Shantui SD22. Operation and Maintenance Manual

CONTROLS | OPERATION

►►

Fasten the belt along your body, but don’t wind the belt

around your body. Belt length can be adjusted on both ends—

the tongue end and the buckle end. The buckle should be right

in front of your body.

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

• In order to shorten the belt, you can pull any of the free

ends of the belt—the buckle end or the tongue end.

• To increase the length, put the belt in right angle with the

buckle or the tongue, and pull the belt.

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

and loosen the belt.

5. When operating a machine equipped with ROPS, be sure

to use the seat belt.

Figure 2-19

►►

Check the bolts and fasteners on the chassis and re-tight-

en if necessary, to ensure that the tightening torque reaches

2-3kgm.

►►

If the seat belt is scratched or frayed, if any fittings are bro-

ken or deformed from long service, replace the seat belt im-

mediately.

►►

The shock absorption ability of the seat meets the ISO7096

Wind direction-

A/C switch/tuning

standard.

adjusting blade

knob for refrigerat-

ing capacity

Wind direction

and wind volume

Air outlet

tuning knob

of the A/C

Figure 2-20

Liquid container’s window

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

and Figure 2-22)

►►

When there are air bubbles in the window of the liquid

container, or when the cooling effect is not very obvious, ask a

specialised maintenance person to fix it.

Liquid container

Figure 2-21

Compressor

Figure 2-22

OPERATION | CONTROLS

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

Fresh air button

2-23)

In order to keep the air in the closed space clean, the air con-

ditioner’s fresh air ventilator is provided.

►►

When the fresh air effect is not obvious after long-time use,

please replace the internal filter of the fresh air ventilator.

Fresh air

Fresh air ventilator

Figure 2-23

Front and rear window defroster

Front window defroster (Figure 2-24)

Front window defroster uses the warm air from the A/C to heat

the front window, so as to achieve the purpose of defrosting.

A/C heater’s start valve

Figure 2-24

Rear window defroster (Figure 2-25)

Rear window defrost switch

Rear window defroster uses the resistance wire on the rear

window to heat the window after being charged with electricity,

so as to achieve the purpose of defrosting.

Rear window defroster wire

Figure 2-25

CONTROLS | OPERATION

When there is dust on the front or the rear window obstructing

Front & rear windshield

washer’s button

your view, use the windshield wiper along with the windshield

washer to clean them. (Figure 2-26)

Figure 2-26

Front windshield washer nozzle

Rear windshield washer nozzle

Figure 2-26

Frequently check the liquid level of the windshield

washer tank, which is located within the battery cover on

the left side of the vehicle. (Figure 2-27)

►►

If the liquid level of the windshield washer tank is too low,

add some windshield washer. Loosen the screw on the back

Windshield washer

of the windshield washer tank, pull it out from the bottom, and

add the windshield washer from the mouth.

Figure 2-27

When the temperature is too low, be careful to prevent

the liquid from freezing.

CONTROLS | OPERATION

►►

The pressure measurement conditions and normal values of various pressure-measuring points:

Technical

Detection

Items to be

requirements

No.

Detection conditions

locations and

checked

(normal values)

methods

Unit: Mpa

Low speed

0.2~0.3

Oil temperature of

"OUT" Port

Torque

torque converter

High speed

0.46±0.15

converter

when engine is

running: 75±5°C

High speed

"IN" Port

0.85+0.2

Oil temperature of

Low speed

2.25±0.2

Transmis-

transmission case

"T/M" Port

sion case

when engine is

running: 75±5°C

High speed

2.4±0.25

Oil temperature of steering

Left

"LC" Port

Steering

clutch when engine is running:

1.6+0.3

clutch

75±5°C

Right

"RC" Port

Left

"LB" Port

Oil temperature of brake when

Brake

2.0+0.25

engine is running: 75±5°C

Right

"RB" Port

"LC" Port

Left

When brake’s oil pres-

Steering

Oil temperature of steering

"LB" Port

sure changes from 0,

baking

clutch and brake when engine

measure the pressure

pressure

is running: 75±5°C

"RC" Port

of the steering clutch:

Right

1.08~1.35

"RB" Port

Noise

When carrying out maintenance of the engine and you are exposed to noise for long periods of time,

wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause

temporary or permanent hearing problems.

OPERATION | THE ELECTRIC SYSTEM (WITHOUT GPS)

2.2 THE ELECTRIC SYSTEM (WITHOUT GPS)

Functions of the combination meter (Figure 2-29)

The combination meter mainly includes engine oil pressure

gauge, the water temperature gauge, the oil temperature

150

180

210

180

210

250

100

250

140

300

100

℃

120

℃

100

150

PSI

BAR

0300 700

gauge, the voltmeter, and the hour meter.

QUARTZ

MURPHY

VOLTS

HOURS

0 7

Figure 2-29

The engine oil pressure gauge (See Figure 2-30)

The range of the engine oil pressure gauge is 0KPa-700KPa.

