Shantui SD22. Operation and Maintenance Manual

MAINTENANCE | MAINTENNANCE

CAUTION

• Do not handle electric systems in rain;

• When checking or cooling water, be careful, as hot water may spurt out to injure people;

• After the engine oil filter or strainer is replaced, exhaust the air from the oil circuit;

• Never add oil by taking out the filter screen of the oil injection port.

Remember that there is high pressure within the hydraulic oil circuit. When you add oil,

drain oil or perform check and maintenance, release the pressure first. The method for re-

leasing pressure is as follows:

• Lower the blade and ripper to ground, extinguish the engine, pull the hydraulic system’s control

lever to each gear position 2-3 times continuously, and then slowly turn loose the oil tank’s cap or

the pipe connector;

• Before changing engine oil, start the vehicle to raise the oil temperature to 30-40°C strain the oil;

• Use clean oil and grease. When checking or changing oil, do not do it in a dusty location, or the

dust can get into the oil;

• Before servicing the gearbox, take all the objects out of your pockets. Be careful, wrenches or

nuts may fall into the box, to create a big trouble;

• Fuel and oil should be kept away from fire;

• Do not use fire to replace lamps for lighting; When changing O-rings, gaskets or other sealing

items, rigorously clean part’s surface, and install them carefully;

• Within the battery box, there is a 24V DC socket, which can be used directly during servicing &

maintenance.

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4.1.1 SERVICE TABLE

NO.

MAINTENANCE ITEMS

MAINTENANCE CONTENTS

CHECK BEFORE STARTING

Checking oil or water leakage

Checking

Checking bolts and nuts

Checking and tightening

Checking electric circuits

Checking and tightening

Checking coolant water level

Checking and replenishing

Checking oil level in engine oil pan

Checking and replenishing

Checking fuel level

Checking and replenishing

Checking oil level in steering clutch

Checking and replenishing

Discharging impurities from fuel tank

Draining water and sediments

Checking dust indicator

Checking and cleaning air filter

Checking brake pedal travel

Checking and adjusting

INITIAL 250 HOURS SERVICE

Fuel filter

Changing the filter’s cartridge

Steering clutch case (including transmission

Changing oil and washing the strainer

case and torque converter)

Hydraulic tank and filter

Changing oil and Replacing filter element

Final drive case

Changing oil

Engine valve’s clearance

Checking and adjusting

EVERY 250 HOURS SERVICE

Lubricating (Checking the following areas, lubricating them and applying grease to them)

Fan pulley

1 place

Tension roller and tension roller’s bracket

2 places

1 places of straight tilt blade, and 2 places

Support arm’s screw rod

of angle blade

Oil cylinder bracket shaft

2 places

Oil cylinder bracket yoke

4 places

Tilt oil cylinder ball joint

Straight tilt blade: 1 place

Support arm’s spherical hinge

Straight tilt blade: 1 place

Blade arm ball joint

3 places

Oblique arm’s spherical hinge

2 places

Various hinged joints of the ripper

18 places

Engine oil pan and filter

Draining oil and replacing the filter element

Gearshift’s oil filter and steering oil filter

Replacing filter element

Final drive case

Checking oil level and replenishing

Hydraulic tank

Checking oil level and replenishing

Generator’s driving belt

Adjusting tension

Water pump’s driving belt

Adjusting tension

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CONTINUED

CHECK BEFORE STARTING

Battery electrolyte

Checking level

Strainer on the bottom of fuel tank

Washing

EVERY 500 HOURS SERVICE

Fuel filter

Replacing filter element

Breather

Washing

Fan belt

Adjusting tension

EVERY 1000 HOURS SERVICE

Lubricating (Checking the following areas, lubricating them and applying grease to them)

Universal joint

8 places

Oblique support arm

2 places

Idler’s tensioning oil cylinder

2 places

Water tank’s radiation fin

Checking and cleaning

Steering clutch’s case

Changing oil and washing the strainer

Final drive case

Changing oil

Hydraulic tank and filter

Changing oil and Replacing filter element

Walking parts

Checking and lubricating

Tubocharger

Checking roller’s clearance

Corrosion resistor

Changing the filter’s cartridge

EVERY 2000 HOURS SERVICE

(Checking the following areas, lubricating

Lubricating

them and applying grease to them)

Equalizer bar’s axle

1 places

Brake pedal

5 places

Breather of the engine’s crankcase

Washing

Tubocharger

Washing

Valve clearance

Checking and adjusting

Engine’s damper

Checking or changing

EVERY 4000 HOURS SERVICE

Checking if the belt is loose and if there is

Water pump

water leakage

Fan pulley and tension wheel

Checking if it is loose

MAINTENCE WHEN NEEDED

Air cleaner

Cleaning and changing

Washing the inside and changing the cool-

Coolant system

ant

Track tension

Checking and adjusting

Track bolt

Checking and tightening

Ed bit and cutting edge

Inverting or changing

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4.1.2 INITIAL 250 HOURS SERVICE

Perform the following maintenance only after the first 250

hours:

1. Fuel filter

2. Steering clutch case (including transmission case and

torque converter)

3. Hydraulic tank and filter

4. Final drive case

5. Engine valve’s clearance

For the replacement and maintenance methods, see “Mainte-

nance for Every 250 Hours, 1000 Hours and 2000 Hours”.

