New holland d180 crawler dozer service repair manual by 1638929

D180 CRAWLER DOZER

Workshop Manual Print No. 604.13.522.00 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 D180 POWER STEERING

SECT. 4

BRAKES AND STEERING CLUTCHES D180 STEERING CLUTCHES

SECT. 4 BIS

UNDERCARRIAGE

SECT. 5

DOZING EQUIPMENT - HYDRAULIC SYSTEM D180 PS

SECT. 6

DOZING EQUIPMENT - HYDRAULIC SYSTEM D180 SC

SECT. 6 BIS

ELECTRICAL SYSTEM

SECT. 7

AIR CONDITIONING UNIT

SECT. 8

F14318

SECTION 0

GENERALITIES TABLE OF CONTENTS

SUBJECT

PAGE

SAFETY RULES ......................................................................................................................................... I-VIII TECHNICAL DATA TABLES Identification data ...................................................................................................................................... 0-3 Table of fluid capacities ............................................................................................................................. 0-4 Main dimensions ....................................................................................................................................... 0-5 Technical data D180 PS - D180 SC ........................................................................................................... 0-6 CONTROL DATA ON THE MACHINE ........................................................................................................ 0-21 TABLE OF WEIGHTS ................................................................................................................................ 0-23 LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS ....................................................................... 0-25 CENTRE OF GRAVITY TABLE .................................................................................................................. 0-27 GENERAL INSTRUCTIONS ....................................................................................................................... 0-28 TROUBLESHOOTING ............................................................................................................................... 0-33 UNITS OF MEASURE ................................................................................................................................ 0-34 TABLE OF TIGHTENING TORQUES ......................................................................................................... 0-36

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 - Do not allow unauthorised personnel to operate service or maintain this machine.

Before operating a machine, always ensure that any unsafe condition has been satisfactorily remedied.

- 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.

- Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system. - 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.

- 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.

- Fasten your seat belt (when provided).

- 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.

- Obey all flag signals and signs.

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

- REMEMBER THAT STARTING FLUID IS FLAMMABLE. Follow strictly the recommendations printed on containers and in the Operation and Maintenance Manual.

- 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.

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

- DO NOT PUNCTURE OR BURN CONTAINERS. - Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. Follow strictly the instructions provided by the Manufacturer.

- 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.

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

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

OPERATION

STARTING

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

- NEVER START NOR OPERATE AN UNSAFE MACHINE.

- Roll Over Protective Structures are required on loaders, dozers, graders, excavators.

SAFETY RULES

NEVER OPERATE machines without ROPS.

Keep cab windows clean and repaired.

- 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.

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

- 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 .

Inspect carefully for flaws or troubles before using. - 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 - Study and familiarise with escape routes alternate to normal exit routes.

- 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.

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

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

- 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.

- 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.

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

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

Choose and shift into the most appropriate gear to keep the speed required, thus preventing any loss of control.

- 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.

- Do not operate machinery in a condition of extreme fatigue or illness. Be especially careful towards the end of working shift. - Do not operate machine with brakes out of adjustment.

- 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.

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

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

- Travel slowly over rough terrain, on slopes or near dropoffs, in congested areas or on ice or slippery surfaces.

- 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.

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

- Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection. - When counterweights are provided, do not work machine if they have been removed.

- Maintain clear vision of areas of travel or work.

SAFETY RULES

- 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.

- 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. - 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 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.

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

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

- Be alert of people in the operating area of the machine.

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

- 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 uprooted 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. - 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.

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.

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

- Always remember to position the transmission drive control in neutral and engage the control lock to secure the machine.

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

- The parking brake is automatically set, when the transmission safety lever is lowered. - NEVER LEAVE THE MACHINE UNATTENDED with the engine running.

- 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.

- 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.

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

III

SAFETY RULES

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

- 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.

- 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. - 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.

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

- 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.

- Always disconnect the master switch before any intervention (i.e. cleaning, repairing, maintaining, refuelling etc.). Do the same when parking for prolonged periods of time to avoid accidental or unauthorised starting.

- 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.

- 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 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.

- 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.

Clean mud or grease from shoes before attempting to mount or operate the machine. - Keep shoes free of mud or grease before climbing or driving the machine. - Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

MAINTENANCE - 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.

GENERALITIES - Before operating or performing any intervention on the machine: â&#x20AC;˘ read carefully all the rules contained by this Manual;

- 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.

â&#x20AC;˘ read and obey all safety related plates and instructions located on the machine. - 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.

SAFETY RULES

- 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.

- Never align holes with fingers or hands; always use appropriate aligning tools. - Eliminate all sharp edges and burrs from re-worked parts.

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

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

- 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.

- 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.

- Shop and/or field service platforms or ladders must be constructed and maintained in accordance with local and national regulations.

- 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.

- 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.

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

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 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.

- BRAKES ARE INOPERATIVE when manually released for servicing. Provisions must be made to maintain control of the machine by blocking or other means.

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

- 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.

- 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.

- 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.

- To move a disabled machine, use a trailer or a low-boy, 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.

- 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 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.

- KEEP HANDS AND CLOTHING AWAY FROM MOVING PARTS. - 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.

SAFETY RULES

- 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.

- 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.

- 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.

- Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.). - Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections

- No bystanders are allowed near the hooking points, chains or cables. - DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

- Compressed air systems can have water deposits created by moisture condensation due to changes of atmospheric conditions. If required, discharge deposits, as instructed.

- Keep the area where maintenance operations are performed CLEAN and DRY. Eliminate immediately all water and oil spillages. STARTING - Do not pile oily or greasy rags; they represent a fire hazard. Store in closed metal container.

- Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

- 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 place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans.

- 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.

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.

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

- Avoid that flammable materials touch exhaust parts. Should this be possible, provide the necessary protections.

- 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 run engine when refuelling and use care if the engine is hot due to the increased possibility of a fire if fuel is spilled.

- 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.

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

DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION.

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

- 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.

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

SAFETY RULES

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

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

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

- 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.

TOOLS

- Before any intervention, make sure that the main switch is OFF.

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

- 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.

Prior to any intervention, install all safety devices according to current rules and regulations. - 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.

- 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.

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

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.

- Never perform adjustments with engine running, except when called for by the above instructions. When changing work shift, check that wheel or rim securing screws and brackets are not loosen; if necessary, retighten to the prescribed torque.

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) 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 °C (599 °F) (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:

2) identify the type of material of the seals, if they are VITON, performing the test illustrated below, on the spare parts; 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; 5) dispose of the materials removed and the protective gloves in a safe manner, without burning them.

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

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

D180 DOZERS

TECHNICAL DATA TABLES

D180

0-3

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) 1

IMPORTANT ENGINE INFORMATION This engine conforms to 2002 U.S. EPA And California Tier I 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.

D150-0R001

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

MODELLO

MARKING

D180 LT (Power Steering)

*FNH180LTN5HC24001*

D180 XLT (Power Steering)

*FNH180XTN5HC25001*

D180 LGP (Power Steering)

*FNH180LPN5HC26001*

D180 LT (Clutch)

*FNH180B1N5HC27001*

D180 XLT (Clutch)

*FNH180B2N5HC28001*

D180-0R001

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

Note:

Oil quantities indicated are those required for periodical changes. - ( ) First supply quantity.

