New holland d150 crawler dozer service repair manual by 1638929

D150 CRAWLER DOZER

Workshop Manual Print No. 604.13.517.00 English

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY. Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual referred to the following key words: WARNING - Cautions directed to avoid improper repair interventions involving potential consequences for the safety of the personnel performing the repairs. DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved.

IMPORTANT NOTICE All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result. Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandised by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandised by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the road, are caused by the failure of some individuals to follow simple and fundamental safety rules and precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something aboiut it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment, there are many conditions that cannot be completely safeguarded against without interfering in the reasonable accessibility and efficient operation. A carefull operator is the best insurance against an accident. The complete observance of one simple rule would prevent many serious accidents. The rule is simple: never attempt to clean, lubricate or maintain a machine while it is in motion.

WARNING Prior to engaging in any maintenance, adjustment or repair operation on machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the devices used for controlling the equipment.

SUMMARY GENERALITIES

SECT. 0

ENGINE

SECT. 1

TRANSMISSION

SECT. 2

FINAL DRIVES

SECT. 3

BRAKES AND STEERING DIFFERENTIAL

SECT. 4

UNDERCARRIAGE

SECT. 5

DOZER EQUIPMENT HYDRAULIC SYSTEM

SECT. 6

ELECTRICAL SYSTEM

SECT. 7

2 D150-2M079

SECTION 0

GENERALITIES TABLE OF CONTENTS

SUBJECT

PAG.

SAFETY RULES ....................................................................................................................................... I - VIII IDENTIFICATION DATA ................................................................................................................................. 0-1 TABLE OF FLUID CAPACITIES .................................................................................................................... 0-2 TABLE OF CENTRE OF GRAVITY ............................................................................................................... 0-3 MAIN DIMENSIONS AND WEIGHTS ............................................................................................................ 0-4 TABLES OF TECHNICAL DATA ..................................................................................................................... 0-8 CHECK DATA ON THE MACHINE ................................................................................................................ 0-19 EQUIPMENT MANOEUVRE TIMES ............................................................................................................ 0-20 LEAKAGES ................................................................................................................................................. 0-21 GENERAL INSTRUCTIONS ......................................................................................................................... 0-22 DIAGNOSTIC CHECKS ............................................................................................................................... 0-28 UNITS OF MEASURE ................................................................................................................................. 0-29 TABLE OF TIGHTENING TORQUES ............................................................................................................ 0-31

SAFETY RULES

WARNING Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine. Read and heed all safety rules before any intervention. SAFETY RULES - Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of anymalfunctioning part or system.

- Do not allow unauthorised personnel to operate service or maintain this machine. - Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.

- Be sure all protective guards or panels are in place, and all safety devices provided are in place and in good operating conditions. - Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. WALK COMPLETELY AROUND the machine before mounting. Sound horn.

- Keep operator's compartment, stepping points, grabrails and handles clear of foreign objects, oil, grease, mud or snow accumulation to minimise the danger of slipping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.

- Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine. - Fasten your seat belt (when provided). - Obey all flag signals and signs.

- Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step grab rails and handles at all times.

- Due to the presence on the machine of flammable fluids, never check or fill fuel reservoirs or batteries near open flames, smoking materials or sparks.

- Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a solid support. Also, controls may be inadvertently moved causing accidental machine or equipment movement.

- REMEMBER THAT STARTING FLUID IS FLAMMABLE. Follow strictly the recommendations printed on containers and in the Operation and Maintenance Manual. - DO NOT PUNCTURE OR BURN CONTAINERS.

- Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

- Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. Follow strictly the instructions provided by the Manufacturer.

- Keep head, body, limbs, hands and feet inside operator's compartment at all times, to reduce exposure to hazards outside the operator's compartment.

- Never use these products near open flames, smoking materials or sparks.

- Be careful of slippery conditions on stepping points, hand rails, and on the ground. Wear safety boots or shoes that have a high slip resistant sole material.

OPERATION

- Do not leave the machine until it is completely stopped.

- Do not run the engine of this machine in closed areas without proper ventilation to remove deadly exhaust gases.

- Check the seat safety belt at least twice a year. If there are signs of wear or fraying or other signs of weakness that could lead to failure, replace it.

STARTING

- Roll Over Protective Structures are required on loaders, dozers, graders, excavators. NEVER OPERATE machines without ROPS.

- NEVER START NOR OPERATE AN UNSAFE MACHINE. Before operating a machine, always ensure that any unsafe condition has been satisfactorily remedied.

- Make sure the Operator's compartment is free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.

SAFETY RULES

- Check monitoring instruments at start-up and frequently during operations. in case the brake pressure gauge shows a pressure lower than the minimum operating pressure, stop immediately the machine .

- Avoid kinking chains or cables. Do not pull through a kinked chain or cable to the high stresses and possibility of failure of the kinked area. Always wear heavy gloves when handling chains or cables.

- DO NOT CARRY RIDERS ON MACHINE

- Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load. Keep exposed personnel clear of anchor points and cables or chains.

- Study and familiarise with escape routes alternate to normal exit routes. - Seat belts are required by current regulations to be provided with Roll Over Protection Structures or cabs. Keep safety belts fastened around you during operation.

- DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

- For your personal protection, do not climb on or off machine while machine is in motion.

- Be alert to soft ground conditions close to newly constructed walls. The fill material and weight of the machine may cause the wall collapse under the machine.

- Make sure that exposed persons in the area of operation are clear of the machine, before starting the engine and operating the equipment. Sound horn. Obey all indications provided by flags and signals.

- In darkness, check area of operation carefully before moving in with machine. Use all lights provided. Do not move into area of restricted visibility.

- NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralised.

- If engine has a tendency to stall for any reason under load or idle, report this for adjustment to proper maintenance authority immediately. Do not continue to operate machine, until condition has been corrected.

Choose and shift into the most appropriate gear to keep the speed required, thus preventing any loss of control. - Do not operate machinery in a condition of extreme fatigue or illness. Be especially careful towards the end of working shift.

- On machines supplied with suction radiator fans, be sure to periodically check engine exhaust parts for leaks, as exhaust fumes are dangerous to the operator.

- Do not operate machine with brakes out of adjustment.

- In case of closed type cabs, always keep an opening with the outside, to ensure a constant air circulation.

- Operate the machine at speeds slow enough to ensure complete control at all times.

- Operators must know thoroughly the performances of the machine they are operating. When working on slopes or near sudden level drops of the terrain, avoid areas where ground is loose or soft since rolling-over or loss of control of machine could result.

- Travel slowly over rough terrain, on slopes or near drop-offs, in congested areas or on ice or slippery surfaces. - When backing, always look to where the machine is to be moved. Be alert to the position of exposed personnel. DO NOT OPERATE if exposed personnel enter the immediate work area. STOP THE MACHINE.

- Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection.

- Maintain a safe distance from other machines. Provide sufficient clearance for ground and visibility conditions. Yield right-of-way to loaded machines.

- When counterweights are provided, do not work machine if they have been removed. - Overtaking manoeuvres must be performed only when absolutely necessary and unavoidable. Beware of possible uneven terrains, poor visibility conditions, the presence of other machinery or persons out of sight.

- Maintain clear vision of areas of travel or work. Keep cab windows clean and repaired. - When machines are operating in tandem, the pusher (rear) must be equipped with the appropriate deflectors to protect the unit in front from the air stream coming from the radiator.

- Operate the machine at a speed adequate to the working conditions in the site and slow enough to ensure complete control at all times.

- When pulling or towing through a cable or chain, do not start suddenly at full throttle; take-up slack carefully.

- Never use the machine as a work platform or scaffolding, nor other inappropriate operations (i.e. pushing railway cars, trucks or other machines).

Inspect carefully for flaws or troubles before using.

SAFETY RULES

- NEVER DRIVE OVER THEM or other surface irregularities that brake traction with the ground, especially when on slopes or near drop-offs.

- Be alert of people in the operating area of the machine. - When operating a machine, know in advance what clearances will be encountered, overhead doors, cables, pipes, bearing load limitations of ground, bridges, floors or ramps.

- Be alert to avoid changes in traction conditions that could cause loss of control. DO NOT DRIVE on ice or frozen ground conditions when working the machine on steep slopes or near drop-offs.

- When roading, find-out what conditions are likely to be encountered, clearances, traffic congestion, type of road surfacing, etc. Beware of fog, smoke or dust elements that obscure visibility.

- Working in virgin and rough terrains is characterised by the presence of all the perils and risks listed above. In these conditions, it is emphasised the danger represented by large tree limbs (possibly falling on the machine), large roots (acting as a leverage under the machine when up-rooted causing the roll-over of the unit) etc..

- When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions will permit a safe traverse. - Explore the working area to identify potential risks such as: slopes, overhangs, pits, demolition rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, closed ambients. In such conditions, proceed with extreme care.

STOPPING - When the machine is stopped for whatever reason, follow the instructions of chapters "Stopping the machine" and "Stopping the engine" of the Operation and Maintenance Instruction Manual.

- Whenever possible, avoid going over obstacles such as rough terrain, rocks, logs highly irregular ground, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care at an angle, if possible. Reduce speed, shift-down. Ease up to the break over point, pass the balance point slowly on the obstruction and ease down on the other side.

- Always remember to position the transmission drive control in neutral and engage the control lock to secure the machine. - The parking brake is automatically set, when the transmission safety lever is lowered.

- In steep down-hill operation, do not allow engine to overspeed. Select proper gear before starting down grade.

- NEVER LEAVE THE MACHINE UNATTENDED with the engine running.

- Avoid side hill travel, whenever possible. Drive up and down the slope. Should the machine slipping sideways, turn it immediately downhill.

- Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

- The grade of slope you should attempt will be limited by factors such as condition of the ground, load being handled, type of machine, speed of machine and visibility.

- Return the controls to rest position. Place the gearshift lever in neutral. Disconnect the master switch and extract the key.

- There is no substitute for good judgement when working on slopes.

- Park in a non- operating and no-traffic area or as instructed. Park on firm level ground if possible. Where not possible, position machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding movements.

- Avoid operating equipment too close to an overhang or high wall, either above or below the machine. Be on the look-out for caving edges, falling objects and slides. Beware of concealment by brush and undergrowth of these danger.

- If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and signals as required. Also provide advance warning signals in the traffic lane of approaching traffic.

- When pushing-over trees, the machine must be equipped with proper overhead guarding. Never allow a machine to climb up on the root structure particularly while the tree is being felled. Use extreme care when pushing over any tree with dead branches.

- Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position.

- When pushing trees with dead limbs, proceed with extreme care. Avoid brush piles, logs or rocks.

- Always disconnect the master switch before any intervention (i.e. cleaning, repairing, maintaining, refuel-

III

SAFETY RULES

ling etc.). Do the same when parking for prolonged periods of time to avoid accidental or unauthorised starting.

