.
2. Use permanent antifreeze.
If there is no permanent antifreeze, the antifreeze with glycol shall be used.
3. Clean soft water shall be used for cooling water, such as tap water.
Warning
1. The antifreeze is flammable, so it should be kept away from fire.
Bulldozer
5-19
Table 5-2 R eplacement of coolant

Type of antifreeze Clean the internal cooling system and replace coolant
time
Permanent antifreeze (for all seasons) Every year (autumn) or 2000 hours
Impermanent antifreeze, including ethylene glycol Every year (winter) or initial 2000 hours
(for winter)
No antifreeze is used Every six months (spring and autumn), (if the
coolant is used up in spring, add it in autumn)
The ratio of antifreeze to be added into the cooling water shall be determined in accordance with the
local lowest temperature in the past (refer to Table 5-3). When determining the mixing ratio, the temperature
shall below -10 ℃ for the best.
Table 5-3Mixing ratio of water and antifreeze
Lowest free air temperature (℃) -5 -10 -15 -20
Total quantity of antifreeze (L) 13 17 20.5 23.5
Total quantity of water (L) 14 40 36.5 33.5
5.8.5 Methods for extending the service life of traveling devices
The service life of traveling device varies with different operating methods, regular inspections and
maintenances. If the following items are taken into account, this machine can be used more effectively.
5.8.5.1 Choose a track shoe suitable for soil texture
You can discuss with the factory to choose the track shoe.
Prevent the track from skidding during operation. When it starts to slip, reduce the operating load.
a) Violent driving, acceleration, parking and unnecessary high-speed operation and sharp turning shall
be avoided.
b) Try to travel straightly. Do not just slew to one single side, and slew to both sides during operation. In
addition, the radius of slewing shall be increased as much as possible.
c) Obstructions on the road shall be cleared before traveling
The vehicle shall face toward the slope while it is working on a slope. Besides, it should not be parked
across the slope, but should be parked toward the slope.

d) If the terrain inclines to left or right, excavation operation shall not be conducted on the slope. You
Bulldozer
shall back the machine up to the level ground before restarting the excavation operation.
e) During bulldozing or ripping operation, if the idler or sprocket skids due to any exposed obstacles that
are difficult to clear away, do not carry out forced operation.
5.8.5.2 Maintenance and adjustment
a) For maintenance and adjustment methods, please refer to the maintenance item of track tensioning
during irregular maintenance.
b) Overhaul shall be performed if the carrier roller leaks oil or if any bolt or nut is loose.
c) You should check the clearance between the guard plates of the idler, for excessive clearance may
cause idler motions and track derailment. (See the adjustment for each part for maintenance methods.).
5-20
5.8.5.3 Maintenance and repair

Early maintenance and repair may reduce maintenance costs.
5.8.5.4 Height determination of grouser
When the track is not loose, check its intermediate portion, as shown in in Figure 5-4 0.
Figure 5-40 Measurement of grouser height Figure 5-40 Measurement of grouser height (continued)
Basic measurement (h):65mm
Repair limit: 25mm
5.8.5.5 Measurement of the external diameter of track roller
a) The height (C) of the track link tread can be measured according to the method shown in Figure 5-41
Figure 5-41 Detection of the external diameter of thrust wheel

b) Let the chain link tread with a height of C touch the track roller, and then measure B.
Bulldozer
c) Calculate the external diameter (A) of track roller:

A = (B-C) × 2
Basic measurement (A): 210mm
Repair limit: 195mm
5-21
5.9 Maintenance Table

5.9.1 Daily Maintenance (see see Table 5-4)
Table 5-4 Daily service
Maintenance items Service time
Daily maintenance
Check for oil leakage and water leakage O
Check for loose bolts and nuts and fasten any loose ones O
Check and repair wire breakage, short circuit and loose joint of electrical circuit O
Check and supplement cooling water O
Check and supplement the fuel O
check and supplement the oil in engine sump O
Check and supplement of the oil quantity of clutch O
Check and supplement of the oil quantity of steering clutch O
Eliminate water and sediment in fuel tank O
Adjust the travel of brake pedal O
5.9.2 Maintenance for every 250 hours (see Table 5-5)

Items with the mark ◎ shall be performed for the new vehicle that has been operated for 250 hours.
Table 5-5 Maintenance for every 250 hours
Service time
250 hours After
Maintenance Items
250
hours
◎Replace the oil in the main clutch, and wash the strainer. O
◎Replace the oil of steering clutch housing (Rear axle housing), and clean the O
strainer.
◎Replace the oil of final drive box. O
◎Replace the oil of working oil tank and filter element of oil tank. O
Bulldozer
Fill grease to the balance beam axis (1 point) O

Fill grease to cylinder outrigger (4 points) O
Fill grease to the cylinder horizontal axis (2 points) O
Fill grease to the cylinder knuckle bearing (2 points) O
Fill grease to the slanted strut (2 points) O
Fill grease to the knuckle bearing of tilt cylinders (1 point)