Hydropower

Cab tilting pump

0.5

MG2

Super

Hypoide 90

HI-TECH 46

Super Gold

Hydropower

Super Gold

–

Agriflù

Grease fittings

Idlers Rollers and track chains

46 (60)

Transmission housing steering/brakes

31 (40)

TorqueconverterTransmission

Final drives (each)

16 (19)

Engine

90 (110) 110 (130) 110 (130)

400

Fuel reservoir

Hydraulic system "BULLDOZER" equipment D180 D180 Power Steering / D180 LGP

28 (30)

QUANTITY Fluids and lubricants (Litres)

Cooling system

ITEM

- 25 to 20 °C (-13 to 68 °F)

SAE 10W - 30

SAE 10W

ATF Type A Suffix A

–

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

API GL5 or MIL-L-2105

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

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

ATF Type A Suffix A

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

Grade TT of reputable quality and make

DIESEL FUEL ASTM No. 2D

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

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 to104 °F)

SAE 15W - 40

NLGI2 consistency

All season

(- 4 to 122 °F)

SAE 80W - 90

ISO 46

- 25 to 20 °C (-13 to 68 °F)

SAE 10W - 30

- 20 °C to 50 °C

- 15 to 40 °C (-5 to 100 °F)

SAE 15W - 40

All season

- 25 to 20 °C (-13 to 68 °F)

SAE 10W - 30 SAE 10W

- 15 to 40 °C (-5 to 104 °F)

–

Down to - 35 °C (-31 °F)

of reference

Outdoor temperatures

SAE 15W - 40

–

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

VISCOSITY GRADE

TABLE OF FLUID CAPACITIES

0-4 D180

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

** *** ****

Half-U (HSU) With angle (HA) 5.6 (197.8 ft3) 3.18 (112.3 ft3) 3460 (136.2 in) 4000 (157.5 in) – 3650 (143.7 in) 1425 (56.1 in) 1030 (40.5 in) 850 (33.5 in) 550 (21.6 in) 10° 10° 472 (18.5 in) 452 (17.8 in) 1100 (43.3 in) 1148 (45.2 in) 5487 (216 in) 5316 (209.3 in) 20530 (45260.9 lb) 19650 (43320.8 lb)

LT 3235 (127.4 in) 3170 (124.8 in) 4210 (165.7 in) 2700 (106.2 in) 1900 (74.8 in) 560-610 (22-24 in) 71.5 (2.8 in) 390 (15.3 in) 2460 (96.8 in) 2510 (98.8 in) – – 17290 (38117.9 lb) Half-U (HSU) 5.6 (197.8 ft3) 3460 (136.2 in) – 1425 (56.1 in) 850 (33.5 in) 10° 550 (21.6 in) 1190 (46.8 in) 5878 (231.4 in) 20800 (45856 Ib)

Half-U 3 m 5.0 (176.8 ft3) 2990 (117.7 in) – 1425 (56.1 in) 800 (31.5 in) 10° 550 (21.6 in) 1190 (46.8 in) 5878 (231.4 in) 20700 (45635 lb)

XLT 3235 (127.4 in) 3170 (124.8 in) 4210 (165.7 in) 3205 (126.2 in) 1900 (74.8 in) 560-610 (22-24 in) 71.5 (2.8 in) 390 (15.3 in) 2460 (96.8 in) 2510 (98.8 in) – – 18390 (40543 lb) With angle (HA) 3.18 (112.3 ft3) 4000 (157.5 in) 3650 (143.7 in) 1030 (40.5 in) 550 (21.6 in) 10° 452 (17.8 in) 1148 (45.2 in) 5316 (209.3 in) 21630 (17685.9 lb)

Straight (HS) 3.7 (130.7 ft3) 3900 (153.5 in) – 1110 836 (32.9 in) 10° 535 (21 in) 1160 (45.7 in) 5675 (223.4 in) 22730 (50111 lb)

LGP 3235 (127.4 in) 3170 (124.8 in) 4210 (165.7 in) 3205 (126.2 in) 2082 (82 in) 762-915 (30-36 in) 71.5 (2.8 in) 390 (15.3 in) – – 2844 (111.9 in) 2997 (118 in) 19410 (42791.7 lb)

Includes ROPS cab, 610 mm (24 in) shoe (915 mm (36 in) for LGP), fuel and operator, for a machine with ROPS substract 300 kg (661.4 lb), for Power Steering version add 330 kg (727.5 lb). Maximum angle ± 25°. With the ripper raised, add 935 mm (36.8 in) to the dozer length. Includes ROPS cab, blade lifting cylinders, lubricants and 10% fuel (for Power Steering version add 330 kg) (727.5 lb).

m3 mm mm mm mm * mm mm mm kg

BLADE DIMENSIONS Blade capacity SAE J1265 L Blade width L1 Width with angle blade** M Blade height N Max. tilt O Max. pitch P Digging depth Q Blade raising from the ground R Machine length with blade*** Operating weight with blade*

mm mm mm mm mm mm mm mm mm mm mm mm kg

TRACTOR DIMENSIONS A Cab height from the ground B Muffler height from the ground C Machine frame length D Pitch E Track F Shoe width G Rib height H Free space from the ground I Carriage width with shoes 560 (22 in) Carriage width with shoes 610 (24 in) Carriage width with shoes 760 (30 in) Carriage width with shoes 915 (36 in) Shipping weight without blade ****

MAIN DIMENSIONS

D180 0-5

D180

0-6 TECHNICAL DATA D180 Power Steering - D180 Steering Clutch TECHNICAL

DATAS

LT/XLT

LGP

Max. speeds FORWARD 1st 2nd 3rd

km/h (mph) km/h (mph) km/h (mph)

4.1 (2.6) 7.1 (4.4) 11.1 (6.9)

4.3 (2.7) 7.0 (4.3) 10.8 (6.7)

REVERSE 1st 2nd 3rd

km/h (mph) km/h (mph) km/h (mph)

5.3 (3.3) 8.5 (5.3) 13.2 (8.2)

5.3 (3.3) 8.6 (5.3) 13.2 (8.2)

Max. towbar pulling effort FORWARD 1st

282 (63.3)

297.0 (66.7)

2nd

160 (36)

168.7 (37.9)

3rd

90.5 (20.3)

95.8 (21.5)

1st

221.7 (49.8)

233.9 (52.6)

2nd

124.7 (28.0)

131.8 (29.6)

3rd

69.5 (15.6)

73.7 (16.6)

REVERSE PERFORMANCES

Ground pressure in operating conditions

kPa

in operating conditions - multi-shank ripper

kPa

71.5

Climbing capacity (FWD) LT/XLT

LGP

1st

3 km/h (1.87 mph)

3,4 km/h (2.1 mph)

2nd

5 km/h (3.1 mph)

5,6 km/h (3.5 mph)

3rd

9.0 km/h (5.6 mph)

10 km/h (6.2 mph)

Raising time (from ground to max. height)

sec

2.9

Controlled lowering

sec

1.4

Floating

sec

1.4

dB(A)

111

Front equipment cycle times (ref. semi-U blade)

Noise Outside (2000/14/CE)LwA Back-up alarm SAFETY DEVICES

Left safety lever It blocks the equipment, cuts-off the transmission and engages the parking brake Right safety lever It blocks the equipment, cuts-off the transmission and engages the parking brake

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0-7 TECHNICAL DATA D180 Engine manufacturer

Cummins

Engine model

6CTAA - 8.3

Engine type: Direct injection, 4-stroke turbocharged, after-cooling Bore and stroke

mm (in)

Total displacement

L (gal.)

Number of cylinders

8.3 (2.2)

D180 LT/XLT

6 HP

Net power kW hp rated @ 2000 rpm peak @1700 rpm

rated @ 2000 rpm peak @1700 rpm

DIN 6270

136

142

182

190

SAE J1349

134

140

180

187

ISO9249

135

141

182

189

EEC 80/1269

136

142

182

190

D180 LGP Net power kW hp

rated @ 2000 rpm

reted@ 2000 rpm

DIN 6270

147

197

SAE J1349

145

194

ISO9249

146

196

EEC 80/1269

147

197

Torque limit ENGINE AND ACCESSORIES

114 x 135 (4.5x5.3)

Fuel consumption (MAX. POWER)

deg kg/h (lb/h)

45 30.7 (67.7)

Starting capacity Standard configuration

째C (째F)

-12 (10)

With cold starting system

째C (째F)

-25 (-13)

Electrical system System voltage Capacity of starter motor

Volt

kW (HP)

Capacity of alternator

7.8 (10.5)

Amp

Radiator Dimensions of transmission heat exchanger Dimensions of body (coolant)

mm (in)

454x1040x114 (18x41x4.5)

Material of body (Inclined and stacked brass tubes with copper fins)

No of tubes per line

Gauge of fins

mm (in)

3.5 (0.1)

Cap pressure

bar (psi)

1.0 (14.5)

mm (in)

500 (19.7)

Air radiator/air Fan diameter N. hoses

Pitch

2.8 2

Radiant surface

dm (in )

