Sir Z.

Jonny
 Content
1. Analyze of crawler Bulldozer’s Development

2. Products category of ZOOMLION Bulldozer

3. Main Components and their Working Principles

4. The Hydraulic System of Bulldozer

Section 1. Analyze of crawler Bulldozer’s Development

With the quantity of engineering machineries increased

rapidly recent years, more resources were consumed and the
vehicle gas they emitted made the air condition even worse.
Therefore, how to reduce the use of power resources and to
protect the environment become a new direction of engineering
machines’ development. Besides, it has become a common
realization that the one who does better at these 2 aspects
will definitely take the lead in the future. At present, domestic
enterprises and some international companies, such as CAT etc.
even make it the strategy of their developing on new products
manufacturing. In addition, to be more intelligence is another
trend.
According to the market analyses, the small bulldozer (whose
power is under 120Hp) can meet the increasing individual
customers’ needs, and it will substitute human labor, thus there’s
great market. Due to a great profits and great attraction of
export in the big bulldozer (whose power is not less than 220Hp),
many enterprises trend put more efforts on this, consequently the
big bulldozer will lead the field on technique.
Secton 2. Pruducts category of ZOOMLION Bulldozer

ZOOMLION bulldozer is manufactured by its earth working

machinery branch company. They are wildly used in road and railway
built, water conservancy and electricity industries, petroleum
industry, building and mining etc. in order to pile stuff, flat earth
and clear ice, snow and rubbish etc. According to market, we have
three primary types of products, they are ZD160-3, ZD220-3 and
ZD320-3. And there are different series corresponding to each
type , that is, the Plateau, the desert, the swamp, super-swamp, the
sanitation, the coal mine and electric plant and the forest. Taking
the ZD160S-3 for example, the illustration is given as follows:
 Z D 160 S -3

ZOOMLION Bulldozer Horse power swamp Improved type

And the meaning of each grapheme is explained in the diagram below:

Super- Coal mine and

plateau swamp desert sanitation forest
swamp electrical plant

G S M H CS D L
 Now that the primary bulldozer producer CAT of U.S
and Komatsu of Japan etc. take a lead in the international
market, foreign customers usually will ask which type of
ours relating to the corresponding product of theirs when
buying our bulldozer. The relationship is illustrated in the
diagram below.
ZOOMLION KOMATSU CAT
ZD160-3 D60，D65 D6

ZD220-3 D80,D85 D7
ZD320-3 D155 D8
Section 3. Main Components and their Working Principles

3.1 what is bulldozer

bulldozer is a machine that is used to shovel and transport
earth, made of traditional industrial tractor and a blade, including
mechanical system, hydraulic system and electrical system. It is
mainly used to pile, transport (for short term), flat stones and
earth, and to clear cabins or ice and snow etc. At present, three
kinds of bulldozer are shown in market, namely , mechanical type,
hydra-mechanical type and full hydraulic, dividing into tyre
bulldozer and crawler bulldozer. The ZOOMLION bulldozer mainly
is hydra-mechanical crawler.
3.2 Components and their working principles of a crawler
bulldozer

Generally speaking, a bulldozer is made of three

parts--engine, chassis and working equipment (Fig.3.1).
The chassis part contains drive system, control system,
undercarriage, track frame and cab. Working equipment
includes blade and ripper.

And the drive line is:

Engine → hydraulic torque converter → universal joint →
power shifting transmission → central drive → steering
clutch → final deceleration → undercarriage (Fig 3.2)

Cab
Tractor

Engine

Working
equipment Undercarriage
Fig. 3.1 Structure of bulldozer
 Engine
Hydraulic torque convertor

Universal joint
Transmission
Central drive
Steering Clutch
Final drive
The undercarriage

