Domestic crawler bulldozer DST-URAL TM 10 and its modifications

Bulldozer TM 10.11 is one of the most popular models of the DST URAL company, located in Chelyabinsk. The machine was created on the basis of the TM 10.00 tractor, supplemented with a ripping device and bulldozer equipment. In its design, the model is in many ways similar to the TM 10.10 series.

The DST URAL plant appeared on the Russian market relatively recently, but has already loudly declared itself. In the shortest possible time, the manufacturer became one of the leaders in the segment, and its products were repeatedly awarded at foreign and domestic exhibitions. Initially, the company was engaged in the repair of construction machines, but in the mid-2000s it switched to its production. The designers of DST URAL used the experience accumulated by Russian manufacturers of special equipment in their developments.

TM 10.11 is one of the company’s most successful models. It has a rich basic package. There are lights in the front and rear areas of the machine, allowing you to work in the dark. The armored bottom increases reliability and makes it safe to operate on uneven surfaces.

The main application of the TM 10.11 bulldozer is loosening and transporting soil over short distances. The model is suitable for working with category I-III soil (without additional loosening) and category IV soil (with preliminary loosening). It is also used for leveling sites, removing snow, uprooting stumps, digging pits and trenches. The equipment is actively used in the mining and forestry industries, road construction and agriculture.

Modifications and features

The TM 10.11 family is available in several modifications (TM 10.11 GST15, TM 10.11 E and others). They differ in the area of ​​use, type of equipment installed, engine and structural elements.

The TM 10.11 series has the following advantages:

• unification of the main components and elements with the machines of the Chelyabinsk Tractor Plant is 85-90% (the highest for components with a high degree of wear). This feature significantly reduces the delivery time for parts - no more than 7 days to any region of the country;
• democratic price. Russian assembly makes the bulldozer accessible to most consumers;
• long service life and reliability;
• wide model range. The model can be purchased in standard and extended configurations, taking into account the needs of the customer;
• simple control of all functions and movement using 2 joysticks;
• high environmental friendliness. The volume of harmful emissions into the atmosphere of the TM 10.11 family is significantly reduced;
• The hydrostatic transmission improves operating comfort while increasing operational reliability.

Bulldozer TM 10.11 is currently synonymous with quality and efficiency at an affordable price.

Basic faults and repairs

The TM 10 bulldozer encounters several types of malfunctions. Chassis failures can be recognized by heating of the rollers and tension wheels. Lubrication, replacement of cuffs or rollers will help correct the situation. The hydraulic system fails for several reasons:

1. Lack of oil, clogged filters in the hydraulic pump, failure of the motion control mechanism. Signs: lack of response to moving joystick elements and moving equipment back and forth. Replacement of worn-out elements or contacting a service center will help solve the problem.
2. Low dozer travel speed may be caused by worn out hydraulic motor or pump, faulty motion control system, elevated oil temperature in the tank, or the use of consumables that do not meet manufacturer's specifications.
3. Increased noise indicates an insufficient amount of oil, worn and clogged filters, and the presence of pinched and jammed parts of the hydraulic lines.

Another large group of faults is related to the battery:

1. Rapid discharge indicates a lack of contact with the generator or wear of the unit. It is necessary to check the availability of charging current or replace the battery.
2. Sulfation of the plates occurs when the vehicle operates for a long time with a low level of electrolyte or due to the presence of foreign substances in it. Repairs include replacing the fluid, replacing the battery, or recharging it.

The presence of a diagram of the construction of special equipment with the designation of all components and systems allows you to independently carry out simple repair procedures. In other cases, it is better to entrust the work to specialists.

Specifications

Dimensions:

• length – 6640-7163 mm;
• width – 3240-3310 mm;
• height – 3420-3440 mm.

The structural weight of the base model is 18,500 kg, the swamp version is 19,400 kg. The operating weight including the ripper reaches 22,600 kg. The ground pressure ranges from 0.039 to 0.075 MPa. Supporting surface area – 6.1 sq.m. The bulldozer can move forward at a speed of 11.28 km/h (8th gear), backward - at a speed of 11.05 km/h (3rd gear).

Refill containers:

• hydraulic system – 100 l;
• cooling system – 60 l;
• engine lubrication system – 32 l.