31.3 (485.1)

Operating pressure

bar (psi)

2 (29)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0-8 TECHNICAL DATA D180 Water pump flow (at normal speed)

L/min (US gpm)

Fan (Blowing) / Soundproof blowing fan

270 (71.3) TRUFLO

Fan diameter

mm (in)

Blade pitch Number of blade Dimension of blades

ABB

762 (30)

704 (27.7)

deg

178x258

mm (in)

(7x10.2) Drive ratio (fan/engine)

0.87:1

Air cleaner Brand

Donaldson

Type

FHG12-0345

Dry type, two stages with safety element and centrifugal separator ENGINE AND ACCESSORIES

Setting of clogging indicator

bar in H2O

0.062 (25)

Initial clogging (@ 13 cum /min) Cummins limit : 15 in H2O

bar in H2O

0.023 (9.4)

Dust containment capacity (@ 13 cum /min) Cummins limit : 25 g/CFM Dimensions

g/CFM

mm (in)

304.8 (12)

Pre-cleaner Rotor/centrifuge assembly, it uses centrifugal force to separate contaminants carried by the air Recommended operation range

efficiency L/min (CFM)

Silencer

85% 9910.9 to 19821.8 (350 รท 700) Donaldson

Horizontal type. Under hood. Dimensions

mm (in)

209x292x600 (8.2x11.5x23.6)

FUEL TANK

TORQUE CONVERTER AND HOUSING

Max. counter-pressure (Cummins limit: 76 mmHg, 1.46 psi) bar (mmHg)

0.10 (75)

Total volume

400 (106)

L (US gal)

Specifications of filler cap

Brand:

Twin Disc

Model:

15" MS 335

Type:

Single stage, single phase

Stall ratio

2.28 : 1

Nominal diameter

mm (in)

381 (15)

Setting of pressure relief valve @ 10 L/min (2.642 gpm)

bar (psi)

10.5 (152.3)

Nominal flow of transmission pump @ 17 bar (246.5 psi) L/min (US gpm)

66.0 (17.4)

Nominal flow of TC @3 bar (43.5 psi)

116.0 (30.6)

L/min (US gpm)

Wet TC housing with scavenger pump

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0-9 TECHNICAL DATA D180 Type:

countershafts

Model:

TM 200

Make:

Specifications:

3 + 3 speeds, speeds and direction modulation valves electronic controls + automatic mode integrated CPU and TM control

PTO capacity Max. torque @ 0 rpm

daNm (lbf.ft)

Max. speed @ 0 torque

169 (1246)

rpm

2183

Specifications: Clockwise rotation (from rear of machine) driven by Torque Converter Shaft specifications: Number of teeth

Module

mm (in)

1.58 (0.06)

Outer diameter

mm (in)

34.87 (1.37)

Filters: TRANSMISSION

Suction: Metal mesh + magnetic rod

mesh

100

Micron

25 abs.

Line: Screwed-on Setting of by-pass valve

bar (psi)

3.44 (49.9)

Collecting capacity @ 3.44 bar (49.9 psi) (ISO 4572)

g (lb)

Filtering area

cm (in )

3075 (476.6)

Loss of charge @ 80 L/min (21.1 gpm)

bar (psi)

0.71 (10.3)

Nominal pressure of element

bar (psi)

34.5 (500.4)

Rupture pressure of element

bar (psi)

70 (1013.3)

Setting of transmission regulation valve (@ 66 L/min) (17.4 gpm) bar (psi)

17 (246.6)

Oil radiator body in aluminium

50 (0.1)

mm (in)

310x1010x150 (12.2x39.8x5.9)

Controls: Finger tip type, FNR pivoting control, shift up-down switches, neutral switch Safety levers Description of auto mode AL Down-shifting of transmission when the engine slows down to a pre-determined speed AS Allows the operator to pre-select the 1st speed in froward and the 2nd in reverse at direction changes

PROPELLER SHAFT

Dimension of shaft Mechanical 7C Nominal length

mm (in)

425 (16.7)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 10 TECHNICAL DATA D180 Gleason type, modular pinion assembly. Forced lube pinion bearings D180 Power Steering

BEVEL GEAR GROUP Ratio: Module:

mm (in)

D180 Steering Clutch

17/36

13/40

10 (0.4)

9.23 (0.36)

The machine uses a differential steering system; this consists of a hydraulic pump, a hydraulic motor, controls, two planetary modules and a steering gear train. The rear transmission has two power inlets. One from the bevel gear for the speed and Forward reverse, the other from the motor, to turn. The steering system is actuated by two "finger tip" (potentiometric levers), located on the left side of the operator's seat. The levers send an electric signal to the microprocessor controlling the two proportional solenoid valves; these valves convert the electric signal into a hydraulic one, piloting 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 planetary modules and the right track chain. The open hydrostatic circuit includes: - main pump the same of the equipment (see hydraulic system)

STEERING SYSTEM

cc/rev

130

- hydraulic motor Bent axis design, axial pistons, fixed displacement motor (with bolt-on movement control valve) Displacement Max. operating pressure

cc/rev bar (psi)

90 350 (5076)

- Steering control valve Closed centre. This section is included in the implement 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 control (blade raising) - Make-up valve It provides pressure to both equipment control pilot valves and to the proportional solenoid valves bar (psi) - Oil radiator Aluminium body By-pass setting

mm (in) bar (psi)

30 (435.1) 590x179x63 (23.2x7x2.5) 5 (72.5)

Planetary modules See "power train" diagram Gear ratio straight travel conditions

Steering line See "power train" diagram

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

1.44

D180

0 - 11 TECHNICAL DATA D180 Gear ratio Hydraulic motor to sprocket

STEERING SYSTEM D180 POWER STEERING

1.92

Performance Min. steering radius Max. differ. track chain speed, no load condition Max. differ. track chain torque at 350 bar

m (in)

1.0 (39.4)

km/h (mph)

4.0 (2.5)

daNm (lbf.ft)

0.72 (5.3)

The steering system is driven by two levers located on the left side of the operator's compartment. During translation, the lever sends a modulated pressure through the electronic control unit and the electroproportional valves to the steering control valve. The first pressure controls the steering clutch disconnection. The second pressure is equal to zero until the first pressure reaches 16 bar (50% of lever stroke). It applies the steering brakes positively. The service brake system is negatively controlled by the brake pedal or by pulling the two levers at the same time. The pedal operation cuts the brake system counterpressure with modulation and applies the braking load with the springs.

STEERING SYSTEM D180

Steering clutches: - Typology

with multiple discs, oil bath through spring electro-hydraulic

- Control

Number of clutch driven discs (sintered) Number of driving discs (sintered) Total area for one clutch Inner diameter Outer diameter Steering filters Suction Metal mesh + magnetic rod

7 (per clutch) 8 (per clutch) 7612 cm3 280 mm 350 mm

mesh

100

Micron

25 abs.

Aligned filters: Screwed-on Setting of by-pass valve

BRAKES

bar (psi)

3.44 (49.9)

Collecting capacity @ 3.44 bar (ISO 4572)

g (lb)

Filtering area

cm (m )

3075 (476.6)

Loss of charge @ 80 L/min

bar (psi)

0.71 (1029.7)

Nominal pressure of element

bar (psi)

34.5 (500.4)

Rupture pressure of element

bar (psi)

70 (1015.5)

Multiple discs, spring actuated, oil released, oil cooled No. of clutch discs Outer diameter Inner diameter Total friction area Friction material No of springs

mm (in) mm (in) cm2 (in2) -

5 350 (13.8) 280 (11) 2771 (429.5) sintered 20

50 (0.11)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 12 TECHNICAL DATA D180 Max. braking torque Pump flow (@engine max. speed) System pressure

BRAKES SECTION STEER./BRAKES

daN (lb) L/min bar (psi)

1016 (2284) 50 25 (362.6)

Fabricated housing Countershaft, double reduction, modular assembly

FINAL DRIVE

Total ratio

12.286

Segments. 9 Elements SPROCKET

No. of teeth Pitch diameter

mm (in)

880.25 (34.6)

Fabricated structure with two sealed boxes

TRACK FRAME

Sealed track tensioner compartment

Link pitch

XLT/LGP

203 (8)

No. of links

Link height

mm (in)

128 (5)

Shoe height

mm (in)

71.5 (2.8)

kg/m (lb/in)

38.2 (2.13)

Weight of shoes per metre UNDERCARRIAGE

mm (in)

Width of standard shoe

mm (in)

560 (22)

915 (36)

Width of optional shoes

mm (in)

610 (24)

762 (30)

XLT/LGP

No. of track rollers

Sequence of rollers from sprocket

SF-DF-SF-DF SF-DF-SF-DF -SF-DF-SF SF-SF-DF-SF

Diameter of rollers No. of support rollers

mm (in) -

210 (8.3)

Diameter of rollers (support)

mm (in)

187.5 (7.4)

Diameter of idler wheel

mm (in)

690 (27.2)

Sliding idler guides with replaceable wear strips Sealed track tensioner compartment. Grease piston for track tension adjustment Single spring.

