1 1

Training Centre-Lecce
CRAWLER DOZER T3

2 2
Training Centre-Lecce
 DESCRIPTION OF THE
TECNICAL FEATURES

WALK-AROUND
GENERAL INFORMATIONS

D180PS-LT-XLT-LGP
3 3
Training Centre-Lecce
 D180PS - LT (7
rollers)

TOTAL SHOES X TRACK CHAIN=40

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

TOTAL SHOES X TRACK CHAIN=45

WIDTH OF SHOES =560-610 mm

5 5
TILT CYL. Training
Training Centre
Centre-Lecce
 D180PS- LGP (8 rollers)

TOTAL
6
SHOES X TRACK CHAIN=45 6
WIDTH OF SHOES =762-915 mm Training Centre-Lecce
 D180PS - LGP – PAT (8 rollers)

7 7
Training Centre-Lecce
 D180PS - LGP – PAT (8 rollers)

8 8
Training Centre-Lecce
 D180 PS LT- WINCH CONFIGURATION

9 9
Training Centre-Lecce
 MAIN FRAME ON ASSEMBLY LINE-START

10 10
Training Centre-Lecce
 MAIN FRAME ON ASSEMBLY LINE-START

11 11
Training Centre-Lecce
 PORTLIBHT- CHECK COOLANT LEVEL

EMPTY POINT

ENGINE COOLER
12 12
RADIATOR SUPPORT Training Centre-Lecce
 ENGINE CORES

13 RADIATOR CORES 13
Training Centre-Lecce
14 HYDRAULIC OIL COOLER 14
Training Centre-Lecce
 PIVOT FOR TILT THE COOLER

TRANSMISSION -CONVERTER COOLER

15 15
Training Centre-Lecce
 AFTER COOLER

TRANSMISSION -CONVERTER COOLER

16 16
Training Centre-Lecce
17
MAIN FRAME BEFORE AND AFTER ENGINE 17
Training Centre-Lecce
 PRE-PAINTING HOOD

UPPER HOODS ASSEMBLY

18 18
Training Centre-Lecce
 CENTRAL FRAMEWORK + ACCESSORIES

19 19
Training Centre-Lecce
 CENTRAL FRAMEWORK ASSEMBLING ON LINE

FINAL-TORQUE 60 daNm

20 20
Training Centre-Lecce
21
ASSEMBLY LINE - 21
UPPER HOOD ON MAIN FRAME Training Centre-Lecce
 RIGHT HOOD OPEN RIGHT HOOD CLOSED
22 22
Training Centre-Lecce
PRE-PAINTING KIT-RESERVOIRS
+
23
ACCESS PANELS 23
Training Centre-Lecce
 24 24
PLATTFORM FOR RESERVOIRS+ROPS Training
Training Centre
Centre-Lecce
 PLATTFORM ASSEMBLING ON THE MACHINE

PRE-TORQUE
1

3
2

25 FINAL-TORQUE- 80 daNm 25
Training
Training Centre
Centre-Lecce
BATTERY ACCESS HOOD+NEW ELECTRICAL RELAY PLATE
26 26
Training Centre-Lecce
 DIESEL FUEL TANK

HYDRAULIC OIL TANK +BREATHER

27 27
Training Centre-Lecce
 LEFT ACCESS PANEL

RIGHT ACCESS PANEL

28 28
Training Centre-Lecce
 PLATE PIVOT
60 daNm
ON REAR TRAMS.

1st

100 daNm

2nd
100 daNm

11 daNm

29 29
TORQUE FOR:PIVOT SHAFT-OMEGA SUPPORT
Training Centre-Lecce
 FRONT CROSS-MEMBER PIVOTS
1 CENTRAL PIVOT
PHENOLIC BUSHING

2 5

Grease point 6

30 30
SIDE PIVOT-STEEL BUSHING Bleeding point Centre-Lecce
Training 7
 MOUNTING OF REAR
TRASMISSION BY HOIST

REAR TRAMSMISSION+UNDERCARRIAGE
ON ASSEMBLY LINE

1 3
31 31
Training Centre-Lecce
 ASSEMBLING OF THE FRONT MAIN FRAME BY HOIST+…

32 32
Training Centre-Lecce
 3
1 2

PRE-TORQUE

CENTRAL PIVOT

12 daNm

33 33
Training Centre-Lecce
TRANSMISSION/TORQUE CONVERTER PROPELLER SHAFT
FINAL ASSEMBLY OF THE FRONT MAIN FRAME+FINAL TORQUE VALUE

