SERVICE MANUAL 1150M Stage IIIB Crawler Dozer PIN NCDC11500 and above; PIN NDDC11000 and above; PIN NEDC11000 and above; PIN NFDC11000 and above Part number 47907866 2nd edition English October 2015 Replaces part number 47619912 © 2015 CNH Industrial America LLC. All Rights Reserved.
SERVICEMANUAL Track(WT)/LowGroundPressure(LGP)[NFDC11000-] 4790786606/10/2015
Product
MarketProduct Engine
F4HFE613F*A002
1150MLongTrack(LT)
[NCDC11500-] Europe
1150MLongTrack(LT) Europe
F4HFE613F*A002
F4HFE613F*A002
1150MLongTrack(LT)
[NEDC11000-] Europe
1150MLongTrack(LT) Europe
1150MWideTrack(WT)/ LowGroundPressure(LGP) Europe
F4HFE613F*A002
F4HFE613F*A002
F4HFE613F*A002
[NDDC11000-]
Europe
1150MWideTrack(WT)/ LowGroundPressure(LGP)
F4HFE613F*A002
[NEDC11000-]
Europe
1150MWideTrack(WT)/ LowGroundPressure(LGP)
1150MWideTrack(WT)/ LowGroundPressure(LGP) Europe
F4HFE613F*A002
LinkProduct/Engine
4790786606/10/2015
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.206]Fuelfilters..........................................................................10.3 [10.216]Fueltanks..........................................................................10.4 [10.310]Aftercooler..........................................................................10.6 Hydrostaticdrive.........................................................................29 [29.218]Pumpandmotorcomponents......................................................29.1 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.104]Fixeddisplacementpump..........................................................35.3 [35.105]Chargepump.......................................................................35.4 [35.359]Maincontrolvalve..................................................................35.5 [35.741]Dozerbladecylinders..............................................................35.6 Tracksandtracksuspension........................................................48 4790786606/10/2015
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Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.011]Fueltanksystem...................................................................55.2 [55.014]Engineintakeandexhaustsystem.................................................55.3 [55.015]Enginecontrolsystem..............................................................55.4 [55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.6 [55.302]Battery............................................................................55.11 [55.408]Warningindicators,alarms,andinstruments....................................55.12 [55.518]Wiperandwashersystem........................................................55.14 [86.110]Dozerblade........................................................................86.1 [86.124]Dozerpushbeamsandstruts......................................................86.2 Platform,cab,bodywork,anddecals.............................................90 4790786606/10/2015
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[90.120]Mechanically-adjustedoperatorseat...............................................90.3 [90.124]Pneumatically-adjustedoperatorseat..............................................90.4
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INTRODUCTION
Contents INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing(*)................................3 Safetyrules(*)..................................................................................4 Safetyrules-Ecologyandtheenvironment(*).................................................5 Safetyrules-Donotoperatetag(*)............................................................6 Safetyrules(*)..................................................................................7 Basicinstructions-Shopandassembly(*)...................................................15 Torque-Minimumtighteningtorquesfornormalassembly(*)...............................17 Torque-Standardtorquedataforhydraulics(*)..............................................20 Torque-Specialtorques(*)...................................................................22 Maintenancechart(*).........................................................................25 Basicinstructions-Movingadisabledmachine(*)...........................................27 Hydrauliccontamination(*)...................................................................36 ConsumablesLoctite®ProductChart(*).....................................................37 Conversionfactors(*).........................................................................43 Generalspecification(*)......................................................................45 Capacities(*).................................................................................49 Generalspecification(*)......................................................................50 Productidentification(*)......................................................................51 Productidentification-Machineorientation(*)...............................................53 4790786606/10/2015 2