TRACK TENSION SYSTEM

Nominal load of spring assembly

daN (lb)

19509 (430173)

Outside diameter of spring

mm (in)

245 (9.6)

Diameter of wire

mm (in)

53 (2.1)

Diameter of grease piston

mm (in)

75 (2.9)

Setting of relief valve

bar (psi)

900 (35.4)

Pivot shaft (near sprocket) and fixed frond cross-member All joints permanently sealed

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 13 TECHNICAL DATA D180

TRACK TENSION SYSTEM

Diameter of pivot shaft

mm (in)

120 (4.7)

Thickness of cross-member

mm (in)

80 (3.1)

Swing travel (track chain)

deg

Idler travel (total)

± 3.5

mm (in)

255 (10)

Width of frame

mm (in)

1040 (40.9)

Width of longeron

mm (in)

100 ÷ 145 (3.9 ÷ 5.7)

mm (in)

1984 (78.1)

Pin diameter

mm (in)

45 (1.8)

Shim of bar

mm (in)

90 (3.5)

Fabricated structure, with two main members. TRACK SUSPENSION SYSTEM

Bolted to steering compartment housing.

Fabricated structure, with two main members. COUNTER FRAME

With integrated mudguards. Total width Bolted to steering compartment housing

HOOK FRAME

Load sensing system, splits the flow with piloted variable pump. The feeding valve provides pressure to both pilot valve controls and the proportional solenoid valves A priority valve provides priority to the steering over the equipment control (blade raising). System pressure

D180 Power Steering

D180 Steering Clutch

Setting of dual pressure relief valve (equipment/steering)

bar (psi)

160/350 180/200 (2320/5076) (2610/2900)

Pressure of piloting line

bar (psi)

30 ÷ 32 (435 ÷ 464)

D180 Power Steering

D180 Steering Clutch

Variable displac.

Fixed displac.

90 (120.7) @ 1950 rpm 350 (5076) 20 ÷ 21 (290 ÷ 304) Rexroth A11V0130 130 1912 249 (65.8) 15 33 ÷ 37

Main pump: axial pistons

HYDRAULIC SYSTEM Governors: constant power control

kW (HP)

Cut-off pressure Load sensing

bar (psi) bar (psi)

Brand Model Max. displacement Pump speed at max. engine speed Pump max. flow Min. displacement Pressure stand-by

cc/rev rpm L/min (gpm) cc/rev bar (psi)

(478.6 ÷ 536.6)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

250

Rexroth A10V0100 88 1912 170 15 28 ÷ 32

D180

0 - 14 TECHNICAL DATA D180 Tool control valve: Piloted, Closed centre, flow partition, with unloading valve.

D180 Power Steering

D180 Steering Clutch

4 spools

3 spools

Brand

Rexroth

Model

4M7 - 22

3M6 - 15

mm (in)

22 (0.86)

15 (0.59)

L/min (gpm)

70 (18.5)

Nominal dimensions st

1 spool Ripper (raising, lowering) 2nd spool Blade tilt (left, right) Max. delivery rd

3 spool Blade (raising, owering, float, with hook) 4th spool Steering motor

Does not exist

Pilot valve Single lever for 2nd and 3rd spool

HYDRAULIC SYSTEM

Brand

Rexroth

Model

5THF6

Auxiliary lever Single lever for 1st spool Brand

Rexroth

model

2TH6

Cylinders: Blade 2-with quick-drop valves and stroke limitation valve Bore

mm (in)

95 (3.7)

Rod diameter

mm (in)

60 (2.4)

Stroke

mm (in)

1250 (49.2)

Bore

mm (in)

140 (5.5)

Rod diameter

mm (in)

70 (2.7)

Stroke

mm (in)

126 (4.9)

Bore

mm (in)

110 (4.3)

Rod diameter

mm (in)

63 (2.5)

Stroke

mm (in)

124 (4.9)

mm (in)

100 (3.9)

Tilt (bulldozer blade)

Tilt (angledozer blade)

Ripper Bore

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 15 TECHNICAL DATA D180 Rod diameter

mm (in)

56 (2.2)

Stroke

mm (in)

480 (18.9)

Hydraulic tank

D180 Power Steering

D180 Steering Clutch

Total tank capacity

L (US gal)

90 (23.8)

Oil tank volume

L (US gal)

70 (18.5)

Capacity oil circuit

L (US gal)

130 (34.3)

110

Strainer Media Metalic mesh Filtration capacity

HYDRAULIC SYSTEM

micron

By-pass valve setting

250

bar (psi)

Max. nominal flow

L/min (gpm) 2

0.2 (2.9) 275 (72.6)

Surface

cm (in )

1480 (229.4)

Pressure drop at max. flow

bar (psi)

0.02 (0.29)

Return filter Media inorganic glass fibre paper Filtration capacity

micron (absolute)

By-pass valve setting

bar (psi)

2.5 (36.2)

Differential switch setting

bar (psi)

2.2 (31.9)

Surface Max. nominal flow

cm (in )

9000 (1395)

L/min (gpm)

440 (116.2)

Cab: Fully enclosed cab, modular, tiltable to 60Â° on the left side. ROPS-FOPS structure with 4 posts. Two doors, two side windows. 4 resilient supports Cab lay-out description Left console: With fully adjustable armrest (satellite) including the Steering and Transmission controls. The console holds: Auto T/M switches, left safety lever, Climatization dashboard. Right console: OPERATOR'S COMPARTMENT

Support for hydraulic joystick and 3rd function lever, adjustable armrest, horn, ashtray, ignition key. Front control module: Monitor, control switches, throttle hand lever (RH) Pedal support: Central brake pedal, decelerator pedal (RH), footrest (2) Cab accessories: Rear mirror Front window windshield wiper, door windshield wipers Rear windshield wiper Ashtray and cigarette light

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 16 TECHNICAL DATA D180 Dom light (2) FM-AM Radio (12 Volt) Can holders 12 V jack for lunch box refrigerator No. of air ducts

Seat Make

Kab

Model

301

Adjustment range

mm (in)

150 (5.9)

Height adjustment

mm (in)

60 (2.4)

kW (HP)

10.4 (13.9)

Other features Fabric coath, with safety belt and tie links Heater group Heating capacity (air inlet temp. -10 °C; air flow 600 m3/h; water inlet temp. 85 °C; water flow 800 L/h) Filter: Media, inorganic glass fibre paper Efficiency Capacity

> 65

micron

0.3

cm (in )

Size OPERATOR'S COMPARTMENT

19600 (3038)

Recirculation percentage: No. of fans (type: SPAL 006-839-22 3 speed - total free flow 1160 m3/h)

No. of fan speeds

Max. cab air flow (free total air flow 1160 m3/h)

m3/h (ft3/h)

Max. pressurization

bar (psi)

500 (17657) 0.0019 (0.028)

Air conditioner group Max. gas charge

g (lb)

1600 (3.5)

Cooling capacity (air inlet temp. +30 °C; air flow 600 m3/h; air relative humidity 55%)

kW (HP)

Re-circulation percentage

6 (8) na

Compressor Make

Sanden

Model

SD7H1SMD7948

Displacement (max. allowed speed 7000 rpm) Thermostat valve setting

cc/rev

160 +1 °C (33.8 °F) open: diff. temp. setting 3.5 °C (38.3 °F)