100 daNm

100 daNm

1
3 360 bar = 100daNm

34 34
Training Centre-Lecce
 SPROCKET ALIGNMENT WITH TRACK CHAIN
SUPPORT ROLLERS+TRACK IDLER

45 daNm

2
PRE-TORQUE

4
35
1 3 35
Training Centre-Lecce
 PUNCHING S/N OF THE MACHINE

36 36
Training Centre-Lecce
 MASTER LINKS

1 4

2
37 37
ASSEMBLING OF THE TRACK CHAINS TIGHTENING TORQUE
Training 70 daNm
Centre-Lecce
38 38
Training Centre-Lecce
 MAINTENANCE
D180PS + ClutchTier3
FOR MORE INFORMATIONS PLEASE CONSULT THE SPECIFIC
OPERATOR’S MANUAL :

P/N 604.35.589.00 D180 PS + CLUTCH -CRAWLER DOZER (uk)

39 39
Training Centre-Lecce
 TABLE OF FLUID CAPACITIES

40 40
Training Centre-Lecce
 EVERY 10
HOURS WORK
(DAILY)

41 41
Training Centre-Lecce
 LUBRICATION OIL LEVEL
Checking

EXPANSION TANK

LOOSEN SLOWLY

42 CULANT LEVEL 42
Checking Training Centre-Lecce
 DRIVE BELT
Inspection

COOLING FAN
Inspection
43 43
Training Centre-Lecce
FUEL PRE-FILTER –with WATER SEPARATOR
Drain
44 condensation 44
Training Centre-Lecce
 TRANSMISS.TORQUE CONVERTER
Check oil level

45 45
Training Centre-Lecce
 EVERY 100
HOURS WORK

46 46
Training Centre-Lecce
BEVEL GEAR,STEERING AND BRAKES-
Cheching the oil level

FINAL DRIVE-
Check oil level (both side)

47 47
Training Centre-Lecce
 FUEL RESERVOIR-
Draining condensation

48 48
Training
Training Centre
Centre-Lecce
 EQUIPMENT HYDRAULIC SYSTEM
Check oil level

OIL MLEVEL MIDDLE 2°OBLO’ (MAX)

Engine ON Min. RPM
Equipment on the ground

max

min

49 49
Training Centre-Lecce
 EVERY 250
HOURS WORK

50 50
Training Centre-Lecce
 TRACK CHAIN
Check /measure the sagging of the track chain in section C

51 51
TRACK CHAIN TENSION ADJUSTMENT VALVE
Training Centre-Lecce
 EVERY 500
HOURS WORK

52 52
Training Centre-Lecce
 ENGINE SUMP- Change oil

DRAIN OIL FROM ENGINE

Open the lower panel

Oil Refiling

ENGINE OIL FILTER

change filtering cartridge
53 53
Training Centre-Lecce
 FUEL FILTER
Replace filter

FUEL PRE-FILTER
Bleeding the air
54 54
Training
Training Centre
Centre-Lecce
 STEERING/BRAKES
DELIVERY OIL FILTER
OPEN THE FRONT GRID Repalce cartridge
55 55
Training Centre-Lecce
 DRAIN OIL FROM TRANSMISSION

56 56
Training Centre-Lecce
 TRANSMISSION/TORQUE CONVERTER
DELIVERY OIL FILTER
Replace cartridge

Oil Refiling

TRANSMISSION OIL DIPSTICK

57 57
Training Centre-Lecce
 CAB AIR FILTERS
Repalce cartridge

58 58
Training Centre-Lecce
59 59
Training Centre-Lecce
 EVERY 1000
HOURS WORK

60 60
Training Centre-Lecce
 BEVEL GEAR STEERING AND BRAKE
Change oil and wash suction filter

OIL DRAINING PLUG

Drain
61 oil 61
Training Centre-Lecce
 BREATHER

Oil Refiling

REAR TRANSMISSION OIL DIPSTICK

62 62
Training Centre-Lecce
TORQUE CONVERTER TRANSMISSION
Wash suction filter and magnetic rod

63 63
Training Centre-Lecce
 RADIATOR
Change Coolant

LOOSEN SLOWLY

64 64
Training Centre-Lecce
 CHANGE CCV FILTERS (BLOW-BY)
65 65
Training Centre-Lecce
 EVERY 2000
HOURS WORK