When the engine runs at a low speed, the oil pressure should

be bigger than 100KPa, and when the engine runs normally,

the oil pressure should be between 250KPa and 550KPa. Dur-

ing cold start, the pressure is sometimes higher, so you should

warm-up the engine first to bring the readings of the meters

within the normal operating range before starting operation.

Figure 2-30

The voltmeter (See Figure 2-31)

The range of the voltmeter is 16-36V. Before the normal op-

eration, the reading of the voltmeter is over 24V, indicating

that the battery’s voltage is normal; if the reading is below 24V,

it means that the battery’s voltage is too low and may make

it difficult to start the vehicle. If you cannot start the engine,

charge the battery.

When the machine is running normally, the engine charges the

battery, and the voltmeter’s reading is around 28V. If the volt-

age is too low or too high, find out the reason and eliminate

the problem before operation.

Figure 2-31

THE ELECTRIC SYSTEM (WITHOUT GPS) | OPERATION

The water temperature gauge (See Figure 2-32)

The range of the water temperature gauge is 40-120°C, in-

dicating the engine’s water temperature. When the machine

runs normally, the reading of the water temperature gauge is

40-100°C. If the temperature is too high and above 100°C, re-

duce the engine speed, to bring the reading back to the normal

range; stop the vehicle to check the water level if necessary.

Figure 2-32

The oil temperature gauge (See Figure 2-33)

This indicates the oil temperature of the hydraulic torque con-

verter, and the normal operating range is 60°C-120°C. During

operation, if the temperature is too high and above 120°C, re-

duce the load, to bring the reading back to the normal range.

Figure 2-33

The hour meter (See Figure 2-34)

This meter records the operation time of the engine, to be

used as the basis for regular maintenance.

CAUTION

Check the instruments from time to time during operation,

to ensure that the operation is normal.

Figure 2-34

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3 THE ELECTRIC SYSTEM (WITH GPS)

The bulldozer’s GPS electric system mainly includes the temperature sensor, the pressure sensor,

the fuel level sensor, the smart unit for signal collection & conversion, and the LCD smart monitor,

and the GPS smart service terminal etc. The sensors are installed in various working parts of the

bulldozer, to collect working parameters in real time, and to transmit the data through LAN; various

smart units can use each other’s data and share the same ports, to carry out various safety protec-

tion and strategic actions.

Note: If the product pictures in this manual are different from the actual products, the actual products

should be based on, and the pictures in this manual are for reference only.

This section aims to provide instructions for users to realize safe and efficient operation as well as

the effective maintenance of the vehicle’s electric system. Understanding the various precautions as

well as the repair & troubleshooting instructions can help effectively avoid various dangerous acci-

dents.

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

WARNING

•

Before operating or maintaining and troubleshooting the electric system, you must read

this section thoroughly.

•

The meters are precision instruments, and in the installation process you should handle

them gently. You cannot directly wash the instruments and any part of the entire electric

system with water.

•

The negative pole’s wire of the meters and the earth wire’s calibration wire should be

separately connected to the main switch end of the power supply or be connected to the

ground through a reliable nearby bond strap; never connect them together with other

equipment to the battery’s negative pole using the same wire.

•

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

reliable and firm.

•

The four screws connecting the dashboard and the instrument box should be tightened to

ensure the normal use of the meters.

•

The installation of all the sensors should ensure that the sensor’s outer threads and their

surface are connected properly, to ensure that the sensor’s bond strap is in good condi-

tion. (We don’t recommend the use of sealant on the mounting face)

•

Before the installation of cables, the installation points of all the bond straps (the surface

in contact with the cable’s terminals) must be rigorously treated to remove the paint and

the oxidized substance, to ensure that the contact surface is smooth and flat and has

good conductance.

•

The protective insulating rubber cover at the end of all the bond straps should not be too

long to negatively affect the normal connection of the bond strap surface.

•

When multiple bond straps are installed at one bond strap point, they should be alternated

with each other, to ensure the complete contact after installation.

•

The bond strap’s mounting pedestal should be fully soldered, and should not be cold-

soldered or contain slag.

•

Ensure that the power switch has good contact during operation, and the contact resis-

tance of the switch’s contact should be within 0.001Ω.

CAUTION

• To avoid causing vehicle-locking fault, the users are strictly forbidden to modify or remove

the GPS system’s elements and circuits.