4.1.3 EVERY 250 HOURS SERVICE

Inject grease to the grease nozzle shown in the figure.

1 place: Fan pulley (Figure 4-1)

2 places: Tension roller and tension roller’s bracket

Figure 4-1

1 place of the support rod (Figure 4-2) 3 places of straight

tilt blade, and 2 places of angle blade

Figure 4-2

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10. Engine oil pan and filter

• Remove the cover installed on the bottom of the body.

Remove the drain plug and release the drain valve. After

draining, tighten the drain valve and the drain plug.

• Use filter wrench to rotate it counterclockwise, to remove

the engine oil filter’s and bypass oil filter’s cartridges. Fill

the new engine oil filter’s and bypass oil filter’s cartridges

with engine oil, apply a small amount of the engine oil on

the gasket, and screw it on the filter’s seat. When the gas-

ket touches the sealing surface, make

3/4-1 more turns.

Figure 4-14

After replacing the filter’s cartridge, add engine oil through

the oil injection port (F) (Figure 4-14).

• And then, let the engine idle for a while, and detect the oil

level. The type of lubricant used depends on the ambient

temperature. See the “USE OF FUEL, COOLANT AND LU-

BRICANTS ACCORDING TO AMBIENT TEMPERATURE”

for reference. The oil should be changed every 6 months.

Before installing the filter’s cartridge, you must inject the

engine oil into the filter’s cartridge.

Always use Shantui genuine filters.

Figure 4-15

11. Gearshift’s oil filter and steering oil filter.

• Remove the bolt (1), pull up the cap (2), and take out the

filter element and the valve along with the cap (2). Remove

the butterfly-shaped nut of the tightening valve (4), and

take out the filter element (3) from the oil filter. Clean the

inner part of the housing and the parts removed, and install

the new filter element in the oil filter. (See Figure 4-15 and

Figure 4-16)

Always use Shantui genuine filters.

Figure 4-16

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12. Final drive case

• Remove Plug (G). If it is found that the oil is not filled near

the bottom side of the plug’s hole, add lubricant via the

plug’s hole. The lubricant used depends on the ambient

temperature. See the “USE OF FUEL, COOLANT AND LU-

BRICANTS ACCORDING TO AMBIENT TEMPERATURE”

for reference. When performing maintenance, park the ve-

hicle on a level ground.

Figure 4-17

13. Hydraulic tank (See Figure 4-18)

• Put the blade and the ripper on the ground horizontally,

stop the engine, and wait for 5min to check the oil level. If

the oil level is not within the red circle in the Observation

Window (G), replenish the hydraulic oil to the oil tank via

the Oil Injection Port (F).

CAUTION

• When the oil temperature is high, do not remove the

cap. Hot oil sometimes can spurt out. When removing

the cap, slowly rotate the cap, to release the internal

pressure. The lubricant type used depends on the am-

bient temperature. See the “USE OF FUEL, COOLANT

AND LUBRICANTS ACCORDING TO AMBIENT TEM-

PERATURE” for reference.

• Before the engine is started, perform the routine check.

Figure 4-18

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14. Generator’s driving belt

• The standard is that when you use a force of about 60N to

Generator

press the belt in the direction shown by the arrow in Figure

4-19, you can press it down by 10mm, or adjustment should

be made. You should also check the belt for damage. When

Accessory

the belt is extended and cannot be adjusted any more, or

transmission

pulley

when there are cuts and cracks, replace the belt immedi-

ately. The two belts should be replaced. After the new belts

are installed, test run them for one hour before check and

adjusting. The V-shaped belt is not allowed to contact the

V-groove’s bottom.

Figure 4-19

15. The water pump’s driving belt (Figure 4-20)

• The check and adjustment method is the same as that of

Tension roller

Water pump

the engine’s driving belt.

pulley

Accessory

transmission

16. Battery electrolyte (Figure 4-21)

pulley

• If the liquid level of the battery is lower than the required

Figure 4-20

level (10-12mm above the limit level), distilled water will

need to be added. If the electrolyte is reduced because of

overflow, inject dilute sulphuric acid of the same concentra-

tion to the battery. Clean the breather hole on the battery’s

cap when checking the liquid level.

• Don’t use the metal funnel to add liquid.

WARNING

• To avoid the gases from explosion, keep fire or sparks

away from the battery.

• If the electrolyte is spilled to skin or clothes, wash with

Figure 4-21

plenty of clean water immediately.

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17. Exhaust impurities and water from fuel tank (Figure

4-22)

• Open the back cover, and loosen the valve on the fuel

tank’s bottom, to exhaust water and impurities.

Figure 4-22

4.1.4 EVERY 500 HOURS SERVICE

Maintenance for every 250 hours service should be car-

ried out at the same time.

1. Fuel filter

• Close the valve on the fuel tank’s bottom (See Figure 4-22),

and use the filter’s wrench to remove the fuel filter’s car-

tridge (Figure 4-23). Fill the new filter’s cartridge with clean

fuel, and apply a small amount of engine oil on the gasket.

Install the filter’s cartridge, tighten it with hand until the

Figure 4-23

gasket contacts the filter’s seat, and then tighten it 1/2-3/4

more turns (Do not tighten it too much).