66 66
Training Centre-Lecce
 FINAL DRIVE- Change oil (both side)

67 67
Training Centre-Lecce
 EQUIPMENT HYDRAULIC CIRCUIT
Change oil and clean return filter
OIL LEVEL IN THE MIDDLE OF MAX

max

min

68
OIL DRAINING PLUG 68
Drain oil Training Centre-Lecce
 EVERY 3000
HOURS WORK

69 69
Training Centre-Lecce
 VALVE CLEARANCE
check valve clearance, with cold engine

EXHAUST 0,50 mm

70
INTAKE 0,25 mm 70
Training Centre-Lecce
 MAINTENANCE
WHEN REQUIRED

71 71
Training Centre-Lecce
 ENGINE AIR CLEANER
Replace cartridges

2
B
1

3
A

4
B

72 72
Training Centre-Lecce
 EQUIPMENT HYDRAULIC CIRCUIT
Change return filter

73 73
Training Centre-Lecce
 RADIATOR CORES
Clean

74 74
Training Centre-Lecce
 PRESSSURE PICK-UP POINTS ON DIAGNOSTIC PANEL

transmission

75 75
Training Centre-Lecce
TEST ON THE BRAKE PEDAL VALVE

76 76
Training Centre-Lecce
DIAGNOSYS, CALIBRATION ,
PROGRAMMING OF THE
JOYSTICK BLADE+RIPPER
ON DOZERS HYDRAULIC
SYSTEM WITH BB3
77 77
Training Centre-Lecce
 DIAGNOSYS, CALIBRATION ,
PROGRAMMING ON DOZERS Section

STEERING SYSTEM WITH BB3 5

78
ON EST Training Centre-Lecce
78
CONFIGURATION OF THE BLADE+RIPPER JOYSTICK
79
ON RS232 PORT WITH EST +CABLE 380002118 79
Training Centre-Lecce
 CONFIGURATION FOR DIAGNOSIS ON IVECO
NEF
80
T3 ENGINE ON 9 PIN DEUTCH PORT WITH 80
EST +ADAPTOR 380001216 Training Centre-Lecce
DOWNLOAD
81 – CONTROL AND MODIFICATION OF THE PARAMETERS OF 81
THE BLADE + RIPPER JOYSTICK –ONLY WITH ENGINEERING
TrainingTOOL
Centre-Lecce
 CAB & CANOPY
D180PS

82 82
Training Centre-Lecce
83
CAB in ROPS config.- D180PS 83
Training Centre-Lecce
 2 FAN

CONDENSER

84 84
Training Centre-Lecce
 SIDE WINDOWS OPENING 180°

85 85
LEFT DOOR Training Centre-Lecce
 DOOR HANDLE (INSIDE)
86 86
Training Centre-Lecce
 ARMREST ASSY-LEFT SIDE

BLADE JOYSTICK +RIPPER-

RIGHT SIDE
87 87
Training Centre-Lecce
88 88
CAB FILTERS (AIR CONDITIONER SYSTEM)Training Centre-Lecce
 CAB COMPONENTS -D180PS / D150

Safety plate

seat

CONTROL PANEL (A.C.)

hydraulic cylynder
89 89
Training Centre-Lecce
 CAB COMPONENTS -D180PS

90 90
Training Centre-Lecce
 MICROCONTROLLER - MHVD4-4FB1X STANDARD CAB
91
ONLY ONE FOR D180 BASE & D180 PS + 1850K-P/N
91
76092397
Training Centre-Lecce
 MOUNTING OF CAB-D180PS (1)

PRE-TORQUE

92 92
Training Centre-Lecce
 MOUNTING OF CAB-D180PS(2)

0,5l- ATF Type A

SAE 10W
Final torque 60 daNm OIL Refiling and bleeding operation on
HAND PUMP
93 93
Training Centre-Lecce
 ENGINE D180PS
IVECO NEF CR 6.7 litre-Tier3
F4HE9684V*J101
HP 210 / KW157 (only x LGP)
F4HE9684F*J101
HP 194 / KW 145 (LT- XLT)
94 94
Training Centre-Lecce
 ENGINE INFORMATION

L
T
X
L
T

L
G
P

95 95
Training Centre-Lecce
 ENGINES WALK-AROUND F4HE9684V*J101 - F4HE9684F*J101
9 1 Nomenclature of engine
7
COMPONENT