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing 1150M strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools. Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein shallberesponsibleforanysubsequentdamages. localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanuofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer. Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specifications,descriptions,and Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks. 4790786606/10/2015 3
Personalsafety
INTRODUCTION Safetyrules 1150M
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury. FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: Noteindicatesadditionalinformationthatclarifiessteps,procedures,orotherinformationinthismanual. otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage. 4790786606/10/2015 4
INTRODUCTION Safetyrules-Ecologyandtheenvironment 1150M Helpfulhints • Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstofilltanks.Suchdeliverysystems • • • • • Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi• • • coolant,etc. Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE CONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycletheused Mandatorybatteryrecycling NOTE: ThefollowingrequirementsaremandatoryinBrazil. CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4790786606/10/2015 5
INTRODUCTION Safetyrules-Donotoperatetag 1150M WARNING Maintenancehazard! Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina visiblearea. W0004A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. havebeencompleted. (A) (D) (E) (B) (F) (C) 87358697 1 TagComponents C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE D.DONOTOPERATE-(Warning!) F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.) 4790786606/10/2015 6
INTRODUCTION Safetyrules 1150M Generalsafetyrules surfaces. thelocationsofservices. forsafety. • DONOTuseyourhandtocheckforleaks.Useapieceofcardboardorpaper. • • • • DONOTattempttoremovematerialfromanypartofthemachinewhileitisbeingoperatedorcomponentsarein clearofdebris. NOTallowanyonetoentertheworkarea. theareaunderneathraisedequipmentduringoperation. Beforestartingthemachine,besurethatallcontrolsareinneutralorparklockposition. Starttheengineonlyfromtheoperator’sseat.Ifthesafetystartswitchisbypassed,theenginecanstartwiththe transmissioningear.Donotconnectorshortacrossterminalsonthestartersolenoid.Attachjumpercablesas Alwayskeepwindows,mirrors,alllighting,andSlowMovingVehicle(SMV)emblemcleantoprovidethebestpossible Operatecontrolsonlywhenseatedintheoperator’sseat,exceptforthosecontrolsexpresslyintendedforusefrom 4790786606/10/2015 7
INTRODUCTION Beforeleavingthemachine: When,duetoexceptionalcircumstances,youwoulddecidetokeeptheenginerunningafterleavingtheoperator’s WARNING Somecomponentsmaycontinuetorundownafterdisengagingdrivesystems. Failuretocomplycouldresultindeathorseriousinjury. W0113A Generalmaintenancesafety Installguardsandshieldsafterservicingthemachine. Donotattempttoclean,lubricate,clearobstructionsormakeadjustmentstothemachinewhileitisinmotionorwhile Alwaysmakesureworkingareaisclearoftools,parts,otherpersonsandpetsbeforeyoustartoperatingthemachine. equipmentinaraisedpositionwhileparkedorduringservice,unlesssecurelysupported. Stoptheengine,removekeyandrelievepressurebeforedisconnectingorconnectingfluidlines. Scaldingcanresultfromincorrectremovalofcoolantcaps.Coolingsystemoperatesunderpressure.Hotcoolant Engine,transmission,exhaustcomponents,andhydrauliclinesmaybecomehotduringoperation.Takecarewhen 4790786606/10/2015 8
INTRODUCTION Wheelsandtires Alwayshaveaqualifiedtiretechnicianservicethetiresandwheels.Ifatirehaslostallpressure,takethetireand whethertiresareinflatedordeflated.ThetireMUSTbecompletelyremovedfromthewheelorrimpriortowelding Drivingonpublicroadsandgeneraltransportationsafety Usesafetychainsfortrailedequipmentwhenprovidedwithmachineorequipment. Whentransportingequipmentormachineonatransporttrailer,makesureitisproperlysecured.BesuretheSMV Beawareofoverheadstructuresorpowerlinesandmakesurethemachineand/orattachmentscanpasssafely Travelspeedshouldbesuchthatcompletecontrolandmachinestabilityismaintainedatalltimes. Pullovertoallowfastertraffictopass. Fireandexplosionprevention Fueloroilleakedorspilledonhotsurfacesorelectricalcomponentscancauseafire. Makesurethefireextinguisher(s)ismaintainedandservicedaccordingtothemanufacturer’sinstructions. Atleastonceeachdayandattheendofthedayremovealltrashanddebrisfromthemachineespeciallyaround necessarydependingontheoperatingenvironmentandconditions. 4790786606/10/2015 9
Generalbatterysafety
INTRODUCTION Donotweldorflamecutanyitemsthatcontainflammablematerial.Cleanitemsthoroughlywithnon-flammable
Donotweld,grind,orsmokenearabattery. Whenusingauxiliarybatteriesorconnectingjumpercablestostarttheengine,usetheprocedureshownintheoperator’smanual.Donotshortacrossterminals.
