1

1
Training Centre
CRAWLER DOZERS

2
2
Training Centre
 DESCRIPTION OF THE
TECNICAL FEATURES

WALK-AROUND
GENERAL INFORMATIONS
D180PS-LT-XLT-LGP 3
3
Training Centre
 D180PS - LT (7 rollers)

TOTAL SHOES X TRACK CHAIN=40

WIDTH OF SHOES:
STANDARD
4 = 560 mm 4
OPTIONAL = 600 mm Training Centre
 D180PS- XLT (8 rollers)

TOTAL
5
SHOES X TRACK CHAIN=45 5
WIDTH OF SHOES =560-610 mm Training Centre
 D180PS - LGP (8 rollers)

TOTAL SHOES X TRACK CHAIN=45

WIDTH OF SHOES =762-915mm

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6
Training Centre
 D180 PS LT- ROPS CANOPY

DASHBOARD ON ROPS CANOPY CONFIGUR.

7
7
Training Centre
 8
8
MAIN FRAME ON ASSEMBLY LINE-START Training Centre
 PORTLIBHT- CHECK COOLANT LEVEL
TRANSMIS./CONVERTER
COOLER

SAND SCREEN

ENGINE COOLER 9
9
Training Centre
 REAR TRANSMISSION COOLER 10
10
Training Centre
 11
11
MAIN FRAME BEFORE AND AFTER ENGINE Training Centre
 PRE-PAINTING HOOD

HOODS ASSEMBLY 12
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Training Centre
 CENTRAL FRAMEWORK + ACCESSORIES

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13
Training Centre
 CENTRAL FRAMEWORK ASSEMBLING ON LINE

FINAL-TORQUE 60 daNm
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14
Training Centre
 RIGHT HOOD CLOSED

ASSEMBLY LINE - 15
15
UPPER HOOD ON MAIN FRAME Training Centre
 LEFT HOODS - OPEN
ACCESSORIES

ENGINE ACCESS PANEL -LOWER

16
16
ENGINE ACCESS PANEL -UPPER Training Centre
 UPPER HOOD WITH PERFORATED AREA

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17
Training Centre
 PRE-PAINTING KIT-RESERVOIRS
+
ACCESS PANELS

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18
Training Centre
 PLATTFORM FOR RESERVOIRS+ROPS

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19
Training Centre
 PLATTFORM ASSEMBLING ON THE MACHINE

2 PRE-TORQUE

1 3

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20 FINAL-TORQUE- 80 daNm
Training Centre
BATTERY ACCESS PANEL+ELECTRICAL COMPONENTS
21
21
Training Centre
 22
22 BATTERY ACCESS PANEL
Training Centre
 DIESEL FUEL TANK

HYDRAULIC
23 OIL TANK +BREATHER 23
Training Centre
 RIGHT ACCESS PANEL LEFT ACCESS PANEL 24
24
Training Centre
 PLATE PIVOT
60 daNm
ON REAR TRAMS.

1st

100 daNm

2nd
100 daNm

11 daNm

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25
TORQUE FOR:PIVOT SHAFT-OMEGA SUPPORT Training Centre
 FRONT CROSS-MEMBER PIVOTS
1 CENTRAL PIVOT
PHENOLIC BUSHING

5
6

3 26
26
SIDE PIVOT-STEEL BUSHING 7 Training Centre
 MOUNTING OF REAR
TRASMISSION BY HOIST

27
REAR TRAMSMISSION+UNDERCARRIAGE
27
ON ASSEMBLY Training
LINE Centre
 ASSEMBLING OF THE FRONT MAIN FRAME BY HOIST

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28
Training Centre
 3
1 2

PRE-TORQUE

CENTRAL PIVOT

12 daNm

5
29
29
TRANSMISSION/TORQUE CONVERTER PROPELLER SHAFT Training Centre
FINAL ASSEMBLY OF THE FRONT MAIN FRAME+FINAL TORQUE VALUE

100 daNm

100 daNm

1
3 360 bar = 100daNm

30
30
Training Centre
SPROCKET ALIGNMENT WITH TRACK CHAIN SUPPORT ROLLERS+TRACK IDLER

45 daNm

2
PRE-TORQUE

4
31
1 3 31
Training Centre
 PUNCHING S/N OF THE MACHINE

32
32
Training Centre
 MASTER LINKS

1 4

2 TIGHTENING TORQUE
95daNm+1/2 TURN
33
33
ASSEMBLING OF THE TRACK CHAINS Training Centre
 34
34
Training Centre
 MAINTENANCE
D180PS=D150PS
FOR MORE INFORMATIONS PLEASE CONSULT THE SPECIFIC

OPERATOR’S MANUAL :
P/N 604.35.043.00 D180PS CRAWLER DOZER
P/N 604.35.022.00 D150PS CRAWLER DOZER

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Training Centre
36 D180PS 36
Training Centre
 D150PS

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Training Centre
 EVERY 10
HOURS WORK
(DAILY)

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38
Training Centre
 LUBRICATION OIL LEVEL
Checking

LOOSEN SLOWLY

CULANT LEVEL
39
Checking 39
Training Centre
 DRIVE BELT
Inspection

40
COOLING FAN 40
Inspection Training Centre
 INLINE STRAINER

FUEL-WATER SEPARATOR FILTERS

41
41
Training Centre
 INLINE STRAINER

TO FUEL PUMP

FROM TANK

FUEL-WATER SEPARATOR FILTERS

42
42
Training Centre
 EVERY 100
HOURS WORK

43
43
Training Centre
 FINAL DRIVE- Check oil level (both side)

BEVEL GEAR,STEERING AND BRAKES-Cheching the oil level 44

44
Training Centre
 FUEL RESERVOIR- Draining condensation

45
45
Training Centre
 EVERY 250
HOURS WORK

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46
Training Centre
 ENGINE SUMP- Change oil

Oil Refiling

DRAIN OIL FROM ENGINE

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47
Training Centre
 ENGINE OIL FILTER - change filtering cartridge

2
1

3
48
48
Training Centre
 EVERY 500
HOURS WORK

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49
Training Centre
 SCREEN FUEL FILTER- change filter

FUEL CUT-OFF VALVE

50
50
Training Centre
 FUEL FILTERS
Replace GASKET 1

FUEL-WATER SEPARATOR FILTERS-Replace filters 51

51
Training Centre
 ENGINE COOLANT FILTER
Replace cartridge

IN OUT

LOOSEN SLOWLY

2
1
52
52
Training Centre
 STEERING/BRAKE
DELIVERY OIL FILTERS
Replace cartridge
OPENING OF THE GRID 53
53
Training Centre
 DRAIN OIL FROM TRANSMISSION

54
54
Training Centre
 TRANSMISSION/TORQUE CONVERTER
DELIVERY OIL FILTERS
Replace cartridge

Oil Refiling

TRANSMISSION OIL DIPSTICK

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55
Training Centre
 EVERY 1000
HOURS WORK

56
56
Training Centre
 VALVE CLEARANCE
check valve clearance, with cold engine

INTAKE……... 0,30mm
EXHAUST….... 0,61mm
CUMMINS SERIES C
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57
Training Centre
 BEVEL GEAR STEERING AND BRAKE
Change oil and wash suction filter

OIL DRAINING PLUG 58

Drain
58 oil
Training Centre
 BREATHER

REAR TRANSMISSION OIL DIPSTICK

Oil Refiling 59
59
Training Centre
TORQUE CONVERTER TRANSMISSION
Wash suction filter and magnetic rod

60
60
Training Centre
 EVERY 2000
HOURS WORK

61
61
Training Centre
 FINAL DRIVE- Change oil (both side)

62
62
Training Centre
 EQUIPMENT HYDRAULIC CIRCUIT
Change oil and clean suction filter (Fa)

OIL LEVEL IN THE MIDDLE OF MAX

max
min

63
OIL DRAINING PLUG 63
Drain oil Training Centre
 RADIATOR
Change Coolant

LOOSEN SLOWLY

64
64
Training Centre
 ENGINE AIR CLEANER
Replace cartridges

2
B
1

3
A

4
B

65
65
Training Centre
 MAINTENANCE
WHEN REQUIRED

66
66
Training Centre
 DIAGNOSTIC PANEL (PRESSURE PICK-UP POINTS)

TRANSMISSION

BRAKE - HYD. MOTOR -STEERING PILOT

67
67
Training Centre
TEST ON THE BRAKE PEDAL VALVE

68
68
Training Centre
EQIPMENT HYDRAULIC SYSTEM
RETURN OIL FILTER
Replace cartridge

69
69
Training Centre
 AIR BLEEDING FROM FUEL SYSTEM
Manual bleeding of the filters

70
70
Training Centre
 SAFETY VALVE+TRACK TENSIONER ADJUSTENT VALVE

D180PS
TRACK CHAIN TENSION ADJUSTMENT VALVE

D150PS
71
71
PRESSURE RELIEF VALVE 900 bar Training Centre
 DIAGNOSYS, CALIBRATION ,
PROGRAMMING ON DOZERS Section

STEERING SYSTEM WITH BB3 5

ON EST
72
72
Training Centre
DIAGNOSYS, CALIBRATION ,
PROGRAMMING ON DOZERS
STEERING SYSTEM WITH
BB3

73
73
Training Centre
 CALIBRATION OF STEERING LEVERS

The calibration procedure is carried

out on the machine prior to any
replacement or repair intervention
CABLE BB3
involving the steering or the
transmission/steering electronic unit.
The calibration on the machine shall
possible in two different mode :
- to use the setting box cable for Palm
BB3 P/N 75301716
- to use the PALM BB3 P/N
753012589. CABLE BB3
SETTING
From functionality point view, the BOX
procedures are same, but the BB3
procedure it is more complete, for to CAB
display, check .change all parameters
on the machines.

