Basic Knowledge of Bulldozers

Techno Training Center

1
The history of Komatsu Bulldozers

KomatsuG25(Left) & G40(Right) farm tractor The first unit of the D50-1 bulldozer
produced in 1947
a competitive demonstration
event held in Manchuria in early 1930s

The largest bulldozer, D575A-3, launched in 2001 D80A produced in 1963 after many
stringent quality control tests
2
D21 D575
Machine weight 3,940 kg Machine weight 152,600 kg
Engine horsepower 32.4 kW (44 HP) Engine horsepower 858 kW (1,150 HP)

3
 Ingersoll-Rand
John Deere
Caterpillar
Komatsu

Liebherr
Kobelco
Hitachi

Volvo

Terex
CNH

JCB
Large bulldozers  
Large excavators    
Mining Large wheel loaders  
Large dump trucks     
Large motor graders  
Bulldozers     
Excavators          
Wheel loaders          
Construction
Dump trucks    
Articulated dump trucks       
Motor graders      
Mini excavators          
Mini wheel loaders         
Utility Backhoe loaders        
Skid steer loaders        
Telescopic handlers      
Forestry equipment   
Others Recycling equipment    
Compactors      
4
 Utilization of Bulldozers

 ・ Ground leveling
 ・ Ripping & Dozing
 ・ Material transportation
 ・ Carrying Scraper
 ・ Pusher for Motor scraper
 ・ Trimming dozer
 ・ Rake dozer

5
6
7
8
9
 Outline of Structure
Hydraulic System for W/E
Operation Control the W/E(Blade Ripper)
Lever, Pedal, Switch, etc

Power Train
Control Speed, Traction, Steering
 System Overview of the Bulldozer

Machine Operation
Input device
Operator

Fuel Dial PCCS lever PPC lever Decel pedal Break pedal

PT controller
Work
Equipment
Hyd. Blade & Ripper
Hyd. Pump Control valve
Actuator control

ECM

Travelling &
Torque Steering
Engine Transmission Final Drive Steering
Converter System
control

Power Line Machine Work

13
Technical Map of Bulldozer(D21 ～ D575A)

14
Power Line

15
History of Bulldozers power train
Tier3
Generation
Direct drive T/M

Transfer engine power to T/M directly by clutch None

disc & plate engagement
(Improve Engine toughness , controllability)

Torque Flow T/M

Transfer engine power to T/M indirectly
Middle &
through Torque converter oil Large class

(Improve power transfer efficiency)

Hydro Shift T/M

Transfer engine power to T/M directly through Only D21
damper. Vibration & shock are absorbed and
transferred to T/M.

(Improve controllability--- Step less transmission)

Hydro Static T/M (HST)

Small Class
Engine power rotate Hyd pump and power
transfer to Hyd motor. By hyd motor rotation
speed , machine can travel as stepless shift. 16
 Direct drive T/M Merit Demerit

・ High efficiency of power ・ Complicated operation

transferring ・ Engine stall under heavy
Engine load (load can’t escape)
・ Engine power fluctuate
depend on load
Transmission
Main clutch

Torque Flow T/M ・ Power transfer efficiency is low

・ Easy operation
・ Less gear shift shock
・ No engine stall under heavy
Engine load (load escape in T/C)
・ High engine toughness
under heavy load
Torque Torque flow
Converter transmission
Hydro Shift T/M ・ Easy operation
・ Less gear shift shock
・ High efficiency of power
transferring
Engine
・ Engine power fluctuate
depend on load
・ High production cost
compared
with direct T/M
・ Engine stall under heavy
load (load can’t escape in T/C)
・ Engine power fluctuate
depend on load

Damper Hydro shift T/M

Hydro Static T/M (HST)

・ Gear shift operation is not ・ Power transfer efficiency is
required. low
・ No power cut by stepless T/M ・ Oil contamination control is
・ No engine stall under load. strictly required.
Engine (load escape by hyd relief)
Hyd motor
・ Max engine power can be used
constantly
PTO Hyd
pump
17
 Type of Transmission & Steering system
Steering :
Making Difference of speed
between the Left and Right trucks.
Transmission Steering System

D575A Output for one side track

D475A Clutch & Brake is split by Clutch and is
D375A held by Brake.
Large
Torque Flow
Both side tracks are
D275AX Transmission
connected by differential
D155AX HSS gear.
D85EX Hydro Static Steering Hydraulic motor makes
D65EX System Difference of speed
Middle D61EX between both tracks via
differential gear.

