Shantui SD22. Operation and Maintenance Manual

MAINTENNANCE | MAINTENANCE

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

The clearance between the half

—

0.036~0.106

0.5

shaft and the bushing

Replacing

Bushing

The clearance between the half

—

0.12~0.270

0.5

shafts out bushing and spacer

Primary gear’s engagement back-

—

0.40~0.623

1.5

lash

Replacing

Secondary gear’s engagement

—

0.48~0.85

1.5

backlash

Press-in force

300 ~ 400KN (30 ~ 40t)

Size of the drive disc after being

2~3.5

pressed in

Nut’s tightening torque

700±50Nm

Press-in force

50 ~ 160KN (5 ~ 40t)

Size of the sprocket hub after be-

39~41

ing pressed in

Press-in force

500 ~ 600KN (50 ~ 40t)

Adjustment

Size of the sprocket hub after be-

39~41

ing pressed in

Press-in force

120 ~ 460KN (12 ~ 40t)

Size of half shaft’s end surface and

599.9(SD22S is 724.5)

steering case

Nut’s tightening torque

1050±150Nm

Sprocket nut’s tightening torque

1050±150Nm

Nut’s tightening torque

950~1150Nm

195

MAINTENANCE | MAINTENNANCE

TRACK

1. TRACK FRAME

s s s D

Figure 4-64

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

Horizontal deforma-

—

7/300

tion

Deformation

Twisted

—

3/300

Repair-

of track frame

The place where the

ing and

idler is installed is

—

changing

outwardly opened

The clearance between the half shaft

—

0.036~0.106

0.5

and the bushing

Tightening torque

760±85N.m

Adjust-

ment

Tightening torque

825±225N.m

196

MAINTENNANCE | MAINTENANCE

2. TRACK TENSION DEVICE

Figure 4-65

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

Free length

817

Buffering spring (big)

Installation

—

154000N

171300N

load

Free length

530

Buffering spring (small)

Installation

—

29000N

Replacing

load

32500N

0.101~

The clearance between oil

—

0.5

cylinder and bushing

0.226

Tension rod assembly’s

150KN (15t)

press-in force

Adjustment

The clearance between

control seat and nut

197

MAINTENNANCE | MAINTENANCE

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

Idler’s outer diameter

774

—

760

Roller track surface’s outer diam-

730

—

715

eter

Repairing

through over-

Width of the raised part

105

—

lay welding

or replacing

Width of the roller track

49.5

—

51.5

Overall width

204

—

194

Shaft collar’s width

—

19.5

The clearance between the shaft

—

0.270~0.390

1.5

and the dual-metal bushing

The interference between the idler

—

-0.03~-0.144

-0.35

and the bushing

Replacing

The axial clearance of the idler’s

—

0.27~0.39

1.5

axle

The clearance between the sliding

—

plate and the bracket

The clearance between the side

—

0.5~1.0

guide and the bracket

Tightening torque

210±5N.m

Adjustment

199

MAINTENNANCE | MAINTENANCE

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

The outer diameter of the track

257

—

247

roller

The outer diameter of the track

249

—

239

roller

Roller track surface’s diameter

222

—

198

Overall width

251.2

—

Repairing

The width of the roller track of the

through over-

55.6

—

66.6

single flange track roller

lay welding

or replacing

The width of the roller track of the

51.6

—

68.6

double flange track roller

The width of the raised shoulder of

—

the single flange track roller

The width of the raised shoulder of

—

the double flange track roller

The width of the raised shoulder of

—

the double flange track roller

Shaft collar’s width

—

18.5

The clearance between the shaft

—

0.31~0.39

1.0

and the dual-metal bushing

Replacing

The interference between the

—

-0.013~-0.121

-0.35

bushing and the track roller

The axial clearance of the track

—

0.40~0.80

1.5

roller’s axle

201

MAINTENNANCE | MAINTENANCE

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The outer diameter of the carrier