CONNECTION SCHEMA
BB3
1.Plate on the cab- 2.Cup - 3. Plug
connector 12 way - 4.Setting box cable
for BB3 -A. calibration switch-
B.DSD/BASE selection switch.
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74
Training Centre
CALIBRATION OF THE STEERING LEVERS UNIT WITH SETTING BOX CABLE ONLY-P/N 75301716
For the connection the setting box cable, follow the schema illustrated in the previous slide to continue advancing as
indicated here below:
Remove plate (1) from the cab front post and extract cup (2) installed on the pre-arranged electrical connector
(3).Connect connector (4) of the setting box cable.
1. Position the two switches on the setting box, as follows:
-Switch A in position “CAL”
- Switch B in position “DSD”
2. To lower the two security levers
3. Position the starter Key switch in “ON” (secon click of the key) and “0” appears on the dispay
4. Press neutral button “N”on the armrest on the display will appears “CAL0”

Starter Key
STARTER Switch
Key Switch DISPLAY
5. Press again neutral button “N” and “00” will appears on the dispay (with this function, the control unit recognises
the ZERO od the levers);
6. Press again neutral button “N” and “CAL1” will appears on the dispay (calibration levers at full stroke);
7. Actuate , at the same time, both levers to full stroke. Staying in this position, press neutral button “N” and “FF” will
appears on the display, subsequently the dispay shows “0”;
8. Release the levers at neutral position (END of calibration levers at full stroke);
9. Reposition the starter key into “OFF”, remove cable (4) from connector (3).
10. Reinstall cup (2) on the connector (3) and reinstall the plate (1) on the cab post.
The calibration of the steering levers of the machine is completed.
75
75
Training Centre
 CALIBRATION OF THE STEERING LEVERS UNIT WITH PALM BB3 -P/N 75301589
For the connection of the strumentation, follow the schema illustrated on
previous slide and on side pictures:
1. Connect connector (4) of the setting box cable, at plug connector 12 way
(3);
2. Position the Starter Key Switch in “ON” (secon click of the key);
3. After the check on the Monitor (first 8 second), position the two switches,
on the setting box, as follows:
- Switch “A” in position “CAL”
- Switch “B” in position “DSD”
4. Press F1 button on PALM BB3;
5. Subsequently on the BB3 display will appears “GO ON ENTER”;
6. Press “ENTER” button on PALM BB3(this is the ZERO of the levers);
7. Subsequently on the BB3 display will appears PUT T1 & T2 MAX
START → ENTER;
8. Actuate , at the same time, both levers to full stroke. Staying in this
position, press “ENTER” button on the PALM BB3;
9.”ADJUSTED” appears on the display, and subsequently MANNESMAN
REXROTH, then release the levers at neutral position; (END of calibration
levers at full stroke);
10. Reinstall cup (2) on the connector (3) and reinstall the plate (1) on the
cab post.
The calibration of the steering levers of the machine is completed.
76
76
Training Centre
 CAB & CANOPY
D150=D180PS

77
77
Training Centre
78
ROPS CAB-D180PS / D150 78
Training Centre
 2 FAN

CONDENSER

79
79
Training Centre
 UNLOCKING HOOK
SIDE WINDOWS OPENING 180°

LEFT DOOR 80
80
Training Centre
 DOOR HANDLE (INSIDE)
81
81
Training Centre
 82
82 CAB FILTER (AIR CONDITIONER SYSTEM)
Training Centre
 CAB COMPONENTS -D180PS / D150

seat
Safety plate

DISPLAY+DATA
CONTROL KEYBOARD

83
hydraulic cylynder
83
Training Centre
 CAB COMPONENTS -D180PS / D150

84
84
Training Centre
MICRO CONTROLLER - MHVD4-4FB1X- CAB CONFIG.
85
STANDARD PER D180 / D180 PS/D150PS -P/N 76092397
85
Training Centre
 MICRO CONTROLLER
MHVD4-4FB1X
CANOPY CONFIGURATION

86
86
Training Centre
 MICRO CONTROLLER STANDARD
87 76092397 x D150PS/D180PS/D180 87
Training Centre
 CANOPY

ROPS CANOPY-D180PS / D150 88

88
Training Centre
 CANOPY

89
89
LAY-OUT-ROPS CANOPY-D180PS / D150 Training Centre
 MOUNTING OF CAB-D180PS / D150

0,5l- ATF Type A

SAE 10W

OIL Refiling and bleeding operation on

HAND PUMP
90
90
Training Centre
LIFTING THE CAB
D180PS=D150PS
91
91
Training Centre
 CAB TILTING

1 2

92
92
Training
STEP 1- OPEN L+R ACCESS PANELS+DISCONNECT ENGINE Centre
THROTTLE
 HAND PUMP WITH
ANTI DROP VALVE

4 5
D180
93
93
STEP 2- OPEN THE HAND PUMP RUBINET+ LOOSEN Training Centre
SCREWS 3+3
 START

6
STEP 3- START TO TILT THE CAB STEP 4- CAB TILTABLED94
94
Training Centre
 LOWERING THE CAB

2
3

1
4

60 daNm
6

95
95
Training
TURN DIVERTER VALVE end USE the HAND PUMP FOR LOWERING THE Centre
CAB
ENGINE D180PS
CUMMINS 6CTAA 8.3TIER2
RATED HP 205/KW 153(LGP only)

RATED HP 190/KW 142 (LT-XLT)

96
96
Training Centre
 FUEL PUMP SIDE VIEW TURBO SIDE VIEW

97
CUMMINS 6CTAA 8.3TIER2 97
Training Centre
 FAN- SOUND SUPPRESSION (optional)

98
98
Training Centre
 ENGINE FAN- (standard)

99
99
Training Centre
 FLOW STREAM THROUGH20°C AFTERCOOLER+
F.D.S. WITH 20°C AMBIENT TEMPERATURE

FROM AIR CLEANER

O
IN U
T

142°C

51°C

TO AFTER COOLER

100
100
Training Centre
CLOSE UP VIEW OF THE TURBOCHARGER + WASTEGATE
 D180PS TIER2-AFTERCOOLER FAN DRIVE SYSTEM+PUMP

101
101
Training Centre
 Hydraulic
Sequence Valves Motor
38 ± 2 bar 8 cc/giro
5 lt/min.

Gear Pump Back pressure

8 cc/giro valve
16 ± 2 bar
19 lt/min.

D180PS TIER2-AFTERCOOLER FAN DRIVE SYSTEM 102

102
Training Centre
 FUEL SYSTEM
103
103
Training Centre
 FUEL SYSTEM - LOW PRESSURE SUPPLY LINES 104
104
Training Centre
 FUEL SYSTEM - HIGH PRESSURE FUEL LINES

INJECTION PUMP-IN LINE

105
105
Training Centre
 DIST.= 0.8 ~1.25mm

DIST. FLYWHEEL - SPEED SENSOR 106

106
Training Centre
 LUBRICATING OIL SYSTEM
107
107
Training Centre
* = from january 2002 n.1 TERMOSTAT

COOLANT SYSTEM
108
108
Training Centre
 COOLANT FILTER (DCA4)

Thermostat

Engine Coolant max

temperature switch

Coolant inlet

FILTER + LUBRICATION OIL COOLER 109

109
Training Centre
 110
110
ENGINE COMPARTMENT TURBO SIDE VIEW Training Centre
 ENGINE COMPARTMENT FUEL PUMP SIDE VIEW
111
111
Training Centre
 FRONT
TRANSMISSION
D150=D180PS
112
112
Training Centre
 TORQUE CONVERTER HYDRAULIC DIAGRAM

113
113
Training Centre
 TRANSMISSION GEARBOX CONTROL VALVE

IMPROVEMENT for the management of theTRANSMISSION:

ELIMINATED THE IMPUT RESTRICTION -A-
ADDED THE RESTRICTION OF THE 2.5mm -B-
114
CHANGED THE SET POINT OF THE SPRING -C- at 1.5 bar 114
Training Centre
 TRANSMISSION CONTROL VALVE SOLENOID
VALVES ENERGISING TABLE • = ENERGISED
FORW. SOL. REV. SOL. SOL. 1st. SOL.3 rd
1st FORW • •
2nd FORW •
3rd FORW • •
NEUTRAL
1st REVE • •
2nd REVE •
3rd REVE • •