Fill grease to the knuckle bearing of strut (2 points) O
Check and supplement of oil quantity of final deceleration box O
Check and supplement of oil of working oil tank O
5-22
Table 5-5 Maintenance for every 250 hours (continued)

Service time
Maintenance Items 250 hours After

250
hours
Replace the fine filter element of gearbox O
Replace the fine filter element of steering clutch O
Wash strainer located in the bottom of fuel tank O
Tension check and adjustment of fan belt

Check and fastening of track bolt O
Cleaning and overhaul of radiator O
5.9.3 Maintenance for every 500 hours and 1000 hours (see Table 5-6)
Table 5-6 Maintenance for every 500 hours and 1000 hours
Service time
Maintenance Items 1000
500 hours
hours
Washing of ventilation device of main clutch O
Washing of ventilation device of steering clutch box O
Washing of ventilation device of final deceleration box O
Fill grease to the half shaft bracket bearing(2 points) O
Fill grease to the universal joint(4 points) O
Replace the steering clutch housing (Rear Axle box), oil and cleaning the strainer. O
Replace the oil of final drive box. O
Replace the oil of working oil tank, clean the filter element. O
Replace the oil of main clutch O
Check of the oil quantity of each part on traveling device
5.9.4 Maintenance for every 2000 hours and 4000 hours ( see Table 5-7)
Bulldozer
Table 5-7 Maintenance for 2000 hours and 4000 hours

and4000
Service time
Maintenance Items 4000

2000 hours
hours
Detection of engine valve clearance O
Overhaul of generator and starter motor O
Clean the ventilation device of engine O
Items for check and service

Overhaul the pump
5-23
5.9.5 Occasional service, as shown in Table 5-8

Table 5-8 Table 5-8 Irregular maintenance
Service time
Maintenance Items
Occasional service
Control the lubrication of handle shaft and pedal shaft O
Overhaul and adjustment of track tensioning device O
Change coolant O
Overhaul, cleaning and replacement of air filter O

Bulldozer
5-24
Chapter Six: Troubleshooting of Common Faults

Chapter Six: Troubleshooting of Common Faults

Though not all troubles and solutions are covered in this chapter, most of the common troubles are
listed.
6.1 Engine
Table 6-1 Engine troubles and solutions
Fault description Possible causes Solutions
The oil pressure indicator Oil filter element has worn down. Replace
light is still on while the Leakage exists in piping and joint. Check and repair or replace
engine is running at high Indicator light is damaged. Replace the indicator light
speed.
The white area of the water Indicator light is damaged. Replace
temperature indicator light Thermostat is damaged. Replace
is bright. Water temperature sensor is Replace
damaged.
Radiator pressure valve Cooling water is insufficient or leaks. Check and supplement cooling
sprays steam. Fan belt is loose. water
Scale and dust deposit in the cooling Adjust, repair or replace
system. Wash
Cooling fin of water tank is clogged Clean or repair
or has worn down. Replace
Thermostat is damaged. Tighten or replace
Tank cap is loose or sealing gasket is Replace
damaged.
Water level indicator light is
damaged.
Starter is operating, but the Fuel is insufficient or air has entered Supplement fuel or exhaust air
engine does not run. into the fuel system. Refer to the part of electrical
Starter runs too slowly. system to repair
Oil pump or nozzle is damaged. Adjust or replace oil pump and
Valve clearance may be improper. nozzle
Check valve clearance
Engine exhaust is white or Oil in oil pan is excessive or fuel is Replace with the specified oil
blue. insufficient. Check and repair
Oil tube of turbocharger is blocked.
Engine exhaust is black. Air filter is blocked. Clean
Oil nozzle is damaged. Replace
Troubleshooting of Common
Supercharger is blocked or damaged. Check, clean or replace

Combustion noise is Fuel with poor quality is used. Replace with the specified fuel
abnormal. Pump is damaged. Check if the engine is overheating
Faults
Muffler is damaged. Replace the muffler

Valve clearance is improper. Adjust valve clearance
6.2 Electrical System
6-1
Table 6-2 Troubl es of electrical system and solutions