Pressure switch (2 level type): LOW LEVEL: HIGH LEVEL: Expansion valve

open 2 bar, closed 2.1 bar open 25 bar, closed 19 bar 2 TON - 6000 kcal/h

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 17 TECHNICAL DATA D180 Condenser Size (front surface) No. of fans (type: SPAL VA 14-BP7/C-34A Fan diameter Fan size

OPERATOR'S COMPARTMENT

mm (in)

690 x 200 (27.2x7.9)

mm (in)

kW (HP)

Tilting system Tilt cylinder Double stroke with stroke-end valves Brand Diameter

Weber mm (in)

45 (1.8)

Hand pump Double stroke with oil tank Brand Nominal displacement

Weber cm3 (in3)

3.6 (0.22)

Alternator Brand

Delco-Remy

Model

EE9059

Capacity

24 Volt-70 Amp

Starter motor Brand

Delco-Remy

Model

ST 9099

Capacity

42MT - 7.8 kW

Batteries No. of elements

No. of connections ELECTRICAL SYSTEM

series

Brand Capacity Discharge

Magneti Marelli Amp h

160 - 12 Volt

Amp

650

Lighting system No. of elements

2 front lights + 2 side work lights

(HP) W

70 (0.09)

2 rear work lights

(HP) W

70 (0.09)

Other main components Main switch

manual

Engine cut-off solenoid

FV 9187

Link fuses

Amp

Fuse boxes

50 & 80 2 x 11 fuses

Four position key starter switch Monitor

24 Volt

MC Elettronica

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 18 TECHNICAL DATA D180

ELECTRICAL SYSTEM

Engine rpm counter

digital

Hourmeter

digital

Fuel level

level indicator

Coolant temperature

level indicator

Steering/transmission display

digital

Steering valves (q.ty 2)

proportional

Transmission control solenoids (q.ty 4)

on-off

Back-up alarm

P.I. 109 dB(A)-1000 Hz

Transmission and Steering electronic control unit

Rexroth

Two push beams hinged to the track frame by ball joint. hydraulic tilt adjustment and mechanical pitch. Equistatic compensator. Pins Diameter

mm (in)

120 (4.7)

Beam height

mm (in)

200 (7.9)

Diameter of front ball joint

mm (in)

108 (4.2)

Width (blade)

mm (in)

3350 (131.9)

Width (tip of corner bits)

mm (in)

3385 (133.3)

Height

mm (in)

1215 (47.8)

Push beams

HS blade:

m (ft )

3.9 (137.7)

Max. raising

mm (in)

1090 (38492)

Penetration into the ground

mm (in)

450 (17.7)

Max. tilt

mm (in)

830 (32.7)

Nominal capacity

BULLDOZER EQUIPMENT

Max. pitch

deg

± 5° 30'

mm (in)

20 (0.8)

Wear components: Two corner bits + three reversible cutting edges Thickness of cutting edges Break-up force (lift cylinders) Break-up force (tilt cylinder) Semi-U blade Width (blade)

3460

Width (tip of corner bits)

mm (in)

3620 (142.5)

Height

mm (in)

1425 (56.1)

Nominal capacity

mm (in)

5.62 (0.2)

m3 (ft3)

1090 (38492)

Penetration into the ground

mm (in)

475 (18.7)

Max. tilt

mm (in)

850 (33.5)

Max. raising

Max. pitch

deg

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

± 5° 30'

D180

0 - 19 TECHNICAL DATA D180 Wear components: Two corner bits + three reversible cutting edges

BULLDOZER EQUIPMENT

Thickness of cutting edges

mm (in)

20 (0.8)

Break-up force (lift cylinders)

Break-up force (tilt cylinder)

C-frame hinged to the track frame by ball joints. Hydraulic tilt adjustment and mechanical pitch adjustment. Side guides. C-frame height Diameter of front ball joint

200 (7.9) mm (in)

150 (5.9)

Width (blade)

mm (in)

Width (tip of corner bits)

mm (in)

4000 (157.5)

Height

mm (in)

1030 (40.5)

m3 (ft3)

3.18 (112.3)

Max. raising

mm (in)

1148 (45.2)

Penetration into the ground

mm (in)

452 (17.8)

Max. tilt

mm (in)

380 (14.9)

Angledozer blade

ANGLEDOZER EQUIPMENT

Nominal capacity

Max. pitch

deg

Âą 5Â° 30'

mm (in)

20 (0.8)

Wear components: Two corner bits + three reversible cutting edges Thickness of cutting edges Break-up force (lift cylinders)

Break-up force (tilt cylinder)

Parallelogram PD180 ripper Two double-stroke cylinders

MULTISHANKS RIPPER LT/XLT

Bore and stroke of cylinder rods

mm (in)

100 x 56 (3.9x2.2)

Bore

mm (in)

480 (18.9)

Length closed

mm (in)

845 (33.2)

Length extended

mm (in)

1325 (52.2)

Cylinder supports and equipment beams in welded boxed structure H. D. semi-curved shanks with replaceable tips No. of shanks

Dimensions (according to ISO 6746/2)

Ripping depth

mm (in)

540 (21.3)

Ripping width

mm (in)

1900 (74.8)

Ground clearance under shank with ripper raised

mm (in)

503 (19.8)

Ground clearance under shank with ripper lowered

mm (in)

390 (15.3)

Total width

mm (in)

2130 (83.9)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 20 TECHNICAL DATA D180

MULTISHANKS RIPPER LT/XLT

Break-up force

daN

15800

Penetration force

daN

6250

Mass

kg (lb)

1600 (3527.4)

Mass of shanks (3 shanks)

kg (lb)

410 (903.9)

Hydraulic oil increment

L (US gal)

10 (2.6)

Parallelogram RP14F ripper One double-stroke cylinder Bore and stroke of cylinder rod

mm (in)

140 x 70 (5.5x2.8)

Bore

mm (in)

380 (15)

Length closed

mm (in)

993 (39)

Cylinder support and equipment beams in welded boxed structure H. D. semi-curved shanks with replaceable tips MULTISHANKS RIPPER LGP

No. of shanks

Dimensions (according to ISO 6746/2)

Ripping depth

mm (in)

432 (17)

Ripping width

mm (in)

1800 (70.9)

Ground clearance under shank with ripper raised

mm (in)

618 (24.3)

Ground clearance under shank with ripper lowered

mm (in)

138 (5.4)

Total width

mm (in)

2030 (79.9)

Break-up force

daN

14050

Penetration force

daN

3470

Mass

kg (lb)

1238 (2729.3)

Mass of shanks (3 shanks)

kg (lb)

192 (423.3)

Hydraulic oil increment

L (US gal)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

5 (1.3)

D180

0 - 21

CONTROL DATA ON THE MACHINE ENGINE Net power flywheel power (ISO 9249) Low idle High idle Implem. stall Torque converter/transmission stall Full stall

kW (HP) rpm rpm rpm rpm rpm

196 HP/ 146 kW (196) 680 ÷ 820 2140 ÷ 2160 2070 ÷ 2210 1780 ÷ 1920 1700 ÷ 1900

At low idle (allowable minimum)

bar (psi)

0.69 (10)

At max. speed (allowable minimum)

bar (psi)

2 (29)

Pressure of filter by-pass

Lubrication

bar (psi)

1.68 (24.4)

Temperature of thermostats

°C (°F)

81 ÷ 83 (178 ÷ 181)

Max. temperature setting

°C (°F)

95 (203)

Setting of BOSCH injectors

bar (psi)

260 ÷ 270

bar (psi)

17 (246.6)

Torque converter safety valve

bar (psi)

10.5 (152.3)

Lube oil pressure relief valve

bar (psi)

3 (43.5)

Main pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

1st speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

2nd speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

3rd speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

Forward clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

Reverse clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.3 to 253.8)

Brakes powering

bar (psi)

22.5 ÷ 27.5 (326.3 to 398.8)

Pressure regulated by brake pedal valve

bar (psi)

18 ÷ 22 (261 to 319)

Powering pressure

bar (psi)