115
115
Training Centre
TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM

( 24 -26 )

116
116
Training Centre
 F

R ARMREST
TO
EMEN
UP INCR

NE
IM I N UZIO
D
IA

DOWN
MARC

117
117
Training
GEARSHIFTING GROUP+STEERING CONTROL LEVERS Centre
(FINGER-TIP)
 INVERSION LOGIC WITH TRANSMISSION IN MANUAL

N.B = THE TRAMSMIS. GEARS ARE UPSHIFTED EACH TIME BITTON UP is PRESSED
THE TRAMSMIS. GEARS ARE DOWNSHIFTING EACH TIME BITTON DOWN is PRESSED
118
118
Training Centre
INVERSION LOGIC WITH TRANSMISSION IN AUTOMATIC-MODE
AUTO SHIFT “AS” ACTIVATED

119
119
Training Centre
INVERSION LOGIC WITH TRANSMISSION IN AUTOMATIC-MODE
AUTO KICK “AL” ACTIVATED

1900 rpm D180

2030 rpm D150

Setting flywheel
173 teeth D150
138 teeth D180
120
120
Training Centre
 BY-PASS HOSE OF TRANSMISSION OIL RADIATOR
FROM torque converter by-pass valve
D180PS TO the transmission lubrication

121
121
FROM oil cooler- TO the transmission lubrication Training Centre
 BY-PASS HOSE OF TRANSMISSION OIL RADIATOR
FROM torque converter by-pass valve
D150PS TO the transmission lubrication

FROM oil cooler- TO the transmission lubrication

122
122
Training Centre
 Transmiss. Oil low pressure sensor 11.5 bar

Transm. Pressure
switch setting at 17 bar

Torque converter
safety valve 10.7 bar

TRANSMISSION
PUMP

CONVERTER
PUMP

123
123
COMPONENTS ON TORQUE CONVERTER Training Centre
 COMPONENTS ON TORQUE CONVERTER
Transm. Pressure
switch setting at 17 bar
TRANSMIS OIL HIGH
TEMPERATURE SW. TRANSMISSION
PUMP

CONVERTER
PUMP

TO TRANSMISS.
OIL RADIATOR

TO PICK-UP
FOR LUBE 124
124
Training Centre
ASSEMBLING SEQUENCE
FOR THE
FRONT TRAMSISSION

125
125
Training Centre
 HANDTRUCK SIDE SHAFTS-CLUTCH -
PACK SPRING-LUBRICATION LINES

CLUTCH PACK SIZE

BY-GO-NO-GO GAUGE
HANDTRUCK SIDE GEARS-HUBS
-PISTONS+COVER 1st 126
126
Training Centre
 BEFORE ASSEMB. AFTER ASSEMB.

REVERSE
SPEED CLUTCH

CLUTCH DRUM + GEAR+SPRINGS+CLUTCH DISCS

127
127
Training Centre
 3dr SPEED CLUTCH COMPONENTS

3dr SPEED CLUTCH +GEARS

128
128
Training Centre
 PREPARATION OF THE FRONT COVER

OIL TRANSFER TUBE

OIL PRESSURE REGULATOR VALVE - 3bar

129
129
Training Centre
HOUSING+COVER+HANDTRUCK PARTS READY FOR ASSEMBLING
130
130
Training Centre
 ASSEMBLING FOR REVERSE ASSEMBLING 3dr SPEED+MANOV. TOOL
SPEED CLUTCH+GEARS +
INTERMEDIATE / (DRIVEN) SHAFT

REV
REV

3rd

SIDE RIGHT ACCESS

131
131
Training Centre
 PREPARATION 2nd DRUM SPEED

MANEUVER TOOLS
2nd

132
132
Training Centre
 INTERMED. SHAFT (DRIVEN)

REV

3rd

REV

TIGHTENING TORQUE 95 daNm

133
133
Training Centre
 2nd SPEED CLUTCH COMPONENTS ASSEMBLING FOR 2nd SPEED CLUTCH

SPRING

134
134 CLUTCH PISTON 2nd +QUICK DISCHARGE VALVE
Training Centre
 1st SPEED CLUTCH COMPONENTS

COVER 1st - FWD SPEED CLUTCH

COVER FOR 3dr - 2nd SPEED CLUTCH

INTERMED. SHAFT“OUT” SIDE 135

135
Training
P.T.O. Centre
SHAFT
 2nd - 3dr
INTERMED. SHAFT
“IN” SIDE

Pressure REV

REV
FWD - 1st
Lubric. REV

OIL SUMP AND OIL PIPES

136
136
Training Centre
 INTERFACE FOR TRANSM. CONTROL VALVE

MOUNTING
137
OF COVER+GASKET 137
Training Centre
 MODULATING VALVES - SPEED

LUBE PRESSURE RELIEF VALVE -3 bar

1st 2nd 3dr MODULATING

REMOVE N. 7 SHIMS FOR D180PS VALVES (SPEED) MOUNTED
REMOVE
138
N. 3 SHIMS FOR D150PS 138
Training Centre
 TRANSMISSION CONTROL VALVE BY VICKERS

3rd 3rd FWD

FWD REV

1st 139
139
MODULATING VALVES REV
Training Centre
 SECTION VIEW OF
TRANSMISSION HOUSING

IN OUT

140
140
Training Centre
 DATA OF CLUTCH DISCS PACK ASSEMBLY

(*)141
Check by measuring the stroke of the mobile piston. 141
(**) Check pre-loading the clutch pack with a load of 197 daNm. Training Centre
 TRANSM.OIL DIPSTICK
VENT

“IN” FRON
TORQUEC0NVERTER

TRANSM.OIL FILTER SUCT. LINE FROM OIL COOLER

142
142
Training Centre
 “OUT” SHAFT TO REAR TRANSMIS.

SHAFT REVERSE+PTO
143
143
Training Centre
 FRONT TRANSMISSION ASSEMBLYED
D180PS
SUCTION FILTERS

TRANSMISSION CONTROL VALVE

144
144
Training Centre
 SUPPLY VALVE BLOCK (Va)
D150PS

TRANSMISSION CONTROL VALVE

FRONT TRANSMISSION ASSEMBLYED 145

145
Training Centre
 FILLING THE TRANSMISSION WITH OIL
HYDROPOWER ATF Type A Suffix A

2,5 Kg

146
146
Training Centre
 TORQUE
CONVERTER
15”MS 335
TWIN-DISC
147
147
Training Centre
 TORQUE CONVERTER+PUMPS

Varioable Transmission pump

displacement
Hydraulic pump

Converter pump

Brake pump
Scavenge pump
148
148
Training Centre
 DISASSEMBLY SEQUENCEOF THE COMPONENTS

REMOVE BEARING RETAINING PLATE

CONVERTER ON WORK BENCH

149
149
Training Centre
 REMOVAL ASSY FROM HOUSING

REMOVE IMPELLER CAPSCREWS

150
150
Training Centre
TORQUE CONVERTER DISASSEMBLED

STATOR

TURBINE IMPELLER

151
151
Training Centre
ASSEMBLING SEQUENCEOF THE TORQUE CONVERTER HOUSING

BEARINGS+SNAP RING NEW SYSTEM WITH OLDHAM JOINT

152
152
Training Centre
 ASSEMBLING FOR THE SPLINE SHAFT SUPPORT+ OLDHAM JOINT

153
153
Training Centre
 FLUID OUTLET

FLUID INLET

OIL BAFFLE
TORQUE CONVERTER HOUSING THREE GEARS TO PUMPS DRIVEN
154
154
Training Centre
 ASSEMBLING SEQUENCEOF THE CONVERTER
ANTICLOCKWISE

3 155
155
Training Centre
 TIGHTENING TORQUE 7.1 daNm TIGHTENING TORQUE 7.7 daNm

156
156
Training Centre
 ASSEMBLING SEQUENCE OF THE PUMPS

TIGHTENING TORQUE 34 daNm

VARIABLE DISPLACEMENT HYDRAULIC PUMP

157
A11VO 130 LRDS/10L 12 N00 157
Training Centre
 FLANGE FOR CARDAN SHAFT
1

3 TIGHTENING TORQUE 3.5 daNm 158

158
Training Centre
 17 bar

10.7 bar

TRANSMISSION PRESSURE RELIF VALVE and TORQUE CONVERTER SAFETY

159
159
Training Centre
NEW SYSTEM WITH OLDHAM JOINT TORQUE 3.5 daNm

3
Transmission and Converter pump

160
160
Training Centre
 FINAL ASSEMBLY OF THE SERVICES PUMPS

Transmission and Converter pump

BRAKE and SCAVENGE PUMP

TIGHTENING TORQUE 3.5 daNm

161
161
Training Centre
 CONVERTER READY FOR ASSEMBLY LINE

ASSEMBLING OF THE 162

162 PIPELINES+VENT
Training Centre
 163
163
Training Centre
 BRAKES
SYSTEM
164
164
Training Centre
 165
165
Training Centre
BRAKE PUMP