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3.1 PRECAUTIONS FOR TURNING ON AND OFF THE MAIN MACHINE

STARTING UP——

1. Put the mains switch to ON

2. Apply the brake

3. Adjust the seat and tighten the seat belt

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

5. Put the gear on NEUTRAL

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

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

8. Put the valve control to LOW IDLE

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

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

engine after the automatic warm up

WARMING UP——

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

2. Unlock the control levers of the work equipments, and cycle the control levers, to ensure that

the work oil runs through all the cylinders and pipes

3. Check the instruments and monitors

WORKING——

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

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

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

4. Release the brake

5. Change the gear to the needed position

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

SHUTTING DOWN——

STEPS

REMARKS

1. Stop the bulldozer in a level area

2. Apply the brake

3. Reduce the speed of all the hydraulic elements

4. Let the engine idle for 5min

5. Put the key switch to OFF

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

7. Observe if there are obvious issues around the bulldozer that need

to be addressed after operation

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.2 THE ENVIRONMENTAL REQUIREMENTS OF THE CONTROLLERS AND MONITORS

1. Power supply: 18~32VDC

2. Operating temperature: -30~+70°C

3. Storage temperature: -40~+85°C

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

5. Atmospheric pressure: 86~106KPa

6. Protection class: IP65

When one or more of the above parameters is out of the required range, the electric system may not

work normally or may become damaged. Please use the system strictly following the above require-

ments on the operating environment, to ensure that the system can work normally.

2.3.3 DESCRIPTION OF THE MONITOR PANEL

180

210

150

210

180

250

100

250

140

300

100

℃

120

℃

150

0 rpm

28.5v

VOLTS

Figure 2-35: GPS system’s monitor panel

This monitor panel consists of 5 dial pointers and 1 LCD smart monitor, as shown in Figure 2-35.

No.

Name

No.

Name

Meter displaying water temperature of

Meter displaying system voltage

the engine

Meter displaying oil temperature of the

Meter displaying engine oil pressure

hydraulic torque converter

Hour meter

LCD Smart monitor

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

2.3.4 DESCRIPTION OF THE SWITCH BUTTON PANEL

Figure 2-36: GPS system’s switch button panel

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

Figure 2-36:

No.

Name

No.

Name

Key starting switch

Side lamp switch

Front lamp switch

Rear lamp switch

Instrument light switch

K1—LCD smart monitor’s Mute/OK key

K3—LCD smart monitor’s Menu/Left &

K2—LCD smart monitor’sUP/Down key

Right key

Operation of the reset switch buttons:

1. K1 Mute/Confirmation Key:

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

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

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

2. K2 Up/Down Key:

a. Move the cursor up or down;

b. Display the next page or the previous page;

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

3. K3 Menu/Left and Right Key:

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

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

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.5 OPERATION OF THE ELECTRIC SYSTEM

The power supply’s main switch

The power supply’s main switch is installed near the battery,

to connect the battery’s negative terminal and the bulldozer’s

body; the power supply’s main switch has a switch-blade struc-

ture, and has two positions: ON and OFF (as shown in Figure

2-37); When the bulldozer does not work for a long time, you

should push the knob of the power supply’s main switch to the

OFF position, to reduce the battery’s consumption. Before the

bulldozer is started, push the knob of the power supply’s main

switch to the ON position.

Figure 2-37: Power switch

Key starting switch

The starting switch is located on the instrument box’s switch

panel. It has four positions (as shown in Figure 2-38), which

are the HEATER position, the OFF position, the ON position

and the START position. When the starting switch is in the

OFF position, the system is in the power off state; when you

insert the key, and turn the starting switch from OFF to ON,

the entire electric system is powered on, and after a short self-

test, the monitors enter the main working window, as shown

in Figure 2-38. Turn the starting switch from ON to START,

Figure 2-38: Key starting switch

and release the key after ensuring that the engine is started,

the starting switch will automatically return to the ON position.

When the starting switch is turned to the OFF position, the en-

gine will stop working.

Smart monitor

The main working window of the smart monitor displays the

fuel level (%), the system’s voltage, the current gear position,

the engine speed and the warnings, as shown in Figure 2-39.

The main functions of this monitor are as follows:

a. Displays the operation the vehicle’s parameters in real time

Engine does not

b. Provide warning information

generate power

c. System setup and vehicle management

Figure 2-39: Smart

monitor’s window

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

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

Window

Check content

Setup management

Fuel level

Engine speed rpm

System voltage

Warm-up indication

Main window

Gear position indication

Alarm for parameters out

of range

Fault alarm

Device fault alarm

Vehicle management

alarm

Fuel level

Cooling water temperature

°C

Torque converter’s oil temperature

°C

Operation parameter

Engine oil pressure Bar

Engine speed rpm

System voltage

Alarm parameters

Flywheel’s number of teeth

Chinese

User setup

Language setup

English

Flywheel’s number of teeth

Alarm parameter setup

(range: 000.00-300.00)

System setup

Testing information (backup)

Vehicle is unlocked on-site to

be opened

Vehicle management

On-site unlocking (dynamic password)

Vehicle is unlocked on-site to

be closed

Hardware: D2460-00030

Monitor’s information

Software: V10

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

3. Warnings

When the LCD smart monitor detects a fault of the bulldozer, it will display the related warnings in

its main window, and give out the buzz to alert the operator. Types of the warning information are as

follows:

Chinese

English

水温传感器断路

Water temp sensor open

水温传感器短路

Water temp sensor short

发动机水温高

Engine water too hot

燃油传感器断路

Fuel sensor open

燃油传感器短路

Fuel sensor short

燃油液位低

Fuel level low

油温传感器断路

Oil temp sensor open

油温传感器短路

Oil temp sensor short

传动油温高

Trans oil temp too high

油压传感器断路

Oil pressure sensor open

油压传感器短路

Oil pressure sensor short

机油压力过低

Engine oil pressure low

预热进行中

Warming

空档

Neutral

发电机不发电

Alternator failed

车辆故障：0010

Vehicle fault: 0010

车辆故障：0011

Vehicle fault: 0011

车辆故障：0012

Vehicle fault: 0012

车辆故障：0020

Vehicle fault: 0020

车辆故障：0030

Vehicle fault: 0030

车辆故障：0031

Vehicle fault: 0031

车辆故障：0032

Vehicle fault: 0032

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

Check system voltage

The dial pointer intuitively displays system voltage in real time

(as shown in Figure 2-40). When the key starting switch is

in OFF, the pointer is back to zero, and when it is in ON, the

pointer points at around 24V. When the engine is running,

pointer should point at around 28V. This meter has a backlight

in purple red, to facilitate use during nighttime.

The LCD smart monitor’s main window dispalys system volt-

age.

When the system voltage is lower than 22V, the charging in-

dicate on the smart monitor will blink, the warming message

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

Figure 2-40: Meter displaying

system voltage

Check the temperature of the cooling water

The dial pointer displays the temperature of the cooling water

in real time (as shown in Figure 2-41), and the display range is

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

use during nighttime.

The LCD smart monitor displays the engine’s cooling water

temperature in real time, and you can check it out by entering

the menu of operation parameters.

1. When the water temperature sensor’s circuit is open, the

pointer is back to zero, the smart monitor gives warning

Figure 2-41: Meter displaying the

“Water temperature sensor’s circuit is open”, and the buzz-

temperature of the cooling water

er sounds.

2. When the water temperature sensor’s circuit is short, the

pointer is at full scale, the smart monitor gives warning

“Water temperature sensor’s circuit is short”, and the buzz-

er sounds.

3. When the water temperature sensor detects a temperature

≥100°C, the smart monitor gives warning “Engine water

temperature high”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after

the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-36) can shield

the buzzer’s sound.

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

Check the oil temperature of the torque converter

The dial pointer displays the hydraulic oil’s temperature intui-

tively and in real time (as shown in Figure 2-42), and the dis-

play range is 60-150°C. This meter has a backlight in purple

red, to facilitate use during nighttime.

The LCD smart monitor displays the oil temperature of the

torque converter in real time, and you can check it out by en-

tering the menu of operation parameters.

1. When the oil temperature sensor’s circuit is open, the

pointer is back to zero, the smart monitor gives warning

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

sounds.

Figure 2-42: Meter displaying

hydraulic oil temperature

2. When the oil temperature sensor’s circuit is short, the

pointer is at full scale, the smart monitor gives warning

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

sounds.

3. When the oil temperature sensor detects a temperature

≥120°C, the smart monitor gives warning “Transmission oil

temperature high”, and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after

the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-36) can shield

the buzzer’s sound.

Check engine oil pressure

The dial pointer intuitively displays engine oil pressure in

real time (as shown in Figure 2-43), and the display range is

0-700KPa. This meter has a backlight in purple red, to facili-

tate use during nighttime.

The LCD smart monitor displays engine oil pressure in real

time, and you can check it out by entering the menu of opera-

tion parameters.

Figure 2-43: Meter displaying

engine oil pressure

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

1. When the oil pressure sensor’s circuit is open, the pointer

is back to zero, the smart monitor gives warning “oil pres-

sure sensor’s circuit is open”, and the buzzer sounds.

2. When the oil pressure sensor’s circuit is short, the pointer

is at full scale, the smart monitor gives warning “oil pres-

sure sensor’s circuit is short”, and the buzzer sounds.

3. When oil pressure sensor detects a pressure ≤1Bar, the

smart monitor gives warning “Engine oil pressure too low”,

and the buzzer sounds.

4. Cancelling a warning should be done about 10s later after

the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-36) can shield

the buzzer’s sound.

Check bulldozer’s operation hours

The dial pointer intuitively displays the bulldozer’s operation

hours in real time (as shown in Figure 2-44), the time is show

in hours, and the smallest display unit is 1/10h.

Check fuel level

Fuel level is displayed as a percentage in real time in the

smart monitor’s main window (as shown in Figure 2-39).

1. When fuel level sensor’s circuit is open, the smart moni-

tor gives warning “Fuel sensor is open”, and the buzzer

sounds.

Figure 2-44: Hour meter

2. When fuel level sensor is short, the smart monitor gives

warning “Fuel sensor is short”, and the buzzer sounds.