31.5 ÷ 35.0 (456.9 to 507.6)

Max. pressure (equipment/steering)

bar (psi)

190/350 (2320.6/5076.3)

TRANSMISSION Pressure relief valve

BRAKES SYSTEM

HYDRAULIC SYSTEM (equipment/steering)

Hold @ neutral

bar (psi)

33 ÷ 37 (478.6 to 536.6)

Hold @ float

bar (psi)

33 ÷ 37 (478.6 to 536.6)

LS delta

bar (psi)

20 ÷ 21 (290 to 304.6)

Float selection

bar (psi)

25 (362.6)

Setting of discharge valve (@ 10 L/min)

bar (psi)

28 ÷ 32 (406.1 to 464.1)

bar (psi)

900 (13053.4)

UNDERCARRIAGE Pressure relief valve

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 22

D180 Power Steering - Steering Clutch (LT/XLT) ENGINE Net flywheel power (ISO 9249) Low idle High idle Implement stall Torque converter/transmission stall Full stall

kW (HP) rpm rpm rpm rpm rpm

182 HP/ 135 kW 780 ÷ 920 2080 ÷ 2220 2070 ÷ 2210 1730 ÷ 1870 1675 ÷ 1875

At low idle (allowable minimum)

bar (psi)

0.69 (10)

At max. speed (allowable minimum)

bar (psi)

2 (29)

Pressure of filter by-pass

bar (psi)

1.68 (24.4)

°C (°F)

81 ÷ 83 (178 ÷ 181)

Lubrication

Temperature of thermostats Max. temperature setting Setting of BOSCH injectors

°C (°F)

95 (203)

bar (psi)

260 ÷ 270 (3771 to 3916)

Pressure relief valve

bar (psi)

17 (246.6)

Torque converter safety valve

bar (psi)

10.5 (152.3)

TRANSMISSION

Lube oil pressure relief valve

bar (psi)

3 (43.5)

Main pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

1st speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

2nd speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

3rd speed clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

Forward clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

Reverse clutch pressure

bar (psi)

16.5 ÷ 17.5 (239.9 to 253.8)

BRAKES SYSTEM Brakes powering

bar (psi)

22.5 ÷ 27.5 (326.3 to 398.8)

Pressure regulated by brake pedal valve

bar (psi)

18 ÷ 22 (261 to 319)

HYDRAULIC SYSTEM (equipment/steering) Powering pressure

bar (psi)

28 ÷ 32 (406.1 to 464.1)

Max. pressure (equipment/steering)

bar (psi)

180/200 (2610.6/2900.7)

Hold @ neutral

bar (psi)

28 ÷ 32 (406.1 to 464.1)

Hold @ float

bar (psi)

28 ÷ 32 (406.1 to 464.1)

LS delta

bar (psi)

20 ÷ 21 (290 to 304.6)

Float selection

bar (psi)

25 (362.6)

Setting of discharge valve (@ 10 L/min)

bar (psi)

28 ÷ 32 (406.1 to 464.1)

bar (psi)

900 (13053.4)

UNDERCARRIAGE Pressure relief valve

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

X X X X

X X X X X X X X

X X X X

X X X

X X X X

CANOPY

X X X

X X X X

CAB

OPER. COMP.

X X X X X X X X X X X X X X X X X X X X X X X X X X

BASIC MACHINE

DOZER BLADE

EQUIPMENT SEMI-U ANGLE BLADE

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

X X X X X X

X X X X X X X X

X X X X X X

X X

X X X X X X X X X X X X X X

X X

X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X X X X X X

SHOES mm (in) TRACK CHAIN FUEL OPERATOR 560 610 RIPPER (22.04) (24.01) STD LONG 10% 100%

TABLE OF WEIGHTS D180 - D180 POWER STEERING

16910 17060 17660 17830 16610 16760 17360 17530

19920 20150 19760 22160 19620 19850 19460 21860 20070 20300 19910 19770 20000 19610 20670 20900 20510 20370 20600 20210 20840 21070 20680 20540 20770 20380

37280 37611 38934 39308 36618 36949 38272 38647

43916 44423 43563 48854 43254 43761 43299 48193 44246 44753 43894 43585 44092 43233 45569 46077 45217 44908 45415 44555 45944 46451 45592 45283 45790 44930

TOTAL WEIGHT

S H I P P I N G

W E I G H T S

O P E R A T I O N A L

D180 0 - 23

D180

0 - 24

TABLE OF WEIGHTS D180 - D180 Power Steering

OPERATOR

FUEL 100%

WEIGHTS TOTAL kg (lb)

610 (24)

20380 (45260.9)

610 (24)

21480 (47686)

915 (36)

22730 (50111)

LT(SC)

560 (22.04)

20050 (44203)

XLT(SC)

560 (22.04)

21150 (46628)

BASIC MACHINE

CAB

SEMI-U BLADE

SHOES (mm) (in)

LT(PS)

XLT(PS)

LGP(PS)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

OPERATIONAL WEIGHTS

D180

0 - 25

LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS kg

Engine assembly

861

1898

Engine (with air cleaner and silencer)

700

1543

Torque converter assembly (with pumps)

161

355

Torque converter + housing

201

Main pump (D180 Power Steering)

132

Main pump (D180)

110

Brake pump

Transmission & converter pump

Radiator assembly (empty)

120

265

Universal joint

Transmission assembly

530

1168

Steering compartment assembly (with final drives)

3060

6747

Steering compartment assembly

1654

3647

Bevel pinion assembly

Bevel gear set

Bevel gear shaft

Steering module assembly (each)

235

518

Starter housing

905

1995

Ring gear

19.1

Ring gear, support

12.2

Hydraulic motor (D180 Power Steering version)

Cover assembly (including gears)

122

269

Final drive assembly (each)

703

1550

Pivot shaft

143

Swing bar

160

353

Shoes (910 mm (35.82 in), each)

Track chain assembly (560 mm (22 in) shoes, 40 elements)

1463

3225

Track chain assembly (915 mm (36 in) shoes, 45 elements)

2276

5007

Shoes (560 mm (22 in), each)

Shoes (610 mm (24 in), each)

Carriage assembly - LT

1514

3330

Carriage assembly - XLT/LGP

1800

3960

Track roller (each)

117

Support roller (each)

Track chain tensioner assembly

233

514

Idler wheel assembly

212

467

Track guide (each)

Fuel tank (empty)

180

397

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 26

LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS kg

Hydraulic tank (empty)

120

265

Battery (each)

108

Battery box

Operator's compartment

950

2094

Operator's compartment (canopy)

â&#x20AC;&#x201C;

Upper frame

480

1058

Hood support

187

Hood

Side panel (upper)

Side panel (lower)

Front grill

Hydraulic control valve (D180 Power Steering)

160

Hydraulic control valve (D180)

Lift cylinder (each)

110

243

Yoke cylinder (each)

1860

4101

Semi-U blade (with equistatic + pushers)

100

220

Push beams (each)

350

772

Tilt cylinder

176

Pivot pin (each)

Angle blade with pushers

1430

3153

C-frame

1140

2513

Ripper assembly

2010

4431

Shank (each)

137

302

Ripper plus cylinder

1600

3527

Main frame (with lower guards)

1470

3241

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 27

CENTRE OF GRAVITY TABLE

Machine configuration: HG mm (in)

LG mm (in)

Blade on ground and ripper on ground

835 (32.87)

1285 (50.59)

Blade on ground and ripper at max. height

880 (34.64)

1320 (51.96)

Blade at max. height and ripper on ground

930 (36.61)

1270 (50)

Blade at max. height and ripper at max. height

980 (38.58)

1310 (51.57)

Blade on ground and ripper on ground

780 (30.70)

1285 (50.59)

Blade on ground and ripper at max. height

965 (37.99)

1345 (52.95)

Blade at max. height and ripper on ground

812 (31.96)

1265 (49.80)

Blade at max. height and ripper at max. height

1020 (40.15)

1312 (51.65)

Blade on ground

780 (30.70)

1575 (62)

Blade at max height

935 (36.81)

1565 (61.61)

Basic machine (no ripper no blade)

910 (35.82)

1230 (48.42)

Basic machine + HSU blade + Ripper

Basic machine + HA blade + Ripper

Basic machine + HSU blade

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

F14320

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 28

GENERAL INSTRUCTIONS INSTALLATION OF SEALS FOR ROTATING SHAFTS

REMOVAL AND INSTALLATION OF ELASTIC RINGS FOR ROTATING SEALING

Please comply with the following advises:

Remove the rings as follows:

- prior to installation, keep the seals half an hour dipped into the same oil they are going to seal;

- press the ring so that one end and part of the inner circumference contact the bottom of the relevant seat (a);

- clean accurately the shaft and make sure that its working surface is undamaged; - direct the sealing lip towards the fluid; in case of an hydro dynamic lip, the grooves must be oriented so that the rotating direction of the shaft, tend to return the oil inside the seal;

- keep the ring in the position above and, acting with a scriber on the other end, free the catches, as indicated in the figure (a).