SCAVENGE PUMP

166
166
Training Centre
 BRAKE VALVE BLOCK
HYDRAULIC DIAGRAM

BRAKE POWERING VALVE BLOCK

167
167
Training Centre
Brake pedal valve

Port A

Port B

168
168
Port T Training Centre
 BRAKE OIL FILTERS

Delivery filter Suction filter

(ref .2 brake hydraulic diagram) (ref .10 brake hydraulic diagram) 169
169
Training Centre
D180PS BRAKE DISENGAGEMENT

3)From the left side of the machine, open the panel under
the cab to reach the diagnostic panel. Rotate the igniction
key in (ON) and safety levers down. Connect hand pump to
pressure pick-up point (1) (see next slide), and actuate it 170
170 disingagement screws M16x2 (A, fig. E) protrudes,
until
indicating the disengagement of piston (S) of about 4.5mm. Training Centre
BRAKES DISENGAGEMENTON D180PS WITH ENGINE INOPERATIVE
and ACCUMULATOR BRAKE VALVE BLOCK UNLOADED

171
171
Training Centre
 BRAKES ENGAGED POSITION

BACK-LACH
WEAR

D. LOCKNUT - S. PISTON - V. SCREW (n. M16x2)

BRAKES DISENGAGEMENT ON D180PS

172
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Training Centre
 STEERING
SYSTEM
173
173
Training Centre
STEERING HYDRAULIC CIRCUIT DIAGRAM
The Steering circuit and that of the EQUIPMENT are only one hydraulic circuit and use the same oil (HI-TECH 46). Although the
two circuits have parts of the system in common, they operate at separate operating pressures, and precisely:
- max. steering circuit pressure 350 ± 5 bar
- max. equipment circuit pressure 160 ± 5 bar
The steering circuit mainly comprises :
- A 130 cc variable displacement AXIAL PISTON PUMP for steering/equipment circuits (ref. P hydraulic diagram in the previous
slide);
- A hydraulic motor for the for the steering functions (ref. M)
- A Control Block (load sensing closed center) controlling the steering/equipment (ref. D)
- A steering piloting valve block (ref. Vp)
- A supply valve block with accumulator (ref. Va)
- TWO steering levers (ref. L)
- A blade control pilot valve, (ref. Ma)
- An oil radiator (ref. S)

The D180PS is provided with a steering differential enabling the dozer to transmit power to both tracks (even differently) in a
bend, changing their speed at tracks, and then to push and steering at the same time.
When operator push the left (as in the previous slide) steering lever (L), reaches the steering piloting valve block (Vp) which let a
piloting signal directly pass to the 4th spool control block (D) actuating the hydraulic motor (M). Inside the piloting unit (Vp) the
presence of the 2 electro proportional valve (3) of a selector valve (16) through the priority valve (4) rated to 40 bar, enable
system to give priority to the steering system with respect to the equipment only in the blade lifting condition, and to use
contemporarily the two circuits.(steering+equipment).
By acting on the steering lever (L) left (or Right) but with the transmission in neutral and without touching the equipment, the
pump hydraulic flow rate will flow into the hydraulic motor (M), the latter, through a steering bevel pair+a transmission shaft+a
gear will enable tracks to move at the same speed, but in opposite direction, causing the machine to countertun. When the
transmission is engaged (machine moving) there is a summation of the effects, i.e. the translation speed (coming from the
bevel gear) is summated to the differential effect which is entered instead through the hydraulic engine. 174
174
Training Centre
 CONTROL FOR STEERING

MECHANICAL
MECHANICALTRAVEL
TRAVELDRIVE
DRIVEWITH
WITH
HYDROSTATIC
HYDROSTATICDIFFERENTIAL
DIFFERENTIALSTEERING
STEERING BB3
FAULT INDICATION

175
175
Training Centre
 D180PS-D150 POWERLINE & D.S.D.

176
176
Training Centre
 Pressure flow
D180 PSasCaratteristica
a function stroke of the -steering
Pressione levers
Corsa Leve

40

30
-bar
pressione (bar)
Pressure

20 pressione

10

0
0 20 40 60 80 100

Leve stroke
Corsa %
(%)

177
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Training Centre

STEERING HYDRAULIC DIAGRAM D180PS
C. Controller 6. Reduction valve (35 bar)
F. Oil Suction Filter
M. Steering Hydraulic Motor
7. Power cut off solenoid valve
8. Power cut off pressure relief valve(45 bar)
D. Equipment steering valve 9. Line LS decompression valve (0.7lt/min)
P. Variable displacement pump 10. Load Sen. double stage valve(160/350 bar)
S. Heat exchanger 11. Pressure relif valve (380 bar)
Ma. Blade control pilot valve 12. Blade control valve
Va. Supply block 13. Blade control spool safety valves
Vp. Steering pilot valve 14. Unloading valve (34bar)
1. Steering control valve 15. Pressure compensator
2. Steering spool safety valve 16. Selector valve
3. Electro-proportional valve 17. Pilotong valve (5 bar)
4. Priority valve (40 bar) 18. Plugs
5. Accumulator 19. Hydraulic breaking valve

178
178
Training Centre
 SUPPLY VALVE BLOCK (Va)

179
179
Training Centre
 SUPPLY VALVE BLOCK (Va)

STEERING PILOTING VALVE (Vp) 180

180
Training Centre
STEERING PILOTING VALVE BLOCK-Vp

181
181
HYDRAULIC DIAGRAM Training Centre
 4th SPOOL - STEERING SECTION M7-22

compensator

Steering spool
Check valves
182
182
Training Centre
 STEERING LEVERS

A RD
H TW
RIG ERING
STE

A RD
E F T W NG
L
E E RI
ST

183
183
Training Centre
 FIXED DISPLACEMENT MOTOR A2 FE90/61W
184
184
Training Centre
 ASSEMBLING FOR MOTOR A2 FE90/61W
185
185
Training Centre
 IMPLEMENT

HYDRAULICS
SYSTEM
186
186
Training Centre
 D180PS HYDRAULIC CIRCUIT DESCRIPTION AND OPERATION
The equipment hydraulic system is common to the steering system due to the sharing of some units to the hydraulic oil itself, but
they respectively have separate circuits and operating pressures:
Equipment system with operating system of 160 ± 5 bar;
Steering system with operating pressure of 350 ± 5 bar.
The equipment hydraulic system shown in the previous slide, is featured by being fitted with a variable displacement piston
pump (ref. P), having a max.flow rate of 248 liters/min, fitted with three regulators : LS (ref.11) CUT-OFF(ref.12) and POWER
REGULATOR (ref. 13) supplying contemporarily (after sucking oil from the 110 liter tank (ref. S):
-a control block M7-22 (ref.D) Load Sensing-flow sharing “Closed Center” with pressure compensator (ref.24) through
port P located on the block. While a connection between power pump (port X) and control block (port LS) allows the sending
of a signal from the control block to the pump regulating the oil flow according to the effective requirements of the actuators,
changing the pump flow up to maximum delivery at max speed (248 lt/min.
Also, the circuit regulates the distribution of the flow according to a logic of priority for the steering, prevailing over the equipment
circuit, when the operation of both of them is required.
-a feed block (ref.Va), which through gate Pr lets oil at 35 bar reach the equipment steering piloting block (ref.Vp), which in
turn, lacking operations combined with steering, feeds always at 35 bar, the two equipment manipulators (ref.Ma) and the
Ripper (ref.Mr). From these pressure reducers piloting signals (0 to 30 bar) depart to the respective user drawers: BLADE-TILT-
RIPPER.
Two safety levers, located on the right and left sides of the driver’s seat, cut-off electrically (in raised position) with a proximity
sensor, the powering of the control pilot valves, preventing accidental movements of the pilot valve.
When the machine is a standing still and the lever is lowered, allowing the machine to perform all working operations.

On the bottoms of the BLADE lifting cylinders, the fast lowering valves (anti-cavitation valve) are always available, which
intervene in the blade fast lowering stage setting to short-circuit the oil going to drainage, and preventing the pump to go into
cavitation.
The blade TILT hydraulic control, is achieved by moving side-ways the equipment manipulator lever (ref.Ma, the is supplied at
70 liters/min thanks to the adjustment system of the rod stroke available on the section.