217

—

207

roller

The outer diameter of the roller

185

—

166

track

Repairing

through over-

lay welding

or replacing

The width of the raised shoulder

—

The width of the roller track

—

The axial clearance of the carrier

Adjusting or

—

0.10~0.13

0.2

roller

Replacing

Tightening torque

560±60N.m

Adjustment

Tightening torque

210±50N.m

203

MAINTENNANCE | MAINTENANCE

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

Track link

216.25

—

219.25

Inverting or

Grouser’s height

—

123(SD22S)

101

replacing

Track link’s height

129

—

117

Bushing’s outer diameter

74.3

—

70.8

The clearance between the pin

—

0.230~0.830

—

and the bushing

The clearance between the

—

0.430~1.030

—

master pin and the bushing

The interference between the

—

0.230~0.344

0.22

Replacing

bushing and the track link

The interference between the

—

0.023~-0.185

0.203

pin and the track link

The interference between the

—

0.138~0.230

0.138

master pin and the track link

One-sided:

The clearance of the track link’s

0~1.1

—

joint surface

Two-sided:

0~2.2

Tightening torque

0.5~1.0

Adjustment

205

MAINTENNANCE | MAINTENANCE

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

The clearance between the seat

—

0.5~0.15

and the spherical head

The clearance between the pin and

—

0.3~0.8

the blade rack’s connector

The clearance between the push

—

0.3~0.8

rod’s pin and the connector

The clearance between the con-

—

0.3~1.1

nector and the blade rack

The clearance between the pin and

—

0.5~1.0

the seat

The clearance between the pin and

—

0.6~1.0

the screw

Replacing

The clearance between the spheri-

—

0.2~0.6

cal head and the seat

The clearance between the cover

—

0.1~-0.4

and the spherical seat

The clearance between the spheri-

—

0.2~0.6

cal head and the seat

The clearance between the cover

—

0.046~0.206

and the spherical seat

The clearance between the pin and

—

0.4~0.8

the seat

The clearance between the bracket

—

0.3~0.7

and the pin

207

MAINTENANCE | MAINTENNANCE

2. END BIT AND CUTTING EDGE

Figure 4-71

Unit: mm

Basic

Standard

Application

Treatment

No.

Items to be checked

size

clearance

limit

methods

The cutting edge’s height

254

—

213

The height of end bit’s outer side

292

—

211

Replacing

The height of end bit’s inner side

254

—

211

End bit’s width

435

—

360

Tightening torque

540±80N.m

Adjustment

208

MAINTENNANCE | MAINTENANCE

OIL CYLINDER BRACKET

1. OIL CYLINDER BRACKET OF SD22, SD22E AND SD22D

Figure 4-72

2. OIL CYLINDER BRACKET OF SD22S

Figure 4-73

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The clearance between the shaft

—

0.072~0.180

0.5

and the bushing

The clearance between the shaft

—

0.060~0.152

0.5

Replacing

and the bushing

The clearance between the shaft

—

0~0.074

0.5

and the bushing

209

MAINTENANCE | MAINTENNANCE

RIPPER

Figure 4-74

Unit: mm

Standard

Application

Treatment

No.

Items to be checked

Basic size

clearance

limit

methods

The clearance between the circular

—

0.230~0.476

1.5

pin and the bushing

The clearance between the tooth

—

1.4~2.6

rack’s hole and the pin

The clearance between the pin and

—

3.7~6.5

the rack hole

Replacing

The wearing of the tooth tip

335

—

225

The wearing of the tooth sleeve

—

Tightening torque

2250±250N.m

210

MAINTENNANCE | MAINTENANCE

4.1.12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

CAUTION

• If nuts, bolts, or other parts are not tightened to the specified torque, it will cause loose-

ness or damage to the tightened parts, and this will cause failure of the machine or prob-

lems with operation.

• Always pay careful attention when tightening parts.

TORQUE LIST

1. Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table be-

low.

• If it is necessary to replace any nut or bolt, always use a Shantui genuine part of the same size

as the part that was replaced.