Always use Shantui genuine filter’s cartridge.

2. Breather

Remove the breather, and use diesel to flush the dust accumu-

lated within it.

• Steering clutch’s case (1 place)

• Final drive’s case (2 places)

3. Fan belt

• Check the V-shaped belt, and if there are the following cir-

cumstances, replace the V-shaped belt:

• When the V-shaped belt contacts the bottom of the pulley’s

groove; when the V-shaped belt is worn, and its surface is

lower than the pulley’s outer diameter;

• when the V-shaped belt has cracks or peels off. For details

about the replacement procedure, see the “Fan belt adjust-

ment”.

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4.1.5 EVERY 1000 HOURS SERVICE

Maintenance for every 250 and 500 hours service should

be carried out at the same time. Inject grease to the grease

nozzle shown in the figure.

Universal joint (8 places)

Add lubricating grease to the half shaft’s bush (Figure 4-24)

(2 places)

Oil cylinder for idler tension (Figure 4-25) (2 places)

Figure 4-24

Water tank’s radiation fin (Figure 4-26)

•

Loosen the guard gate’s bolt, and open the guard gate.

Use compressed air to blow sundries such as mud, dust or

leaves off from the water tank’s radiation fin. You can also

use steam or water to replace the compressed air. Check

the water tank’s rubber tube for cracks or embrittlement,

and replace it if necessary. Check the rubber tube’s clamp

to see if it’s loose.

Figure 4-25

Steering clutch case (including the bevel gear case)

and transmission case.

•

Screw off the oil drain plug on the transmission case’s

housing, and tighten it again after draining the old engine

oil.

•

Add the engine oil to the required oil level through the

transmission case’s oil port.

•

Choose an oil listed in the “USE OF FUEL, COOLANT AND

LUBRICANTS ACCORDING TO AMBIENT TEMPERA-

TURE”, and add it from the oil injection port.

•

Remove the drain plug on the bottom of the body (the ar-

row in Figure 4-27) to drain the oil, and tighten the drain

plug again after draining the oil.

Figure 4-26

Figure 4-27

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•

Remove the left floor, the bolt, the cap, the steering clutch’s

strainer and the magnet; loosen the bolt, and after cleaning

the inside of the housing, the strainer and other parts re-

moved, re-install them back to their appropriate positions.

•

If the strainer is damaged, change a new strainer.

•

After replacing the gearshift and steering oil filter’s element

(See “EVERY 250 HOURS SERVICE”), add the required

amount of engine oil through the oil injection port. Amount

of oil added: 90L (Figure 4-28). The lubricant used depends

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

Figure 4-28

COOLANT AND LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE” for reference.

Final drive case (Figure 4-29 and Figure 4-30)

•

Remove the oil filler plug from two sides of the body, and

then remove the drain plug to drain the oil. After the drain-

ing, tighten the drain plug.

•

Inject the required amount of the engine oil through the

oil filler plug (See “EVERY 250 HOURS SERVICE”). The

lubricant type used depends on the ambient temperature.

See the “USE OF FUEL, COOLANT AND LUBRICANTS

ACCORDING TO AMBIENT TEMPERATURE” for refer-

ence. Amount of oil added on each side: SD22, SD22E and

SD22D: 41L; SD22S and SD22R: 51L.

Figure 4-29

7. Hydraulic tank and filter(Figure 4-31-Figure 4-33)

• Remove the drain plug on the bottom of the oil tank, and

loosen the drain valve. After draining, tighten the valve and

drain plug. Remove the bolt, cap and filter element. Clean

the removed parts and filter’s inside, and install the new

filter element. Inject the required amount of the hydraulic

oil through the oil injection port-F (See the “EVERY 250

HOURS SERVICE”). Amount of oil added: 110L. The lubri-

cant type used depends on the ambient temperature. See

the “USE OF FUEL, COOLANT AND LUBRICANTS AC-

Figure 4-30

CORDING TO AMBIENT TEMPERATURE” for reference.

Always use Shantui genuine filters.

Figure 4-31

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8. Walking parts

• Stop the vehicle on a level ground, and check the oil con-

sumption in the track roller, carrier roller, and idler one by

one. (Figure 4-34)

• Slowly screw loose the seal bolt (Figure 4-35) to see if

there is oil seeping out from the threads. If yes, it means

that there is enough oil, and you should tighten the bolt im-

mediately. If there is still no oil flowing out after the seal bolt

is completely removed, it means that there isn’t enough oil.

In this case, you should require your local Shantui distribu-

tor to make necessary repair.

Figure 4-32

9. The roller of the tubocharger has clearance

• Contact your local Shantui distributor for necessary check

or repair.

10. Corrosion resistor (water filter)

• Shut down the corrosion resistor’s water inlet/outlet valve.

Use the filter’s wrench to turn the corrosion resistor’s fil-

Figure 4-33

ter cartridge counterclockwise to remove it. Apply a small

amount of oil on the sealing surface and install a new ele-

ment. During installation, tighten 1/2-3/4 turns after the

sealing surface is in contact with the cap. (Don’t turn it too

tight.) After the replacement, open the valves.

Always use Shantui genuine filters.

Figure 4-34

Figure 4-35

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4.1.6 EVERY 2000 HOURS SERVICE

Maintenance for every 250, 500, and 1000 hours service

should be carried out at the same time.