- smear the sealing lip with a film of lubricant (oil is preferred to grease); - install the seal into its seat by pressing it or using a punch with a flat contact face; absolutely avoid hammering it; - when pressing the seal, make sure that it is entered perpendicularly to its seat and once the pressing is over, make sure, when requested, that is seated against the shoulder; - in order to avoid damaging the sealing seat with the shaft, it is recommended, during the installation of the two parts, to insert an appropriate seal.

Re-install the elastic rings as follows: INSTALLATION OF O-RINGS Lubricate the seals before placing them into the relevant seats so as to avoid that, during the installation, they tend to roll, thus altering their correct positioning, being furled, causing prejudice to their sealing function.

- Press the ring so as to have one end and part of the inner circumference touching the bottom of the relevant seat (b);

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 29

- install the ring in the position describe above and lift the free end (b) moving it until the two catches engage correctly (c).

CLEANING After disconnecting the electrical system, clean accurately all the parts to be disassembled, preferably using steam. In many repair or service workshops, caustic compounds are used to eliminate all traces of grease, dirt, paint or remains of sealing materials etc. from the parts. These compounds are very useful and efficient when used correctly; however they can cause considerable damages to certain components. Materials such as aluminium, rubber, fibres, sintered bronze and alloying elements are particularly sensitive to all highly concentrated caustic compounds. Some heat exchangers are made with aluminium fins. To clean internally or outside these parts, the use of solvents not reacting with aluminium are recommended.

b DISASSEMBLY It is always recommended, for any intervention on engines or other assemblies removed form the machine, that appropriate stands are used. Make available baskets or containers sufficient to store all the smaller size parts disassembled. Take particular care of machined faces of the components, placing them, after the disassembly, on shelves or wooden blocks.

c RECOMMENDATIONS FOR THE DISASSEMBLY AND REASSEMBLY OF GROUPS The following information, of a general nature, are intended to facilitate the disassembly and reassembly of groups. Consequently, read and heed them when performing this type of operations.

When identical parts are disassembled, such as valves, tappets etc., place them in appropriate containers to ensure the same mating order when reassembling.

ASSEMBLY Clean accurately all the components to be reassembled, as described by the various chapters of the Manual. The use of the proper special tools shown in the Manual is recommended. Note â&#x20AC;&#x201C; When applying sealing adhesive compounds, comply with the instructions provided with commercial products.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 30 The manufacturer, prescribes, unless differently specified, the following adhesive compounds: RHODOSIL CAF 1, or LOCTITE 510. Whenever possible, press bushes into their correct position using a press. In the event it is necessary to use a hammer to install a bush, use an appropriate punch to avoid damaging the bush. Lubricate ball bearings prior to their installation. Lubricate the sealing lip of all seals, prior to their installation. Whenever possible, install new seals; in particular new gaskets must be used on engine cylinder heads. Use screws with the dimensions and grade indicated, referring to the part number of the Spare Parts Catalogue.

HIGH PRESSURE PIPES, CONNECTIONS, HOSES AND PIPES This chapter provides correct recommendations and procedures to be followed during the disassembly of pipes and relevant connections. - Keep all internal and external threads clean; - Remove the plugs just before connecting the pipes and plug at once all open connections. - Do not use or reuse semi flanges out of shape more than 0.6 mm in the centre (see figure). - Make sure that the seats of O-rings are undamaged. - Lubricate all O-Rings. - Make sure that O-Rings are in place in the relevant seat. - Tighten regularly so as to avoid distortions or damages to O-Rings.

When indicated, safety washers, split pins and locking wires etc. must be used.

- Install pipes and support bands letting the latter slightly loosen (tighten the band only after tightening the connections).

Comply with the prescribed tightening torques indicated in the "Tightening torques" section of this Manual, using an appropriate torque wrench.

- Make sure that the hoses reach the corresponding part to be connected to without forcing their position.

Self-locking nuts must be replaced at each disassembly, to ensure a constant good performance against loosening.

- In the event a hose is mounted straight, let enough space to absorb contractions caused by pressure. - Hoses must not be rolled (see figure) or touching one another or touching other parts, especially if moving.

Wrong

Correct

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 31

- Make sure that the dimension of the bands is appropriate for the outer diameter of the pipe to be tighten to avoid possible rubbings (see figure).

Wrong

- Make sure that bands are installed in a correct position so that the hose is kept away from obstacles (see figure).

Correct

- Do not install bands on small diameter curves, to avoid that, under pressure, forces are generated in the pipe (see figure: the dotted lines indicate the contraction that the hose could be subject to under the action of the pressure).

Wrong

Correct

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 32

O-RINGS Field of application DESIGNATION

BASE ELASTOMER

TEMPERATURE of OPERATION (*)

- 40 to 120 °C (- 40 to 248 °F) NBR

FIELD OF APPLICATION

MINERAL OIL AND GREASE, COOLANTS, 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)

FLUOROCARBON (VITON)

FPM

ETHYLENE PROPYLENE

EPDM

MVQ

SILICON

- 40 to 200 °C (- 40 to 392 °F)

- 40 to 150 °C (- 40 to 302 °F)

-60 to 200 °C (- 76 to 392 °F)

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

GENERAL FUELS, NON FLAMMABLE FLUIDS, ACIDS, SOLVENTS, MINERAL OIL TO BE USED WITH TEMPERATURES > 100 °C (212 °F)

BRAKE FLUID (DOT 3), STEAM, HOT WATER, SILICON OIL AND GREASE. WARNING: NOT TO BE USED WITH MINERAL OIL AND GREASE

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

NOTE: (*) Temperature indicated for static applications, provided as indication only.

O-RING PROPERLY INSTALLED

O-RING PRESSURISED

O-RING EXTRUDED

O-RING BROKEN

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 33

TROUBLESHOOTING GENERALITIES For a fast troubleshooting, we recommend the compliance with the following rules:

a) Knowing the machine. It is impossible to research the causes and formula te a diagnosis of troubles without having a good knowledge of the machine. Thus it is recommended that the descriptions regarding the arrangement and the operation of the various groups provided by the Repair Manuals are carefully read.

e) Diagnosis Once the trouble is identified. prepare a list of the possible causes with the help of the suggestions of the chapter for the group involved and identify the correct one, using practical tests, starting from the most probable causes and the easiest tests.

b) Inspection with the operator Many trouble originate from a bad use or insufficient maintenance. Check with the operator if the machine was previously subject to the current trouble and eventual interventions have been performed with appropriate equipment and genuine spare parts. Also, check the environmental working conditions of the machine and make sure that current maintenance is performed.

c) Operating the machine The best way to ascertain the conditions of the machine is to test it under real working conditions. During such test, check: - the correct operation of the monitoring instrumentation; - the performance of the machine; - eventual odours or signs of overheating; - noises different from normal operation noises; identify their origin and the operating conditions during which they occur.

d) Inspection of the machine After the test of item c, stop the machine and have a visual inspection. Check whether the various groups show leakages of fluids, loosen bolts, failures of deformations etc.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 34 UNITS OF MEASURE

CLASSIFICATION OF STANDARD COMPONENTS TO DETERMINE THE TIGHTENING TORQUES

The units of measure used in this Manual are those adopted by the International System (I. S.) superseding those previously used by the M.K.S. system. Force:

decanewton (daN) supersedes kilogram (kg)

Pressure:

bar, supersedes kg/cm2

Torque:

decanewton x meter (daN meter) supersedes kg-m

To convert the units of measure, the following table applies:

Note – In case, in the different sections, the tightening torque is not listed, refer to the table "TIGHTENING TORQUES", only after identifying exactly the component.