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 Steering levers

Display

Hydraulic
motor

M7 22
Control Block

HYDRAULIC SYSTEM-LOGIC DIAGRAM

188
188
Training Centre
 DOZER EQUIPMENT HYDRAULIC C. Heat exchanger
D. Equipment steering control valve
SYSTEM - LEGENDA - M. Steering hydraulic motor (see section Steering)
P. Variable displacement piston power pump 90kW/1950 RPM
Ma. Blade control pilot valve
Va. Supply block
Vp. Steering pilot valve
S. Hydraulic oil reservoir
1. Blade spool
2. Tilt spool
3. Ripper spool
4. Hydraulic oil filter clogging indicator light
5. Load Sensing double stage valve (160 / 350 bar)
6. Blade control spool safety valves (210 bar)
7. Tilt control spool safety valves (210 bar)
8. Ripper control spoolsafety valves (210 bar)
9. By-pass valve
10. Unloading valve (34 bar)
11. Load sensing regulating valve
12. Cut-Off valve (350 bar)
13. Constant power control valve (90 kW 1950 RPM 120.7 HP)
14. Accumulator 0.7 lt
15. Reduction valve (35 bar)
16. Supply block pressure relief valve (45 bar)
17. Supply block solenoid valve
18. Priority valve
19. Electro proportional valve
20. LS line Decompression valve (stabilising the LS signal 0.7 lt/min)
21. Main safety valve
22. Piloting valve
189
189 23. Selector valve
24. Pressure compensator Training Centre
 EQUIPMENT HYDRAULIC DIAGRAM D180PS

190
190
Training Centre
 LOAD SENSING M7-1213-20/4M7-22 - REXROTH DISTRIBUTOR DRAWERS

191
191
Training Centre
 LOAD SENSING-REXROTH -M7-1213-20/4M7-22
EQUIPMENT CONTROL VALVE

The D180PS EQUIPMENT/STEERING control block is a high

pressure closed center, capable of satisfying the requirements of
2 systems, which even if separate, share some main hydraulic
components.
Control block M7-22 comprises 4 spool respectively supplying :
the 1st drawer controls the blade, with a flow rate of 180/240 liters
the 2nd drawer controls tilt, with a flow rate of 70 liters;
BLADE the 3rd drawer controls the ripper with a flow rate of 165/170 liters;
the 4th drawer controls the hydraulic steering engine with 225
liters.
A 2-stage valve with 160/350 bar controls the feed pressures of
TILT the equipment/steering systems.
A selection valve present on the Vp piloting unit circuit, in the case
of the contemporary use of steering/equipment, gives the priority
to the steering, by switching over at the same time to the 350 bar
RIPPER second stage the main 2-stage main safety valve.
The first 3 spools are provided with safety valves set to 210±5 bar,
the same are not available on the 4th hydraulic engine spool
because they are directly located on the hydraulic engine.
In the distributor there is also available an unloading valve, 34 ±
STEERING 2 bar-and 15 liters/min (at min.RPM). This guarantees different
functions in the D180PS steering/equipment hydraulic circuit with
the manipulator in neutral.
Finally gate LS is located always on the distributor body, in direct
connection with pump gate X.

EQUIPMENT CONTROL VALVE REXROTH M7-1213-20/4M7-22

192
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Training Centre
 L S Double stage valve
160/350 ±bar Decompression valve 0,7 L/min

Main Relief valve Unloading valve

380 +10 bar 34 ±2 bar

Relief anti-cavitation
Blade+float rod valve 210 ± 5bar (3+3)

Tilt rod

Ripper rod

One way valves

Body Compensator
193
193
Training Centre
 194
194
A11VO 130 LRDS/10L-NSD 12N00-EQUIPMENT/STEERINGTraining
PUMP Centre
 1. 3-regulator variable displacement pump.
2. Displacement control servopiston.
3. Cut-off regulator (380 bar).
4. Flow regulator LS (21 bar).
5. Power regulator (90 Kw a 1950 RPM)

4
21 bar

1
3

380 bar
5
2

170 Kw a
2100 RPM

1 AXIAL PISTON PUMP

2 4
5
3

195
195
Training Centre
 AXIAL PISTON PUMP

FLOW RATE ADJUSTMENT (DECREASE)

When the engine is off, the pump is in the top displacement

position due to the force of the spring on the servopiston 2.

At star-up the pump starts sucking oil from the tank. With
controls on neutral (closed center distributor) pressure on
delivery line P increases and it is felt on the delivery 4
regulator control surface.

Delivery regulator 4 compares supply pressure on branch P

with LS pressure signal coming from users. When controls
are in neutral the LS line is connected to drainage, and
hence the small delivery regulator piston starts moving to the
right due to the delivery effect of pressure on branch P..

The pressure signal taken from the delivery line is addressed

to the servopiston and it will operate in opposition to the
spring force, changing the distribution plate inclination to
which the axial pistons are connected, thus obtaining the
reduction of the displacement to the bottom value when
pressure on delivery line reaches the delivery regulator
calibration value (21 bar).

196
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Training Centre
 AXIAL PISTON PUMP

FLOW RATE ADJUSTMENT (INCREASE)

Let us now suppose we are operating with one of the users

crossed by an LS line setting the actuator speed with a
certain control lever stroke. During operation, e.g. because of
a sudden resistance, load variation causes a pressure signal
variation on line LS.

21 bar The distributor rod stroke imposes a set ∆p astride the

concerned drawer.

For the sake of simplicity let us propose a numerical

380 bar example:
Delivery pressure: 85 bar
∆p on drawer: 21 bar
LS pressure : 85 - 21 = 64 bar
90 Kw a flow rate 4 regulator calibration : 21 bar
1950 RPM Regulator 4 total calibration (spring+LS): 64 + 21 = 85 bar

In a traditional system, in order to keep the actuator speed, it

would be necessary to increase the distributor stroke, and
hence operate further on the control lever, while in this case
the LS pressure, operates on the regulator spring side, and
switches over the small piston 4 by connecting to drainage
the servopiston 2, the control spring of which will tend to tilt
the pump plate till the top value of its displacement.

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Training Centre
 AXIAL PISTON PUMP

CUT-OFF ADJUSTMENT (max. pressure).

A specially heavy use of the machine causes the

system to try to always require more and more flow
rate and more and more pressure. These two
parameters, as it is well-known, combined together
generate a physical magnitude identified as
21 bar hydraulic power. For obvious reasons, its value
must never exceed the power expressed by the
Diesel engine.

380 bar Should e.g. the external loads generate a pressure

equal to the cut-off 3 regulator setting value, fixed in
our application to 380 bar, the delivery pressure will
switch over the regulator 3 small piston addressing
90 Kw a the pressure signal taken from P (delivery) to act
1950 RPM against the servopiston 2 adjustment spring tilting the
pump plate to the position of the minimum
displacement.

In practice of the two parameters used to generate

the hydraulic power (i.e. flow rate and pressure), one
is cut down (flow rate) and reduced to the minimum
allowed by system, in order to keep the hydraulic
power below the power value expressed by the
Diesel engine.

198
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Training Centre
 AXIAL PISTON PUMP

POWER ADJUSTMENT
(90 Kw at 1950 RPM-with hyperbolic feature)
This third adjustment unit controls the max. hydraulic power
limit that can be absorbed. In practice the pump is calibrated
to absorb a maximum hydraulic power of 90 Kw at 1950 RPM
of the thermal engine. When this limit is exceeded, the flow
4 rate is reduced as pressure increases so that the product of
21 bar the 2 (flow rate x pressure) never exceeds 90 Kw.
The above is meant to avoid that the absorbed hydraulic
3 power is so high to excessively overload the thermal engine,
and set it to stall.
380 bar
5

90 Kw a
P 1950 RPM

Vg max Vg min

199
199
Training Centre
 BLADE LIFTING CONTROL CYLINDER

SECTION OF THE BLADE CYLINDER

200
200
Training Centre
 TILT CYLINDER
Bulldozer Version

SECTION OF THE TILT CYLINDER

PER VERSIONE ANGLEDOZER :

Diameter of ROAD 70mm
Diameter of PISTON 110mm
STROKE of CYl. ROD 124mm

201
201
Training Centre
 SECTION OF THE RIPPER CYLINDER

RIPPER CYLINDER

202
202
Training Centre
 POWER CONTROL
PORT- X

Load Sensing VALVE

CUT-OFF VALVE

VARIABLE DISPLACEMENT PUMP A11VO 130 LRDS

203
203
Training Centre
 SUPPLY VALVE BLOCK (Va)

STEERING PILOTING VALVE (Vp) 204

204
Training Centre
 CHECK VALVE - 5 bar-HYDRAULIC HEAD
To radiator From radiator

To tank

From control valve To port S HY. motor

205
205
Training Centre
 206
206
Training Centre
 REAR
TRANSMISSION
ASSEMBLING

207
207
Training Centre
 REAR TRANSMISSION HOUSING 208
208
Training Centre
 APPROACH OPERATIONS FOR BEARINGS CASES+PINION
209
209
Training Centre
 ASSEMBLING EPICYCLOIDAL CROWN +GEAR WITH WIRE
210
210
Training Centre
 DETAILS PINIONS+SHAFT+EPICYCLOIDAL CROWN GEAR
211
211
Training Centre
 EPICYCLOIDAL ASSY DISASSEMBLED
212
212
Training Centre
 SPIDER ASSY