Lubricating, Inject grease to the grease nozzle shown in

the figure.

1. Equalizer bar’s shaft (1 place)

2. Brake pedal’s axle (Figure 4-36) (5 places)

Figure 4-36

3. Tubocharger

• The excessive carbon black or grease adhered to the tu-

bocharger pump impeller may influence the normal perfor-

mance of the tubocharger, and sometimes may damage the

tubocharger. Contact your local Shantui distributor for nec-

essary check or cleaning. Do not use steel brush or similar

things to do that, to avoid the pump impeller’s surface from

being damaged.

4. Valve clearance

• Contact your local Shantui distributor to check the valve

clearance, because this requires special tools.

4.1.7 EVERY 4000 HOURS SERVICE

Maintenance for every 250, 500, 1000, and 2000 hours ser-

vice should be carried out at the same time.

1. Water pump

• Check pulley to see if it’s loose or if there is leakage of

grease or water. If yes, contact your local Shantui distribu-

tor to repair or replace the water pump.

2. Fan pulley and tension wheel

• Check the wheels to see if they are loose or if there is leak-

age of grease. If yes, contact your local Shantui distributor

to repair or replace the wheel assembly.

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4.1.8 MAINTENCE WHEN NEEDED

The following items should be checked and serviced when

required depending on the result of visual inspection.

Air cleaner

Inspection:

•

If the monitor lamp of the monitor’s air filter blinks, you

should clean the air cleaner’s element. Stop the engine

when doing the cleaning.

Figure 4-37

Clean or replace the outer filter element:

•

Remove the butterfly-shaped nut (1) and the outer filter

element (Figures 4-37 and 4-38), and clean the inside of

the air cleaner’s housing. Clean and check the outer filter

element (For the cleaning method, See the “Outer filter

element cleaning method”). For every time the outer filter

element is cleaned, tear off one letter sticker on the inner

element’s label plate (Figure 4-39), and install the cleaned

outer filter element.

•

When the sealing gasket (2) or the butterfly-shaped nut (1)

is damaged, they should be replaced. (Figure 4-38)

•

Check the inner filter element’s mounting nut to see if it’s

Figure 4-38

loose. If yes, tighten it.

Letter

Lable plate

sticker

Replace the inner filter element (when the outer filter

element has been cleaned for 6 times or when the in-

ner filter element is damaged)

•

Remove the outer filter element first, and then remove the

inner filter element. Cover the air intake. Clean the inside of

the air cleaner’s housing, and remove the air intake’s cap.

•

Install the new inner filter element to the connector, and

then tighten it with nut. Install the outer filter element.

Figure 4-39

Figure 4-40

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CAUTION

•

An outer filter element that has been cleaned for 6 times and has been used for 1 year

should be replaced, and the inner filter element should also be replaced at the same time.

•

Do not clean or replace the air cleaner’s element when the engine is running.

•

Do not attempt to clean the inner filter element and use it again.

4. Outer filter element cleaning method

a .Cleaning using the compressed air

• Use dry compressed air (less than 0.7Mpa) to blow the inside of the filter element directly along

the pleat. Continue to directly blow it along the outer pleat, and then repeatedly blow the inner

side. Finally check if the filter element is already clean.

b. Washing with water

• Use tap water (less than 0.3Mpa) to flush along the inner pleat of the filter element, and then

flush along the outer pleat. Repeat this, and check after it is dry.

c. Using a cleaning agent

• In order to remove the grease and carbon black on the filter element, you can dip it in the luke-

warm water containing a neutral cleaning agent to clean it, and then use clean water to rinse it.

Check after it is dry.

• Using dry compressed air (less than 0.7Mpa) to repeatedly blow it inside out can dry it more

quickly.

• Do not heat it to dry it.

• Using lukewarm water (about 40°C) to replace soap water is also very effective.

• After cleaning and drying it, when checking it by dropping a lamp into the outer filter element, if

you find that there are small holes or there are already some very thin parts, replace the outer fil-

ter element. (Figure 4-40)

• If the outer filter element can still be used, after dusting, keep it in a dry location.

• When cleaning the outer filter element, do not use other objects to knock or impact it.

• An outer filter element with an unevenly or deformed pleat or a damaged gasket cannot continue

to be used.

CAUTION

•

When using the compressed air, wear the safety glasses and other objects that can en-

sure safety.

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Clean the inside of the cooling system

1. Replace coolant, corrosion resistor and clean the inside of the cooling system according

to the table below.

Cleaning inside of cooling

Kind of coolant

system and changing

Replacing corrosion resistor

coolant

Every year (autumn) or every

Permanent type antifreeze (All

2000 hours, whichever comes

season type)

first

Every 6 months (spring, au-

Every 1000 hours and when

Non permanent type antifreeze

tumn) (Drain antifreeze in

cleaning the inside of the cool-

containing ethylene glycol (win-

spring, add antifreeze in au-

ing system or when changing

ter, one season type)

tumn)

coolant

Every 6 months or every 1000

Not using antifreeze

hours, whichever comes first

• Stop the machine on level ground when cleaning or changing the coolant.

• Use a permanent type of antifreeze. If, for some reason, it is impossible to use permanent type

antifreeze, use an antifreeze containing ethylene glycol.