Fig.3.2 Drive line of bulldozer

 3.2.1 Engine
(1) Profile of engine
Bulldozer is equipped with diesel engine,
mainly composed of engine block, crankshaft-
connecting rod and piston mechanism, cylinder
caps, rocker chamber and cover, valve-train
mechanism, combustion system, lubricating
system, cooling system, exhaust gas
turbocharger, intake and exhaust system and
so on. In our products, ZD160-3 is equipped
with Weichai diesel engine while ZD220-3 and
Weichai Engine ZD 320-3 are equipped with Cummins diesel
engine. For some detail information, please
refer to diagram 2.1.
 发动机 ZD320-3 ZD220-3 ZD160-3

型号 康明斯NTA855-C360 康明斯NT855-C280Ⅲ WD10G175E15

型式 增压中冷立式四冲程 增压水冷立式四冲程 增压水冷立式四冲程

缸数-缸径X行程 6-139.7X152.4mm 6-139.7X152.4mm 6-126X130mm

活塞排量 14000ml 14010ml 9726ml

额定功率 239KW 162KW 120KW

额定转速 2000r/min 1800r/min 1850r/min

最大扭矩 1509N.m/1400r/min 1078N.m/1250r/min 768N.m/1200r/min

燃油消耗率 ﹤242g/Kw.h ﹤208g/Kw.h ﹤225g/Kw.h

Diagram 3.1 parameters of engine

(2) Principle of engine’s starting

When starting a engine, the starting motor is given a

great instant current by the battery, the motor central
shaft on which a small gear is fixed will extend out to mesh
with the flywheel, then the motor will drive flywheel rolling
by gear meshing. Thus flywheel drives the crankshaft to roll
making the pistons move regularly up and down to compress
the air, finally fire the diesel. When engine begins to work,
motor’s central shaft moves back to its initial position,
meanwhile, engine outputs power.
(3) Power outputting device of engine

The engine power outputting device is composed of

flywheel house and power take-off case. They are
used to distribute and output engine power. Flywheel
transmits power to three gear pumps and the driving
system , to insure bulldozer function well.

Note: the three pumps mounted on take-off are

transmission pump, steering pump and working pump
respectively.
3.2.2 Power driving system
The power driving system
of bulldozer mainly composed
Take-off
of hydraulic torque case
convertor, universal joint,
transmission, central drive,
steering clutch, steering
brake and final drive. They Flywheel
are all mounted on the track house
frame (Fig.3.3).
(1) Hydraulic torque convertor
Central drive
and steering Transmis- Convertor Engine
clutch sion

Fig.3.3 Driving system of bulldozer

 Hydraulic torque convertor is one of the core components in
bulldozer, and it is mainly composed of pump impeller, turbine, stator,
scavenge pump, oil filter and 2 valves (an overflow safety valve at
entrance, a reducing valve at exit) etc. Fig. below shows the outline of
a convertor.
Pump impeller
Scavenge pump

Turbine

Oil filter
Stator
overflow safety
valve reducing valve

Scavenge
Output shaft pump

Oil filter
Meshing with
(inside)
flywheel
 The pump impeller is driven to revolve in a
high speed when the engine starts. oil inside
the internal cavity of convertor takes off
beating on turbine by the strong centrifugal
force of impeller. the turbine that is fixed
together on outputting shaft then begins to
move under such rushes. oil flying out from
turbine goes to the stator to change direction
backing to impeller, thus, over and over
happens this circus, power is transmitted with
a relative low rolling velocity but a great
torque. by this way, the convertor transfers
drive constantly to ensure bulldozer work well.
 (2) Universal joint
To assure smooth transmitting power and the coaxiality of the convertor
output shaft (equaling to the engine crankshaft) with respecting to the
main shaft of transmission within a permissible limit (30 ～ 50 μm), an
universal joint is used, and it is installed between the hydraulic torque
convertor and transmission. The main parts of universal joint are cross
assembled heads, connecting plates and bolts which are cooperated with
gear box and convertor, as shown in Fig. 3.4.