D51EX/PX HST Both side tracks have

each set of Hydraulic
Small D39EX/PX Hydro Static Transmission
Small D37EX/PX
Pump and motor.
Each tracks are controlled
D31EX/PX individually.
Power Train Skelton (Sample:D65A Torque Flow T/M)

Sprocket Track Shoe

Transmission

Steering
Clutch
Torque Converter

Engine

Final Drive

Universal Joint

Steering Brake

19
 Torque Converter
Turbine Stator Pump
Turbine Pump

Stator

Rotated by Change Driven by

oil flow direction of engine.
Output Shaft
comes from return oil It makes oil
Pump. flow from flow.
turbine to
pump.
Torque Converter Cut-away model

Pump

From Turbine
Engine
(Input)

To T/M
(Output)

Stator

Lock-Up Stator
Clutch Clutch

21
 Ref. : Performance Curve of Torque Converter
*with Fixed Stator
Traction
Output

Engine
Output
Convert to the Heat
Torque Ratio Efficiency

Traction
Output

Feature of Torque conveter

-No Engine stall (Fluid Coupling)
-Torque multiplied effects
The Traction force is increased when vehicle speed
is decreased due to external load.
-Low efficiency during high speed travel (fixed stator)
(Improvement of efficiency by lock-up, stator control)
Speed Ratio
22
Disc Clutch
ディスククラッチ 1. Clutch housing
2. Clutch piston Clutch “Disengaged”
3. Disc
4. Plate Clockwise rotation Input in Sun Gear [A]
From control valve 5. Return spring
6. Pin
Planetary Gear[B] start rotation toward
A. Sun Gear
B. Planetary Pinion counter clockwise
C. Ring Gear
D. Carrier

Ring Gear[C] start rotation toward

clockwise (Same direction as Sun gear)

Clutch “Engaged”
クラッチ”入”の場合(Ring gear Fixed)
Clockwise rotation Input in Sun Gear [A]

Planetary Gear[B] start rotation toward

counter clockwise

Since Ring Gear[C] is not rotated, Planetary

Gear [B] rotate Carrier [D] toward clockwise
(Same direction as Sun gear)

Inside of Disc [3] and outside of Ring Gear [C] are meshed each other, and rotate together.
Plate [4] is fixed in Clutch Housing [1] by Pin [6], slightly move only axial direction.
23
 Planetary Type Transmission

Directional Clutches Speed Clutches

 T/M Structure (Power transmission route) D155A-2

3rd 2nd 1st

Double
Structure

Input Shaft
To PTO

To
Output
Shaft

Forward/Reverse Group Speed shift Group

ECMV installed machine has possibility of

Either “F” or “R” clutch ON occurrence of “Double clutch engagement. And
cause serious T/M damage

Power from Input shaft is

output from “Carrier” Either 3rd, 2nd, 1st clutch is engaged, speed
-> Input to Carrier of 3rd clutch is reduced depend on gear shift.
pack. -> Power is transferred to output shaft.

25
Modulating Valve Function

When shift F&R, 1st to 2nd , prevent sudden engagement of clutch, moderate shift shock.

 Comfort riding, improve durability of power train system

[Graph] Relation of time progress and clutch pressure increasing

Clutch pressure

A: Filling time
B: Build up time
C: Modulating time

Time (Sec)
26
Control of Clutch engaging pressure

Type Modulating Valve ECMV

(Mechanical Type) (Electric control type)

It consists of a modulating valve and a speed valve.
By mechanical operation, a modulating valve raises
clutch oil pressure gradually at the time of a gear
shift.
Outline The transmission has only one modulating valve.
The speed valve changes the direction of oil flow and
then it changes speed range and F-R.(directional
valve)
（ Electronic 　 Control 　 Modulation 　 Valve ）
-Each clutch pack has independent ECMV.
-Output oil pressure is controlled proportionally to
solenoid current.
-the Oil pressure is increase gradually by control of
the PT controller.
-Clutch oil pressure is detected by the fill-switch.