- Never lower attachments or tools other than seated in operator's seat. Sound horn. Make sure area near the attachment is clear. Lower the attachment slowly. DO NOT USE FLOAT POSITION of hydraulic system.

- Keep shoes free of mud or grease before climbing or driving the machine.

- Place master switch in OFF, securely block the machine and lock it every time you leave it unattended. Return keys to authorised security. Heed all shut-down operations of the Operation and Maintenance Instruction Manual are followed.

- Never attempt to operate the machine or its tools from any position other than seated in the operator's seat. - When maintenance operations require moving hydraulically operated attachments by means of machine's hydraulic system remember that all manoeuvres must be made only when seated in the operator's seat. Before starting machine or moving attachment or tools, set brakes , sound horn and call for an all clear. Raise attachment slowly.

MAINTENANCE GENERALITIES

- Always block booms or parts of the machine which must be raised to perform interventions under them with external devices. Do not allow persons to move into the vicinities nor standing under equipment not being blocked. Unless you are totally sure about your safety, avoid staying under raised equipment, even in case it is blocked.

- Before operating or performing any intervention on the machine: â&#x20AC;˘ read carefully all the rules contained by this Manual; â&#x20AC;˘ read and obey all safety related plates and instructions located on the machine.

- Do not place the body, limbs or fingers into sharp articulation uncontrolled openings of the machine and without proper protections, unless they are blocked in a safe manner.

- Do not allow unauthorised personnel to perform any maintenance operation. Do not perform maintenance operation without prior authorisation. Follow all recommended maintenance and service procedures.

- Never perform interventions with engine running, except as called for in a Manual. Do not wear loose clothing or jewellery near moving parts.

- Keep operator's compartment free of all loose objects that are not properly secured. - Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.

- When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully. - Shop and/or field service platforms or ladders must be constructed and maintained in accordance with local and national regulations.

- Disconnect batteries and tag all controls according to current regulations to warn that work is in progress. Block machine and all attachments that must be raised according to current regulations.

- Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step grab rails and handles at all times.

- Due to the presence of flammable fluids, never check or fill fuel tanks, batteries, nor use starting fluid near lighted smoking materials or open flames.

- Do not perform any service operation on the machine with a person seated in the operator's compartment, unless he is an authorised operator co-operating in the operation to be performed.

- Brakes are inoperative when manually released for servicing. Provisions must be made to maintain control of the machine by blocking or other means.

SAFETY RULES

- The fuel filling nose must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated.

- Make sure that all mechanic's tools are in good conditions. NEVER USE tools with mushroomed heads or frayed. Always wear eye protections. - Move with extreme care when working under the machine, its attachments and or on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, ear plugs.

- Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load.

- When performing operations requiring running of the engine, have a qualified operator in the operator's seat at all times with the mechanic on sight. Place the transmission in neutral and set the brakes and safety lock.

- To move a disabled machine, use a trailer or a lowboy, if available. In case towing is needed , use all necessary signals required by local and national regulations, and follow the directions provided in this Manual.

- KEEP HANDS AND CLOTHING AWAY FROM MOVING PARTS.

- To load/unload a machine from transporter, choose a level surface ensuring firm support to the wheels of truck or trailer. Use strong access ramps, with adequate height and angle. Keep surface free of mud, oil or slippery materials.

- For field service, move machine to level ground, if possible, and block it. If work on an incline is absolutely necessary, first block machine and its attachments securely, than move it to level ground as soon as possible.

- Anchor the machine securely to the bed of truck or trailer and block wheels or tracks with appropriate wedges.

- Do not trust worn and /or kinked chains and cables: do not use them for lifting or pulling operations. To handle them, always use heavy gloves.

- Never align holes with fingers or hands; always use appropriate aligning tools.

- Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load. Keep exposed personnel clear of anchor points and cables or chains.

- Eliminate all sharp edges and burrs from re-worked parts.

- No bystanders are allowed near the hooking points, chains or cables.

- Use only approved grounded auxiliary power sources for heaters, chargers, pumps and similar equipment to reduce the hazards of electrical shocks.

- DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

- Lift and handle heavy parts with a lifting device of proper capacity. Be sure parts are supported by proper slings and hooks. Use lifting eyes if provided. Watch-out for people in the vicinity.

- Keep the area where maintenance operations are performed CLEAN and DRY. Eliminate immediately all water and oil spillages.

- Never pour gasoline or diesel fuel into open, wide and low containers. Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, non-flammable, non-toxic commercial solvents.

- Do not pile oily or greasy rags; they represent a fire hazard. Store in closed metal container.

- When using compressed air for cleaning parts, use safety glasses with side shields or goggles. Limit pressure to 2 bar (29 psi), in accordance with local and national regulations.

- Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine. Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn.

- Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes. - Do not smoke or permit any open flames or spark near when re-fuelling or handling flammable materials.

- Rust inhibitors are volatile and flammable Use only in well ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool well ventilated place, secure against unauthorised personnel.

- Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine.

- Do not carry loose objects in pockets that might fall unnoticed into open compartments.

SAFETY RULES

- Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly or fall.

- Do not adjust engine fuel pump when machine is moving.

- Wear welders protective equipment such as dark safety glasses, helmets, protective clothing, gloves and safety shoes, when welding or burning. Wear dark safety glasses near welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION.

- Do not run the engine with air intakes, door or protections open.

- Do not lubricate the machine with engine running.

ELECTRICAL SYSTEM

- Know your jacking equipment and its capacity. Be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under jack is appropriate and stable.

- Disconnect batteries prior to any intervention on machine or electrical system (cleaning, repair, maintenance).

- The load lifted by jacks is always dangerous: it is necessary to transfer loads to appropriate blocking as a safety measure, before proceeding with service or maintenance work, according to local or national regulations.

- Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-). Avoid short-circuits of the terminals. Follow thoroughly the instructions of this Manual.

- Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.).

- Before any intervention, make sure that the main switch is OFF. - BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion.

- Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections - Compressed air systems can have water deposits created by moisture condensation due to changes of atmospheric conditions. If required, discharge deposits, as instructed.

- Before any intervention, make sure that there are no fuel or electrolyte leakages; eliminate them before proceeding with further work. When recharging batteries in closed ambients, make sure that there is appropriate ventilation to prevent possible accidental explosions due to the accumulation of gases generated during the recharge.

STARTING - Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes. - Do not place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans.

HYDRAULIC SYSTEM - Fluid escaping under pressure from a very small hole can be almost invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE HANDS. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.

ENGINE - Loosen the radiator cap very slowly, to release pressure from the system, before removing it. All coolant level topups must be performed with engine OFF. - Avoid that flammable materials touch exhaust parts. Should this be possible, provide the necessary protections.

- Stop the engine and release all pressures in the system before removing panels, housings, plugs or covers.

- Do not run engine when refuelling and use care if the engine is hot due to the increased possibility of a fire if fuel is spilled.

- In case pressures must be measured, use instruments of adequate capacity. Always follow the recommended procedures.

- Never attempt to check or adjust fan belts when engine is running.

SAFETY RULES

TOOLS

- Clutches and brakes of this machine and eventual auxiliary equipment and attachments (such as operating cylinder or winches control valves) must always be properly adjusted in accordance with the instructions provided by the Manuals of the Manufacturer.

- Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position. Prior to any intervention, install all safety devices according to current rules and regulations.

- Never perform adjustments with engine running, except when called for by the above instructions.

- In case equipment on the machine must be operated by hydraulic systems, remember to proceed only after seating in the operator's compartment. Make sure that there are no persons in the operating area of the machine. Alert people before operating using the horn and by voice. Move the equipment very carefully.

- When changing work shift, check that wheel or rim securing screws and brackets are not loosen; if necessary, retighten to the prescribed torque.

- Do not use machine to transport loose objects, unless proper devices for this purpose are provided.

WARNING On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the hydraulically, mechanically, and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment.

VII

SAFETY RULES

SAFETY RULES FOR SEALS

VITON SEALS (fluoroelastomer)

2) identify the type of material of the seals, if they are VITON, performing the test illustrated below, on the spare parts;

Seals, especially VITON O-Rings, (normally coloured red) are used in systems operating at high temperatures, since this materials resists the effects of heat. However, in the event this material is subject to heat exceeding 315 Â°C (in practice, only in case of fire or when using welding flames) fluoridic acid is generated. This acid is highly corrosive and could cause severe burns, if in contact with the skin. Every time it is necessary to intervene on components equipped with VITON rings, for which an exposure to excessive temperatures is suspected, the following procedures must be applied:

3) in case it is verified, or there is a reasonable doubt that the components are made of VITON, the contaminated area MUST be decontaminated before proceeding with further operations; 4) wear neoprene rubber or PVC gloves and protection goggles or face screen, and wash accurately the contaminated zone with a solution of hydraulic lime (found at building stores) and water, so that a milky liquid is obtained. Rinse carefully with steam or running water;

1) inspect visually, without touching them, all seals showing signs of damage due to high temperature. They look black and tacky;

5) dispose of the materials removed and the protective gloves in a safe manner, without burning them.

TEST FOR THE DISCRIMINATION OF RUBBER (BUNA N) MATERIALS AND "VITON" (FLUOROELASTOMER) MATERIAL

WATER

WATER TRICHLOROETHYLENE

NITRILIC/BUNA N RUBBER

VITON" FLUOROELASTOMER

FLOATS SINKS

VIII

D150

CRAWLER DOZER

TECHNICAL DATA TABLES

0-1

GENERALITIES

D150

IDENTIFICATION DATA A. Engine data plate The engine data plate is visible by opening the engine left side panel and it includes all the identification data and other important information related to the engine. 1. Engine serial number (E.S.N. Engine Serial Number Cummins) ins

Cummins Engine Company Inc. Box 3005 Columbia, Indiana 47202-3005

Warning injuty result and warranty is voided it fuel rate or rpm or altitudes exceed published maximum values for this model and application. Date of Mfg Made in Great Britain by Cummins Engine Co. Ltd.

C.I.D./L

CPL

Engine Serial No.

Family

Cust. Spec. Engine Model

Low idle RPM Valve lash cold

Engine

Rasted HP/KW

mm3/st

Fuel rate at rated HP Timing-TDC

Firing Order st

RPM

D150-2M002 D150-2M005

IMPORTANT ENGINE INFORMATION This engine conforms to 2003 U.S. EPA And California Tier 2 and EU Stage II regulations for heavy duty non-road compression ignition diesel cycle engines as applicable. THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL

B. Machine identification plate The identification plate includes the main data of the machine and it is visible under the operator's seat.