Fig. 3.4 An universal jonit

(3) Transmission
As another core component of bulldozer, the transmission is
used to transfer power from torque convertor to central drive with
change of speeds or directions. And it consists of tow parts –
transmission box and speed controlling valve.
The speed controlling valve is composed of dynamic regulator
valve, quick-return valve, reducing valve，speed valve, safety valve
and direction valve, and it decides the hydraulic oil whether pours
into transmission box or not. Meanwhile, the transmission provides 3
forward, 3 reverse spends and a neutral gear. It is of a constant-
mesh type with helical gears and it is composed of 4 groups of
planetary gears mechanisms and 5 groups of clutches.
The planetary gear mechanism contains several central
shafts, planetary frames and planet gears. The clutch is
of hydraulic meshed and spring detached structure,
including outer ring with internal teeth, cylinder, plates
and piston. When transmission works, the main shaft is
always rolling, the states of clutches and corresponding
planet gears decide the speed of final bevel gear shaft.
 Control valve
And shifting gears, the corresponding
clutch would mesh the gear to roll,
changing the speed of final bevel gear,
consequently, changing the speed or
direction. The structure of Transmission
transmission is shown as Fig.3.5.
(Note: due to the structure is
complicated and the working principle
is hard to tell in detail, no further
explanation is given here. Plz go for
some professional data if necessary.) A transmission
 Planetary
gear
Coupling mechanism
plate (in)

Piston

Shaft
Gear (out)
rings

Plates

Press-
ing

Cylinder

Spring
Fig. 3.5 transmission box
(4) Central drive and Steering clutch

The central drive is part of the drive line where the power
from transmission is divided into two crosswise directions, toward
the left and the right, to drive the sprocket wheels through
steering clutch and final drive. It consists of a big bevel gear,
central shaft, several bearings and seats and coupling plates
(Fig.3.6)
The steering clutch is a wet-type multi-disc clutch, used to
pass or cut off the power from central drive to final drive (just
like switch). It is mainly composed of brake drum, pressing plates,
discs, plates, inner and outer drums, springs and piston etc.
 In general, spring force press plate to clamp
discs and plates tightly on he internal drum so as to
keep the clutch engaged, thereby transmits the
drive from bevel gear shaft to the final drive. Well,
when steering operation is given, hydraulic oil enters
into a sealed cavity a sealed cavity to push the piston

pressing the springs, making the discs and plates

separated from pressing plate. At this moment, the
steering clutch will no longer transfer torque to final
drive,
as a matter of fact, the bulldozer will turn to left or right
according to the operation.

Central Steering Brake

drive clutch band

Fig.3.6 Central drive and Steering clutch

(5) Final drive
The function of the final drive is to reduce further the speed
and to let the power from steering clutch transfer to sprocket
wheels and then to the track, driving the bulldozer forward or
backward.
1st small

1st big

2nd small

2nd big

Gear hub

sprocket

Fig.3.7 the structure of final drive

In fact, the final drive gear train is a two-stage
reducer with two spur gears and two pinions (Fig.3.7).
The floating oil seal is adopted between the
sprocket hub and the final drive case as well as
between the sprocket wheel nut and sprocket
support, this kind of sealing is reliable and with long
service life.

3.3 The undercarriage

 The undercarriage is a foundation for supporting the
overall weight of bulldozer. It still has to bear the working
resistance and various forces acted on bulldozer by ground
surface. And it is mainly composed of track and track roller
(Fig.3.8).
The track roller mainly consists of track frame, track
rollers, carrier roller, idler and recoil spring, the track frame
is main part of the undercarriage. The overall weight of
bulldozer is transmitted to track through track rollers, which
have of function of guiding the whole machine to travel
straightly and preventing the track slide out sideways,
 Fig.3.8 the undercarriage

idler Carrier Double-sides Single-side

Sprocket
roller track roller track roller
as to the carrier roller, it is used for supporting the upper part
of track between idler and sprocket wheel, to prevent excess
sag of the track, and to reduce the vibration and jumping of
track while travelling, as well as to prevent track slide out
sideways. For the recoil system, it is mainly about a recoil spring,
which is connected to the idler by
its front part. Its function is to
ensure the track to keep a proper
tension in normal operation, and to
buffer the impact while the dozer
meets with some obstacles or
Track Frame impacts on idler when travelling on
an uneven ground.
3.4 Working equipment
The working equipments of ZOOMLION bulldozer are blade
and ripper, which are used to complete various assignments. At
present, 4 kinds of blades are manufactured, they are tilt blade,
angle blade, U blade and sanitation blade, and 2 kinds of ripper,
single tooth and three-tooth (Fig 3.9).