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Data are approximate* Last updated: 04/04/2017 10:00:29

Main working bodies:

Hemispherical blade with hydraulic distortion:

• width – 4000 mm;
• height – 1550 mm;
• capacity – 6.6 cubic meters;
• weight – 2660 kg.

Straight rotary blade:

• width – 4280 mm;
• height – 1140 mm;
• capacity – 4 cubic meters;
• weight – 2540 kg.

Single-shank ripper:

• weight – 1860 kg;
• maximum depth – 660 mm.

Three-shank ripper:

• weight – 2260 kg;
• maximum depth – 660 mm.

Photo

Design and operating features

The TM 10.11 bulldozer is based on the design of the TM 10.00 tractor, which is why these machines are similar in many elements. The welded supporting frame is characterized by increased rigidity. It is able to withstand heavy loads, which allows the equipment to be used in the harshest conditions. The chassis is based on a 3-point rigid suspension with a spring or a balancing beam (depending on the version). The track rollers are mounted on K-shaped carriages, where oscillatory movements are absorbed by polyurethane cushions. The carriages are assembled on a trolley rigidly attached to the frame. A special feature of the chassis is micro-suspension, which is provided by 3 high-strength rubber pads and makes working on the machine more comfortable.

The track consists of 42 shoes with a width of 500 mm. The tension in the tracks is adjusted via a hydraulic mechanism. The chassis includes 2 support rollers and 6 support rollers on each side, which are lubricated for the entire period of operation.

TM 10.11 is offered with several transmission options. Basic versions are equipped with manual transmissions with 12-speed gearboxes (8 forward, 4 reverse speeds). The control in this case is hydroserved. This type of transmission is simple and reliable. Dry friction band brakes are used as the braking system.

The latest modifications of TM 10.11 are equipped with a BOSCH-REXROTH hydrostatic transmission, produced in Germany. It is characterized by an increased service life, smooth running and stepless switching. The gearbox is made on the basis of a hydraulic pump-hydraulic motor pair; the control is electro-hydraulic. Individual elements and final drives are made in Germany/Italy, which has a positive effect on the reliability of the transmission. The hydraulic braking system operates on the basis of closed multi-disc clutches.

The hydraulic system is a separate unit. It uses a tandem pump NSh-100/50A-3L with a capacity of 180 l/min. The maximum pressure in the system is 18 MPa. The filtration system uses double cleaning: at the suction after the hydraulic pump (pressure element) and at the drain (full flow filter).

The line of equipment used with the TM 10.11 bulldozer is represented by the following devices:

• hemispherical blade type E (basic equipment);
• straight rotary blade;
• single-shank ripper type H;
• three-shank ripper.

For the TM 10.11 model, the DST URAL plant has created a special hexagonal cab with an armored roof and double glazing, which simultaneously provides excellent visibility and operator protection. Fresh air ventilation, complemented by an air filter, and a heater improve operating comfort. The cabin itself is sprung, so vibration in the cabin remains minimal under any conditions. Additionally, ROPS/FOPS protective systems are offered, increasing safety in the event of foreign objects falling onto the roof or equipment overturning. The cabin meets modern requirements, a spacious interior with a comfortable seat with adjustment for weight and height reduces operator fatigue during work. Protection of the bottom and hydraulic circuit hoses protects against accidental damage. Options include air conditioning, external battery storage, an emergency hatch on the roof, a ripper light, an anti-vandalism system and an auxiliary heater.

Movement control is performed via a 4-position joystick, and the operation of attachments is controlled in the same way. This mechanism allows an operator without experience to effectively operate the machine.

Maintenance of the TM 10.11 model is simplified due to the following solutions:

• segmented drive wheel, reducing the amount of work associated with maintenance;
• visual indicator on the hydraulic tank;
• open design of the final drive;
• special pressure filters;
• wide side doors of the engine compartment.

"DST-Ural": course for renewal

The history of Chelyabinsk began in 2000 with the repair and modernization of T-170 tractors. Seven years later, the accumulated experience made it possible to create a bulldozer of our own design, TM-10, which was recognized as the best among competitors at a competition in Belarus. Since then, a wide range of equipment has been created that is well known in the Russian Federation. The outgoing year is marked by interesting new products that will allow us to strengthen ourselves in new and traditional market segments for the company.