Specifications

Thread

Width

diameter

across

Target value

Torque range

of bolt (a)

flats (b)

(mm)

N.m

kgf.m

ibft

N.m

kgf.m

ibft

13.2

1.35

9.8

11.8-14.7

1.2-1.5

8.7-10.8

3.2

23.1

27-34

2.8-3.5

20.3-25.3

6.7

48.5

59-74

6.0-7.5

43.4-54.2

113

11.5

83.2

98-123

10.0-12.5

72.3-90.4

172

17.5

126.6

153-190

15.5-19.5

112.1-141

260

26.5

191.7

235-258

23.5-29.5

170.0-213.4

360

267.6

320-400

33.0-41.0

238.7-296.6

510

52.3

378.3

455-565

46.5-58.5

336.3-419.5

688

70.3

508.5

610-765

62.5-78.0

452.1-564.2

883

651

785-980

80.0-100.0

578.6-723.3

1295

132.5

958.4

1150-1440

118.0-147.0

853.5-1063.3

1720

175.0

1265.8

1520-1910

155.0-195.0

1121.1-1410.4

2210

225.0

1627.4

1960-2450

200.0-250.0

1446.6-1808.3

2750

280.0

2025.2

2450-3040

250.0-310.0

1808.3-3242.2

3280

335.0

2423.1

2890-3630

295.0-370.0

2133.7-2676.2

211

MAINTENANCE | MAINTENNANCE

2. Tighten the hydraulic hoses according to the tightening torque in the table below

Specifications

Thread

Width

diameter of

across flats

Target value

Torque range

bolt (a)(mm)

(b)(mm)

N.m

kgf.m

ibft

N.m

kgf.m

ibft

9/16-18UNF

4.5

32.5

35-63

3.5-6.5

25.3-47.0

11/16-16UN

7.5

54.2

54-93

5.5-9.5

39.8-68.7

13/16-16UN

103

10.5

75.9

84-132

8.5-13.5

61.5-97.6

1-14UNS

157

115.7

128-186

13.0-19.0

94.0-137.4

13/16-12UN

216

159.1

177-245

18.0-25.0

130.2-180.8

212

MAINTENNANCE | TROUBLESHOOTING

4.2 TROUBLESHOOTING

Although not all the faults are included in this chapter, most common faults are included.

4.2.1 ENGINE

Engine oil pressure monitor flashes when

Engine does not start when starting motor

engine speed is raised after completion of

is turned

warm-up.

1. Add fuel;

1. Add oil to specified level;

2. Check if air has entered the fuel system;

2. Replace engine oil filter element;

3. Calibrate or replace oil pump and oil noz-

3. Check the tubes and connectors for oil

zle;

leakage.

4. Check valve clearance;

5. Run the starting motor at a low speed (See

Steam is emitted from top part of radiator

ELECTRIC SYSTEM).

(pressure valve).

1. Add cooling water, and check for water

Exhaust gas is white or blue

leakage;

1. Add oil to specified level;

2. Adjust fan belt’s tension;

2. Change to specified fuel;

3. Clean inside of cooling system;

3. Check supercharger for leakage.

4. Clean or repair the water tank’s radiation

fin;

Exhaust gas turns black

5. Replace thermostat.

1. Clean or replace air filter;

6. Tighten radiator cap or replace its gasket.

2. Replace oil nozzle;

3. Clean or replace supercharger.

Water temperature is higher than 100°C.

1. Replace thermostat;

Abnormal noise generated (combustion or

2. Check water temperature sensor ;

mechanical)

3. Check water temperature gauge and water

1. Change to specified fuel;

temperature sensor.

2. Check if the engine is overheated;

3. Replace muffler;

4. Adjust valve clearance.

213

TROUBLESHOOTING | MAINTENNANCE

4.2.2 ELECTRIC SYSTEM

4.2.3 CHASSIS

Lamp does not glow brightly even when the

Oil pressure in torque converter fails to rise

engine runs at high speed.