Tilt blade Angle blade

 U blade Sanitation blade

Single tooth ripper Three teeth ripper

Fig.3.9 all kinds of working equipments

Section 4. The Hydraulic System of Bulldozer

The hydraulic system of bulldozer is mainly composed of

transmission & torque converting hydraulic system, steering
system and working system. And various pumps, valves, strainers,
filters, cylinders, pipes and tanks are the necessary elements of
each circuit.
4.1 Symbols in hydraulic engineering
In hydraulic engineering, we usually use some certain symbols
to represent the corresponding element, and a figure with some
related symbols to show the principle of a hydraulic system. And
it is really helpful for us to master it and to diagnose problems in
practice. However, those elements on a figure sometimes are not
at the same position with they are in a real vehicle. First of all,
let take a look at those elemental hydraulic symbols, as shown at
Fig.4.1.
 Fig.4.1 Hydraulic symbols
Pipe lines
Measuring point

Pipe line

Relief valve (certain Vol)

Pipe line for beforehand

Pipe line for leakage Relief valve (alterable Vol)

Intersection of pipe

pumps
Un-intersected lines

Flowing direction of oil Certain volume

Oil tank Alterable volume

 cylinders
Motor

Check valve

Oil cooler
Overflow valve

Reducing valve Strainer, filter

4.2 The principle of hydraulic system

4.2.1 The working principle of ZD160-3 hydraulic system

(1) Transmission & torque converting circuit

Transmission pump draws oil through strainer from

transmission house and transfers them into transmission control
valve via oil filter. and the oil is divided into two flows: one to
the dynamic regulator valve, the other to the quick-return valve.
When no operation given, oil at regulator entrance is stopped
firstly, but then the pressure raises, and a certain amount of oil
will pass when it reaches to 20 kg/cm2, flowing to the overflow
valve (which is at the entrance of convertor) to get into
convertor. When pressure is more than 7.5～8.5 kg/cm2, this
valve will be opened and the extra oil will overflow to
transmission house.
 As oil enter convertor constantly, a scavenge
pump is used here to draw oil back to steering case,
in order to keeping the oil inside convertor at certain
amount which is enough for convertor to function well.
Besides, the oil pressure inside ought to be kept at
2 ～ 3 kg/cm2, thereby a reducing valve is installed at
exit of convertor. When pressure is more than 4.5
kg/cm2, some oil will overflow to the oil cooler. Then
the oil goes to lubricate the revolving components in
take-off case and transmission box respectively, and
finally back into transmission.
 Well, when operation on transmission control valve comes,
the oil prefer to flow to the quick-return valve, and a steam of
oil goes to the metering hole beforehand, to make the valve
spool move fast repeatedly by a differential pressure between
two sides of the body, cause no spring included in it. The oil
flows to speed valve and direction valve then, to change driving
speed and direction of bulldozer. And still, the relief valve
mounted here ensures safety by leaking those extra oil into
house, and the reducing valve is to guarantee pressure of 1st
gear is 12.5 kg/cm2. Fig. 4.1 will help us to recognize the
principles illustrated above.
Fig.4.1 transmission and
torque converting system
(2) The steering circuit
The steering oil pump draws oil from steering case through
strainer, and through filter, the oil will be divided into two flows:
one flows to steering valve while the other to safety valve. When
no operation acts, the oil flowing to safety valve will overflow to
oil cooler, in order to lubricating the moving parts in transmission
box and take-off house. The rest of oil goes back to steering
case. However, when operation comes the oil will flow to steering
clutch and assistant brake valve respectively in order, to realize a
steering of bulldozer. The schematic drawing of the return lines
of steering clutch and steering brake are shown as Figs.4.2.
 Fig.4.2 Steering system
1.Strainer
2.Steering pump
3.Filter
4.Safety valve
5.by-pass valve
6.Oil cooler
7.Steering valve
8.Assistant valve
9.Braking valve
10，11.steering clutch
12.Steering case
13.Lubrication
4.2.2 The working principle of ZD220/320-3 hydraulic system
(1) Transmission & torque converting circuit