The latter is identified by a coded eight digit number, allowing a complete description of the item.

Example: I

multiply

to obtain

0.9807

daN

kg/cm2

0.9807

bar

kgm

0.9807

daNm

/ a

e / f

I - Standard index digit Force Pressure Torque

It is always represented by the digit 1. This number indicates that the item can be fabricated in different versions, differing for the material and coating.

a - b - c - d - e - Standard base digit Note – For current repair needs, the following equivalencies can be considered valid: kg = daN; kg/cm2 = bar; kgm = daNm.

To convert the units of measure of the International System into an Anglo Saxon system, please refer to the following table: multiply

to obtain

2.205

Length

0.03937

Pressure

bar

14.5

psi

Torque

daNm

7.373

lbf.ft

Flow

L/min

0.2642

US gal/min

Temperature

°C

°C + 32

°F

Power

9 1.341 5

0.2642

US gal

km/h

0.6213

mph

Mass

It is a number always composed of five digits identifying the dimensional specifications of the item

f - Material index digit This digit indicates the material used fro a defined item. Its meaning is indicated in the table to follow.

g - Coating index digit

Capacity Speed

It indicates the coating applied to a defined item.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 35 Class of strength 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

Ottone

Messing

Brass

Laiton

Alluminio

Aluminium

Rame

Kupfer

Copper

Cuivre

100

10K

Free from other metal materials

NOTICES - Lubricate with engine oil the fixtures up to diameter 24, with tallow for larger diameters. - The tolerance on tightening torques is Âą 5%. - The strength classes R80, R100, R120, must be intended as follows:

10.9 supersedes R 100 12.9

R 120

supersedes R 80

supersedes R 100

} }

for screws

for nuts

CDT = cadmium plated; FOSF = phosphatised; ZNT = zinc plated.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

D180

0 - 36

TABLE OF TIGHTENING TORQUES In the event, the tightening torque of bolts and nuts is not specifically indicated in the single sections, the same can be found in the table listed 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 (lbf.ft) daNm (lbf.ft)

With polyamaide ring Normal daNm (lbf.ft)

Low type daNm (lbf.ft)

Diameter and pitch

normal ZNT daNm (lbf.ft)

autoblocc. ZNT daNm (lbf.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

CHAPTER

SUBJECT

PAGE

1.1

GENERAL SPECIFICATIONS ................................................................................................. 1-3

1.2

SERIES "C" ENGINE DATA ..................................................................................................... 1-5

1.3

DIAGRAMS OF SERIES "C" ENGINE ..................................................................................... 1-8

1.4

MOUNTING OF ENGINE ON FRAME .................................................................................. 1-11

1.5

AFTERCOOLER FAN DRIVE SYSTEM ................................................................................ 1-12

1.6

THROTTLE LINKAGE ........................................................................................................... 1-14

D180

1-3

ENGINE

1.1 GENERAL SPECIFICATIONS 1. The Series C engine is a diesel for heavy duty applications characterised by several design concepts tending towards simplicity and a high compactness.

F14321

Series C Length

2. The engine incorporates, in a single solution, all the most important characteristics and advantages of modern diesel technology.

3. The engine has been entirely designed with metric dimensions. the only discrepancy with these specifications involves the use of connections for pipes and plugs with SAE standards. The specifications of accessories change depending upon the Supplier. Technical publications list metric values with the equivalent SAE values.

Width

1118

679

Height mm

26.7 694

Weight kg

27.3 606 1336

Technology • • • • • • • •

In-line cylinders Water cooled 4 stroke Turbocharged Afterc-ooled Direct injection Metric dimensions Air flow cooling

Engine components •

Metric specifications

Pipes connections and plugs •

SAE standards

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

1-4

D180

ENGINE

IDENTIFICATION OF THE ENGINE Engine data plate The engine data plate provides the identification data and other important information about the engine. Have the engine data here below available when contacting a Cummins Authorised Repair Centre. The information data on the plate are compulsory when procuring Spare Parts. 1. Serial number of the engine (E.S.N.) 2. Control Parts List (CPL) Note â&#x20AC;&#x201C; Do not change the engine data plate unless authorised by Cummins Engine Company, Inc.

4. The engines are designated as follows: The first digit indicates the number of cylinders, the letter to follow indicates the series of the engine, the remaining letters indicate the air intake (T = turbocharged) and the last numbers indicate the total displacement in litres.

5. The total displacement of the engine is 8.27 litres (504.5 in), the bore is 114 mm (4.5 in) and the stroke 135 mm (5.3 in). The firing order is the same as for the other inline, 6 cylinder Cummins engines, 1-5-3-6-2-4.

Nomenclature Model of industrial engine 6

8.3

No. of cylinders Series C Turbocharged After-cooled Total displacement in litres

Specifications of engine series Total displacement Bore Stroke

8.27 L (504.5 in) 114 mm ((4.5 in) 135 mm (5.3 in)

Firing order

1-5-3-6-2-4

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

ENGINE

D180

1-5

1.2 SERIES "C" ENGINE DATA Generalities D180 LT/XLT D180 LGP Bore: ............................................................................. 114 mm [4.49 in] ......................... 114 mm [4.49 in] Stroke: .......................................................................... 135 mm [5.32 in] ......................... 135 mm [5.32 in] Total displacement: ....................................................... 8.27 L [504.5 in3] ......................... 8.27 L [504.5 in3] Net flywheel power (ISO 9249) .................................. 182 HP / 135 kW .......................... 96 HP / 146 kW Low idle ......................................................................... 830÷970 rpm .............................. 830÷970 rpm High idle ................................................................... 2080÷2220 rpm .......................... 2140÷2160 rpm Implem. stall .............................................................. 2070÷2210 rpm .......................... 2070÷2210 rpm Torque converter / transmission stall ......................... 1730÷1870 rpm .......................... 1780÷1920 rpm Total stall ................................................................... 1675÷1875 rpm .......................... 1700÷1900 rpm Compression ratio ....................................................................... 16.5 : 1 ....................................... 16.5 : 1 Firing order: ........................................................................... 1-5-3-6-2-4 ................................. 1-5-3-6-2-4 Valve clearance Intake: .................................................................. 0.30 mm [0.012 in] ...................... 0.30 mm [0.012 in] Exhaust: ............................................................... 0.61 mm [0.024 in] ...................... 0.61 mm [0.024 in] Engine rotation (seen from front side of engine): .................... Clockwise ................................... Clockwise Intake .....................................................Turbocharged with after-cooled .. Turbocharged with after-cooled Engine weight (with standard accessories) Dry: .................................................... 603 ÷ 612 kg [1330 ÷ 1380 lbs] .... 603 ÷ 612 kg [1330 ÷ 1380 lb] Filled (with engine fluids) ................... 635 ÷ 658 kg [1400 ÷ 1450 lbs] .... 635 ÷ 658 kg [1400 ÷ 1450 lb]

Lubrication system

Oil pressure At low idle (minimum allowed) .................................................................. 0.69 bar (69 kPa) [10 psi] At nominal rpm (minimum allowed) ............................................................. 2 bar (207 kPa) [30 psi] Pressure differential for oil filter by-pass valve opening ............................... 1.68 bar (172 kPa) [25 psi] Oil flow at rated speed (minus the flow through the pressure relief) ............ 106.8 L/min [28.2 US gpm] Oil temperature at rated speed ................................................................ 99 at 126 °C [210° at 260 °F] Oil temperature thermostat Fully open (oil flowing through heat exchanger ......................................................... 116 °C [241 °F] Closed (part of the oil by-passes the heat exchanger) .............................................. 104 °C [219 °F] Oil sump capacity (all engines) (high - low) .............................................. 18.9 a 15.1 L [20 a 16 US qt] Total capacity of system ............................................................................................ 23.8 L [25.2 US qt]

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