• The corrosion resistor (water filter) must be replaced.

• The cooling water has to be the tap water used in cities. When diluting the coolant, use distilled

water or tap water (soft water). Natural water, such as river water or underground water (hard

water), contains a large amount of minerals (calcium, magnesium etc), and is easy to form water

scale inside the engine or the radiator. Once scale accumulates in the engine or the radiator, it’s

very hard to be removed. We recommend you to use water less than 100PPM.

• The ratio of antifreeze to water depends on the ambient temperature. When deciding the ratio

of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate

table given below.

• It is actually better to estimate a temperature about 10°C lower when deciding the mixing rate.

• The ratio of antifreeze to water during the transportation of the machine should be determined

according to a temperature about 20°C lower than the expected lowest temperature during the

transportation. (If you cannot make an estimate, please mix them at the biggest ratio, or if the

conditions cannot be met, drain all the coolant, and re-add it as required before operation).

The blending ratios of water and antifreeze are shown in the table below:

Min. atmospheric

Above

-15

-20

-25

-30

-35

-40

temperature °C

-10

Amount of

antifreeze %

Amount of water

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Clean the cooling system

•

Turn off the engine, and shut down the corrosion resistor’s

water inlet/outlet valve.

•

Slowly rotate the radiator’s cap until it is open. (Figure 4-41)

•

When removing the radiator’s cap, you must slowly rotate

the cap, to release the pressure.

•

Loose the water drain valve on the bottom of the water tank

and the water drain valve on the two ends of the oil cooler,

to drain the cooling water. (Figure 4-42)

•

Close the water tank’s water drain valve and the water

Figure 4-41

drain valve on the two ends of the oil cooler, and add clean

water (tap water used in cities), until the water is added to

the water intake’s edge. When the water reaches the water

intake’s edge, let the engine idle, open the water tank’s wa-

ter drain valve and the water drain valve on the two ends of

the oil cooler, and continue to add clean water to the water

tank, until the clean water continuously flows out from the

water drain valve for 10min.

•

When draining the water, adjust water flow, to ensure that

the water added is equivalent to the water drained, and to

keep the water tank full of water all the time. When the wa-

ter becomes completely clean, stop the engine. Open the

Figure 4-42

water drain valve and the water drain valve on the two ends

of the oil cooler to drain the water, and then close the water

drain valve and the water drain valve on the two ends of the

oil cooler.

•

Use the cleaning agent bought in the market to clean the

cooling system. Follow the instructions of the cleaning

agent.

CAUTION

• Antifreeze is flammable, so keep it away from flame.

• If the water temperature is high, don’t remove the cap,

as hot water may spurt out.

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3. Add the coolant

• After cleaning the cooling system, drain all the water, and

then close the water drain valve, and slowly add the cool-

ant (the coolant mixed according to the region where the

machine is used), until coolant overflows from the water

intake.

• Let the engine idle for 5min, and then run at an intermedi-

ate speed for 5min, to exhaust the air accumulated in the

cooling system. (During operation, open the radiator’s cap).

After the engine has stopped running, wait for 3min, add

coolant, until it reaches the required level, and then tighten

the cap.

Track tension

1. Inspection

• Stop the machine on level ground (stop with the transmis-

sion in FORWARD without applying the brake). Then place

a straight bar on the track shoes between the carrier roller

and the idler (Figure 4-43), and measure the clearance be-

tween the bar and the grouser at the midpoint. If the clear-

ance is 20 to 30mm, the tension is standard.

2. Adjustment

• In order to increase tension, pump in grease through the

grease fitting with a grease pump (Figure 4-44). On the oth-

Figure 4-43

er hand, in order to loosen tension, slowly rotate the plug

in the opposite direction for one turn, to squeeze out the

grease. If pump in the grease until S is 0mm (Figure 4-45),

and the tension is still loose, this shows that the bushing is

seriously worn and thinned. Contact your local Shantui dis-

tributor to repair or replace the track.

• If the plug or other parts are made too loose, due to the

high pressure from pumping in the grease, the parts are

easy to fly out. If the grease cannot be pumped in smoothly,

move the vehicle forward and backward for a distance.

Figure 4-44

Figure 4-45

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CAUTION

• When loosening the plug, do not do it by more than an

entire turn. Also, do not loosen any other parts except

for the plug.

Check and tighten track shoe bolts

• If the machine is used with track shoe bolts being loose,

they will break, so tighten any loose bolts immediately. First

tighten to a tightening torque of 400±40N•m, then check

that the nut and shoe are in close contact with the link con-

tact surface.

• After checking, tighten a further 120° ± 10°.

Turn or Replace the end bit and the cutting edge (Figure

4-46)

• Before the end bit and the cutting edge is worn to the edge

of the blade, turn the cutting edge over and replace the end

bit. If both sides of the cutting edge are worn, replace the

cutting edge. Raise the blade to a suitable height, put the

block beneath the push rod, to prevent the blade from fall-

ing down. Remove the end bit and the cutting edge, and

Figure 4-46

clean the mounting face. Replace the new end bit, turn over

the cutting edge (or change a new one), and tighten with

nuts. Tightening torque: 627±78N•m (64±8kgm). After oper-

ating for a few hours, tighten the nuts.