1. Turbo HOLSET HX 35
8
2. Alternator

3. Exhaust manifold
10
4. Starter motor

5. Oil lub. To turbo

6. Oil drain pipe from turbo

7. Tappet Cover

CONNECTIONS
3 8. Air IN from filter

9. Ari to AFTERcooler

10. To exhaust system

6 2
4 5

96
96
TURBO SIDE VIEW Training Centre-Lecce
 ENGINES WALK-AROUND F4HE9684V*J101 - F4HE9684F*J101
2 Nomenclature of engine
5 10 COMPONENT

1. High-pressure pump with supply pump

6
2. Common rail
9
3. Fuel filter

4. High pressure pipe (for CR supply)

5. Intake manifold with air temp.press.sensor

6. Fuel return pipe line from electro-injectors

7. EDC7 EV31 engine Controller

8. Engine cable

9. Damper + phonic wheel

10. PRE - FUEL Filter

8
4
7
3
1
97
97
RAIL SIDE VIEW Training Centre-Lecce
 ENGINE SENSORS PER TRASMISSION DATA VIA
SERIAL CONNECTORS RS232

Oil pressure Water Temperature RPM sensor

98 98
Training Centre-Lecce
 Breather to Expansion tank

Grid heater - cold start

Hot water in the cab

99 99
Training Centre-Lecce
 HYDRAULIC CIRCUIT (COMMON RAIL)
1. Electro-injector –
2. Common rail –
3. Pressure limiter
for fuel return –
4. Common rail
relief valve –
5. Prefilter mounted
on chassis –
6. High pressure
pump –
7. Mechanical rotor
pump –
8. Fuel filter.

The hydraulic system is composed of a low pressure circuit and

a high pressure circuit.
100 100
Training Centre-Lecce
 HYDRAULIC DIAGRAM (COMMON RAIL)
DRAIN
DRAIN
DRAIN
SUCTION (LOW PRESSURE)
HIGH PRESSURE PUMP FEED (Low pressure)
HIGH PRESSURE PUMP FEED (Low pressure side)

HIGH PRESSURE

1. High pressure pump – 2. Limiter valve on high pressure pump, 5 bar – 3. Regulator valve on fuel return
line from electro-injectors, from 1.3 – 2 bar – 4. Common rail relief valve –5. Common rail – 6. Pressure
sensor – 7. Electro-injector – 8. Return line – 9. Control unit heat exchanger – 10. Manual priming pump –
11. Prefilter mounted on chassis – 12. Fuel filter – 13. Mechanical feed pump – 14. Fuel filter – 15. Pressure
regulator
101 – 16. Drain pipe from high pressure pump – 17. By-pass valve – 18. By-pass valve. 101
Training Centre-Lecce
Cooling circuit

The cooling system includes a forced circulation

closed circuit, composed of:

01. Coolant centrifugal pump;

02. Engine oil heat exchanger;
03. Coolant circulation control thermostat;

The normal operation pressure of the coolant under

normal operating conditions is 1.00 bar

A. Re-circulation of the refrigerant in the engine with

thermostat closed Ricircolo (< 81°C - 180 °F).
B. Thermostat open - refrigerant flowing to radiator -
(>81°C - 180 °F).
A B

Coolant flowing out from thermostat

Coolant flowing into the circuit

Coolant inlet to the pump

102 102
Training Centre-Lecce
Lubrication circuit

The lubrication system includes a forced

circulation closed circuit composed of:

01. Pressure relief valve, incorporated in

the oil filter support;
02. Oil filter cartridge;
03. Water/oil heat exchanger;
04. By-pass valve on filter;
05. Gear pump, located on front part of
cylinder block driven by crankshaft;

The operating pressure under normal

operating conditions is 2 - 3.8 bar.

Minimum operating pressure is 1.0 bar.

Oil under pressure

Return oil (dropping by gravity)
Filling point

103 103
Training Centre-Lecce
Injection system “Common Rail”
Electronic components
Description
Ref.