Vyacheslav Mamedov
The state is finally taking steps to restore the domestic industry supplying tractors and bulldozers that are in demand in construction, the oil and gas sector, land reclamation work, etc. For several years, bulldozer manufacturers in Russia have taken active steps to limit the import of Chinese tractors sold in countries of the Customs Union at dumping prices, but there was no result. As a result of unfair competition, the capacity of Russian factories of this profile turned out to be 25% loaded, which borders on the reality of their closure.

Bulldozer TM-10.11 GST9 with YaMZ-236M2 diesel engine and hydrostatic transmission

Only in the summer of this year, the Eurasian Economic Commission (EEC) established a cause-and-effect relationship between the dumped imports of Chinese tractors and bulldozers and the material damage caused to the economies of the countries that are members of the EAEU. In this regard, the EEC proposed introducing an anti-dumping duty for a period of 5 years in the amount of 10 to 44%. A decision on introducing a duty is expected at the end of 2015.

A lot depends on this step, in particular, we are able to increase the production of bulldozers of various classes that are in demand on the market to 50 units. per month already in 2016, replacing imported Chinese tractors. At the same time, factory designers worked on new product samples, based on marketing research and carefully studying the wishes of potential buyers. The modernized bulldozers of the TM-10 series are now available with four diesel engines to choose from: YaMZ-238M with a power of 240 hp. s., Deutz BF06M, also developing 240 hp. s., and MMZ-260.4, the maximum power of which is 210 hp. s., or with a 180-horsepower YaMZ-236M. The engine life of the Yaroslavl Motor Plant has been increased to 15 thousand engine hours, which is the largest value among Russian-made analogues. The new running gear of the bulldozers is made with rolling K-shaped bogies with rollers, sprung with polyurethane cushions, while the bogies are rigidly fixed to the frame. The use of such a design, similar to that used on heavy-duty Komatsu and Caterpillar tractors, ensured maximum traction and significantly reduced slipping of the track shoes on the ground compared to a traditional undercarriage, especially on rocky terrain. The achieved soil adhesion parameters, as well as the high power of diesel engines, led to the fact that the performance of the TM-10 bulldozer was 30% higher than its class 10 counterparts with a traditional chassis.

Movement and attachments are controlled using joysticks

The electronically controlled hydrostatic transmission consists of only 6 elements. It includes 4 hydraulic pumps (pump-motors) with a minimum service life of 10 thousand engine hours (in reality - 20 thousand engine hours) and 2 final drives made in Germany or Italy with a service life of 20 thousand engine hours. The unit guarantees a stepless change in traction force, with the maximum traction being achieved at zero speed. High maneuverability of the bulldozer is ensured by stepless changes in speed and direction of movement, including movement of the tracks in the opposite direction. Hydraulics and onboard planetary gearboxes are protected from overload by an automatic system for maximum pressure and temperature. The entire transmission is completely sealed. The controller is housed in a protected housing and is not exposed to moisture or dirt. The use of a hydrostatic transmission increased the reliability of the bulldozer by 20% compared to a model with a hydromechanical transmission. This is, in particular, due to the smaller number of transmission elements and the absence of rotation clutches.

Hydraulic pumps operate at no more than 75% of maximum power. High maintainability is achieved by block replacement of units constantly available in warehouses in Moscow and Chelyabinsk. High efficiency is achieved by the fact that when operating at full power, the efficiency decreases not by 35%, as with a hydromechanical transmission, but by 10%. The efficiency, depending on the operating mode, is 75–80%. The brake system is a “hydraulic lock” with normally closed multi-disc clutches.

Trolleys with K-shaped carriages guarantee maximum traction on the ground

Bulldozers are equipped with straight or hemispherical blades with a volume of 4.2 to 9 m3, maximum thrust depending on engine power is from 17 to 21 tons, average weight is 19–22 tons. Various types of rippers are installed: with 1, 3, 4, 6 and 8 teeth for any soil.