3. When fuel level sensor detect fuel level ≤10%, the smart

monitor gives warning “Fuel level low”, and the buzzer

sounds.

4. Cancelling a warning should be done about 10s later after

the parameter is back to normal.

5. Pressing the K1 key (as shown in Figure 2-36) can shield

the buzzer’s sound.

Check engine speed

Engine speed is displayed in real time in the smart monitor’s

main window (as shown in Figure 2-39).

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

Definitions and descriptions of other warnings

When the engine does not have output, the smart monitor gives warning “Engine does not gen-

erate power”, and the buzzer sounds.

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

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

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

When the bulldozer’s smart monitor gives warning “Vehicle fault 0010”, all the dial pointers (ex-

cept for the meter displaying battery voltage) are back to zero. You need to contact your equip-

ment supplier.

When the bulldozer’s smart monitor gives warning “Vehicle fault 0011”, all the dial pointers (except

for the meter displaying battery voltage) are back to zero. The GPS antenna is not properly con-

nected, and you should check it out and fix it.

When the bulldozer’s smart monitor gives warning “Vehicle fault 0012”, all the dial pointers (ex-

cept for the meter displaying battery voltage) are back to zero. The communication card of the

smart service system does not work properly, and you should check it out and fix it.

When the bulldozer’s smart monitor gives warning “Vehicle fault 0020”, all the dial pointers

(ex-

cept for the meter displaying battery voltage) are back to zero, and the engine cannot be started

normally. You need to contact your equipment supplier.

When the bulldozer’s smart monitor gives warning “Vehicle fault 0030”, all the dial pointers

(ex-

cept for the meter displaying battery voltage) are back to zero, and the engine cannot be started

normally. You need to contact your equipment supplier.

When the bulldozer’s smart monitor gives warning “Vehicle fault 0031”, all the dial pointers

(ex-

cept for the meter displaying battery voltage) are back to zero, and the engine cannot be started

normally. You need to contact your equipment supplier.

10. When the bulldozer’s smart monitor gives warning “Vehicle fault 0032”, all the dial pointers

(ex-

cept for the meter displaying battery voltage) are back to zero, and the engine cannot be started

normally. You need to contact your equipment supplier.

CAUTION

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

eration.

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

2.3.8 IN-LINE FUSE

There are some in-line fuses in the instrument box of this ma-

chine, as shown in Figure 2-47. When the meters and the GPS

system do not have power supply, you need to check the cor-

responding inline fuses to see if they are already blown. Re-

place the fuses after eliminating the corresponding faults.

►►

Replace a fuse with another of the same capacity.

Before replacing a fuse, be sure to turn off the start-

ing switch.

Figure 2-47: Illustration of

In-line fuse

2.3.9 POWER SOCKETS

This machine provides the 24V power socket in the accumula-

tor box. If you repair the machine during nighttime and tempo-

rarily need the 24V power supply, you can open the accumula-

tor box’s cover to see the 24Vpower socket.

2.3.10 WARM-UP AND START

Turn the key switch to ON (Figure 2-48) to turn on the warm-

up switch (Figure 2-48). When the engine’s water temperature

is above 0°C, the system will not enter the warm-up state, and

will only indicate it by lighting up the warm-up indicator for 2

seconds. When the engine’s water temperature is below 0°C,

the system will automatically enter the warm-up state, and the

duration that the indicator is on is the warm-up time, which is

related to the voltage. When the voltage is 24V, the warm-up

time is 26±2 seconds.

Figure 2-48

OPERATION | THE ELECTRIC SYSTEM (WITH GPS)

When the indicator is off, it means that the warm-up is over, and the engine can be started; if the

engine is not started within 30 seconds (during this period the warm-up plug remains electrified), the

system will automatically stop working; if the engine is started, the indicator will be on, the warm-

up plug will continue to be electrified, the solenoid valve will automatically connect the oil circuit,

the system will automatically enter the post-heating stage (during this stage the warm-up plug, the

solenoid valve and the indicator remain electrified), and the post-heating time is determined by the

engine’s water temperature. When the battery’s voltage is below 15V or when the temperature sen-

sor has an open circuit, the system will not enter the warm-up state, and the indicator will blink for

15 seconds to alarm.

2.3.11 CAB’S HEAD LAMP SWITCH

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

49)

2.3.12 WINDSHIELD WIPER SWITCH

These switches (as shown in Figure 2-49) are used to operate the following windshield wipers:

(1)—Rear Window Wiper

(2)—Front Window Wiper

High speed

Low speed

OFF

Head lamp switch, Fan switch

Windshield wiper switch

Figure 2-49

THE ELECTRIC SYSTEM (WITH GPS) | OPERATION

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

SYSTEM

The bond straps of construction machinery’s electric system can have many types of faults. For ex-

ample, the engine does not have sufficient power or is not easy to be started, the lamps are not lit

up, the meters do not have accurate displays or are easy to give false alarms, etc.