(the vehicle cannot start to move)

1. Check, repair loose terminals, disconnec-

1. Check and repair oil pipes or connectors

tions;

for air leakage;

2. Adjust engine belt tension.

2. Check or replace gear pump;

3. Add oil to transmission case;

When the engine runs at a high speed, volt-

4. Clean and replace transmission case’s fil-

meter indicates not charging (not within the

ter.

green zone)

1. Check generator;

The hydraulic torque converter is overheat-

2. Check and repair circuit.

1. Tighten or replace fan belt.

Abnormal noise is generated from alterna-

2. See the ENGINE part.

tor

3. Clean or replace oil cooler.

Replace generator.

4. See the “Oil pressure in torque converter

Starting motor does not crank when igni-

fails to rise” part.

tion switch is turned ON.

The vehicle does not move when gear shift

1. Check and repair circuit and relay;

lever in any position

2. Charge the battery;

1. Add oil to the steering clutch case.

3. Replace starting motor.

2. See the “Oil pressure in torque converter

fails to rise” part.

Pinion of starting motor keeps going in and

3. Check or replace gear pump.

out

4. Clean oil filter.

1. Charge the battery;

2. Replace starting motor.

When pull the steering lever on one side,

the vehicle continues to move forward with-

Starting motor disengages before engine

out steering.

starts

• Adjust brake.

1. Check and repair circuit ;

2. Charge the battery.

Machine doesn't stop when brake pedal are

depressed.

When the engine stops (starting switch is

• Adjust brake.

in the “ON” position, engine oil pressure

gauge is 0.

Track comes off

1. Replace engine oil pressure sensor;

• Sprocket is abnormally worn

2. Check and repair circuit.

• Adjust track tension

Blade rises too slowly or does not rise at all

• Add oil to the hydraulic tank

214

MAINTENNANCE | PRECAUT. FOR DISASSEMBLY & ASSEMBLY

4.3 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

4.3.1 DISASSEMBLY

1. Before disassembling bulldozer’s any part, read the manual carefully, so that you have a thor-

ough understanding of the parts to be disassembled. Knowing the structure and role of various

parts is an important factor in successfully performing the servicing.

2. During disassembly, pay adequate attention to the direction and position of every part. If neces-

sary, make the identification marks. Meanwhile, pay attention to the sequence of removing vari-

ous parts from the bulldozer, to ensure the correct installation of the parts.

3. Use special tools required. If you don’t have special tools, use similar ones. When ordinary tools

can damage related parts in one way or another, you must use special tools.

4. Tapered or closely matched parts should be closely installed in their original places. If these

parts are already loose, check their wear.

5. The removed parts should be cleaned and orderly put together. Measures should be taken so

that they will not be covered by dust. Two types of cleaning liquids should be used: one for

washing away the dirty things, and another for rinsing.

CAUTION

Filters, magnetic plugs and breather covers are all parts that you should pay special atten-

tion to when washing and cleaning them

215

PRECAUT. FOR DISASSEMBLY & ASSEMBLY | MAINTENNANCE

4.3.2 ASSEMBLY

1. All the parts should be clean before being assembled. Replacement parts are usually covered

with anti-rust agent, and you should wipe off the anti-rust agent first.

2. In most cases, the installation of bearings, bushing, oil seals and other similar parts should use

the special installation tools. Using a hammer to directly knock a part into place is a bad habit.

Usually, you need to put a wood block or soft metal part beneath the part to be installed to trans-

mit the impact from the hammer.

3. Spring washers, flat washers, tongue washers and cotter pins are all very important parts. But

because of their small size, they are easy to be missed out during assembly. When installing

fasteners such as bolts and nuts, check the tightening methods of these parts for compliance.

4. A torque wrench should be used in places where the torque limit is specified. When fixing cov-

ers or similar parts with many bolts (such as valve body etc), tighten the bolt symmetrically and

gradually, to let the pressure be evenly distributed.

5. The matching markings are not the identification markings for parts that go with each other, and

instead they represent a way to show that you should align them as much as possible. Never

misunderstand them.