The machines are equipped with a sprung hexagonal operator's cabin with double glazing. There is supply ventilation with a filter, an emergency hatch, ROPS/FOPS, and an external battery compartment. The sprung seat has a seat belt. Movement and attachments are controlled using four position joysticks. Bulldozers are equipped with fuel tanks with a capacity of 310 liters. The maximum forward/reverse speed is limited to 12 km/h.

An important milestone for the plant workers was the mastery of production of KVG-280 cable laying machines for the implementation of the state program for the transition to fiber-optic communication systems for small settlements in Russia, as well as the implementation of the tasks of cellular operators to introduce mobile high-speed Internet throughout the country. The level of provision with such communication channels is currently 5–10 times less than in the EU countries.

Crawler tractor TM-10.00B GST9 MTO1

The KVG-280 cable layer is designed for trenchless laying of cables with a diameter of up to 65 mm and signal tape. To improve operating efficiency, engineers equipped the machine with a unique vertically vibrating knife. When cutting soil, the knife oscillates, which, depending on the characteristics of the soil and the speed of movement, leads to a reduction in traction resistance by 30–60%. Compared to the traditional method of laying cables in a trench, the new technology with the new KVG-280 reduces labor intensity by 7–8 times.

Currently, the KVG-280 cable layer is already operating in the Sverdlovsk, Rostov, Lipetsk and Irkutsk regions. In total, the program for the construction of fiber-optic communication lines provides for the laying of cables with a length of 200 thousand km.

Self-propelled welding unit TM-10 GST9

Experience in operating new cable laying machines has revealed their strengths: cables can be laid effectively in soils of hardness categories from 1 to 4. The depth of the knife is 1300–1500 mm, it is possible to adjust the tilt of the knife; Thanks to the use of an 8-roller bogie and a 600 mm track, the machine operates on soft soils, including peaty, swampy and waterlogged soils. The presence of a hydrostatic transmission guarantees high traction (up to 28 tons) up to a speed of 1.8 km/h. In a destructible environment, particles are separated from the mass and begin to vibrate under the influence of the knife. The soil is displaced from the base of the trench and the base of the cable route is leveled. The top layer of soil does not collapse and fills the trench with the cable. Almost no traces of the work remain. KVG-280 is capable of laying cables moving at speeds of up to 2.5 km/h.

Recently, the plant created another promising model of special equipment - the TM-10.00B GST9MT01 tracked tractor, designed to work as part of a complex that creates roads - “winter roads”. The first sample will serve as the basis for the snow compactor. The machine can also be used as the basis for drilling rigs, pipe layers, special vehicles for off-road work, etc. A special feature of the tractor is that it has two cabins. The YaMZ-236M2 diesel engine is coupled with a Bosch-Rexroth hydrostatic transmission. The curb weight of the vehicle is 15,000 kg.

Another new product was a unique self-propelled welding unit based on the TM-10GST9 tractor, designed for work in construction, during major and current repairs of gas and oil pipelines. The model is prepared for testing. Gas and oil workers are looking forward to it.

100-ton pipelayer TG-50.100E2 BDF GST

In 2015 in Minsk, as part of the annual meeting on the operation of the linear part of main pipelines with the participation of OJSC Gazprom, specialists held a presentation of the new pipe layer model TG-50.100E2 BDF GST with a maximum lifting capacity of 100 tons and an operating weight of 56–60 tons. The machine is designed for laying main pipelines with pipes with a diameter of 1000 to 1420 mm.

The basis of the machine is a caterpillar tractor, offered with three diesel engines (to choose from): YaMZ-7511.10, developing a power of 400 hp. s., 412-horsepower YaMZ-651 and 480-horsepower Cummins QSX15-C500. The diesel engines are interlocked with Bosch-Rexroth hydrostatic transmissions, working together with onboard planetary gearboxes of our own making. The pipelayer chassis has nine track rollers, two of which are support rollers. The link pitch is 230 mm. There are 52 shoes with a width of 860 mm on each side. The supporting surface area is 7.3 m2, and the average ground pressure is 0.86 MPa. Loading capacity at a boom radius of 2.5 m is 50 t, at a boom radius of 1.22 m - 100 t, boom length - 8.6 m. The pipe layer is equipped with a double-drum winch with a hydraulic drive. In the transport state, the pipelayer includes a tractor weighing 25 tons, an internal counterweight weighing 13 tons, a boom weighing 2.5 tons and a folding counterweight weighing 14 tons.