The construction machinery’s electric system uses the low-voltage DC power supply, adopts the se-

rial connection, parallel connection or mixed connection circuits, and all the circuits have a positive

terminal and negative terminal. All the circuits from the loads would need to be directly connected

to the battery’s negative terminal through wires. If separate wiring is adopted, there would be more

than one hundred wires on the battery. In order to save the wires and to facilitate installation, the cir-

cuits of general construction vehicles would use a single wire, which means that the battery’s posi-

tive terminal is directly connected to various electric devices, the battery’s negative terminal is di-

rectly strapped to the metal part of the vehicle’s frame, the negative terminals of electric devices are

strapped to the nearby metal part of the vehicle’s frame, and the metal part of the engine and the

chassis (beam frame) is used as the public pathway. This type of connection in which the negative

terminal is connected to the body of the vehicle is called bond strapping. It is also known as earthing

or metal connecting. Negative terminal’s bond strapping has a number of benefits including less in-

terference to the electronic devices, less electrochemical corrosion to frame and body, and firm con-

nection. Today most construction machines and vehicles adopt negative terminal’s bond strapping.

The body of a construction machine generally has more than two main bond straps. One of them

is the battery’s negative terminal wire, and the other is the bond strap between the engine and the

beam. The form of these bond straps is different from ordinary wires. They are usually copper wires

above 50mm2, and the current carrying capacity is large. Malfunction of bond strap is very easy to

occur. For example, the failure to clean the paint on the frame before the entire vehicle leaves the

factory, a loose fastening bolt of the engine’s bond strap, the makeshift installation during the recon-

nection of bond straps, or the increased resistance of bond strap’s connector due to corrosion all

can cause improper contact, forcing the current to try to go through other circuits, causing voltage

drop or failure. Malfunction of bond straps can cause many obvious or hidden faults to circuits. In

the ignition system, if engine’s bond strap does not function properly, the engine may not be started.

In the starting circuit, if engine’s bond strap does not function properly, the starter’s speed will be re-

duced, the armature will be heated, and over time, it will be very easy to have the starter burned. In

the lighting circuit, if the bond straps of the lamps do not function properly, the lamps may not be lit

or the lamps may be dim. Therefore, knowing the role of bond straps can avoid many faults and the

wrong judgment during the troubleshooting of the electric system.

OPERATION | OPERATION

2.4 OPERATION

WARNING

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

tion.

2.4.1 CHECK BEFORE STARTING ENGINE

►►

Form a habit to check before starting engine. Never be imprudent and careless. This is

good for the safety of both people and vehicle.

Check oil or water leakage

Before starting the engine, look around the machine and under the machine to check for loose nuts

and bolts, or leakage of oil, fuel, or coolant, and check condition of the work equipment and hydrau-

lic system. Check also for loose wiring, play, and collection of dust at places which reach high tem-

peratures.

Check bolts and nuts

Check for loose nuts and bolts, and tighten them if necessary. Pay special attention to air cleaner,

carrier roller bracket and track shoe bolts.

Check electric circuits

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

OPERATION | OPERATION

Check cooling water level (Figure 2-50)

Turn open the radiator cap (1) (Figure 2-50), and check if the

water is at the required level. Add water if necessary.

Add cooling water after the engine has stopped. Add water to

the sub-tank to the full (until the water overflows), and then

start the engine and let it idle for 5min and check again. If the

water level is lower than required, continue to add water. If

the water added is increased abnormally, look for leakage and

solve it in time.

CAUTION

Figure 2-50

When cooling water is overheated, turn the cap (1) loose

slowly, to release the internal pressure before opening it,

to avoid boiling water from spurting out to have people in-

jured.

Check oil level in engine oil pan (Figure 2-51)

When the engine has stopped, take out the dipstick(G), and

check the oil level on the side marked “Engine stopped”. When

the engine is idling, check to see if the engine oil pressure

gauge and water thermometer are within the normal range

first, and then take out the dipstick (G) to look at the oil level

on the side marked “Engine idling”. If oil needs to be added,

open the injection mouth to add oil. The types of engine oil

Figure 2-51

depend on the ambient temperature. See the “USE OF FUEL,

COOLANT AND LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE”. When checking oil level, park the vehicle on

a level ground. When adding engine oil, do not let the oil level

be higher than the “(H)”mark. When checking oil level, do not

rely on engine oil level monitor alone.

Check fuel level

Remove the fuel tank cap, and pull out the dipstick (G) (as

shown in Figure 2-52) to check the oil level.

After completing work, fill the fuel through filter screen. Before

operating the bulldozer, make sure there is plenty of fuel in the

tank so that the engine fuel line does not become aerated.

Fuel tank capacity: 450L

CAUTION

Figure 2-52

When adding fuel, never let the fuel overflow. This may

cause a fire.

OPERATION | OPERATION

Check steering clutch case oil level (including transmis-

sion case and torque converter)

As shown in Figure 2-53, use dipstick (G) to check the oil lev-

el. If needed, oil should be added through the filter screen (F).