4.3.3 ASSEMBLY AND DISASSEMBLY OF BEARINGS

1. Dust is harmful to all the bearings. Dust is often the cause of the noise from bearings and the

cause for the accelerated deterioration of lubricant. When replacing bearings, you can only open

the package of the bearings after all the other installation work has been completed.

2. Use gasoline as the cleansing liquid for bearings. If you have access to the compressed air, you

can also use kerosene and diesel for cleaning, and then use the compressed air to blow away

the dust.

3. When installing the bearings, the position should be correct. Let the bearings closely contact the

raised shoulder or the bearing support’s ring, to reduce the excessive clearance on both ends.

216

MAINTENNANCE | PRECAUT. FOR DISASSEMBLY & ASSEMBLY

4.3.4 OIL SEAL INSTALLATION

1. When installing the oil seal, the oil seal’s labial margin sealing engine oil or gear oil should face

inward (the side used to seal the oil), to improve the oil sealing performance; the oil seal’s labial

margin sealing the lubricating grease should face outward, and when sufficient new lubricating

grease is pumped in, the old lubricating grease is easy to be squeezed out.

2. The oil seal should closely contact the raised shoulder or the oil seal’s seat ring.

3. Before installing the oil seal, apply a layer of lithium-based lubricating grease on the labial mar-

gin, or the oil seal may be scratched due to the friction from the dry friction surface during the

initial period of operation.

4. When installing the oil seal, you can use a conduit to let the oil seal slip into the seat (See Fig-

ure 4-75A). If you don’t have such as conduit, you can use a brass sheet to produce a makeshift

conduit (See Figure 4-75B).

5. When pressing the oil seal into the seat (See Figure 4-75C), you must use a suitable tool, to

make the pressure applied on the end surface of the oil seal even. The diameter of the tool

should be 0.5-1mm smaller than the seat hole, and its free end should have a shape suitable for

being hammered.

Figure 4-75: Oil seal installation of the A, B and C

217

ADDITIONAL TABLE | MAINTENNANCE

4.4 ADDITIONAL TABLE: USE OF FUEL, COOLANT AND LUBRICANTS AC-

CORDING TO AMBIENT TEMPERATURE

Rated

Ambient temperature and suitable oil

usage

Locations

(liter)

-30

-20

-10

45°C

Engine

-10~ -30 light diesel

450

Fuel tank

SAE10W-30

Engine

oil pan

*SAE15W-40

SAE10W-30

Torque con-

verter

Transmis-

*SAE15W-40

122

sion case

Steering

case

SAE30

SAE10W-30

Hydraulic

110

oil tank

*SAE15W-40

SD22: 82

SAE10W-30

SD22E:

Final drive

case

*SAE15W-40

SD22S:

102

Track roller

0.28~0.32

Carrier

SAE85W-140

0.47~0.53

roller

Idler

0.28~0.53

The re-

maining

Suitable

No.2 and No.3 lithium-based lubricating grease

lubricating

amount

locations

Soft water + antifreeze

Engine

Coolant

Soft water

218

MAINTENNANCE | ADDITIONAL TABLE

Note:

1. Oil marked with “*” is the alternative to the oil in the column, and when the oil in the above line

is not available, the oil with * can be used as the alternative.

2. All the lubricant brands are the CF Class. If the CD Class is used, the oil change time should be

1/2 of the required time.

3. When ambient temperature is lower than -20°C, the oil in the engine oil pan should be changed

to SAE5W-20.

4. When adding oil, pull out the filter screen from the oil injection port first, use clean diesel to wash

it clean, and then put it back to the oil injection port before going ahead to add oil. Oil that has

been fully sedimented should be used.

5. The amount of oil or grease added should meet the requirement, not too much or too less.

6. The tools for adding oil or water must be clean, and they should be put in covered boxes or cabi-

nets after use.

7. Before draining oil, preheat the oil to 30-40°C.

SAE is the internationally accepted oil numbering system.

219

Shantui SD22. Operation and Maintenance Manual - 6