D150-2M003

D150-0R001

C. Marking and serial number On the right side of the transmission housing it is possible to read, etched on the upper side, the MARKING of the machine composed of: - manufacturer code (the first three digits FNH); - machine code (150LT); - check letter "N"; - year of production “5” for 2005; - manufacturing plant H (Lecce Plant); - product line “C” (Dozer); - serial number (last 5 digits). Depending upon the configuration of the machine, the marking is one of the following:

MODEL

MARKING

D150 STD PAT PS

*FNH150LTN5HC20001*

D150 STD BD PS

*FNH150BDN5HC21001*

D150 XLT PAT PS

*FNH150XTN5HC22001*

D150 LGP PAT PS

*FNH150LPN5HC23001*

D150-0R002

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

24 4

Equipment hydraulic system

Final drives (each)

Idlers Rollers and track chains

Hydropower

Cab tilting pump

The quantities of oil indicated are those required for periodic changes. - ( ) Quantity of first filling.

MG2

Grease fittings

Super

Hypoide 90

HI-TECH 46

- 25 to 20 °C (-13 to 68 °F)

SAE 10W - 3

SAE 10W

ATF Type A Suffix A

–

API CE oppure CCMC D4 oppure MIL-L-2104 E

API GL5 oppure MIL-L-2105

DIN 51524 PART - 1 DIN 51524 PART - 2 ISO VG 46

API CF-4/SG oppure CCMC D4 oppure MIL-L-2104 E

Periodical change Half normal interval One quarter normal interval

Down to 0.5 % sulphur From 0.5 to 1 % Over 1 %

If the content of sulphur of the fuel exceeds 0.5 %, change the engine oil as follows:

All season

-15 to 40 °C ( 5 to 104 °F)

SAE 15W - 40

NLGI2 consistency

All season

SAE 80W - 90

-20 °C to 50 °C

- 25 to 20 °C (-13 to 68 °F)

SAE 10W - 30 ISO 46

-15 to 40 °C (5 to 104 °F)

SAE 15W - 40

ATF Type A Suffix A

-10 to +50

15W-40 All season

-10 to +50 -30 to +20

DIESEL FUEL ASTM No. 2D Grade TT of reputable quality and make

Mixture of water and antifreeze at 50%. The mixture provides oxidation, foaming, corrosion, scaling and freezing protection properties down to - 35 °C (- 31 °F).

International Classification

15W-40 10W-30

–

Down to - 35°C

Outdoor temperat. of reference

SAE 10W

API CF-4/SG MIL-L-2104E ACEA E2 API CH 4 ACEA E3

–

Agriflù mixed with 50% water protects down to - 35 °C (- 31 °F)

VISCOSITY GRADE

GENERALITIES

In the event engine oil with classification “CH4” is used, the change interval can be extended to 500 hours providing that the ambient temperature does not exceed 38 ° C (100 °F) and that the percentage of sulphur in the fuel does not exceed 0.5 %. In case of particularly heavy duty operation, reduce the greasing intervals.

Note:

Super Gold

Transmission housing steering/brakes

0.5

Hydropower

31 (40)

Torque converter Transmission

Super Gold HSP*

Super Gold

14.2 (17)

Engine

–

Agriflù

270

18 (20)

Cooling system

Fluids and lubricants

Fuel reservoir

QUANTITY Litri

ITEM

TABLE OF FLUID CAPACITIES 0-2 D150

0-3

GENERALITIES

D150

TABLE OF CENTRE OF GRAVITY Machine configuration: HG

Base machine + blade HS + Ripper Blade on the ground and ripper on the ground Blade on the ground and ripper at max. height Blade at max. height and ripper on the ground Blade at max. height and ripper at max. height

845 (33.26 in) 870 (34.25 in) 868 (34.17 in) 1005 (39.56 in)

1160 (45.66 in) 1175 (46.25 in) 1145 (45.07 in) 1150 (45.27 in)

Base machine + blade PAT + ripper Blade on the ground and ripper on the ground Blade on the ground and ripper at max. height Blade at max. height and ripper on the ground Blade at max. height and ripper at max. height

800 (31.49 in) 825 (32.48 in) 820 (32.28 in) 875 (34.44 in)

1175 (46.25 in) 1205 (47.44 in) 1160 (45.66 in) 1195 (47.05 in)

Base machine + blade HS Blade on the ground Blade at max. height

805 (31.69 in) 845 (33.27 in)

1260 (49.60 in) 1360 (53.54 in)

Base machine + blade PAT Blade on the ground Blade at max. height

750 (29.53 in) 926 (36.46 in)

1470 (57.87 in) 1380 (53.54 in)

Basic machine (without blade and without ripper)

965 (37.99 in)

1130 (44.49 in)

Note: LG = Horizontal distance from sprocket C/L HG = Ground clearance

Lg D150-2M010

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-4

D150

GENERALITIES

COLD STARTING (Optional)

AUXILIARY APPLICATIONS

Upon request, a cold starting device facilitating the starting of the machine at particularly low temperatures is available.

Some of the equipment described and illustrated in this Manual is provided in determined markets to satisfy specific requirements. Additional devices and special applications can be provided upon request, in agreement with the Sales Organisation. Some accessories upon request are listed here below: Air conditioner, Cold starting, Blade: HS or folding HS for LGP version, HSU or PAT, Ripper, 1 kg fire extinguisher, Diagnostics, Forest Rops (sweeps), Outer sound suppression, 550 mm shoes.

MAIN DIMENSIONS AND WEIGHTS TYPE OF BLADE

Blade width mm (in)

Blade capacity SAE J1265 cu m (cu yd)

Tilt mm (in)

Pitch

Digging depth mm (in)

Blade max. lift mm (in)

Width Weight with blade with blade mm (in) kg (lb)

(HS)

3180 (125.19)

1100 (43.34)

3.10 (4.0)

550 (21.6)

±10°

406 (16.0)

1105 (43.5)

4750 (187.0)

14.811 (*) (32.650)

Semi-U (HSU)

3180 (125.19)

1320 (52)

4.12 (5.36)

550 (21.6)

±6°

480 (18.9)

1105 (43.5)

5025 (197.7)

15.011 (*) (33.095)

STD PAT

3200 (126)

1100 (43.34)

3.15 (4.05)

450 (17.7)

±5°

490 (19.30)

950 (37.4)

4950 (194.9)

14.915 (*) (32.280)

XLT PAT

3200 (126)

1100 (43.34)

3.15 (4.05)

450 (17.7)

±5°

490 (19.30)

950 (37.4)

5315 (209.28)

15.677 (*) (34.560)

LGP PAT

4000 (157.5)

1000 (39.4)

3.15 (4.05)

550 (21.6)

±5°

590 (21.66)

900 (35.43)

5315 (209.28)

16.810 (**) (37.060)

* Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 500 mm (20 in). ** Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 800 mm (32 in).

MACHINE BASE mm (in)

SHOES

WEIGHT

mm (in)

kg (lb)

GROUND BEARING AREA cm2 (in2)

PRESSURE ON GROUND kPa

STD BD (HSU)

2550 (87.7)

500 (19.5)

550 (21.6)

15.011 (33.095)

15.126 (33.277)

25.500

28.050

57.7

52.9

STD PAT

2550 (87.7)

500 (19.5)

550 (21.6)

14.915 (32.280)

15.030 (33.065)

25.500

28.050

57.4

52.6

XLT PAT

2985 (116.4)

500 (19.5)

550 (21.6)

15.677 (34.560)

15.805 (34.770)

29.850

32.835

51.5

47.2

LGP PAT

2985 (116.4)

800 (31.50)

16.810 (37.060)

47.760

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

34.5

0-5

GENERALITIES

D150

500 mm 370 mm

3080 mm

3060 mm

Bulldozer HS arrangement

1900 mm

2550 mm

2400 mm

3650 mm 4750 mm

D150-2M007

500 mm 370 mm

3060 mm

3080 mm

HSU Bulldozer arrangement

2550 mm 3650 mm

1900 mm 2400 mm

5025 mm D150-2M007

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-6

D150

GENERALITIES

1100 mm 450 mm

950 mm

490 mm

3060 mm

3080 mm

STD PAT Arrangement

5°

2550 mm

3200 mm

3650 mm

5°

2950 mm

1900 mm 2400 mm

25°

~ 400 mm

25°

35 mm

4950 mm

5470 mm

D150-2M008

1180 mm 450 mm

950 mm

490 mm

3060 mm

3080 mm

XLT PAT Arrangement

5°

2985 mm 5°

4010 mm 5315 mm

2140 mm 800 mm

2940 mm 3200 mm D150-2M133

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-7

GENERALITIES

D150

550 mm

900 mm

590 mm

3060 mm

3080 mm

LGP PAT Arrangement

5°

2985 mm 5°

4010 mm 5315 mm

2140 mm 800 mm

2940 mm D150-2M009

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-8

D150

GENERALITIES

TABLES OF TECHNICAL DATA DIMENSIONS

MASS

Total Total Total Total Total Total

length (basic tractor) length (with HS blade) length (with semi-U HSU blade) length ("STD PAT" version) length ("XLT PAT" version) length ("LGP PAT" w/ 800 mm, 32 in shoes version)

mm mm mm mm mm mm

(in) (in) (in) (in) (in) (in)

3890 4750 5025 4950 5315 5315

(153) (187) (198) (195) (209) (209)

Total Total Total Total Total Total

length (basic tractor w/500 mm shoes) length (with HS blade) length (with semi-U HSU blade) length ("STD PAT" version) length ("XLT PAT" version) length ("LGP PAT" w/ 800 mm, 32 in shoes version)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

2450 3180 3180 3200 3200 4000

(96) (125) (125) (126) (126) (157)

Total height (BD, STD PAT)

mm (in)

3060 (120)

Total height (with ROPS canopy)

mm (in)

3080 (121)

Track gauge (BD, STD PAT) Track gauge (XLT PAT, LGP PAT) Minimum ground clearance (SAE J1234) Track chain length bearing on ground (BD, STD PAT) Track chain length bearing on ground (XLT PAT,LGP PAT) Width of track shoe (standard)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1900 (75) 2140 (84) 370 (15) 2550 (100) 2985 (117) 500 (20)

Weight in shipping order (including ROPS, 500 mm, 20 in shoes, lubricants, engine coolant, 10 % fuel)

kg (lb)

12865 (28362)

Weight in work order (w/ PAT blade, ROPS cab, 500 mm, 20 in shoes, lubricants, engine coolant, 10 % fuel and operator)

kg (lb)

14915 (32882)

Speed / Pull PERFORMANCES

1st forward 2nd forward 3rd forward

Km/h / daN (mph/lbf) Km/h / daN (mph/lbf) Km/h / daN (mph/lbf)

4.3 / 21300 (2.7 / 47884) 7.0 / 12100 (4.3 / 27202) 11.0 / 6800 (6.8 / 15287)

1st forward 2nd forward 3rd forward

Km/h / daN (mph/lbf) Km/h / daN (mph/lbf) Km/h / daN (mph/lbf)

5.4 / 16770 (3.3 / 37700) 8.7 / 9420 (5.4 / 21177) 13.0 / 5230 (8.1 / 11757)