PLANETARY GEAR DISASSEMBLED

213
213
Training Centre
 ASSEMBLING FOR EPICYCLIC REDUCTION GEAR ASSY
214
214
Training Centre
 TORQUE 12.5 daNm + VALIDATION

215
215
Training Centre
 ASSEMBLING FOR RIGID PIPELINES 216
216
Training Centre
 TESTING PROCEDURES FOR THE REAR TRANSMISSION
217
217
Training Centre
 Port S
Port A
Port T-to tank

Brake pressure
Port B to diagnostic panel
Discharge line
T port pedal valve

Discharge line
Brake control line R+L side DR port valve block

Brake disc COVER + PIPELINES

Lubrication C line
218
218
Training Centre
FRONT+REAR TRANSMISSION

219
219
Training Centre
 220
220
Training Centre
 NEW CRAWLER DOZERS
D150 Tier2
RESIDENT TRAINING
PROGRAMM
221
221
Training Centre
 DESCRIPTION OF THE
TECNICAL FEATURES

WALK-AROUND
GENERAL INFORMATIONS
D150 - TIER2
222
222
Training Centre
 D150
D150 XLT
XLTPAT
PAT(8(8rollers)
rulli)
ROPS CAB
CONFIGURATION

223
D150 LGP PAT (8 rollers)
223
Training Centre
 ROPS CAB
CONFIGURATION

224
224
D150 LT PAT (7rollers) Training
TrainingCentre
Centre
 CONFIGURAZIONE ROPS CANOPY

METTERE FOTO IN
VERSIONE canopy
non LGP ma XLT 8
rulli

D150 LGP PAT (8 rulli) D150 XLT PAT (8 rulli)

225
225
Training Centre
 BRAKE SYSTEM

TOW HOOK
D150 LGP PAT 226
226
Training Centre
 D150 PAT-C-FRAME GRID 2 ITEM 227
227
Training Centre
228
MAIN FRAME ON ASSEMBLY LINE-START 228
Training Centre
 TRANSMIS./CONVERTER COOLER

ENGINE COOLER 229

229
Training Centre
 PORTLIBHT- CHECK COOLANT LEVEL

WATER RADIATOR BLOCK +CONNECTION

230
230
Training Centre
 PRE-PAINTING HOOD

HOODS ASSEMBLY 231

231
Training Centre
 PRE-PAINTING KIT-RESERVOIRS+ACCESS PANELS

232
232
Training Centre
CENTRAL FRAMEWORK + ACCESSORIES

ASSEMBLING ON LINE
233
233
Training Centre
 ASSEMBLY LINE -
UPPER HOOD ON MAIN FRAME

234
234
Training Centre
REAR TRANSMISSION ON
ASSEMBLING LINE

235
235
Training Centre
FRONT MAIN FRAME+RADIATOR

236
FRONT MAIN FRAME ASSEMBLY
236
Training Centre
FINAL ASSEMBLY OF THE FRONT MAIN FRAME+FINAL TORQUE VALUE

60 daNm
30 daNm

237
CROSS/BAR
237
Training Centre
SUPPORT
 C-FRAME+PARTS
238
238
Training Centre
 1

3
4

30 daNm

C-FRAME+PARTS ASSEMBLY 239

239
Training Centre
 SUPPORT ROPS ASSEMBLING +FINAL TORQUE VALUE

1
80 daNm

2 3
4

240
240
Training Centre
 AIR CLEANER+CLOGGING SENSOR

241
241
Training Centre
 TRANSMISSION and TORQUE CONVERTER BREATHER

242
242
Training Centre
 TRANSMISSION/TORQUE CONVERT.
DELIVERY OIL FILTER

243
243 STEERING/BRAKES DELIVERY OIL FILTER
Training Centre
 SAFETY LEVERS

OPERATION CONDITION SECURITY CONDITION

244
244
Training Centre
 LEFT ACCESS PANEL 245
245
Training Centre
 STEERING PILOTING VALVE BLOCK Vp

190/380 bar
160/350 bar

TRANSMISSION+STEERING+BRAKE+PUMP
PRESSURE PICK-UP POINTS
246
246
Training Centre
 RIGHT ACCESS PANEL 247
247
Training Centre
 248
248
Training Centre
 ENGINE-D150
CUMMINS 6BT 5.9-C TIER2
RATED HP 150 / KW 112

249
249
Training Centre
 FUEL PUMP SIDE VIEW
250
250
Training Centre
 EXHAUST/TURBO SIDE VIEW

251
251
Training Centre
 FRONT VIEW REAR VIEW 252
252
Training Centre
 FROM AIR CLEANER

TO AFTER COOLER

CLOSE UP VIEW OF THE TURBOCHARGER+WASTEGATE

253
253
Training Centre
 TURBOCHARGED SYSTEM
254
254
Training Centre
 DIST.= 0.8 ~1.25mm

255
DIST. FLYWHEEL - SPEED SENSOR 255
Training Centre
 ALTERNATOR-WATER PUMP-OIL FILTER-FAN-BELT TENSIONER
256
256
Training Centre
 COOLANT SYSTEM

COOLANT INLET FROM RADIATOR

257
257
Training Centre
 LUBRICATING OIL SYSTEM 258
258
Training Centre
 DISTRIBUTOR FUEL PUMP VE+COLD START INJECTION -KSB
259
259
Training Centre
COLD START INJECTION
ADVANCE -KSB

260
260
Training Centre
 FUEL SYSTEM

TIMING TDC= 0,8mm

INLINE STRAINER

FUEL FILTER+FUEL LIFT PUMP+DISTRIBUTOR FUEL PUMP VE

261
261
Training Centre
 COLD START RELAY- 200 A

GRID HEATER (COLD START OPTIONAL) 262

262
Training Centre
 FRONT+REAR ENGINE SUPPORT

263
263
Training Centre
 2
1

5
3

264
264
FRONT+REAR SUPPORT 30daNm Training 60daNm
REAR SUPPORT Centre
 AFTER COOLER

265
265
Training Centre
 FLOW STREAM THROUGH AFTERCOOLER
WITH 20°C AMBIENT TEMPERATURE

IN
20°C
O
U
T

142°C

51°C

INTAKE ACTION DONE

FROM ENGINE266
FAN
266
Training Centre
267 ENGINE COMPARTMENT TURBO SIDE VIEW 267
Training Centre
 ENGINE COMPARTMENT PUMP VIEW

268
268
Training Centre
 269
269
Training Centre
 CONVERTITORE
DI COPPIA
13”- TWIN-DISC
270
270
Training Centre
 TORQUE CONVERTER ASSEMBLING

1 2

4 5

7.0 daNm
271
271
ROLLING TORQUE-0.1 ÷ 0.2daNm Training Centre
 TORQUE CONVERTER+PUMPS

VARIABLE DISPLACEMENT
TRANSMISSION
HYDRAULIC PUMP
PUMP

BRAKE PUMP

CONVERTER
SCAVENGE PUMP
PUMP

272
272
Training Centre
 PUMPS+PIPEING CONNECTION
TRANSMISS.OIL LOW
SENSOR AT 11.5 bar

TO TRANSMISSION
AT 15 bar

TRANSMISSION OIL TEMPERATURE

SENSOR 119°C
FROM TANK

273
273
Training Centre
 BRAKES
SYSTEM
274
274
Training Centre
 GENERAL DESCRIPTION
BRAKE HYDRAULIC DIAGRAM

275
275
Training Centre
 276
276
Training Centre
 BRAKE PUMP

SCAVENGE PUMP 277

277
Training Centre
BRAKE VALVE BLOCK
HYDRAULIC DIAGRAM 5
BREAK OIL LOW
PRESSURE SWITCH 11.5bar

6
P
7

278
278
DR
BRAKE POWERING VALVE BLOCK Training Centre
Brake pedal valve

Port A

Port B

279
279 Port T
Training Centre
 BRAKE OIL FILTERS

Delivery filter Suction filter

(ref .2 brake hydraulic diagram) (ref .10 brake hydraulic diagram) 280
280
Training Centre
 CENTRAL BRAKE DRUM +O-RING 281
281
Training Centre
 BRAKE PINION
282
282
Training Centre
 CENTRAL BRAKE ASSEMBLING

283
283
Training Centre
 CENTRAL LUBRICATION LINE
BRAKE DRUM

PRESSURE LINE

D150- BRAKES AND STEERING DIFFERENTIAL GEARBOX

284
284
Training Centre
 DISENGAGING THE BRAKES

N. 2 screws
M16 x 2

285
285
Training Centre
 CHECK AND INSPECTION
FOR BRAKE PACK

286
286
Training Centre
 STEERING
SYSTEM
287
287
Training Centre
 STEERING HYDRAULIC DIAGRAM D150PS