Transmission pump draws oil through strainer from steering

case and transfers them into transmission control valve via oil
filter. and the oil is divided into two flows: one to the dynamic
regulator valve, the other to the quick-return valve. When no
operation given, oil at regulator entrance is stopped firstly, but
then the pressure raises, and a certain amount of oil will pass
when it reaches to 25 kg/cm2, flowing to the overflow valve
(which is at the entrance of convertor) to get into convertor.
When pressure is more than 8.7 kg/cm2, this valve will be opened.
When pressure is more than 8.7 kg/cm2, this valve will be opened.
and the extra oil will overflow to steering case. As oil enter
convertor constantly, a scavenge pump is used here to draw oil
back to steering case, in order to keeping the oil inside convertor
at certain amount which is enough for convertor to function well.
Besides, the oil pressure inside ought to be kept at 4.5 kg/cm2,
thereby a reducing valve is installed at exit of convertor. And
when pressure is more than 4.5 kg/cm2, some oil will overflow to
the oil cooler, then goes to lubricate the revolving components in
take-off case and transmission box respectively, and finally back
into steering case.
 However, when operation on transmission control valve
comes, the oil more prefer to flow to the quick-return valve,
and a steam of oil goes to the metering hole beforehand, to
make the valve spool move fast repeatedly by a differential
pressure in two sides of the body, cause no spring included in it.
The oil flows to speed valve and direction valve then, to change
driving speed and direction of bulldozer. Besides, the relief
valve mounted here ensure safety by leaking those extra oil
into house, and the reducing valve is to guarantee pressure of
1st is 12.5 kg/cm2. Fig. 4.1 will help us to recognize the
principles illustrated above.
Fig.4.3 transmission &
converting system
(2) The steering circuit

The steering oil pump draws oil from steering case

through strainer, and through filter, the oil will be divided
into three flows: one flows to steering valve, one to safety
valve and one to the servo valve, which controls the working
equipments.
When no operation acts, the oil flowing to safety valve will
overflow to the torque convertor, to participate the working
circuit, and the oil flow to cooler when getting out from
convertor, and after that, the cooled oil will lubricate the
moving parts in transmission box and take-off house. The rest
of oil goes back to steering case.
 However, when operation comes the oil will flow to
steering clutch and assistant brake valve respectively
in order, to realize a steering of bulldozer.
The schematic drawing of the return lines of
steering clutch and steering brake are shown as
Figs.4.4
Fig.4.4 transmission and converting system
4.3 Operation principle of working hydraulic system

The working pump draws oil from hydraulic oil tank and
transfers the oil to blade lift valve, blade tilt valve and ripper
valve. These three valves are connected with series of oil pipeline
of working equipment. By controlling those valves, the oil flows to
the blade lift cylinder, blade tilt cylinder and ripper cylinder
respectively to make blade and ripper work as required. The
return oil from those cylinders flows back to the hydraulic oil
tank via a oil filter. The pressure of the whole system is
controlled by safety valve, the normal pressure is 137 kg/cm2. An
oil-supplement valve and quick-fall valve are provided in the oil
return line of blade lifting device to enable the blade to get down
quickly and improve the working efficiency, meanwhile An oil-

supplement valve and overload valve are placed in the ripper oil
return line to raise the working efficiency and protect the
working cylinders and pipelines. In tilting oil return line is
installed a metering check valve, in order to prevent tilting too
fast. Besides, there are two check valves mounted in blade lift
valve and ripper valve respectively, to prevent a momentary
lowering of blade or ripper while raising and falling of the
cylinders, duo to the weight of working equipment.
All valves mentioned above except quick-fall valve are
installed in hydraulic oil tank, and the structure is compact.
 Perfect our
service with a
efficient working
capability and a
sincere attitude!