SPEEDS / PULL

(Standard shoes 500 mm, 20 in wide)

PRESSURE ON GROUND

CLIMBING CAPACITY

w/ blade "PAT" and ROPS cab 60% 30% 10%

(1st forward) (2nd forward) (3rd forward)

Kpa (psi) Km/h (mph) Km/h (mph) Km/h (mph)

57.4 (8.3) 3.0 (1.9) 5.0 (3.1) 9.0 (5.6)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-9

GENERALITIES

D150

TABLES OF TECHNICAL DATA ENGINE

Model Type

Bore and stoke

CUMMINS 6BTAA 5.9 4-stroke, in-line vertical, direct injection turbocharged, aftercooled, low emission 102 x 120 mm (4 x 4.7 in)

Total displacement

5.9 litres (360 in3)

Number of cylinders

Net power at flywheel (SAE J1349)

140 HP /104 kW (at 2200 rpm)

Net power at flywheel (DIN 6270)

142 HP / 106 kW (at 2200 rpm)

Net power at flywheel (ISO 9249)

142 HP / 105 kW (at 2200 rpm)

Net power at flywheel (EEC 80/1269)

142 HP / 106 kW (at 2200 rpm)

Maximum torque

650 Nm (146.1 lbf) (at 1300 rpm)

Maximum power speed

2000 (rpm)

Maximum idle speed

2460 (rpm)

Low idle speed

850 (rpm)

Fuel consumption (at max. power) Starter motor Alternator Batteries - std oversized Radiator Dimensions of radiator core Pressure of radiator cap Water pump flow (at engine 2200 rpm) Fan Air cleaner

Exhaust silencer TRANSMISSION/ TORQUE CONVERTER Torque converter

Transmission

25 kg/h (55 lbs/h) 24 Volt - 6.8 kW (9.1 HP) 24 Volt - 70 Amp 2 x 12 Volt - 100 Amph 2 x 12 Volt - 160 Amph Air - water with tubes and in line core 930 x 453 x 114 mm (36.6 x 17.8 x 4.5 in) 1.0 bar (14.5 psi) 157 lt/min (34.5 gpm) Blower, 6-blade, diam 711.2 mm (28 in) DONALDSON - Dry, 2-stage twith safety element and centrifugal separator, clogging indicator Horizontal, dimensions 655 x diam 228 mm (25.8 x diam 9 in) Single stage, single phase, diam. 13" Stall ratio 2.33 : 1 The propeller shaft actuates through a gear train: – equipment pump – transm. pump + converter pump – oil scavenger pump + brake pump "Power shift" transmission, 3 forward and 3 reverse speeds with FINGERTIP CONTROL type electric control. Neutral button allowing disengaging directly the speed engaged shifting the transmission into neutral. AL function button and As function button. Modulating valves on For and REV, speed engaging modulating valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 10

D150

GENERALITIES

TABLES OF TECHNICAL DATA TRANSMISSION/ TORQUE CONVERTER

Torque converter - transmission group Transmission pump delivery (at max. power speed) Converter pump (at max. power speed)

lt/min (gpm)

Pump combined with converter powering oil pump and oil scavenger pump. 70 (18.5) (17 bar, 246.6 psi)

lt/min (gpm)

53 (14) (3 bar, 43.5 psi)

Suction

Metal mesh and magnetic rod, filtering capacity 100 micron.

Delivery

Cartridge type (SPIN ON) with paper cartridge and by-pass valve, filtering capacità capacity 25 micron.

Transmission filters

Pressure relief valve

Mounted on converter cover

Pressure relief valve (at flow of 10 lt/min, 2.6 gpm)

(psi) bar

10 ± 0.5 (2.6 ± 0.1)

Transmission pressure (at flow of 10 lt/min, 2.6 gpm)

(psi) bar

13.75 ± 0.5 (3.6 ± 0.1)

Transmission pressure (at flow of 70 lt/min, 18.5 gpm)

(psi) bar

17.0 ± 0.5 (4.5 ± 0.1)

Safety lever valve

In the locked position, it prevents the shifting of gears and the starting of the engine and it engages the parking brake.

Transmission gearshift

Electro-hydraulic of a FINGER TIP CONTROL type with semi-open pattern.

F N R

UP 1strd - 2nd -3rd 3 - 2nd - 1st DOWN

Controls: Fingertip type, FNR pivoting control, Shift-up/down neutral switch. Safety lever. election of operating mode - AS - AL

automatic AUTO - SHIFT automatic AUTO - LOW

Description of auto mode AL

Downshifting when the engine drops to a pre-determined speed.

It provides the operator with the pre-selection of the 1st gear forward and 2nd gear reverse when shifting direction.

Propeller shaft Nominal length

With two universal joints and sliding shaft mm (in)

265.5 (10.4)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 11

GENERALITIES

D150

TABLES OF TECHNICAL DATA STEERING SYSTEM

The machine uses a differential steering system; this consists of a hydraulic pump, a hydraulic motor, two epicyclical control modules and steering gear train. The rear transmission has two power inputs. One from the bevel gear set for the speeds and forward & reverse, the other from the motor to steer.The steering system is actuated by two "finger top" potentiometric levers located on the left side of the operator's compartment. The levers send an electric signal to the microprocessor that controls the two electro proportional valves. These valves convert the electric signal into a hydraulic signal, to pilot the steering section of the main valve.This section controls the pump flow to the hydraulic motor that, through the steering gear train, actuates the two epicyclical modules and the right track chain. Open hydrostatic circuit includes: main pump The same of the equipment (see hydraulic system)

cm3/rev (in3/rev)

75 (4.6)

Hydraulic motor Bent axle design, axial pistons, fixed displacement motor (with bolted movement control valve) Displacement Maximum operating pressure

cm3/rev (in3/rev) bar (psi)

63 (3.8) 350 (5076.3)

Steering control valve - Closed centre - load sensing. - Load sensing. - This section is included in the equipment control valve Steering control - Electro-Hydraulic control with two proportional valves - Integrated CPU for steering and Tm control Priority valve - it provides priority to the steering over the equipment cont (blade lifting). Make-up valve - It provides pressure to both equipment control pilot valves and the electro proportional valves

bar (psi)

31.5 to 35 (456.9 to 507.6)

Setting of minimum pressure valve, hydraulic motor

bar (psi)

5 (72.5)

Epicyclical modules Gear ratio straight

â&#x20AC;&#x201C;

travel conditions

1.33

Steering Gear ratio

â&#x20AC;&#x201C;

Hydraulic motor to sprocket

215

Performance Min. steering radius Max. diff. speed of track chain unloaded condition

m (ft)

1.6 (5.2)

Km/h (mph)

3.0 (1.9)

KNm (ft.lb.)

57 (4.2)

Max. diff. torque track chain at 350 bar (5076.3 psi)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 12

D150

GENERALITIES

TABLES OF TECHNICAL DATA BRAKES

Single, multiple-disc brake, spring actuated and oil cooled. No. of brake discs

Outer diameter

mm (in)

227.6 (8.9)

Inner diameter

mm (in)

173.5 (6.8)

Total friction area

cm (in )

Friction material

2045 (317) sintered

N . of springs Max. braking torque Pump delivery (@ engine max. speed) System pressure

12 daNm (ftlb) lt/min (gpm) bar (psi)

460 (3391.6) 53 (14) 25 (362.6)

Steering filters Suction Metal mesh + magnetic rod

mesh

100

Line: Spin-on By-pass valve setting

Micron bar (psi)

Accumulation capacity @ 3.44 bar (49.9 psi) (ISO 4572) gr (lb)

25 abs. 3.44 (49.9) 50 (0.11)

Filtering area

cm2 (in2)

3075 (476.6)

Pressure drop @ 80 lt/min (21.1 gpm)

bar (psi)

0.71 (10.3)

Nominal pressure of element

bar (psi)

34.5 (500.4)

Breaking pressure of element

bar (psi)

70 (1015.3)

Steering compartment Fabricated housing. FINAL DRIVES

Counter shaft, double reduction, modular assembly. Total ratio

SPROCKET

Sectors

1:10.8 7

N . of teeth Pitch diameter TRACK FRAME

Fabricated structure with two closed boxes. Sealed track tensioner compartment

UNDERCARRIAGE

Link pitch

28 mm (in)

790.94 (31.1)

mm (in)

176 (6.9)

N . of links

Link height

mm (in)

106 (4.2)

Shoe height

mm (in)

55 (2.2)

Kg/m

26 (17.7)

Width of standard shoe

mm (in)

500 (19.7)

Width of optional shoe

mm (in)

550 (21.6)

Weight of shoe per meter

No of rollers per track (STD version) Sequence of rollers from sprocket

7 SF-DF-SF-DF-SF-DF-SF

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0 - 13

GENERALITIES

D150

TABLES OF TECHNICAL DATA UNDERCARRIAGE

TRACK TENSIONER

Diameter of rollers

mm (in)

195 (7.7)

No of track rollers (version XLT/LGP) Sequence of rollers from sprocket Diameter of rollers

mm (in) mm (in)

8 SF-DF-SF-SF-DF-SF-DF-SF 195 (7.7)

No of track rollers Diameter of rollers Diameter of idler wheel

mm (in) mm (in)

2 165 (6.5) 660 (26)

Sliding track tensioner guides with replaceable wear strips. Sealed track tensioner compartment. Grease piston to regulate the track chain tension. Single spring. Nominal load of spring assembly Outer diameter of spring Diameter of rod Diameter of grease piston Pressure relief valve setting

UNDERCARRIAGE SUSPENSION SYSTEM

MAIN FRAME

Diameter of pivot shaft Thickness of cross-member Swing travel (track) Travel of idler wheel (total)

100 (3.9) 70 (2.7) Âą 3.5 245 (9.6)

mm (in) mm (in)

900 (35.4) 264 x 108 (10.4 x 4.2)

mm (in)

1984 (78.1)

mm (in) mm (in)

56 (2.2) 90/55 (3.5/2.2)

Fabricated structure, with two main members. With integral mudguards.

Bolted to steering compartment housing. Diameter of pin Bar width

HYDRAULIC SYSTEM

mm (in) mm (in) deg mm (in)

Fabricated structure, with two main members. Bolted to steering compartment housing.

Total width of main frame TOW BAR

13500 (3034.9) 200 (7.9) 44.5 (1.7) 75 (2.9) 950 (13778.6)

Pivot shaft (near sprocket) and fixed front cross beam. All joints permanently lubricated.