-Individual control for each clutch pack is possible.

-Simple structure -The smooth engaging of clutch by pressure control.
Merit -No risk for double engagement
-Smooth speed shifting by cooperative control for
each ECMV.
(Power transmitting is not cut during shifting)

- Individual pressure control for each clutch is -Risk of double engagement due to trouble of the fill
impossible switch.
Demerit - Power transmitting is cut a momentarily when
shifting. - Oil management is severe. 27
HST(Hydro Static Transmission) Ex) D31-22

There are 2 sets of Hydraulic pump & motor.

Capacity of Pump & Motor are controlled
individually Left and Right.
*Include Steering function.

The basic structure of the HST Bulldozer is common.

-Size of pump and motor.
-Type of changing capacity in motor (3 stage type or variable).
are different depend on model and generation.
 Type of Steering System
components D21 D31 D37 D39 D51 D61 D65 D65 D85 D155 D275 D375 D475 D575
(A/P/PL (EX/PX (EX/PX (EX/PX (EX/PX (EX/PX/WX (EX/PX/WX (EX/PX
& systems -8) -22) -22) -22) (EX/PX-22) -15E0) -15E0) -16) -15E0) (AX-6) (AX-5E0) (A-6) (A-5E0) (A-3)

HSS
Steering system
Clutch & HST (HPV95) (HPV95) (HPV95) (HPV95) (HPV190) (HPV180) Clutch & Brake
Brake Electronic control ( EPC valves ) (HMF95) (HMF95) (HMF95) (HMF95) (KMF140) (HMF180) driven by ECMV
EPC on Control valve ( HST )
Travel Type Mono lever PCCS electric lever mono lever
(F-R/ shift/ Hall IC type PCCS Hall IC
steering) Control Mechnical PCCS Hall IC type (for HST) PCCS Hall IC type (for HSS & Clutch/brake) (heavy type (for HSS electric SW
operating & C/B)
force)

Clutch & Brake ・・・ Middle & Large Size Bulldozers, Old machines

Disengage the clutch of turning side, power transmit to opposite side.

After clutch disengaged, engage brake disc & plate, sharp turn is possible. Spin turn is
not possible.
There are 2 categories by steering brake type.
・ Multiple disc clutch + Band brake
・ Multiple disc clutch + Multiple disc brake

HSS(Hydro-Static Steering) ・・・ Small & Middle Size (-EX, -AX)

No clutch structure, only brake disc & plate are installed for stopping machine. Steering for
LHS&RHS is controlled by rotating direction of HSS motor.
Spin turn and dozing during steering is possible.

HST(Hydro-Static Transmission) ・・・ Small size bulldozers (-EX)

As same as Hyd excavators, steering is controlled by rotation difference of both

LHS&RHS travel motors. Spin turn and dozing during steering is possible. 29
 Steering Clutch & Brake
Output shaft Bevel gear shaft Output shaft

Bevel gear
LHS LHS RHS RHS
Steering Steering Steering Steering
Brake Clutch Clutch Brake
 HSS System

Hydro- Static Steering System

 HSS (Hydro Static Steering System)

HSS Motor

The idler for left axes

(inverse rotation)

Sun Gear (Input) : HSS Motor Input

Carrier (Input) : Bevel Gear
Ring Gear(Output) : Final drive Output
Bevel gear
shaft
32
HSS control system

The steering spool in the

control valve is driven by the
EPC output pressure. Both
side EPC valve is controlled
by command current from
T/M, Steering controller.

HSS pump pressure oil

flows to HSS motor and
HSS gear train makes LH
steering, RH steering or
counter rotation.

33
Final Drive

34
Final Drive (Ex. D375A-6)
[ 16 ]

[ 26 ]
[ 68 ]

[ 79 ]

[ 15 ]

35
Floating seal

Seal ring prevent dirt and water intrusion

O-Ring from outside.