288
288
Training Centre
 D150PS STEERING HYDRAULIC DIAGRAM
LEGENDA
C. Microcontroller
F. Oil suction filter
M. Steering hydraulic motor
D. Equipment steering control valve
P. Variable displacement piston power pump 58kW/2000 RPM
Ls. Steering levers
Ma. Blade control pilot valve
Va. Supply block
Vp. Steering pilot valve
1. Steering control spool
2. Plugs
3. Electro proportional valve
4. Priority valve (40 bar)
5. Accumulator 0.7 lt
6. Reduction valve (35 bar)
7. Supply block solenoid valve
8. Supply block pressure relief valve (45 bar)
9. Selector valve
10. Piloting valve
11. Pressure compensator
12. Steering motor safety valves
13. Hydraulic breaking valve 289
289
Training Centre
 STEERING HYDRAULIC MOTOR

STEERING CONTROL SPOOL

290
290
Training Centre
 STEERING LEVERS

A RD
GH TW G
RI E R IN
STE

A RD
E F T W NG
L RI
E
STE

291
291
Training Centre
 SUPPLY BLOCK - Va
STEERING PILOT VALVE - Vp
292
292
Training Centre
 SOLAR ASSY+EPICYCLOIDAL PLATE+SPIDER ASSY
293
293
Training Centre
 EPICYCLIC
REDUCTION
GEAR
LEFT
+
RIGHT
294
294
Training Centre
295 STEERING HYDRAULIC MOTOR-VIEW 295
Training Centre
 T

HYDRAULIC MOTOR PORTS

296
296
Training Centre
 REAR
TRANSMISSION
ASSEMBLING
297
297
Training Centre
 298
298
Training Centre
REAR TRANSMISSION HOUSING - SANDBLASTING AREA
 SETTING OF THE BEVEL GEAR SET
backlash of the teeth pinion/gear

pinion locking tool

299
299
BACKLASH=0.25⌦0.33m Training Centre
SETTING OF THE BEVEL GEAR SET-teeth contact face (see pag.4-75 SM)

300
300
Training Centre
 TORQUE ON BEARINGS SUPPORT

TOP VIEW SIDE VIEW 301

301
Training Centre
 SYMBOLS TO COUPLING-3 item one KIT

BEVEL GEAR PINION+CROWN

BRAKE PINION
302
302
Training Centre
 shims
NOT GOOD

2
4

1 3

GOOG 303
303
Training
INSTAL.and SETTING OF THE BRAKE PINION+ BEVEL GEAR teeth contact Centre
face
 Reassembly and installation of the crown gear assembly

304
304
Training Centre
 D150PS -DIFFERENTIAL GEARBOX
INSTALLATION OF THE BRAKE GROUP
before steering group

EPICYCLIC REDUCTION GEARS+BRAKE GROUP

305
305
Training Centre
 REASSEMBLY OF THE STTERING GROUP
INTO THE TRANSMISSION HOUSING

HOIST
306
306
Training Centre
 TIGHTENING TORQUE OF SCREWS -11 daNm

307
307
Training Centre
 INSTALLATION OF THE BRAKE GROUP

TIGHTENING TORQUE
OF SCREWS -13308
daNm
308
Training Centre
 CENTRAL LUBRICATION LINE
BRAKE DRUM

PRESSURE LINE

D150PS -DIFFERENTIAL GEARBOX- TOP VIEW

309
309
Training Centre
 SIDE-REAR- VIEW

SIDE-FRONT - VIEW

310
310
Training Centre
 APPLY LOCTITE 518
TIGHTENING TORQUE -30 daNm

311
311
INSTALLATION OF THE FINAL DRIVE GROUP Training Centre
 Reassembly and installation of the +
SECTORS ON THE HUB OF SPROCKET

TIGHTENING TORQUE
OF NUTS -40 daNm
SPROKET HUB
SPROKET HUB
STANDARD For LGP only
312
312
Training Centre
 INSTALLATION of the SPROCKET

TIGHTENING TORQUE
OF SCREWS -100 daNm

313
313
Training Centre
 REAR TRANSMISSION ASSY - LGP + STANDARD CONFIG.

STANDARD CONFIG. 314

314
Training Centre
 FRONT + REAR TRANSMISSION STANDARD CONFIG.

315
315
Training Centre
 REAR
TRANSMISSION
COVER
ASSEMBLING
316
316
Training Centre
PREPARATION AND ASSEMBLING FOR SHAFT ASSY 317
317
Training Centre
 2

PROCEDURE FOR ASSEMBLING

THE DOUBLE GEARS

3 318
318
Training Centre
 TORQUE-27 daNm

319
PROCEDURE
319 FOR ASSEMBLING THE DOUBLE GEARS
Training Centre
 SPECIAL TOOL
O-RING 320
320
Training Centre
 PRE-TORQUE

FINAL TORQUE-30 daNm

321
321
Training Centre
HYDRAULIC MOTOR COVER ASSY-BOTTON VIEW

SHAFT+GEARS

FILLING WITH HYDRAULIC

OIL HI-TECH 46-(2,5 Kg)

322
322
TOP VIEW Training Centre
 INSTALLATION OF THE REAR TRANSMISSION COVER 323
323
Training Centre
 95 lit. 25 lit.

25 lit.

TEST 1,5 bar X 2 min. + FILLINGS 324

324
Training Centre
 HYDRAULIC BENCH TEST
325
325
Training Centre
 IMPLEMENT

HYDRAULICS
SYSTEM
326
326
Training Centre

Q= 120 lt/min (31.6 gpm)
Q=150 lt/min (39.6 gpm)
Q=50 lt/min (13.2 gpm)
Q=70 lt/min (18.5 gpm)
Q=150 lt/min (39.6 gpm)
Q=150 lt/min (39.6 gpm)
Q=150 lt/min (39.6 gpm) 3. Ripper spool
Q=150 lt/min (39.6 gpm)
327
C. Heat exchanger
D. Equipment steering control valve
M. Steering hydraulic motor (see section Steering)
P. Variable displacement piston power pump 90kW/1950 RPM
Ma. Blade control pilot valve
Va. Supply block
Vp. Steering pilot valve
V. Quick drop valve
S. Hydraulic oil reservoir
1. Blade spool
2. Tilt spool
4. Hydraulic oil filter clogging indicator light
5. Load Sensing double stage valve (160 / 350 bar)
6. Blade control spool safety valves (210 bar)
7. Tilt control spool safety valves (210 bar)
8. Ripper control spoolsafety valves (210 bar)
9. By-pass valve
10. Unloading valve (30 bar)
11. Load sensing signal regulating valve
12. Cut-Off signal valve (350 bar)
13. Constant power control valve (58 kW 2000 RPM- 76 HP)
14. Accumulator 0.7 lt
15. Reduction valve (35 bar)
16. Supply block pressure relief valve (45 bar)
17. Supply block solenoid valve
18. Priority valve
19. Electro proportional valve
20. LS line Decompression valve (stabilising the LS signal 0.7 lt/min)
21. Main pressure relief valve (390 bar)
22. Piloting valve
23. Selector valve
24. Pressure compensator
25. Angle spool safety valve (210 bar) 327
26. Angle control spool
27. Angle solenoid valve
Training Centre
 EQUIPMENT HYDRAULIC DIAGRAM D150PS

328
328
Training Centre
 D150PS HYDRAULIC CIRCUIT
DESCRIPTION AND OPERATION

329
329
Training Centre
 QUICK DROP VALVES

V. Quick drop valve

11. Ball
Cl. Blade control cylinder
12. Piston
Ct. Tilt control cylinder
13. Quick drop valve piston
1. Ripper spool
14. Spring
2. Blade control spool
15. Stroke end valve 330
3.330Tilt control spool
10. Safety lever
16. Stroke end valve seat Training Centre
 Assembling blade control cylinder

331
331
Training Centre
 FLOW STREAM ANGLE
ANGLE PUSH BUTTON

a4 b4

L1 L2

332
332
Training Centre
 ANGLEDOZER

RIPPER

TILT

LIFT

ANGLE

STEERING

EQUIPMENT CONTROL VALVE REXROTH M6-1081-00/54M6-15

333
333
Training Centre
 ANGLEDOZER
STEERING

LOAD SENSING-REXROTH -M6-1081-00/5M6-15M3P

EQUIPMENT CONTROL VALVE
ANGLE
The D150PS EQUIPMENT/STEERING control block is a high
pressure closed center, capable of satisfying the requirements of
2 systems, which even if separate, share some main hydraulic
components.
LIFT Control block M6-22 comprises 5 spool (4 spool only x
bulldozer) respectively supplying :
the 1th drawer controls the hydraulic steering with 150 liters
the 2th drawer controls the angle with 150 liters
TILT
the 3st drawer controls the lift, with a flow rate of 150 liters
the 4nd drawer controls tilt, with a flow rate of 70/50 liters;
RIPPER the 5rd drawer controls the ripper with a flow rate of 150/120 liters.