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LUBRICATION TABLE (THE SD22 SERIES BULLDOZERS)

Number

Lubricating

Lubrication cycles

No.

Parts to be lubricated

Lubricants

of points

tools

(hours)

Fan pulley

Grease

Grease gun

250

Tension roller

Grease

Grease gun

250

Tension roller’s bearing

Grease

Grease gun

500

support

Oil cylinder’s spherical

Grease

Grease gun

250

hinge

Oil cylinder’s supporting

Grease

Grease gun

250

shaft

Support arm’s spherical

Grease

Grease gun

250

hinge

Lubrication support arm’s

Grease

Grease gun

250

screw bar

Oil cylinder’s support

Grease

Grease gun

250

Adding oil every 10

Engine oil pan

Oil

Oil pot

hours, and changing oil

every 250 hours

Steering oil filter element

250

Brake pedal

Grease

Grease gun

2000

Universal joint

Grease

Grease gun

1000

Washing it once every

Washing the strainer

500 hours

Fuel control lever’s shaft

Grease

Grease gun

2000

Brake lock lever

Grease

Grease gun

2000

Transmission case con-

Grease

Grease gun

2000

trol lever

Blade control lever’s

Grease

Grease gun

2000

shaft

Oblique support arm for

Grease

Grease gun

1000

lubrication

Washing it once every

Washing the fuel strainer

250 hours

Checking it every 250

Final drive’s gearbox

Oil

Oil pot

hours, and changing it

every 1000 hours

Adding oil every 10

Steering case

Oil

Oil pot

hours, and changing oil

every 1000 hours

Checking it every 250

Hydraulic tank

Oil

Oil pot

hours, and changing it

every 1000 hours

Hydraulic tank’s oil filter

Replacing it every 1000

element

hours

Idler’s adjusting rod

Grease

Grease gun

250

Equalizer bar’s main

Grease

Grease gun

250

shaft

Replacing it every 250

Fuel filter element

hours

Replacing it every 250

Engine oil filter

hours

Oblique oil cylinder’s

Grease

Grease gun

250

spherical hinge

Various hinged joints of

Grease

Grease gun

250 hours

the ripper (optional)

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MAINTENANCE | MAINTENNANCE

4.1.10 ADJUSTMENT OF VARIOUS PARTS

Adjusting the brake pedal

1. Inspection

• When the brake lining is worn, the stroke of the steering

pedal will increase to make steering difficult. When the

stroke is over 190mm (when the braking force is reduced),

make adjustment as follows: standard stroke: 110-130mm

(when the engine is idling and the operation force is 150N)

Figure 4-47); 75mm (the stroke when the engine is not run-

ning).

2. Adjustment

• Remove the rear cover and the inspection cover. Tighten

the adjusting bolt until the tightening torque is 50N.m, to

Figure 4-47

make the lining and the braking drum in close contact (step

down the braking pedal to confirm the contact condition).

And then, rotate the adjusting bolt for 7/6 turns in the oppo-

site direction. The stroke of the two brake pedals should be

made the same, or the brake flexibility of the two sides will

not be the same. If A, the size of the adjusting bolt, is less

than 71mm, please contact your local Shantui dealer to get

the new brake lining.

Idler

If the idler is forced to rotate for a long time, the guide plates

on the side, on the top and on the bottom as well as the di-

recting plate will gradually become worn, causing the idler to

swing left and right, or the track’s links will get out of the idler

because the idler becomes tilted, or the idler and the links will

become unevenly worn. Therefore, you must adjust the idler

whenever it’s necessary according to the following procedure,

to enable it to be in a good operational state.

1. Adjusting the guide plates on the side(Figures 4-48~49)

• Drive the machine for 1-2m on a level ground, to tighten the

track evenly, and then stop the vehicle. Check the clear-

ance “A” between the side guide plate and the track frame

(the guide plate on each side has 4 clearances: left, right,

top, and bottom).

• If any of the clearances is over 4mm, loosen bolt (1), re-

move certain number of shims (2), and then adjust the

clearances to the standard values: 0.5~1.0mm. The shim’s

thickness is 0.5~1.0mm.

• When loosening the bolt (1), be sure not to rotate the bolt

for more than 3 turns.

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MAINTENNANCE | MAINTENANCE

Adjusting the directing plates (4) and the top & bottom guide plates (6) (Figures 4-50~4-51)

•

Measure the clearance “B” between the track frame’s upper wearing plate (3) and the directing

plate (4) as well as the clearance “C” between the top & bottom guide plates (6) and the track

frame’s lower wearing plate. If the sum of the two clearances “B” and “C” is over 5mm, reduce it

to 2mm. The method is to pull out shim (7), to reduce it to the required thickness, and add a shim

of the same thickness to shim (8). Such adjustment can be completed using the following proce-

dure.

•

It is normal if clearance “C” is 0mm. Measure clearance “B” and minus 2mm from the value of “B”

to get the shim’s thickness (for example, if B=5mm, then the adjusting shim’s thickness should be

5-2=3mm). Shims (7) and (8) can be shims that can be pulled out.

•

Loosen bolt (9) (there are a total of 4 bolts inside and outside) until you can’t feel the force of the

spring.