Width of main frame Section UPPER FRAME

daN (lbf) mm (in) mm (in) mm (in) bar (psi)

Load sensing system with piloted variable displacement pump with flow partition. The power valve block provides the pressure to both pilot valve controls and electro proportional valves. A priority valve provides priority to the steering over the equipment control (blade lifting). System pressure Setting of dual pressure relief valve (equipment/steering) Piloting pressure Main pump Axial piston pump Regulators: constant power control CUT-OFF pressure pressure sensor (load sensing) Brand

bar (psi) bar (psi)

160/350 (2320.6/5076.3) 31.5 to 35 (456.9 to 507.6)

kW (HP) bar (psi) bar (psi)

58 (78) at 2000rpm 350 (5076.3) 21 (304.6) Rexroth

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 14

D150

GENERALITIES

TABLES OF TECHNICAL DATA HYDRAULIC SYSTEM

Model Max. displacement Pump speed at maximum engine speed Pump max. delivery Min displacement Discharge valve setting

A11V075 c3/rev (in3/rev)

75 (4.6)

rpm lt/min (gpm) c3/rev (in3/rev) bar (psi)

2000 150 (39.6) 15 (0.9) 30Âą2 (435Âą29)

Control valve Closed centre, flow partition, 4-spool or 5-spool for PAT version with piloted discharge valve. Brand

Rexroth

Model

5M6 - 15

1st spool: - Ripper (raising, lowering control)

lt/min (gpm)

120/150 (31.7/39.6)

lt/min (gpm)

50/70 (13.2/18.5)

lt/min (gpm)

150 (39.6)

lt/min (gpm)

150 (39.6)

lt/min (gpm)

150 (39.6)

2 spool: - Blade tilt (left, right) rd

3 spool: - Blade (raising/lowering /floating control) th

4 spool: - Angle th

5 spool: - Steering hydraulic motor Pilot valve Single lever for 2nd and 3rd spool + button. Brand

Rexroth

Model

5THF6

Auxiliary lever Single lever for auxiliary spool. Brand

Rexroth

Model

2TH6

Lift cylinder Blade (HS/HSU) 2 w/ quick drop valves and stroke limiting valves Bore

mm (in)

80 (3.1)

Diameter of rod

mm (in)

45 (1.8)

Stroke

mm (in)

1185 (46.6)

Lift cylinder Blade (PAT). Bore

mm (in)

90 (3.5)

Diameter of rod

mm (in)

50 (1.9)

Stroke

mm (in)

826 (32.5)

Bore

mm (in)

125 (4.9)

Diameter of rod

mm (in)

63 (2.5)

Stroke

mm (in)

140 (5.5)

Tilt (Bulldozer blade)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 15

GENERALITIES

D150

TABLES OF TECHNICAL DATA HYDRAULIC SYSTEM

Tilt (PAT blade) Bore

mm (in)

125 (4.9)

Diameter of rod

mm (in)

63 (2.5)

Stroke

mm (in)

135 (5.3)

Bore

mm (in)

100 (3.9)

Diameter of rod

mm (in)

50 (2)

Stroke

mm (in)

509 (20)

mm (in)

110 (4.3)

ANGLE (PAT) STD/XLT

ANGLE (PAT) LGP Bore Diameter of rod

mm (in)

55 (2.2)

Stroke

mm (in)

509 (20)

Bore

mm (in)

125 (4.9)

Diameter of rod

mm (in)

70 (2.8)

Stroke

mm (in)

380 (15)

Total capacity of tank

lt (gal.)

78 (20.6)

Oil tank capacity (max. level)

lt (gal.)

63 (16.6)

Ripper

Hydraulic tank

Strainer Medium: metal mesh. Filtering capacity

micron

By-pass valve setting

bar (psi)

Max. nominal delivery

lt/min (gpm)

250 0.2 (2.9) 210 (55.5)

Surface

cm2 (in2)

1940 (300.7)

Pressure drop at max. flow

bar (psi)

0.016 (0.2)

Return filter Medium: inorganic glass fibre paper. Filtering capacity

bar (psi)

Differential switch setting

bar (psi)

2.2 (31.9)

Surface

cm2 (in2)

9000 (1395)

lt/min (gpm)

440 (116.2)

Max. nominal delivery SAFETY CAB

micron

By-pass valve setting

2.5 (36.2)

Cab: Fully enclosed cab, modular, tiltable 60Â° leftward. ROPS-FOPS structure w/ 4 vertical beams. Two doors, to side windows. 4 elastic supports Description of cab arrangement Left console: With armrest (satellite) fully adjustable, including the Steering and Gearshift controls. The console includes also: Auto T/M switches and left safety lever. Right console: Front equipment control pilot valve and 3rd function lever, right safety lever, armrest, starter key, horn and ashtray.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 16

D150

GENERALITIES

TABLES OF TECHNICAL DATA SAFETY CAB

Dashboard (monitor) with control switches, manual throttle. Pedal support: - Brake central pedal, decelerator, pedal, and footrest. Cab accessories: - Rear mirror. - Front wiper, door window wiper. - Rear window wiper. - Ashtray and cigarette lighter. - Ceiling light (2). - FM-AM radio (12 Volt). - Drink holder. - Fridge 12 Volt socket. No. of air ducts

Seat Brand

Kab

Model

301 C/ROPS 865 C/COND. CAB

Range of adjustment mm (in) Height of adjustment mm (in) Other features: - Cloth upholstery, with safety belt and connections for cab and PVC for ROPS Heater group Heating capacity

Kcal

Filter: Medium: inorganic fibre glass paper. Efficiency Capacity Dimensions

micron cm2 (in2)

Air conditioner group Max. gas charge

gr (lb)

Compressor Brand Model

>89% 20 13680 (2120.4)

1800 (3.9)

Sanden SD7H1SMD7948

Condenser Brand Air flow No. of fans

m3/h (gpm)

Cab tilting system Double stroke tilt cylinder with stroke-end valves. Brand Diameter Hand pump Double stroke with oil tank. Brand Nominal displacement

150 (5.9) 60 (2.4)

AUTOCLIMA 1570 (5755) 2

mm (in)

POWER PACKER 25 x 45 (1 x 1.8)

c3/stroke (in3/stroke)

POWER PACKER 4 (0.2)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 17

GENERALITIES

D150

TABLES OF TECHNICAL DATA ELECTRICAL SYSTEM

Alternator Brand Model Capacity Starter motor Brand Model

Delco-Remy ST 9181

Batteries No. of elements Brand Capacity Discharge

2 (in series) Magneti Marelli 100/160 Ah - 12V 440/650

Lighting system No. of elements 2 front lights + 2 side work lights (all on cab) 2 rear work lights Other main components Master switch Engine cut-off solenoid Link fuses Fuse boxes Starter key Dashboard Engine rpm counter Hourmeter Fuel level Coolant temperature Steering/transmission display Steering valves (q.ty. 2) Transmission gearshifting solenoids (q.ty 4) Reverse indicator Transmission and Steering electronic controller BULLDOZER EQUIPMENT

Delco-Remy EE9059 Delco 24V - 70A

Ah Amp

W (HP) W (HP)

Amp

24 V

70 (0.09) 70 (0.09) manual FV 9187 50 & 80 2 x 11fuses four position MC Elettronica digital digital level indicator temperature gauge digital proportional on-off P.I. 109 dB(A)-1000Hz Rexroth

Two push beams pivoting on the track frame through a ball joint. Tilt hydraulic regulation and pitch mechanical regulation. Equistatic compensator. Ball joint Diameter

mm (in)

110 (4.3)

HS blade: Width (blade) Height Nominal capacity Max. lifting Digging depth Max. tilt Max. angle

mm (in) mm (in) m3 (ft3) mm (in) mm (in) mm (in) deg

3180 (125.2) 1100 (43.3) 3.1 (109.4) 1105 (43.5) 406 (16) 550 (21.6) Âą 10

mm (in) mm (in) mm (in) m3 (ft3) mm (in) mm (in) deg

3180 (125.2) 1320 (52) 4.1 (144.8) 1105 (43.5) 480 (18.9) 550 (21.6) Âą6

mm (in)

25 (0.9) -

Semi-U HSU blade Width (blade) Height Nominal capacity Max. lifting Digging depth Max. tilt Max. angle Wear components: Two corners + two reversible cutting edges Thickness of cutting edges Break-up force (lift cylinders) Break-up force (tilt cylinder)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 18

D150

GENERALITIES

TABLES OF TECHNICAL DATA PAT EQUIPMENT

C-frame hinged to track frame. Tilt hydraulic control and pitch mechanical adjustment. Front ball joint Diameter PAT blade Width (blade) Height Nominal capacity Max. lift Digging depth Max. tilt Max. pitch Wear components: - Two corners + two reversible cutting edges - Thickness of cutting edges - Break-up force (lift cylinders) - Break-up force (tilt cylinder)

MULTI-SHANK RIPPER

mm (in)

130 (5.2)

mm (in) mm (in) m3 (ft3) mm (in) mm (in) mm (in) deg

3200 (126) 1100 (43.3) 3.15 (111.2) 950 (37.4) 490 (19.3) 450 (17.7) Âą5

mm (in)

20 (0.8) -

Multi-shank parallelogram ripper Brand Model No. of teeth Thickness of shank mm (in) Ripping width mm (in) Ripping depth mm (in) Ground clearance under shank with ripper lifted mm (in) Ground clearance under crossbar with ripper lowered mm (in) Total width mm (in) Dimension of tool carrier bar mm (in) Break-up force daNm (ft.lb.) Penetrating force daNm (ft.lb.) Multi-shank parallelogram ripper Brand Model One double stroke cylinder. Bore x diameter piston rod mm (in) Stroke mm (in) Cylinder support and equipment arms in welded boxed structure. H.D. semi-curved shanks and replaceable tips. Q.ty of shanks Thickness of shanks mm (in) Ripping depth mm (in) Ripping width mm (in) Ground clearance under shank with ripper lifted mm (in) Ground clearance under crossbar with ripper lowered mm (in) Total width mm (in) Dimension of tool carrier bar mm (in) Break-up force daN (lbf) Penetrating force daN (lbf) Weight kg (lb)

RECO RP10F 3 1700 (66.9) 365 (14.4) 474 (18.7) 164 (6.4) 1890 (74.4) 170 x 220 (6.7 x 8.7) 13980 (103074) 4867 (35884.4)

RECO RP12F 125 x 70 (4.9 x 2.8) 380 (15)

3 45 (1.8) 495 (19.5) 1800 (70.9) 460 (18.1) 170 (6.7) 2040 (80.3) 220 x 255 (8.7 x 10) 10350 (76310.5) 5190 (38265.9) 1552 (3421.6)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 19

GENERALITIES

D150

CHECK DATA ON THE MACHINE ENGINE Net power at flywheel (ISO 9249) Low idle High idle Equipment stall Converter/transmission stall Total stall

HP/kW rpm rpm rpm rpm rpm

141 / 105 750 to 950 2320 to 2460 2310 to 2450 1960 to 2100 1850 to 2050

Lubrication At low idle (minimum allowed) At high idle (minimum allowed) Filter by-pass pressure Thermostat temperature Thermostat maximum temperature setting BOSH injector setting

bar (psi) bar (psi) bar (psi) 째C (째F) 째C (째F) bar (psi)