Sealing surface: Both seal slip each other, but

oil is not leaked since both faces adhere.
Seal ring

Seal ring prevent oil leakage from inside of case

Rotation side (sprocket) No Rotation side (Case)

Notes;
1. Never adopt oil on the O-Rings when assembling
2. Never hit floating seal when installing

36
Undercarriage

37
Undercarriage 1) Track frame

Track frame Pivot shaft

Oscillate type Rigid type

Track frame can oscillate around pivot Single structure made by
shaft. Mainly employed for medium- welding track frame and main
and large-sized. frame together and used for
small-sized models mainly. Oscillatable
＜ Features ＞ ＜ Features ＞
When the track of either side rides High rigidity and simple ●Track frame
over an obstacle, shocks are reduced. structure.
Equalizer bar
Pivot shaft

Idler Track frame Carrier roller Sprocket

Track roller Track roller guard

State after track frame is installed
38
Undercarriage 2) Idler cushion

Adjusting to optimum tension

High tension Loose

39
Type of Sprockets

Solid type

Supply parts

Segment type

40
Undercarriage 3) Link assembly

Bushing is meshed
with tooth bottom of sprocket

Grease-lubricated type (Dry type) Oil-lubricated type (Wet type) PLUS Type
The space between the pin and bushing is filled
The space between the pin and bushing is filled (Parallel Link Undercarriage System)
with oil for lubrication. Since the pin and center bushing rotates, the
with grease for lubrication.
＜ Features ＞ outside of the bushing is worn less.
＜ Features ＞
○Early wear of the pin and bushing is ＜ Features ＞
○Simple structure and low cost.
prevented and the link pitch is not elongated. ○The wear life of the bushing is elongated
○If grease decreases, the bushing and pin come
○Oil may leak. greatly. (The wear life of the bushing is
in contact, and that can cause elongation of the
○Structure is complicated and cost is higher elongated to about twice, although that
link pitch.
than grease-lubricated type. depends on the jobsite)
○R & M cost can be reduced.

41
 Hydraulic System for Working Equipment

HSS
motor

components D21 D31 D37 D39 D51 D61 D65 D65 D85 D155 D275 D375 D475 D575
(A/P/PL (EX/PX (EX/PX (EX/PX (EX/PX (EX/PX/WX (EX/PX/WX (EX/PX
& systems -8) -22) -22) -22) (EX/PX-22) -15E0) -15E0) -16) -15E0) (AX-6) (AX-5E0) (A-6) (A-5E0) (A-3)
Hydraulic
CLSS ( DB valve ) CLSS CLSS CLSS ( CB valve)
system
Control valve Mechnical ( CB valve) ( DB valve) CLSS(CA) Tandem
(DB12) (DB19+14) (CB22) (DB19+14) (CB22) (CA26)

pump Varible Piston Pump ** : Common with HSS pump circuit

Tandem gear
* : Common with Fan pump
(LPV45)* (LPV45)* (LPV45)* (LPV45)* (HPV95)** (HPV95)** (HPV95)** (HPV95)** (HPV190)** (HPV112) (HPV190) (HPV140+140)

Cooling fan drive Mechanical hydraulic drive ( with reversible hydraulic motor ) Mechanical
(Pump) belt drive (LPV45) (LPV45) (LPV45) (LPV45') (LPV30) (LPV30) (LPV30) (LPV30) (LPV45) (LPV64) (LPV90+30) (LPV90+30) belt drive
(Motor) (LMF16) rear side of the machine (LMF28) (LMF28) (LMF28) (LMF28) (LMF65) (LMF65) (LMF150) (LMF180)

Control Lever Mono Palm lever

system system Mechanical PPC EPC PPC
control press. --- HST charge pump Self-Pressure Reducing Valve (Fan pump) Gear pump

Present models of bulldozers employ CLSS system Type of Valves

Feature Small Class : DB valve
-There are many type of valves Middle & Large Class : CB valve
Only D475 : CA valve
-The CB valve is used only for the bulldozer.
-Steering priority valve is installed (The machine with HSS system)
-Hydraulic drive fan system is employed widely in bulldozers.
Small Class : Fan system is included with W/E system
Middle & Large : Set of Pump & motor are installed