Cable laying machine KVG-280 on laying a fiber-optic communication line

The new pipelayer model will complement the offered range of models, including the TG-12.24; TG-20.32; TG-30.50 and TG-40.65. Hydrostatic transmissions supplied by the German company Bosch-Rexroth provide machines with the DST-Ural brand with high cross-country ability and maneuverability, as well as increased positioning accuracy in operation and, most importantly, along the edge of the trench. Due to the high smoothness of movement guaranteed by such a transmission (with continuously variable gear shifting under load), the safety of pipes is ensured at a high level, and they are very expensive. Working with just one joystick, operators report ease of control of the machine and low levels of fatigue at the end of the shift. The latter circumstance is important, including in order to ensure constant high quality of work. In fact, the use of hydrostatic transmissions allows pipelayers to turn around on the spot, thus improving their maneuverability dramatically.

Currently, a domestic hydrostatic transmission from PSM-Hydraulics (Ekaterinburg) is offered as an alternative. The use of hydraulic planetary boom and hook lifting winches from European manufacturers has led to an increase in the smoothness of lifting operations, in which jerking and jerking are completely eliminated. Experience in operating such winches shows their reliable operation at low temperatures and high dust levels. The resource of the planetary mechanism of winches is close to unlimited.

Separate floating craft with a cabin and power plant for an underwater cable-laying bulldozer

Pipelayers are equipped with the following safety systems and devices: an AZK-10 device for protection against overloads and load tipping, a protection device when working in the area of ​​power lines, an indicator signaling the weight of the load being lifted, the maximum load capacity, the magnitude of the boom reach, and the angle of inclination of the boom relative to the horizon. A limiter is also installed to automatically stop the hook, a boom extension indicator to determine the maximum load capacity, a flashing light and a buzzer that operates in parallel with the load limiter, as well as a device for automatically stopping the boom in the extreme position.

The plant's products are used throughout Russia

In 2015, the plant's designers developed a unique underwater cable-laying bulldozer TM-10.10PV GST12 KVG-220, which has no analogues in the world. The machine is designed to operate underwater to a depth of 40 m, including on the sea (ocean) shelf. Its cabin and power plant are located on a detachable vessel, from where the tracked base is remotely controlled. The possibility of underwater operation ensured complete sealing of the elements of the hydrostatic transmission, which is standard for a conventional bulldozer. After complete immersion in a swamp or sand-water suspension, the transmission does not require disassembly.

It is only necessary to monitor the condition of the oil in the hydraulic system in case the neck of the hydraulic tank is submerged and, if necessary, change the oil.

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Engine

TM 10.11 is offered with 2 power plant options:

1. 4-stroke engine YaMZ 238M2-2, produced by Yaroslavl. The V-shaped diesel engine with liquid cooling, compression ignition, mechanical speed control and direct injection is not supercharged. In terms of design, it is an analogue of the YaMZ-236M2 model used on the TM 10.10 bulldozer, and differs from it in additional cylinders. The engine is characterized by versatility, ease of operation and a high degree of maintainability.

Characteristics of the YaMZ 238M2-2 unit:

• working volume – 14.86 l;
• rated power – 176 (240) kW (hp);
• maximum torque – 883 Nm;
• number of cylinders – 8;
• cylinder diameter – 130 mm;
• specific fuel consumption 214(157) g/kW per hour (g/hp per hour).

2. 4-stroke DEUTZ BF06M engine made in Germany. The unit has a turbocharger, a horizontal shaft, liquid cooling and direct fuel injection. Design features include a cast iron cylinder head, an electronic governor, a cast iron crankcase, a forged crankshaft with counterweights, and an injector for each cylinder.

DEUTZ BF06M engine characteristics:

• working volume – 7.15 l;
• rated power – 233 (313) kW (hp);
• maximum torque – 1050 Nm;
• number of cylinders – 6;
• cylinder diameter – 108 mm;
• specific fuel consumption – 204 (150) g/kW per hour (g/hp per hour).