•

Loosen bolt (1). Be sure not to rotate the bolt for more than 3 turns.

•

Use a stick to adjust guide frame (5) upward, to make clearance “C” 0mm. Remove shim (7) ac-

cording to the required shim’s thickness determined in the first step. Add shim (7) to shim (8)

(you need to complete this process for 8 places: the inside and outside of the left and right guide

plates as well as the front and back of each side. Before and after the adjustment, the total thick-

ness of shim (7) and shim (8) combined remains the same. If the total thickness of the two shims

is increased or decreased due to carelessness, the preload of the spring installed within the

guiding device will become inappropriate. Shim (7) and shim (8) are consisted of several pieces

of two types of shims: the 1mm shim and the 2mm shim. Tighten the spring seat’s bolt (9). The

tightening torque of bolt (1) is 500~620Nm. The maximum adjustment allowed for the top & bot-

tom guide plate is 6mm.

Figure 4-48

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MAINTENANCE | MAINTENNANCE

Fan belt

Because fan belt has an automatic tension device, its tension

always remains constant and has nothing to do with the V-belt.

The belt does not need to be adjusted until it is damaged. But

when replacing the old belt with a new one, you should check

if size “A” is 113±5mm (Figure 4-49), and when its value is not

within this range, it should be adjusted.

When changing the V-belt, you should change both belts at the

same time.

Figure 4-49

Walking parts

The check and adjustment of track tension: For rocky areas,

the track should be slightly tighter. For areas with clay and

sandy soil, the track should be a little bit loose (See “Mainte-

nance when needed” for check and adjustment methods).

Figure 4-50

1. Measuring height of grouser

• Take a tight track shoe and measure the height of grouser.

(Figures 4-50 and 4-51)

Standard height (H): 72mm

Repair limits (H):25mm

Figure 4-51

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MAINTENNANCE | MAINTENANCE

2. Measuring outside diameter of track roller (Figure 4-52)

• Measure the dimensions (size C and B) of link tread as

shown. Calculate outside diameter of track roller (Size A):

A=(B-C)X2

Standard size (A): 222mm

Repair limits (A):198mm

Figure 4-52

Adjustment of blade (See “Chapter 3, Bulldozing Opera-

tion”)

1. Adjustment of the ripper’s ripping depth (Figure 4-53)

• Use the two pin holes on the ripper shank to make the

adjustment, and generally the hole on the bottom is used.

When you need to increase the ripping depth, use the up-

per hole. You can point an iron rod with a sharp end to pin

(1) and hit it with a hammer, and then pull out pin (2), to

change the mounting hole’s position of the tooth angle (top

or bottom).

2. The replacement of the ripper tooth tip and the guard

plate after being worn (Figure 4-54)

• After the ripper tooth tip and the guard plate ripper are

worn, when replacing them, use a hammer to knock out the

Figure 4-53

pins in the figure. You can switch the three tooth tips ac-

cording to their wear level, to extend their service life.

Figure 4-54

179

MAINTENNANCE | MAINTENANCE

Unit: mm

No.

Items to be checked

Specifications

Measures

Standard

Standard size

Repair limit

The outer diameter of the

clearance

guider’s neck

—

77.75

The outer diameter of the

contact surface of the shaft

105

—

104.9

Chrome

coupling’s oil seal

plating or

The inner diameter of the con-

replacing

tact surface of the gear seal-

135

—

135.3

ing ring

The inner diameter of the

sealing ring’s contact surface

—

60.1

of the guide roller’s axle

The sealing ring of the guide

Width: 4.0;

Width: 3.5;

—

roller’s axle

Thickness: 5.2

Thickness: 4.9

The sealing ring of the turbine

Width: 2.5;

Width: 2.0;

—

shaft

Thickness: 2.5

Thickness: 2.2

The clearance between the

oil scavenger pump’s driving

—

0.16~0.43

0.50

Changing

gear and pump impeller

Oil scavenger pump’s axial

—

0.13

0.25

clearance

Oil scavenger pump’s radial

—

0.15

0.30

clearance

Tightening torque

55±5N.m

Tightening torque

70±5N.m

Tightening torque

115±10N.m

Adjustment

Tightening torque

12±1N.m

Tightening torque

115±10N.m

Tightening torque

58±2N.m

181

MAINTENNANCE | MAINTENANCE

TRANSMISSION CASE

Figure 4-57

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The clearance between the No.1,