Antidote(internal):Drinklargequantitiesofwaterormilk.Donotinducevomiting.SeekmedicalattentionimmediInstructionalseatsafety Theinstructionalseatistobeusedonlywhentraininganewoperatororwhenaservicetechnicianisdiagnosinga • • • • • • 4790786606/10/2015
Followmanufacturer’sinstructionswhenstoringandhandlingbatteries.
INTRODUCTION Operatorpresencesystem Yourmachineisequippedwithanoperatorpresencesystemtopreventtheuseofsomefeatureswhiletheoperator isnotintheoperator’sseat. Reflectorsandwarninglights Seatbelts Seatbeltinspectionandmaintenance: • • • Periodicallycheckbelts,buckles,retractors,tethers,slacktake-upsystem,andmountingboltsfordamageand wear. • • Replacebeltsthathavecutsthatcanmakethebeltweak. • • • • • • RefertoChapter4—OperatingInstructionsforproperuseandadjustmentofseatbelts. 4790786606/10/2015 11
INTRODUCTION Air-conditioningsystem Theair-conditioningsystemisunderhighpressure.Donotdisconnectanylines.Thereleaseofhighpressurecan Theair-conditioningsystemcontainsgasesthatareharmfultotheenvironmentwhenreleasedintotheatmosphere. PersonalProtectiveEquipment(PPE) WearPersonalProtectiveEquipment(PPE)suchashardhat,eyeprotection,heavygloves,hearingprotection,protectiveclothing,etc. DoNotOperatetag Beforeyoustartservicingthemachine,attacha‘DoNotOperate’warningtagtothemachineinanareathatwillbe Hazardouschemicals paints,adhesives,coolant,etc.requiredforthefunctionofyourmachinecanbehazardous.Theymaybeattractive Checkwithlocalenvironmentalandrecyclingcentersoryourdealerforcorrectdisposalinformation. ofchemicalsorpetrochemicalsubstances. Utilitysafety • • Applytheparkbrake,stoptheengine,andremovethekey. • positionandcallforhelp.Ifyoucanleaveyourpositionwithouttouchinglines,jumpclearofthemachinetomake 4790786606/10/2015
INTRODUCTION
Electricalstormsafety
Mountinganddismounting Maintainathree-pointcontactwithsteps,ladders,andhandholds. Donotusethesteeringwheelorothercontrolsoraccessoriesashandholdswhenenteringorexitingthecabor operator’splatform. Workingatheights Whenthenormaluseandmaintenanceofthemachinerequiresworkingatheights: • • • Spraying • plumbing.Insomecasesadecontaminationsolutionisrecommendedbythechemicalmanufacturer. • Alwaysfollowchemicalmanufacturerssafetyinstructionswhenmixingandapplyingherbicidesandchemicalsto • 4790786606/10/2015
•
Ifanelectricalstormshouldstrikeduringoperation,remaininthecab.Donotleavethecaboroperator’splatform.
INTRODUCTION Rolloverandtipover • • • Operatingtheunitonsteepgradesmayresultinamachineoverturn.Itistheoperator’sresponsibilitytomakea • • • Donotoperatetheunitonpoorlyconstructedorunderratedramps.Therampsmaycollapseandcausethesprayer • • 4790786606/10/2015