TRANSMISSION Pressure relief valve Torque converter safety valve Lube oil pressure relief valve Main pressure 1st speed clutch pressure 2nd speed clutch pressure 3rd speed clutch pressure Forward clutch pressure Reverse clutch pressure

bar bar bar bar bar bar bar bar bar

(psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)

17 (246.6) 10.5 (152.3) 3 (43.5) 16.5 to 17.5 (239.3 to 253.8) 16.5 to 17.5 (239.3 to 253.8) 16.5 to 17.5 (239.3 to 253.8) 16.5 to 17.5 (239.3 to 253.8) 16.5 to 17.5 (239.3 to 253.8) 16.5 to 17.5 (239.3 to 253.8)

BRAKE SYSTEM Brakes powering Pressure regulated by brake pedal valve

bar (psi) bar (psi)

22.5 to 27.5 (326.3 to 398.8) 18 to 22 (261 to 319)

HYDRAULIC SYSTEM (equipment/steering) Operating pressure Maximum pressure (equipment/steering) Wait @ neutral Wait @ float Delta LS Float selection Unloading valve setting (@ 10 lt/min, 2.6 gpm)

bar bar bar bar bar bar bar

31.5 to 35.0 (456.9 to 507.6) 190/350 (2755.7/5076.3) 33 to 37 (478.6 to 536.6) 33 to 37 (478.6 to 536.6) 21 (304.6) 25 (362.6) 28 to 32 (406.1 to 464.1)

UNDERCARRIAGE Setting of pressure relief valve

bar (psi)

(psi) (psi) (psi) (psi) (psi) (psi) (psi)

0.69 (10) 2 (29) 1.68 (24.4) 81 to 83 (177.8 to 181.4) 95 (203) 260 to 270 (3771 to 3916)

900 (13053.4)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 20

D150

GENERALITIES

EQUIPMENT MANOEUVRE TIMES BLADE LIFTING (PAT version) From ground level to max. height

2.3 (sec)

BALDE LOWERING (PAT version) From max. height to ground level in power down

1.3 (sec)

From max. height to max, depth in power down

–

From max. height to ground level in float

1.3 (sec)

From max. height to max. depth in float

–

Waiting time machine w/ blade

0 (sec)

TILT (PAT version) Left side of blade from max. to min. height

1.3 (sec)

Right side of blade from max. to min. height

1.2 (sec)

ANGLE (PAT version) Right side of blade from rear to forward position

3.3 (sec)

Left side of blade from rear to forward position

3.3 (sec)

RIPPER LIFTING (mod. RP12F) From ground level to max. height

1.2 (sec)

RIPPER LOWERING (mod. RP12F) From max. height to ground level

1.1 (sec)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 21

GENERALITIES

D150

LEAKAGES NOTE PRIOR TO STARTING ANY TEST IT IS NECESSARY TO WARM-UP THE HYDRAULIC OIL TO 60 to 65 °C (140 to 149 °F) PERFORMING SEVERAL HYDRAULIC STALLS (MAX. DURATION OF EACH SINGLE STALL 5 sec.s) INTERVALLED BY MOVEMENT OF THE EQUIPMENT.

No.

TEST

Machine configuration

Lift the front side of the machine to max. height by lowering the blade. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

≤ 15 mm (0.6 in)

Raise the rear side of the machine to max. by actuating the ripper lowering. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

≤ 15 mm (0.6 in)

With blade on the ground actuate the left tilt control to stroke-end. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

≤ 40 mm (1.6 in)

With blade on the ground actuate the right tilt control to stroke-end. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

≤ 60 mm (2.4 in)

Raise the blade to max. height. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

LIMIT

≤ 15 mm (0.6 in)

Raise the ripper to max. height. Evaluate the movement of the blade cylinder rod, keeping the unit in the conditions described here above, with engine inoperative, for 15 minutes.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

≤ 15 mm (0.6 in)

0 - 22

GENERALITIES

D150

GENERAL INSTRUCTIONS INSTALLATION OF SEALS ON ROTATING SHAFTS Please follow these cautions: - prior to the installation, keep the seals soaking in the same oil they shall work with for half an hour;

- during the pressing, make sure that the seal is introduced perpendicular to the seat and once the installation is completed, that it contacts the bottom face; - to prevent that the sealing lip is damaged by the shaft, it is suggested that during the installation an appropriate seal be placed in between.

- clean accurately the shaft and make sure that its working surface is undamaged; - direct the sealing lip toward the fluid; in case of a hydro dynamic lip, the rifling must be oriented considering the movement direction of the shaft, moving the fluid toward the inside of the seal; - smear the sealing lip with a film of lubricant (oil is preferred over grease);

INSTALLATION OF O-RINGS Lubricate the seals prior to inserting them in the relevant seats that, during the installation phase, tend to twist thus altering the correct positioning, jeopardising the sealing function.

- insert the seal into the relevant seat pressing it or using a punch with a flat face; avoid absolutely to strike it with a hammer or a mallet;

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

GENERALITIES

D150

0 - 23

REMOVAL AND INSTALLATION OF ROTATING SEALING RINGS Remove the rings as follows: - press the ring so that one end and part of the inner circumference adhere to the bottom of the relevant seat (a); - keep the ring in the above position and, using a scriber on the opposite end, free the detent as shown in figure (a). Re-install the elastic rings as follows: - press the ring so that one end and part of the inner circumference adhere to the bottom of the relevant seat (a);

a 1850-2R0378

- install the ring in the above mentioned position and lift and move the free end (b) until the two detents (c) are correctly hooked.

b 1850-2R0379

c 1850-2R0380

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 24

GENERALITIES

RECOMMANDATIONS FOR THE DISASSEMBLY AND REASSEMBLY OF GROUPS The following information, of a general type, have the purpose of facilitating the disassembly and reassembly of groups.

D150

DISASSEMBLY It is always recommended for any intervention on the engine or other groups removed from the machine, use the appropriate supporting rigs.

Thus please read and heed them carefully when performing the work.

Always make available boxes and containers capable of holding small parts removed. Take particular care that machined surfaces of various parts are resting, after the removal, on wooden blocks or shelves.

CLEANING

When disassembling similar parts, such as valve tappets etc. are placed in appropriate containers, so that the same installation sequence is re-established.

After disconnecting the electrical system, clean accurately all the parts to be disassembled, preferably with a jet of steam. In many repair or service shops caustic compounds are used to eliminate traces of grease, dirt, paint and remains of seals etc. from the parts. These compounds are very useful and effective when properly used, but can cause serious damages to certain materials. Materials such as aluminium, rubber, fibres sintered bronze and alloying agents are sensitive to all highly concentrated caustic compounds. Some heat exchangers are built with aluminium fins. To clean them both internally and externally these parts the use of solvents not reacting with aluminium is recommended.

ASSEMBLY Clean accurately all components to assemble as described in the various paragraph of the manual. The use of special tools illustrated in the manual is recommended.

Note â&#x20AC;&#x201C; For the applications of sealing compounds please comply with the instructions prescribed on the various commercial products.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 25

GENERALITIES

D150

The manufactured prescribes, unless differently specified, the following sealing compounds: VIT type C or RHODORSIL CAF 1, or LOCTITE 510. Whenever possible, press the bushes into a correct position, using a press. If the use of a hammer is required to install a bush, use an appropriate punch to prevent damaging the bushes. Lubricate ball bearings and bushes before installing them in the relevant pins. Lubricate the sealing lip of new seals. In particular, new seals must always be used for engine cylinder heads. Use fittings of dimensions and specifications as indicated referring to the part numbers listed in the Parts catalogue. When prescribed, use safety washers, split pins, locking wires etc. Comply with the prescribed tightening torques as indicated in the "tightening torque" section of this Manual, using an appropriate toque wrench. Self-locking nuts must be replaced at each installation to ensure constantly a good resistance to the loosening.

HIGH PRESSURE PIPES, CONNECTIONS, HOSES AND STEEL PIPES

Max = 0.6 mm (0.02 in)

D350R0406

Wrong

Correct

This chapter explains recommendations to be followed during the installation of pipes and the relevant connections.

D350R0407

- Keep all inner threads clean. - Remove immediately the caps before connecting the pipes and plug all open ends. - Never use or re-use flanges or half-flanges deformed more than 0.6 mm (0.02 in) in the centre (see figure). - Make sure that the seat of O-Rings is not damaged.

Wrong

Correct

- Lubricate the O-Rings. - Make sure that the O-Rings are well seated. - Tighten regularly to prevent distortions or damages

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350R0408

0 - 26

D150

GENERALITIES

- Tighten regularly to prevent distortions or damages to the O-Rings.

Wrong

- Install pipes and supporting straps letting the latter slightly loosen (tighten the strap after tightening the connections). - Ensure that the pipes can reach the opposite side to be connected without being forced.

Correct

- If a pipe is installed in a straight position, allow sufficient room to absorb contractions due to the pressure. D350R0410

- Pipes must not be twisted (see figure) nor touch one another nor touching other parts, especially moving parts. - Make sure that the dimensions of bands is correct in relation to the diameter of the pipe to be secured to prevent possible rubbing (see figure). - Do not install a band over a minimal curve to prevent that under pressure, the hose is stressed (see figure: the dotted part indicates the contraction that the pipe can be subject to under the effect of the pressure). - Make sure that bands are installed in the right position so that the hose is kept away from obstacles (see figure).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350R0409

0 - 27

GENERALITIES

D150

O-RINGS - Fields of application DESIGNATION

BASE ELASTOMETER

WORKING TEMPERATURE (*)

-40 to 120 °C (-40 to 248 °F) NBR

FIELD OF OPERATION

MINERAL OIL AND GREASE, COOLANT, FUEL WATER UP TO 70 °C (158 °F) AIR UP TO 100 °C (212 °F)

NITRIL BUTADIENE -30 to 125 °C (-22 to 257 °F)

-40 to 200 °C (-40 to 392 °F)

FUELS IN GENERAL, NON FLAMMABLE FLUIDS, ACIDS, SOLVENTS, MINERAL OILS. TO BE USED WITH TEMPERATURE > 100 °C (212 °F)

ETIL PROPILENE

-40 to 150 °C (-40 to 302 °F)

BRAKE LIQUID (DOT 3) STEAM. HOT WATER. SILICON OIL AND GREASE WARNING: DO NOT USE WITH MINERAL OIL AND GREASE

SILICON

-60 to 200 °C (-76 to 392 °F)

AIR, WATER GAS, HIGH ANILINE POINT MINERAL OIL, STEAM. USED AS STATIC SEAL ONLY

FUORO CARBON (VITON)

FPM

EPDM

MVQ

SAME COMPATIBILITY OF NBR 60 " 75 IRHD, BETTER RESISTANCE TO EXTRUSION USED ONLY AS STATIC SEAL

NOTE: (*) Temperatures prescribed for static applications, provided as indication only.

