239 COMPARISON OF C = ABLE CONTROL VERSUS: HYDRAULIC. CONTROL BLADE OPERATION ie Tyaut 1. Simpl incontacion,operaion Timeicieaaa ity to produe high down pes 2. Liftand drop can be performed onthe blade. | ie 2. Precise setting ofthe blade is ata faster rae pense | 3 Depth of cutis regulated by the weight of the bade ony 3. Hyicaeyemdomimeanie | ic riaddnen hence elablityie reac, {Pedic msinenanceaandsontine laces needed 4. Theyeepetrednmedum nd sml siedoer 6. Skiliegiedtomamantesysemiee Pee eoereNY Boa, |. Opisontetg si 1. Vertical operating range ofthe bade cha es 11.9 OPERATION OF DOZER US OPERATION OF DOZER 11.9.4 Digging ‘This is performed by moving the dozer in a forward direction. During this operation the edge ofthe blade may be in the same horizontal plane as the crawlers. For dip cutting, the edge along with the blade may be lowered. Figures 11.14(a) and (b) show these two operations respectively. Pury 4 eat ——— @ ) Fig. 11.14 (a,b) Digging 11.9.2 Braking Piles Material stored in bulk, in the from of a pile, may be knowcked down and redistributed in the remaining space by walking the crawler into it with the blade at the desired angle as shown in Figure 11.15. 11.9.3. Transporting and Spreading These activities are done within a limit of about 100 m. Transportation is done by dragging the loose soil by the dozer blade in front of the equipment The spreading of loose material is done by adjusting the dozer blade slightly above the ground 11.10 DOZER BLADE CAPACITY Figure 10.16 shows the major dimensions of a dozer blade. f= height of blade L = length of blade Therefore, theoretical load = /2h? LY (LA) Where y= specific weight of the material. On level or horizontal ground 20 per cent centre bulging was found. Hence: 2 Load = 122 y= 0,610" (11.2)lopment of Heavy Earth Moving Maching Latest Devel 234 TD — ee SANT ee erp et _i e el te Material botore dozer Fig. 11.16 Blade dimension 41.11_EFFECT OF GRADE 11.11.1, Downhill ‘The blade generally pushes 4 per cent more for each per cent of down slope as found in actual practice on a level floor Hence on a 25 per cent grade the machine pushes almost double the amount of its normal load on level ground. 11.11.2. Uphill ‘A half load in comparison with load on level ground is pushed up in a 20 per cent grade and one-fourth of the load is pushed in a 100 per cent grade. This is mainly to counteract W sin Where W is the dozer weight and is the slope. 11.11.3 Output Estimated output is given by where H = heaped blade capacity (in loose m}) C= cycle time (travel time + fixed time) loose cu my/hour Fixed time = 0.15 minutes (nearly), if only forward and reverse lever shifting is requited. ‘3 minutes (nearly), if both forward and reverse shifting is required. (Incline or grade).Dozer 235 11.12, INSPECTION BEFORE STARTING wl 1, Walk around the machine and cheek for any trac hoses, hydraulic clinders, final drive, radiates and lio Check tightness of bolts and nuts. Check the mountings of air cleaner, ‘aterleakage. Examine connection of high pressure , iators and floating seals, 3. 4. 5. Check fuel level, water evel and lubricating oil level (SAE-30, below 10° C SAE 10 W). 6. Operate travel lever and brake pedal for proper functioning Check the operation of the blade control lever, muffler, and track roller supports, Check for broken electric wires. 7 . specially for its leaking arrangement. 11.13 PROCEDURE FOR STOPPING THE ENGINES 1. Cool the engine gradually by running it at idling speed for about five minutes 2. Place the fuel control lever in the engine stop position to stop the engine. 3. Tum the starting switch key to the off position and remove Key. 11.14 PRECAUTIONS FOR OPERATION 1, Avoid turning the machine on a slope since the machine tends to slip sideways, 2. Always stop the machine on a Mat, stable ground, 3, When the torque converter oil temperature gauge indicator exceeds the green range, reduce load and wait for the temperature to decrease. 4, ‘Never step on the decelerator pedal when going uphill as the engine speed will decrease and climbing ability will be reduced. 5. If the fuel level is too low, try to avoid the operation of the engine on a slope, as the engine may draw excess air. 41.15 MAINTENANCE, COMPONENT - WISE 1.15.1 Blade and Arms 1. Any material sticking on the front wall should be scraped off. 2. The edge of the blade should be inspected for its sharpness. 3. Comer pieces should be secured properly. 4, Hinge points of both pitch arms and push arms should be inspected for any play and then lubricated properly. 41.15.2 Blade Operation Control Unit 1. Cable should be inspected for loosening of any strand, wear and tear or rusting, and replaced if needed. 