The lubricant type used depends on the ambient temperature.

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

CORDING TO AMBIENT TEMPERATURE” for reference.

Figure 2-53

When checking oil level, stop the engine.

When operating on a slope of over 20 degree, the oil level

should be at the (H) HIGH level.

Drain the sediment in fuel tank (Figure 2-54): Turn loose the

valve (1) on the bottom of fuel tank, to drain the water and

sediment in the fuel.

Figure 2-54

Check brake pedal’s journey (Figure 2-55)

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

130mm (operating force is 15kg). When the engine stops, the

stroke is about 75mm. If the pedal’s stroke is over 190mm,

the brake function is not adequate, and you should make ad-

justment following the “Adjustment” section.

Figure 2-55

OPERATION | OPERATION

2.4.2 OPERATION METHODS AND STEPS

1. Check the positions of various control levers before start-

Lock

ing (Figures 2-56 and 2-57). (1)—Brake lock lever, (2)—

Gear shift lock lever, (3)—Steering control lever, (4)—Gear

shift lever, (5)—throttle gear shift lever. Adjust the opera-

Free

tor’s seat, so that the operator can completely step down

the brake pedal while leaning against the seat back.

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

Figure (2-56)

Figure 2-56

3. Gear shift lever (4) is in the NEUTRAL position, and gear

shift lock lever (2) is in the LOCK position (Figure 2-57).

Free

Lock

Figure 2-57

4. The blade and ripper should be lowered to the ground, and

their control lever lock button should be in the LOCK posi-

tion. (Figure 2-58)

Lock

Figure 2-58

5. Starting engine

• Pull the throttle level (5) to the idling position. (Figure 2-57)

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

2-59)

• When engine started, release the starting key (1), and the

key will automatically return to the

(ON) position. (Figure

2-59)

OPERATION | OPERATION

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

• The key should not stay in the “Starting” position

for

more than 10s.

• When the fuel is empty and you want to start the engine,

add sufficient fuel first and then let the fuel fill the core of

fuel filter and exhaust the air in the fuel system before start-

ing the engine again.

Figure 2-59

Checks after starting engine

•

After starting the engine, perform the following checks:

•

Let the engine run at a low speed, until the engine oil pres-

sure is within the normal range.

•

Pull the throttle control lever (5) to let the engine idle at a

mid-range speed for about 5 min. (Figure 2-60)

•

Do not run the engine at low or high idle for more than 20

minutes. If it is necessary to run the engine at idling, apply

Free

a load from time to time or run the engine at a mid-range

speed.

•

After engine temperature is increased, check various me-

Lock

ters for abnormality.

•

Let the engine continue to run at a low-load, to let water

Figure 2-60

temperature rise. Water temperature between 74-91°C is

most ideal.

•

Check the color of exhaust for abnormalities, such as ab-

normal sound or vibration.

•

Do not suddenly accelerate the engine before the machine

reaches full operating temperature.

•

If engine oil pressure is not within the normal range, stop

the engine immediately, and check for reasons.

OPERATION | OPERATION

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

• Step down the deceleration pedal (1) to reduce engine

speed, so that there is no impact when the vehicle is start-

ed (Figure 2-65).

Figure 2-65

• Put the gear shift lever (4) to the needed position, and the

vehicle will start to move (Figure 2-66)

5. Pull throttle control lever (5), to accelerate the engine (Fig-

ure 2-66)

6. Through the gear shift lever (4) you can select any speed

without stopping the vehicle. (Figure 2-66)

• Forward←→Reverse

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

This can preventing impacting vehicle. Step down the de-

celeration pedal, to reduce engine speed, bring the gear

shift lever to the needed Forward or Reverse gear, and then

Figure 2-66

release the deceleration pedal, to accelerate the engine.

OPERATION | OPERATION

2.4.5 PARKING

Push the throttle control lever (5) to the idling position, to re-

duce engine speed. Push the gear shift lever (4) to the NEU-

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

Step down the crossing part in the middle of the left and right

brake pedal (2), and the vehicle stops (Figure 2-65); pull the

brake lock lever (1) to the LOCK position (Figure 2-69), to lock

the gear shift lock lever (2) (Figure 2-66).

Figure 2-69

Push the blade control lever (3) and ripper control lever (4)

to the Lowering position, to lower the blade and ripper to the

ground. And then press the blade control lever’s lock button (1)

and ripper control lever’s lock button (2). (Figure 2-70, 2-71)

CAUTION

Park the vehicle on a firm and level ground as far as pos-

sible, and avoid parking it in a dangerous place.

Figure 2-70

Figure 2-71

OPERATION | OPERATION

2.4.6 STOPPING ENGINE

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

(OFF) position, and the engine

will stop running. Pull out the key. If you suddenly stop the vehicle when the engine is not cooled, it

will dramatically shorten the lifecycle of the engine. Never suddenly stop the vehicle unless in emer-

gency.