O-RING PROPERLY INSTALLED

O-RING UNDER PRESSURE

EXTRUSION OF O-RING

FAILURE OF O-RING

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 28

GENERALITIES

D150

DIAGNOSTIC CHECKS GENERALITIES For a fat troubleshooting, please follow these rules:

a) Knowing the machine. It is impossible to perform any troubleshooting and to formulate a diagnosis without knowing well the machine. Thus it is recommended that the descriptions contained in the Repair Manual about the configuration and the operation of the different groups be read carefully.

e) Diagnosis Once the trouble is identified, make a list of possible causes with the help of the suggestions in the chapter relative to the group involved and identify the correct one by performing the appropriate tests, starting from the most probable causes and from the easiest tests.

b) Check with the operator. Many troubles are originated by an improper operation or insufficient maintenance. Check with the operator whether the machine experienced previously troubles similar to the ones in progress and whether any intervention was performed using appropriate tooling and genuine spare parts. Also, check the ambient working conditions of the machine and make sure that current maintenance is performed.

c) Operating the machine. The best way to check the conditions of a machine is to operate it under normal working conditions. In doing this check: - the correct operation of the monitoring instrumentation; - the performance of the machine; - possible odours or signs of overheating; - abnormal noises; identify their origin and the operating conditions when they occur.

d) Inspecting the machine. After the test of item c, stop the machine and have a visual inspection. Check whether the various groups show signs of leakage of fluids, loose fixtures, failures or deformations etc.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 29

GENERALITIES

D150

UNITS OF MEASURE The units of measure in this Manual are those implemented by the International System (S.I.) replacing those previously used by the M.K.S. system. Force:

decanewton (daN) supersedes kilogram (kg)

Pressure:

bar, supersedes kg/cm2

Torque:

dacanewton x meter (daN m) supersedes kg m

For the conversion of units of measure, the following table applies:

Force Pressure Torque

multiply

to obtain

0.9807

daN

kg/cm2

0.9807

bar

kg m

0.9807

daN m

Note – For current repair needs, the following equivalences are considered valid: kg = daN; kg/cm2 = bar; kg m = daN m.

CLASSIFICATION OF STANDARDISED PARTS FOR THE DETERMINATION OF TIGHTENING TORQUES

Note – In the event, in the different sections, no tightening torque is prescribed, please refer to the table "TIGHTENING TOQUES" only after identifying exactly the item.

The latter is identified by an eight-digit coded number fully designating the part.

Example: I /

e / f

I - Index number of standard It is always indicated by digit 1. This digit indicates that the part can be made in several versions differing for the material and coating.

a - b - c - d - e - Bas number of the standard For the conversion of units of measure from the International System to British System please refer to the following table: multiply

to obtain

Mass

2.205

Length

0.03937

Pressure

bar

14.5

psi

daN m

7.373

lb ft

l/min

0.2642

gal/min (US)

Temperature

°C

9 9 °C + 32 5

°F

Power

1.341

0.2642

gal. (USA)

Km/h

0.6213

mph

It is a number always composed of five digits identifying the part and its dimensional specifications.

f - Index number for the material This digit indicates the material prescribed for a specific item. Its meaning is indicated in the table to follow.

g - Index number for the coating Torque Flow

Capacity Speed

It is a digit indicating the coating prescribed for a specific item.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 30

D150

GENERALITIES

Resistance class and type of material

Index no. of material (f) FIAT

UNI

DIN

SAE

BSI

BNA

R 40

D - 4S - 4A

R 50

5S - 6S

R 80

R 100

100

Brass

Aluminium

Copper

10K

Free for other metal materials

CAUTION - Lubricate bolts and nuts with engine oil for diameters up to 24 mm, with tallow for larger diameters. - The tolerance of tightening torques is Âą 5%. - Strength classes R80, R100, R120 must be considered as follows:

10.9 supersedes R 100 12.9

} }

for screws

R 120

supersedes R 80

supersedes R 100

for nuts

CDT = cadmium plated; FOSF = phosphatised; ZNT = zinc plated. Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 31

GENERALITIES

D150

TABLE OF TIGHTENING TORQUES When the tightening torque of bolts and nuts is not indicated in the single sections, this can be obtained from the table here below:

Diameter and pitch mm

NUTS (ZNT)

SCREWS (ZNT / DEIDR)

Class of strength: 10 (R 80)

Class of strength: 10.9 (R 100)

normal

low type

daNm (lb.ft.) daNm (lb.ft.)

with polyamaide ring normal daNm (lb.ft.)

low type daNm (lb.ft.)

Diameter and pitch

normal ZNT daNm (lb.ft.)

autoblocc. ZNT daNm (lb.ft.)

M6 x 1

1.3 (9.6)

M6 x 1

1.3 (9.6)

1.2 (8.8)

M8 x 1.25

3.2 (23.6)

2.6 (19.2)

3.9 (28.7)

3.2 (23.6)

M8 x 1.25

1.3 (9.6)

3.5 (25.8)

M10 x 1.25

7.2 (53)

5.2 (38.8)

8.2 (60.4)

6.2 (45.7)

M10 x 1.25

7.1 (52.3)

7.9 (58.2)

M10 x 1.5

6.5 (47.9)

5 (36.8)

7.7 (56.8)

6 (44.2)

M10 x 1.5

6.5 (47.9)

7 (51.6)

M12 x 1.25

13 (95.8)

8.7 (64.1)

14.5 (106.9)

10.2 (75.2)

M12 x 1.25

12.7 (93.6) 13.9 (102.5)

M12 x 1.75

11 (81.1)

8.1 (59.7)

12.9 (95.1)

9.6 (70.8)

M12 x 1.75

11 (81.1)

12 (88.5)

M14 x 1.5

19.5 (143.8)

13 (95.8)

21.6 (159.2)

15 (110.6)

M14 x 1.5

20 (147.5)

22 (162.2)

M14 x 2

18 (132.7)

12.5 (92.2)

20 (147.5)

14.6 (107.6)

M14 x 2

18 (132.7)

19 (140.1)

M16 x 1,5

30 (221.2)

17 (125.3)

34 (250.7)

20 (147.5)

M16 x 1.5

30 (221.2)

33 (243.3)

M18 x 1.5

45 (331.8)

25 (184.3)

50 (368.6)

29 (213.8)

M18 x 1.5

45 (331.8)

48 (353.9)

M18 x 2.5

M20 x 1.5

60 (442.3)

30.5 (224.9)

64.5 (475.5)

35 (258)

M20 x 1.5

60 (442.3)

65 (479.2)

M20 x 2.5

M22 x 1.5

80 (589.8)

41 (302.2)

M22 x 1.5

80 (589.8)

90 (663)

M22 x 2.5

M24 x 2

100 (737.3)

47 (346.5)

108 (796.2)

52.5 (387)

M24 x 2

100 (737.3)

110 (811)

M24 x 3

M27 x 2

95 (700.4)

40.1 (295.6)

M27 x 2

100 (737.3)

M30 x 2

130 (958.4)

49.9 (368)

M30 x 2

140 (1032)

M33 x 2

170 (1253.4)

M33 x 2

190 (1400.9)

M36 x 3

220 (1622.1)

M36 x 3

240 (1769.5)

M16 x 2

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 1

ENGINE TABLE OF CONTENTS PARAGRAPH SUBJECT

PAGE

1.1 1.1.1 1.1.2

GENERAL SPECIFICATIONS OF SERIES B ENGINE ............................................ 1-1 Engine main specifications .................................................................................... 1-1 Engine identification ............................................................................................... 1-2

1.2

DESIGN FEATURES ................................................................................................

1-3

1.3

SERVICEABILITY ....................................................................................................

1-8

1.4

SECURING THE ENGINE TO THE FRAME ..............................................................

1-9

1-1

ENGINE

D150

For the disassembly, inspection and reassembly of the engine series B5.9 please refer to the Cummins publications that can be procured from the Service organisation The main specifications and data of the engine installed on D150 are listed here below

1.1 GENERAL SPECIFICATIONS OF SERIES B ENGINE 1.1.1 ENGINE MAIN SPECIFICATIONS Number of cylinders Bore Stroke Total displacement Net flywheel power (DIN 6270) Net flywheel power (SAE J1349) Net flywheel power (ISO 9249) Net flywheel power (EEC 80/1289) Engine weight dry less flywheel and electrical equipment Firing order Idle speed Maximum no-load speed Maximum torque speed Maximum power speed Maximum torque Clearance between valves and rocker arms Intake Exhaust Compression ratio Rotation, seen from front side of engine Air intake Lubrication system Lube pressure at low idle Lube pressure at setting speed Cooling system Coolant capacity Setting of thermostat Start Maximum opening Radiator cap pressure with system at 104 °C (220 °F)

6BT AA5.9 6 102 mm (4 in) 120 mm (4.72 in) 5.9 litres (360 in3) 142 HP/106 kW 140 HP/104 kW 142 HP/105 kW 142 HP/106 kW 432 kg 1-5-3-6-2-4 850 rpm 2460 rpm 1500 rpm 2200 rpm 650 Nm (146 lbf) at 1300 rpm 0.25 mm (0.009 in) 0.50 mm (0.020 in) 17.5:1 clockwise turbocharged w/ aftercooler

0.69 bar (10 psi) 2.07 bar (30 psi)

9.8 litres (2.6 gal.) 83 °C (181° F) 95 °C (203° F)

1.03 bar (14.9 psi)

Air intake system Maximum allowable restriction on intake at rated speed and load with clogged cartridge

635 mm H2O

Exhaust system Maximum allowable restriction on intake at rated speed and load

76.2 mm Hg

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-2

ENGINE

D150

1.1.2 ENGINE IDENTIFICATION Engine data plate The engine data plate includes identification data and other important information relative to the engine. Always have the following engine data available when communicating with a Cummins authorised repair Centre. The information on the data plate are essential when ordering spare parts. To order parts it is necessary to specify Serial number of the engine (E.S.N.) Check list of the parts (CPL)

D150-2R0098

Fig. 1-1 Engine are designated as follows: The first digit indicates the number of cylinders, the letter to follow identifies the series of the engine, the remaining alpha digits indicate the air intake (T = turbo charged) and the last digits indicate the total displacement in litres.

Model nomenclature of industrial engine 6 B T A 5. 9 No. of cylinders Series B Turbocharger Aftercooler Total displacement D150-2R0099

Fig. 1-2

The total displacement of the engine is 5.9 litres (360 in3), the bore is 102 mm (4.01 in) and the stroke is 120 mm (4.72 in). The firing order is the same of all Cummins in-line 6-cylinder: 1-5-3-6-2-4.