2. The pulley groove and its mountings should be inspected for any damage or jamming and rectified. 3. The drum surface of the cable unit should be inspected and corrected, if necessary. ‘4. Inspect for any leakage of hydraulic hoses, oil seals, ete. 5. Inspect for smooth operation of blade lifting cylinders. 6. Inspect the operation of safety valves, locking valves, ete. 7, Clean and replace the oil strainers.rh Latest Development of Heavy Earth Moving Macting 11.153. Transmission System 1. Operate the main clutch to test proper functioning: 2, Inspect the intermediate brake by applying it 3. Transmission gear box oil level should be checked. 4, Gear box bearing should be inspected. 5. Functioning of steering clutches should be inspected 6. Driving sprockets should be checked. 11.15.4 Undercarriage Unit 1. The shoe and its profile should be checked 2. Excessive sagging of the chain should be corrected. 3. Inspect the condition of the track and carrier rollers. 4, Tighten different mountings and bolts. 14.16 MAINTENANCE OF DOZER 11.16.1 Daily Maintenance 1. Check engine crank case, main clutch and steering clutch case oil levels and add if necessary. 2. Record engine oil pressure (a) at idle condition, and (b) at full rpm load. 3. Clean air cleaner element. 4. Drain oil from the fuel oil filter and the final tank sump. 5. Check radiator coolant level and add if necessary. 6. Check linkage. 7. Check operator's report. 8. Check floating seals for any sign of oil leakage. 9. Check wiring for discontinuity, shorting or loose terminals. 10. Check mounting bolts and nuts. 4.16.2 100 hours 1. Repeat daily maintenance 2. Change engine oil. 3. Change engine oil filter element 4, Lubricate generator. 5. Clean front tank breather 6. Check air system and its connections. 7. Check electrolyte level in the batteries. 8. Check turbo charge clearance: (i) Redial 5 t0 33 thousandth of an inch (ii) End play 6 to 19 thousandth of an inch.Dozer 11.16.3200 hours. 1, Repeat 100 hours maintenance. 2. Lubricate cranking motor. 3. Change engine oil bypass filter element. 4. Check corrosion register. 5. Check engine coolant. 6. Check and adjust belt tension. 7. Change fuel filter element, 8. Replace air cleaner element. 9. Check operator's report. 10. Check and correct oil level in the final drive case and hydraulic tank. n. Check steering clutch oil filter element. 12. Check and tighten loose track shoe mounting bolts. 11.16.4 400 hours 1, Repeat 200 hours maintenance. 2, Clean fuel pump screen and magnet. 3. Check fan drive pulley. 4. Check generator and cranking motor. 5. Steam and clean radiator fins. 6, Check and clean radiator fins.. 7. Change cooling fluid. 11.16.5 800 hours: 1, Repeat 400 hours maintenance. 2, Adjust injector valves. 3. Tighten manifold nuts and cap screw. 11.16.6 1800 hours 1. Repeat 800 hours maintenance. 2. Change oil of the following units: (i)_ main clutch case (ii) steering clutch case (iii) final drive case, and (iv) hydraulic tank. 3. Check alternator and steering motor 4, Clean main clutch case oil strainer 5. Drain fuel float tank. 6. Flush cooling carriage components. 7. Check undercarriage components. 8. Clean the inside of the fuel tank. 237238 11.17 _TECHNICAL DETAILS 41.17.41 D155 A-Bullozer Operating weight Maximum drawbar pull Engine model FHP Torque pressure Ground pressure Transmission Number of track shoes on each side Capacity Speed 4117.2. D355 A -3 Bulldozer Operating weight Max. draw bar pull Engine model FHP Torque converter Transmission Speed [Number of track shoes on each side Capacity Ground pressure Use of Dozer in projects Latest Development of Heavy Earth Moving Mactng 32,510kg, 65,000 ke KT-1150C 320 @ 2000 rpm ‘Three element single stage 0.92 ke/em Power shift three forward and 1 41 10.4 cum 11.8 krvhour (forward) 13.7 kmv/hour (reverse) three reverse 43,840 kg 88,00 kg KTA-LISOC 410@2000rpm “Three element single stage single phase Power shift four forward and for reverse 12.7 kmh (forward) 12.6 knw/h (reverse) 39 152.cum 1.06 kg/em? Fig. 11.17 Dozer cutting plane surfaceDozer 239 Fig. 11.18 Cutting up the gradient Fig. 11.17, the dozer is working on level ground and the cutting materials are infront of dozer blade. Which Fig. 11.18 shows the dozer working in up the gradient with full of material in front of blade. Fig. 11.19 Dozer mounted on 4-crawler unit 11.19 shows the latest designed dozer mounted on 4-crawler unit (2-on each side). This type of dozer is capable of moving very fast with load. They can be manoeuvred easily with load both during cutting, shifting and spreading in a