0.14~

No.3 and No.4 sun wheels and

—

0.37

the planetary gear

The clearance between the No.2

0.13~

—

sun wheel and the planetary gear

0.43

The clearance between the gear

0.13~

—

ring and the planetary gear

0.48

The tooth clearance of the output

0.20~

—

gear

0.51

The thickness of the driven plate

5.4

4.6

of clutches numbers 1 through 4

The thickness of the drive plate

7.0

6.2

of clutches numbers 1 through 4

The thickness of the No.5

Replacing

5.4

4.6

clutch’s driven plate

The thickness of the No.5

5.0

4.2

clutch’s drive plate

Free length

64.1

The spring of the No.1 clutch

Installation

—

133N

106N

load

Free length

45.7

44.8

The spring of the No.2 clutch

Installation

—

96N

77N

load

Free length

45.7

44.5

The spring of the No.3 and No.4

—

clutches

Installation

126N

101N

load

183

MAINTENNANCE | MAINTENANCE

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The clearance between the

pressure-adjusting valve

—

0.035~0.058

0.064

and valve body

The clearance between the

safety valve and the Slave

—

0.035~0.058

0.064

valve

The clearance between the

—

0.020~0.048

0.054

safety valve and the piston

The clearance between the

fast return valve and valve

—

0.035~0.056

0.062

body

The clearance between the

pressure relief valve and

—

0.035~0.058

0.064

valve body

The clearance between the

pressure relief valve and

—

0.020~0.048

0.054

the piston

The clearance between the

change valve and valve

—

0.035~0.058

0.064

body

The clearance between the

—

0.035~0.058

0.064

safety valve and valve body

Replacing

The clearance between the

—

0.020~0.048

0.054

safety valve and the piston

The clearance between the

—

0.035~0.058

0.064

speed valve and valve body

Free

51.2

The pressure-adjusting

length

—

valve’s spring

Installation

86.5N

77.9N

load

Free

38.5

37.3

The pressure-adjusting

length

—

valve’s spring (big)

Installation

217N

195N

load

Free

43.8

42.6

The pressure-adjusting

length

—

valve’s spring (small)

Installation

403N

363N

load

Free

50.7

Pressure relief valve’s

length

—

spring

Installation

219N

197N

load

Free

75.8

length

Safety valve’s spring

—

Installation

14.1N

13.4N

load

185

MAINTENNANCE | MAINTENANCE

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

0.1 (Mea-

The clearance between the

sured by being

pressure-adjusting valve and

—

installed be-

valve body

hind the cross

Repairing

shaft)

Replacing

The clearance between the

—

0.25~0.33

0.75

safety valve and the Slave valve

Rotational torque: 20~30N.m

The clearance between the

(Measuring at the end based on the small

Adjustment

safety valve and the piston

bevel gear)

The match of bevel gear’s bolt

—

0~0.042

0.1

The inner diameter of the contact

surface of the bearing support’s

145

—

145.3

sealing ring

Replacing

The width of the sealing ring

4.5

—

4.0

The width of the sealing trough

4.5

—

5.0

The press-in force of the coned

150~300KN

—

splint

(15~30T)

The size of the central drive shaft

6±0.5

—

after being pressed in

Tightening torque

700±50N.m

—

Adjustment

The connecting disc’s end jump

—

0.03

The connecting disc’s radial jump

—

0.08

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MAINTENNANCE | MAINTENANCE

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The thickness of the drive

2.9

—

2.0

Replacing

tooth piece

The unevenness of the drive

Correction or

<0.20

—

0.3

tooth piece

replacement

The thickness of the driven

4.7

—

3.7

Replacing

tooth piece

The unevenness of the

Correction or

<0.20

—

0.3

driven tooth piece

replacement

The thickness of the assem-

bly of the drive tooth piece

50.3

—

and the driven tooth piece

The tooth clearance be-

tween the drive tooth piece

—

0.3~0.4

1.0

and the inner hub

The tooth clearance be-

tween the driven tooth piece

—

0.3~0.4

1.0

and the outer hub

The inner diameter of the

inner hub and the sealing

245

—

245.3

ring’s contact

The width of the sealing ring

4.9

—

Replacing

The width of the sealing

—

trough

Free

145.15

141

length

Spring (big)

—

Installation

2291N

2420N

load

Free

137.83

length

146.5

Spring (small)

—

Installation

1320N

1380N

load

The diameter of the outer

425

—

420

hub

189

MAINTENNANCE | MAINTENANCE

Unit: mm

Items to be

No.

Specifications

Measures

checked

Tolerance

Standard

Allowable

The clearance

size

clearance

limit

between valve body

Shaft

Hole

and valve core

-0.035

+0.013

0.035~

0.08

-0.045

0.058

The clearance

-0.030

+0.015

0.030~

between the valve

0.08

-0.040

0.055

core and the piston

The clearance

-0.035

+0.013

0.035~

between valve stem

0.08

-0.045

0.058

and valve body

The clearance be-

-0.030

+0.018

0.030~

tween brake valve

0.08

-0.035

0.053

and valve body

The clearance be-

-0.030

+0.015

0.030~

tween brake valve

0.08

-0.040

0.055

and piston

The clearance

between the control

+0.023

+0.170

0.068~

0.2

lever and the bush-

+0.002

+0.086

0.168

ing

The clearance

between the control

+0.019

+0.156

0.067~

0.2

lever and the bush-

+0.001

+0.086

0.155

Replacing

ing

Standard size

Repair limit

Instal-

Free

Axle reset spring

lation

Load

length

load

27.2

6.02kg

35.3

5.7kg

Steering valve

15.8

3.5kg

60.9

3.2kg

spring

Steering valve reset

91.6

4.53kg

90.6

4.3kg

spring

Steering valve

20.5

3.61kg

3.3kg

spring

Brake adjusting

28.5

25.5

3.0kg

2.8kg

spring

Brake valve reset

50.5

2.36kg

49.5

2.2kg

spring

Brake valve reset

4.48kg

88.5

4.15kg

spring

Brake valve’s action

13.7

Adjustment

trip

193

Shantui SD22. Operation and Maintenance Manual - 5