Specifications of engine 6B 5.9 Total displacement Bore Stroke Firing order

litres 5.9 (360 in3) mm 102 (4.01 in) mm 120 (4.72 in) 1-5-3-6-2-4 D150-2R0100

Fig. 1-3 Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

1-3

ENGINE

1.2 DESIGN FEATURES An automatic belt tensioner is used to provide a correct tension. On series B a variety of mounting positions for fan hubs and belt tensioners usable for auto, industrial and marine applications are available. This front view of the engine illustrates a belt driven fan hub.

Belt automatic tensioner

Fan hub

D150-2R0101

Fig. 1-4 This is the gear train available on Series B engines. All gears are hardened and of an helicoidal teeth type for strength and silent operation. The alignment with reference marks is used between crankshaft gear and camshaft gear. On engines equipped with rotary injection pumps, the timing alignment occurs between the injection pump gear and the camshaft gear. Engines equipped with in-line injection pump do not require a timing between injection pump and camshaft.

Camshaft gear with injection pump drive gear Crankshaft gear with camshaft gear D150-2R0102

Fig. 1-5 The cylinder block incorporates several innovative design features. The block casting includes arrangements for: - Oil heat exchanger housing. - Water pump intake. - Oil pump housing. - Water pump chamber. - Coolant by-pass duct.

Coolant by-pass duct

Oil heat exchanger Water pump chamber

Water pump inlet

Oil pump housing D150-2R0103

Fig. 1-6

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1-4

ENGINE

D150

Other design features of the cylinder block casting require: - A block design with a rim for higher strength; - Bored cylinders for pistons with 120 mm (4.72 in) centre to centre distance and 18 mm (0.71 in) cylinder, so that space is provided to a dry sleeve, if required by service interventions. - Piston cooling. Rimmed block Piston cooling nozzle D150-2R0104

Fig. 1-7 The cylinder head is a single piece designed for a crossed flow with two valves per cylinder. This feature maintains the exhaust energy, cooling slightly, the short exhaust gaps.

Crossed flow cylinder head

D150-2R0105

Fig. 1-8 An exhaust manifold of a pulsation type coupled to the turbine housing with twin intake is used to improve the efficiency of the engine.

Twin intake turbine housing Pulsation exhaust manifold

D150-2R0106

Fig. 1-9 The design of the cylinder head includes: - Integral intake manifold. - Integral thermostat housing. - Integral fuel filter housing.

Intake manifold

Fuel filter supports

Thermostat housing

D150-2R0107

Fig. 1-10 Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

1-5

ENGINE

An additional design feature of the cylinder head includes cast integral valve guides and hardened valve seat surfaces. Service parts and procedures are available for grinding operations and installation for valve guides.

Integral valve guide

Rocker arm group D150-2R0108

Fig. 1-11 The length of the injection pump requires the repositioning of the fuel filter toward the rear of the engine. This is possible by using a distance filter support.

D150-2R0109

Fig. 1-12 The timing is composed of a camshaft, tappets, push rods and rocker arm group. Besides the intake and exhaust valve cams, the camshaft has a special cam to power the fuel pump.

Rocker armgroup Fuel pump Push rods

Camshaft Tappets D150-2R0110

Fig. 1-13 A single bush of the camshaft, located in the first shaft bore, is used to support the axial thrust of the accessory drives. The remaining journals turn in the camshaft bores in the cast iron block. Service bushes and the procedure to grind and install bushes for all journals of the camshaft are available. Camshaft bush Camshaft journal D150-2R0111

Fig. 1-14 Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-6

ENGINE

D150

The power components of the engine are distinguished for special features - Piston. - Conrods. - Crankshaft.

Power components

Piston

Conrod Crankshaft

D150-2R0140

Fig. 1-15 The conrod is of an angled split type. This design allows having the largest possible big end, to provide strength and long life. The design of the angled split employs a larger surface bearing, thus improving the wear resistance. A piston ceiling oil jet lubricates the bush of the conrod small end.

Small end

Conrod Large end

D150-2R0113

Fig. 1-16 Naturally aspirated engines use aluminium conrod bearings lined, at the rear, by steel, whereas turbo charged engines use tri-metal bearings lined at the back by steel. Service bearings are of the tri-metal type with steel back lining.

Conrod bearings

Aluminium with steel back lining

Tri-metal with steel back lining D150-2R0114

Fig. 1-17 Emissions, applications and power settings determine the type of pistons to be installed on the engine. Similar features of the pistons are a high turbulence top chamber, a free floating pin held by circlips and cast aluminium bodies.

D150-2R0115

Fig. 1-18 Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-7

ENGINE

D150

Turbocharged engines use pistons with three ring seats. a single high nickel content insert with a Keystone profile ensures optimised anti-wear features to the upper ring seat. The most powerful turbocharged engines use an anodised lining on the piston face and on the head to increase life.

Inserto NIresist

Always check the spare part numbers or be sure about the right configuration of the piston to be used as a replacement. Stantuffo turbocompresso

D150-2R0116

Fig. 1-19 The crankshaft is an integral steel forged balanced component. Crossed inner drillings provide lubrication to the conrod bearings. The main and conrod journals are significantly larger than competitive engine crankshafts.

D150-2R0117

Fig. 1-20 Another technical feature is the use of pressed steel parts to reduce the engine weight. These light components include the timing gear cover, valve cover with breather group and engine sump.

D150-2R0118

The design objectives are: - Simplicity. - Reliability. - Durability. - Reduction of components. - Better serviceability.

Fig. 1-21

D150-2R0119

Fig. 1-22 Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-8

ENGINE

D150

1.3 SERVICEABILITY No special tools are required for routine overhauls on series B engines. The tools required are those illustrated hereby.

D150-2R0120

Fig. 1-23

No special repair/rebuild procedures are required for series B engines. Normal high quality standards applicable for engines of similar power are adequate.

Rebuilding procedure: · · · · ·

Disassembly Replacement of worn parts Grinding the valves De-glassing of sleeve walls Cleaning the cylinder head and cylinder block · Re-assembly D150-2R0121 Fig. 1-24

The Cummins engine Company developed repair tools usable to maintain, ovehaul and repair series B engines: Please refer to CUMMINS Manuals to toubleshoot failures and to define the tooling.

Repair tools

D150-2R0122

Fig. 1-25

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1-9

ENGINE

D150

1.4 SECURING THE ENGINE TO THE FRAME

7 6

7 15

8 3 9 9 7

13,14 8

9 3 9 12

D150-2R0095

Fig. 1-26 N. 1 2 3 4 5

Description L. h. support R. h. support Block Nut 24X2X28 Screw 24X2X80

Screw 12X1,75X30

7 8

Washer 12X24 Screw 16X1,5X50

Tightening torque

41 to 45 daNm (302.38 to 331.88 ft lb) 17 to 18,5 daNm (125.38 to 136.44 ft lb)

N. 9 10 11

Description Washer 16X30X3 Nut 16X1,5X18 Stud

12 13 14 15 16

Nut Support - rear left Support - rear right Screw 12X1,75X40 Screw 12X45

Tightening torque

47,5 to 52,5 daNm (350.31 to 387.19 ft lb)

32,5 to 35,5 daNm (239.69 to 261.81 ft lb)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 2

TRANSMISSION TABLE OF CONTENTS PARAGRAPH SUBJECT

PAGE

2.1 2.1.1

GENERAL DESCRIPTION ........................................................................................ 2-2 Transmission converter hydraulic diagram ............................................................. 2-2

2.2

TROUBLESHOOTING ............................................................................................... 2-6

2.3 2.3.1 2.3.2 2.3.3

TESTS ...................................................................................................................... Torque converter stall test ..................................................................................... Delivery pressure test procedure ........................................................................... Transmission gearshifting electric control valve .....................................................

2-10 2-10 2-10 2-11

2.4 2.4.1 2.4.2 2.4.3 2.4.4

PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER ........................ Removal ................................................................................................................ Re-Installation ........................................................................................................ Disassembly .......................................................................................................... Reassembly ...........................................................................................................

2-13 2-13 2-14 2-15 2-24

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8

PROCEDURES FOR THE REPAIR OF THE TRANSMISSION .................................. Removal ................................................................................................................ Re-Installation ........................................................................................................ Disassembly .......................................................................................................... Overhaul of forward the speed clutch ..................................................................... Overhaul of 3rd speed ............................................................................................. Overhaul of reverse speed clutch .......................................................................... Modulating valves (Disassembly/Assembly) .......................................................... Pressure relief valve (Disassembly/Assembly) ......................................................

2-25 2-25 2-26 2-27 2-41 2-43 2-48 2-51 2-52

2.6 2.6.1 2.6.2

SPECIFICATIONS AND DATA .................................................................................... General data .......................................................................................................... Tightening torques (Torque converter) .................................................................... Tightening torques (Transmission housing) ............................................................ Transmission Data (Transmission clutches) ........................................................... (Transmission clutch discs) ...................................................... (1st - 2nd - 3rd speed transmission clutch modulating valves) ..... (Lube oil pressure relief valve) ................................................. (Forward/reverse modulating valves) ........................................ (Transmission pressure relief and torque converter safety valve) (Torque converter - transmission feeding pump) ....................... (Oil filters) ................................................................................

2-56 2-56 2-57 2-58 2-59 2-61 2-61 2-62 2-63 2-64 2-65 2-66

2.6.3

2.7

LIST OF OVERHAUL SPECIAL TOOLS ..................................................................... 2-67

2-2

TRANSMISSION

D150

2.1 GENERAL DESCRIPTION 2.1.1 TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM The transmission is of a "power-shift" type with three forward and three reverse speeds. The system is powered by a dual pump feeding the transmission and the torque converter (1). The pump sucks oil from the transmission housing through filter (6) and circulates it purifying further through filter (2). A valve (set at 2.5 bar) (36.25 psi) protects filter (2) against over pressures due to the clogging of the cartridge or excessively thick oil. The feeding pump of the hydraulic system steering clutches sucks the oil accumulated in the torque converter support housing, through a mesh filter (14) and returns it to the transmission housing. The oil delivered by feeding pump (1) after being purified by filter (2) reaches pressure relief valve (3) establishing and maintaining the pressure setting of the oil controlling the transmission clutches. Safety valve (16) protects the torque converter and the heat exchanger against accidental pressure in-

crements, normally due to cold and excessively thick oil, discharging the flow excess into the pump delivery line (1). The oil flowing out the torque converter, passes through the heat exchanger, the manifold and it is distributed to the lube and cooling ducts of the transmission clutches. The maximum lube pressure is limited by valve (15) set at 3 bar (43.5 psi). Modulating valves (9) make the engagement of the clutches progressive, regulating the pressure increment in the control circuits. A low engine lube oil pressure or an excessive lube oil temperature are indicated on the dashboard in the cab. Quick discharge valves on the 2nd and 3rd speed clutches, during the speed engagement phase, are in closed position, under the action of pressurised oil. When shifting from one speed to another, the relevant control cylinder is connected to the discharge and the pressure drop causes the centrifugal force to prevail over the action of the oil, moving the balls outwards, facilitating a quick discharge.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

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