2.4.7 OPERATION IN SPECIAL CLIMATE CONDITIONS

Precautions for low temperature:

1. If the temperature is too low, it will be difficult to start the engine, and the cooling water will be

frozen, causing negative impacts on the vehicle, so you should take appropriate measures, and

select oil and water according to the “USE OF FUEL, COOLANT AND LUBRICANTS ACCORD-

ING TO AMBIENT TEMPERATURE”.

2. When the atmospheric temperature is lower than 0°C, to prevent the cooling water from freez-

ing, you can use the antifreeze based on the lowest temperature. For the mixing proportion and

usage methods of water and antifreeze, see “CLEAN INSIDE OF COOLING SYSTEM”.

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

4. When the weather becomes warm, drain the antifreeze (except for the permanent antifreeze),

and clean the cooling system, before replacing the clean water.

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

ice, they will damage the oil cylinder’s oil seal.

CAUTION

• Water without antifreeze should be thoroughly drained during the nighttime of winter, to

prevent the parts from being cracked by freezing. Note: Do not drain water in areas such

as oil cooler.

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

malfunction of engine.

• Antifreeze is flammable, so be careful of fire.

• When the ambient temperature drops, the capacity of the battery will also drop. If the bat-

tery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as

close as possible to 100%, and insulate it against cold temperature so that the machine

can be started easily the next morning.

OPERATION | OPERATION

2.4.9 PRECAUTIONS

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

• If you do need to park the vehicle on a slope, face the head of vehicle downhill, and lock the

brake pedal. When the slope is big, you can slightly cut the blade into the ground, to prevent ve-

hicle from slipping.

2. When the vehicle travels on a slope, the longitudinal slope should not be over 30 degree, and

when going uphill, do not travel backward.

3. When you start the vehicle on a slope, step down the left-right brake pedal first, and then pull

the gear shift lever to Gear 1, while slowly releasing the brake pedal. If the engine speed is too

fast, you can use the brake pedal to reduce speed.

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

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

oil to H level.

CAUTION

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

tremely dangerous.

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

• If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck

in air because of the angle of the machine or the swaying of the machine. If this makes the

engine stop, the braking effect will be reduced, so be careful not to let the fuel level in the

fuel tank become too low.

DOZING OPERATION | OPERATION

2.5 DOZING OPERATION

Reasonably choosing the models as well as the adjustment

and operation methods of the blade according to the dozing

objects is very important to extending the lifecycle of the ve-

hicle, reducing the operator’s fatigue, and increasing produc-

tivity.

The SD22 bulldozer is suitable for the general operating con-

ditions. The SD22E bulldozer is suitable for loose soil. The

SD22S is suitable for operating in swamps.

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

“angle blade”, and the “U-Blade”. They are suitable for differ-

ent terrains and operation objects.

The effective dozing distance is 70m at the maximum. For

long-distance application, using a fork lift is more economical.

2.5.1 OPERATION OF BLADE AND RIPPER

The control levers and buttons of the work equipments. See

“The Roles of Various Controls” (See 2-1-2)

2.5.2 BLADE ADJUSTMENT

Angle blade adjustment

1. Adjustment of angle blade’s turning angle

►►

The two sides of the blade can be adjusted to be 25º. (Fig-

ure 2-75)

• Raise the blade to be 400-500mm above ground, and put a

block under the C-Frame.

• Pull out the pins (1) on both sides to remove the push rod’s

Figure 2-75

arm (2) from the C-Frame (Figure 2-76)

• After putting the blade into an angle, install the push rod’s

arm (2) to the needed position. (the push rod frame has

three supports on each side), and then insert the pin (1).

CAUTION

After removing push rod’s arm, be careful that the blade

will swing freely.

Figure 2-76

OPERATION | DOZING OPERATION

2. Adjust of angle blade’s tilt

►►

The biggest tilt of blade: 500mm (Figure 2-77)

a. Raise the blade to be 400-500mm above ground, and put a

block under the C-Frame.

Figure 2-77

b. Loosen jack bolt (1), insert an iron bar into the hole of the

support rod (2) to rotate the support rods on the two sides, to

elongate and shorten them respectively. Tilt the blade to the

required height, and then tighten jack bolt. (Figure 2-78)

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

1338mm, and the blade’s tilt should be within 500mm.

• Do not attempt to tilt the blade to more than 500mm, to pre-

vent unwanted effect.

Figure 2-78

►►

When using the adjusting rod to turn the support arm, the

blade should be above ground before tilting it.

c. Adjustment of gaskets

• The standard thickness of the adjustment gaskets between

the blade lift cylinder’s piston rod and cap is 4mm (Figure

2-79).

• Remove some gaskets, to adjust the spherical clearance

between oil cylinder’s piston rod and cap. The suitable

clearance maintained with gaskets is 0.2~0.6mm.

Figure 2-79

Shantui SD22. Operation and Maintenance Manual - 2