Fault description Possible causes Solutions
Light turns dark while the engine is Contact of the wire line is poor. Check terminal for looseness
working at high speed; Light flashes Generator belt is loose. and check wire line for
while the engine is working. disconnection.
Adjust
The charging indicator light is on all Generator is damaged. Replace
the time while the engine is working Contact of the wire line is poor. Check and repair
at high speed.
Engine is with abnormal noise. Generator is damaged. Replace
The motor does not rotate while Contact of the wire line is poor. Check and repair
turning the starter key to the starting Battery is short of electric Charge
position. charge. Replace
Starting motor is damaged.
Pinion gear of starting motor gets in Battery is short of electric Charge
and out unsteadily. charge.
Rotational speed of starting motor is Battery is short of electric Charge
too low. charge. Replace
Starting motor is damaged.
The starting motor disengages Contact of the wire line is poor. Check and repair
before the engine is started. Battery is short of electric Charge
charge.
The monitor light of engine oil Oil pressure sensor is damaged. Replace
pressure is on when the engine Contact of the wire line is poor. Check and repair
stopped (starting switch is in
position of “On”).
Ext ernal surface of inlet air Contact of the wire line is poor. Check and repair
preheater feels hot by hand. Air intake preheater is damaged. Replace
Preheating switch is damaged. Check and repair
Faults
6-2
6.3 Chassis
Table 6-
6-33 Troubl e of chassis and solution
Trouble Troubleshooting Solution
The main clutch overheated Oil level of clutch is too low or too high Adjust it to the specified oil
quantity.
Oil leakage from main clutch Replace the main clutch
Strainer is clogged Clean or replace
Insufficient circular flow because of the Replace the main clutch
worn main clutch
Put shift lever on any gears, Lack of hydraulic oil in the steering Supplement specified oil.
vehicles can’t be started.
clutch Refer to “The pressure of
The pressure of torque converter does not torque converter does not
rise rise”
Gear pump is worn, blocked Overhaul, replace
Oil filter is blocked Washing
The vehicle keeps moving The steering brake has function failures. Adjust
forward after drawing the
steering lever on onside.
The vehicle has not stopped The brake pedal is adjusted improperly. Adjust
after the brake pedal is
pressed down.
The track runs off the rails, Track is too loose Adjust the tension
and is abnormal for wearing.
The blade is lifted up too Hydraulic oil is not enough. Supplement specified oil
slowly or cannot be lifted
up.
Note: Please contact the factory for repair if you have troubles beyond the above-mentioned items. The
driver shall keep original records about the machine and report them to the manufacturing company to
improve the design and quality. The records include machine’s operating hours, maintenance time, failures
and troubleshooting.
Faults
6-3

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ZOOMLION

Maintenance Manual for ZD160T

First Edition of June 2012

machines, we provide this Maintenance Manual for you.

please call our local service engineers.

hope that all users can understand.

Safety Information ...........................................................................................................................................................

Chapter One: Safety Criterion for Bulldozer Maintenance ..............................................................................

1.1 Basic Safety Requirements for Maintenance.............................................................................................. 1-1

1.2 Precautions for Maintenance.......................................................................................................................... 1-2

Chapter Two: General Drawing and Main Parameters of Bulldozer .............................................................

2.1 Outline Drawing of Bulldozer....................................................................................................................... 2-1

2.2 Main Technical Parameters of Bulldozer.................................................................................................... 2-1

3.1 Structure and Principle of Various Parts...................................................................................................... 3-1

3.2 Hydraulic System.......................................................................................................................................... 3-13

3.3 Electrical System........................................................................................................................................... 3-68

3.4 Working Device............................................................................................................................................. 3-69

Chapter Four: Maintenance of Bulldozer ...............................................................................................................

4.1 Maintenance Information of Bulldozer........................................................................................................ 4-1

4.2 Maintenance of Electrical System................................................................................................................. 4-2

4.3 Maintenance of Hydraulic System................................................................................................................ 4-3

4.4 Maintenance of Various Parts........................................................................................................................ 4-3

4.5 Oil for Various Parts and Coolant............................................................................................................... 4-11

4.6 Wearing Parts................................................................................................................................................. 4-15

4.7 Tightening Torque Table.............................................................................................................................. 4-16

Five:: Maintenance Schedule of Bulldozer

5.1 Daily Maintenance........................................................................................................................................... 5-2

5.2 Initial 100 Hours.............................................................................................................................................. 5-7

5.3 Every 250 Hours.............................................................................................................................................. 5-7

5.4 Every 500 Hours............................................................................................................................................ 5-12

5.5 Every 1000 Hours.......................................................................................................................................... 5-12

5.6 Every 2000 Hours.......................................................................................................................................... 5-16

5.7 Every 4000 Hours.......................................................................................................................................... 5-17

5.8 Maintenance When in Need ......................................................................................................................... 5-17

5.9 Maintenance Table........................................................................................................................................ 5-22

6.1 Engine................................................................................................................................................................ 6-1

6.2 Electrical system.............................................................................................................................................. 6-2

6.3 Chassis............................................................................................................................................................... 6-3

Chapter One: Safety Criterion for Bulldozer Maintenance

Maintenance Safety Criterion

1.2 Precautions for Maintenance

Chapter Two: General Drawing and Main

Chapter Two: General Drawing and Main Parameters of

General Drawing and Main

Table 2-1 Main technical parameters of Z D160T-3 series bulldozer

Maximum torque (Nmr/min) 830/1100～1200

Two-stage reduction cylindrical straight gear

Sprayed beam, semi-rigid, suspended structure

General Drawing and Main

Table 2-2 Overall dimension of ZD160T-3 series bulldozer (Straight blade)

ZD160T-3 ZD160TS-3 ZD160TSH-3 ZD160TCS-3

Figure 2-2 Outline dimension of the ZD160T-3 series bulldozer

Chapter Three: Structure and Principle for

Chapter Three: Structure and Principle for Various Parts of

3.1 Structure and p rinciple of v arious parts

Structure and Principle for Various

(Main clutch or hydraulic torque

Figure 3-2 Flywheel housing assembly