project. The upper portion of chain have no carrier roller; so height of the crawler unit is less providing many such other advantagesLatest Development of Heavy Eath Moving Machin, 240 PROBLEMS rates in an up hill gradient of 5%. Wht woulg Problem 1. A dozer blade having dimensions 4315 mm x 1875 mm oP be the output of dozer? Solution: Capacity on level ground as per equation (11.2) is given bY . Soyo ent mn wre cael 9 bean: 30.61? Leu.m For 20% grade output reduction 50% For 5% grade output reduction by inter pollution 12.5% . Output Q = 0.6 1? L (1 - 0.125) 0.6 x 1.8752 x 4.315 * 1.875 = 7.964 cum, Ans. Problem 2. A dozer blade having dimensions 4315 mm x 1875 mm operates on level ground. The average speed of the dozer is 10 KMPH. What would be the hourly output of dozer, if the materials is to shifted over a distance of $0 m? ‘Assume that the cutting length to be 50m. Solution: Assumptions (i) Depth of cut for the dozer 10 em. (Gi) As soon as the dozer attains maximum capacity, no further cutting is done, but the materials is shifted beyond 50 m. (iii) This is being followed for the whole length of 50 m before the blade. (iv) If further cutting is required, the dozer is to shifted laterally for further action, (¥) This is being down till the job is completed. Let xm be the length of cut by dozer, when it attains maximum capecity. Hence we have the eqn. 6x1.875? x SATS SxS W211 $315 x0.1 7 Hence cutting plan for the dozer would be as follows Phase | Je —— Outing + je siting fb} 21.4 m a] bp» 2.9m —} fb} cutting ——} }-— siting —o} + 2.9m ——__+] — 78m —4 Phase! cutting 78m Phase I! Phase I — cutting time + shifting time + backward + forward. Speed of dozer = 2 =2.77 ms x Phase I Time = 289 ime Sexo *OSm+0.1Sm+ 0.23 + 0.15 +0.15 +0.13 + 0.66 m = 39.6 sec Phase U Time = 289-403 =0134034 —28 z 36x 6x60 Hy 72796 sec.borer 244 Phase IL a8 ¢ I Time Foxe t° 15 = 0.036 + 0.15 = 0.186 m = 11. 16 sec Total time = 39.6 + 27.96 + 11.16 = 78.72 sec Dozer output = Phase I output + Phase If output + Phase If output = 2X OL x 4.315 + 211 x OL x 4.315 + 7.8 x Ol x 4.315 = 9.06 + 9.06 + 3.3657 21.4857 cum, Hence hourly output of dozer ae %3600 = 982.5 cu.m/Hr. Ans. EXERCISE 1. Distinguish between an angle dozer and a tilt dozer. Explain the floating of a dozer blade. 2. Before certifying a dozer for duty, what inspections would you suggest? Discuss. 3. Why are hydraulically operated dozer preferred to cable operated dozers? 4. Explain with a neat sketch the blade operation circuit of a hydraulically operated dozer. 5. Why is the daily and periodical maintenance essential for the undercarriage unit of a dozer? What will be the effect on the performance of the dozer if the track chain is kept loose? 6. Why are only crawler mounted dozer to be found instead of rubber tyred ones at surface mining projects? 7. Draw and explain the kinematic diagram for the power transmission system of a dozer. 8. A dozer blade having dimension of 4315 x 1875 mm operates in an uphill gradient of 5 per cent. What would be the output of the dozer? 9. The required output of a dozer on level ground is as found in problem No. 8. What size of blade will you select if the height to 1 length, ratio of the blade is 0.437 ‘Ans. 1530 x 3560 mm 10. A dover blade having dimensions as indicated in problem No. 8 operates on level ground. The average speed of the dozer is 10 km/hour. What would be the hourly output of the dozer if the material is to be shifted over a distance of 100 ine Ans. 412.5 cu m/hour 11. A dozer blade has dimensions 4315 mm x 1785 mm, Calculate the capacity of the dozer when it operates on down the gradient of 7%. Deduce any expression you have used. ‘Ans. 10.55 cum 412. A damage road is to be repaired by dozer. The effective length of the road is 150 m and width 15 m. The blade dimension is 4315 mm and 1875 mm. Assuming forward speed of dozer is 5 KMPH and reverse speed of the dodger is 15 KnvHr. Calculate the time required to complete the job is cutting $ em through out the road space of 150 m x 15 m. Mention clearly your assumptions. ‘Ans. 20 min. 40 see. 13. The dozer as given in problem No. 12 operates under the same conditions in the same area with variation of depth of cut become 10 cm through out the road, what will be the time requirement for the job. ‘Ans. 4 min, 12 see. 14, A dozer having blade dimension of 4315 mm x 1785 mm operates in the following conditions (@ up to gradient of 5%; 7%; 10% and 12%. (ii) Down the gradient of 5%; 7% 10% and 12: Calculate the output of dozer in cu.m in each case and draw the graph showing variation of output against gr up and down the gradient separately.