A 2-stage valve with 160/350 bar controls the feed pressures of the
equipment/steering systems.
A selection valve present on the Vp piloting unit circuit, in the case
of the contemporary use of steering/equipment, gives the priority to
the steering, by switching over at the same time to the 350 bar
second stage the main 2-stage main safety valve.
The first 3 spools are provided with safety valves set to 210±5 bar,
the same are not available on the 4th hydraulic engine spool
because they are directly located on the hydraulic engine.
In the distributor there is also available an unloading valve, 30 bar-
and 12 liters/min (at min.RPM). This guarantees different
functions in the D150 steering/equipment hydraulic circuit with the
manipulator in neutral.
Finally gate LS is located always on the distributor body, in direct
connection with pump gate X.
334
334
BULLDOZER Training Centre
 A11VO 75 LRDS/10L-NSD 12N00
EQUIPMENT/STEERING PUMP

FILLING
335
WITH HY.OIL 335
HI-TECH 46 -1,5 Kg Training Centre
 A11VO 75 LRDS/10L-NSD 12N00-EQUIPMENT/STEERING PUMP

TORQUE
CONVER

336
336
Training Centre
 HYDRAULIC OIL RESERVOIR

337
337
Training Centre
 STEERING PILOTING VALVE -Vp
338
338
Training Centre
 Va-PILOT VALVE
POWERING BLOCK

339
339
Training Centre
PUSH-BUTTONS MANIPULATORS
340
PAT VERSION 340
Training Centre
 RIPPER & BLADE CONTROL VALVES+LEVERS-PAT VERSION
341
341
Training Centre
RIPPER & BLADE CONTROL VALVES+LEVERS/STANDARD VERSION
342
342
Training Centre
 BLADE CONTROL VALVE - EXPLODED VIEW

343
343
PLUNGER ASSY- OPEN Training Centre
 PRESSURE - MANIPOLATOR STROKE
344
344
Training Centre
 CHECK VALVE - 5 bar-HYDRAULIC HEAD

To tank

From control valve To port S motor 345

345
Training Centre
 ELECTRICAL
SYSTEM
D150 = D180PS
346
346
Training Centre
 D180 PS Caratteristica Corrente - Corsa

800

700
600
Corrente (mA)

500

400 Corrente
300
200
100

0
0 10 20 30 40 50 60 70 80 90 100
Corsa (%)

COURRENT V/S STEERING LEVERS STROKE

347
347
Training Centre
 PRIMARY DIAGNOSTIC CODES
DEFECT CODE

LEFT STEERING SOLENOID VALVE SHORT CIRCUIT OR INTERRUPTION E001

RIGHT STEERING SOLENOID VALVE SHORT CIRCUIT OR INTERRUPTION E002

FORWARD SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E004

REVERSE SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E008

FIRST GEAR SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E016

THIRD GEAR SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E032

LEFT STEERING LEVER POTENTIOMETER CONNECTION SHORT CIRCUIT OR INTERRUPTION E064

RIGHT STEERING LEVER POTENTIOMETER CONNECTION SHORT CIRCUIT OR INTERRUPTION E128

348
348
Training Centre
 SECONDARY DIAGNOSTIC CODES
E001 E002 E004 E008 E016 E032 E064 E128
E001 E001 E003 E005 E009 E017 E033 E065 E129

E002 E002 E006 E010 E018 E034 E066 E130

E004 E004 E012 E020 E036 E068 E132

E008 E008 E024 E040 E072 E136

E016 E016 E048 E080 E144

E032 E032 E096 E160

E064 E064 E192

E128 E128
349
349
Training Centre
 ELECTRICAL SYSTEM -1°-LA SOLA DIFFERENZA
E’ NELL’AREA :AVVIAMENTO e SICUREZZA

D150 D180PS
350
350
Training Centre
 ELECTRICAL
SYSTEM-2°-
area
COMANDI

351
351
Training Centre
 ELECTRICAL
SYSTEM-3°-
area
MONITOR

352
352
Training Centre
 ELECTRICAL
SYSTEM-4°-

SERVIZI
area (LUCE)

353
353
Training Centre
 ELECTRICAL
SYSTEM-4°-
SERVIZI
area (TERGI)

354
354
Training Centre
 ELECTRICAL
SYSTEM-4°-
SERVIZI
area
(ventilazione+clima
+ radio)

355
355
Training Centre
 ELECTRICAL SYSTEM-
4°-
SERVIZI
area
(ventilazione+clima+ radio)

356
356
Training Centre
 MONITOR SENDERS 1
LOCATION ON ENGINE
5
1. Air cleaner clogging sensor

2. Engine coolant max temperature switch 2

3. Engine RPM sensor
4. Engine oil low pressure
5. Alternator 4
6 7
3
LOCATION ON OIL-FUEL RESERVOIRS
6. Fuel level sensor

7. Hydraulic oil filter clogging sensor

D180PS
LOCATION ON TORQUE CONVERTER
8. Brake-clutches low oil pressure sensor (set
8
at 11.5 bar)
9. Transmission oil low pressure sensor (set 10
at 11.5 bar) 9

10. 357
357Transmission oil temperature sensor (set
at 119°C) Training Centre
Sul telaio
 MONITOR SENDERS
1 5
LOCATION ON ENGINE
1. Air cleaner clogging sensor

2. Engine coolant max temperature switch

3. Engine RPM sensor D150 3
2

4
4. Engine oil low pressure
5. Alternator

6 7

LOCATION ON OIL-FUEL RESERVOIRS

6. Fuel level sensor

7. Hydraulic oil filter clogging sensor

LOCATION ON TORQUE CONVERTER

8. Brake-clutches low oil pressure sensor (set
8
at 11.5 bar)
9. Transmission oil low pressure sensor (set 9
at 11.5 bar) 10

10. Transmission oil temperature sensor (set 358Sul telaio

358
at 119°C) Training Centre
D180PS
STARTER MOTOR

359
TrainingD150
359
Centre
 Engine water temperature

D150
D180PS
360
ALTERNATOR 360
Training Centre
 D150
D180PS

361 AIR CONDITIONED COMPRESSOR 361

Training Centre
 FUSIBILI LINK D180PS

50A

80A 50A
80A

D150
362
362
Training Centre
 RELAY & DIODE BOX
(with AIR CONDITION.+
COLD START

RELAY & DIODE BOX

STANDARD
(with HEATER only)
RELAY & DIODE BOX
D150
363 (with AIR CONDITION.)
363
Training
ONLY Centre
COLD START
 T

D180PS
With TIMER x ENGINE STOP

150A
90A
PIATE RELAY & DIODE- STANDARD Starting
(with HEATER only) relay 90A

T
NEW Eng stop
relay 150A

PIATE RELAY & DIODE

364
364
(with AIR CONDITION.) 90A
150A
Training Centre
 D180PS
WITH TIMER x ENGINE STOP

T
Same for all dozers

Cold start

NEW Eng stop

relay 150A
Starting
Relay air condition. PIATE RELAY & DIODE relay 90A
365
365 (WITH AIR CONDITIONED+
COLD START RELAY Training Centre
 SOLENOID VALVE WIRES FOR BLADE
ANGLE MOVEMENT- PAT VERSION ONLY

CONNECTOR+WIRE FOR
FLOAT DETENT

366
366
Training Centre
 PLUG CONNECTOR 12 WAY+
MAIN CONNECTORS 19-21-23 WAYS

ROPS CANOPY CONFIGUR.

367
367
Training Centre
ROPS CAB CONFIGUR-D150-D180PS
 DASHBOARD ON ROPS CANOPY DASHBOARD ON ROPS CAB
CONFIGUR-D150 - D180PS CONFIGUR-D150-D180PS

BOX FUSE ON CANOPY CAB

368
368
Training Centre
 BOX FUSES

BOX FUSE ON STANDARD CAB

A B

369
369
ON ROPS CANOPY Training Centre
 ELECTRONICS STOPCOCK + BLOW-BY MOTOR

370
370
Training Centre
 AIR CONDITIONED COMPONENT (E.C.C.)
DISPLAY+DATA CONTROL KEYBOARD

Da rifare con pannello

smontato perché lacpu e
unica-cabrini

CPU
Motor for recirculation
and air control
371
371
Training Centre
 OPERATOR SAFETY PROXIMITY SWITCH

372
372
Training Centre
ELECTRO-PROPORTIONAL VALVE

BREAK OIL LOW

PRESSURE SWITCH

(Va) BLOCK D150

SOLENOID VALVE
373
373
(Va) BLOCK D180 Training Centre
 BACK-UP ALARM + HORN

374
374
Training Centre
 IGNICTION KEY

MASTER SWITCH 375

375
Training Centre
 BATTERY AREA
D180PS

D150

376
376
Training Centre
 Pedal brake pressure switch+decelerator pedal proximity swtich
for inhibition of the AUTO-KICK DOWN

377
377
Training Centre
 378
378
Training Centre
 END OF THE PRESENTATION

Training Centre

379
379
Training Centre