1 Coolant temperature sensor

2 Electro-injector

3 Rail pressure sensor

4 BOOSTER Air temperature/pressure

sensor
5 Starter motor

6 Timing sensor

7 Pressure regulator solenoid valve

8 Fuel temperature sensor

9 EDC7UC31 electronic control unit

10 Crankshaft sensor

11 ENVIRONMENT PRESSURE SENSOR

12 Engine oil pressure/temperature

sensor
13 Pre-post heating resistance

104 104
11 Training Centre-Lecce
 In the NEW NEF engine TIER3 CR because of the presence of the additional
second lobe for E.G.R INTERNAl, the adjasting procedure of clearance
between the rocker arms and valves cannot be used for all the valves only
performing two time the crankshaft,
Every cylinder must be adjusted
bringing him at T.D.C. (top dead center)
and adjust/set the clearance for both
valves of the same cylinder.
ONE -by- ONE….
Adjust the clearance between the rocker arms
and valves with an allen wrench (1), box
wrench (3) and feeler gage (2).
The operating clearance is:
70520
Intake valves 0,25 ÷ 0,05 mm
Exhaust valves 0,50 ÷ 0,05 mm
ADJUST
105
THE CLEARANCE BETWEEN THE 105
ROCKER ARMS AND VALVES Training Centre-Lecce
 KINEMATISM (ROD/PLATE) FOR
ACCEL./DECEL +
LOW IDLE SWITCH SENSOR

106 106
Training Centre-Lecce
 ENGINE FAN

107 107
Training Centre-Lecce
 FLOW STREAM THROUGH20° AFTERCOOLER+
F.D.S. WITH 20°C AMBIENT
C TEMPERATURE

FROM AIR CLEANER O

U
T
IN

142°C

51°
C

TO AFTER COOLER

108 108
Training Centre-Lecce
 DIST.= 0.8 ~1.25mm

DISTANCE - FLYWHEEL - SPEED SENSOR

109 109
Training Centre-Lecce
110 110
Training Centre-Lecce
 FRONT
TRANSMISSION
D180PS
111 111
Training Centre-Lecce
 TORQUE CONVERTER HYDRAULIC DIAGRAM

FOR

REV
III

II
I
PRESSURE LINE (16 -17 bar)
SUCTION LINE

LUBRICATING LINE (3 bar) +DISCHARGE AT TANK

DISCHARGE LINE AT COLD OIL ENGINE ON

112 CONVERTER LINE SAFETY LEVER ON (RAISED)
112
Training
NEUTRAL Centre-Lecce
CONDITION
 TORQUE CONVERTER HYDRAULIC DIAGRAM
F

1ST- FORWARD

FOR

REV
III

II
I
PRESSURE LINE (16 -17 bar)
SUCTION LINE
LUBRICATING LINE (3 bar) +DISCHARGE AT TANK
ELECTRICAL SIGNAL MICRO-CONTROLLER
ENGINE ON
113
ELECTRO-SOLENOID VALVE
SAFETY LEVER OFF (LOWERED)
113
CONVERTER LINE
1STTraining
- FORWARDCentre-Lecce
CONDITION
 TRANSMISSION CONTROL VALVE SOLENOID
VALVES ENERGISING TABLE • = ENERGISED
FORW. SOL. REV. SOL. SOL. 1st. SOL.3
rd
1st FORW • •
2nd FORW •
3rd FORW • •
NEUTRAL
1st REVE • •
2nd REVE •
3rd REVE • •

114 114
Training Centre-Lecce
 III I

REV FWD

115 115
Training Centre-Lecce
TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM

( 24 -26 )

116 116
Training Centre-Lecce
 F

R ARMREST

UP

N DOWN

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

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

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

1900 rpm D180

2030 rpm D150

Setting flywheel
120 173 teeth D150120
T2
Training Centre-Lecce
132 teeth D180 T3
 BY-PASS HOSE OF TRANSMISSION OIL
RADIATOR
FROM torque converter by-pass valve
D180PS TO the transmission lubrication

121 121
FROM oil cooler- TO the transmission lubrication
Training Centre-Lecce
 Transmiss. Oil low pressure sensor 11.5 bar

Transm. Pressure
switch setting at 17 bar

Torque converter
safety valve 10.7 bar

TRANSMISSION
PUMP

CONVERTER
PUMP

122 122
COMPONENTS ON TORQUE CONVERTER Training Centre-Lecce
 COMPONENTS ON TORQUE CONVERTER
Transm. Pressure
TRANSMIS OIL HIGH switch setting at 17 bar
TEMPERATURE SW.
TRANSMISSION
PUMP

CONVERTER
PUMP

TO TRANSMISS.
OIL RADIATOR

TO PICK-UP
FOR LUBE
123 123
Training Centre-Lecce
ASSEMBLING SEQUENCE
FOR THE
FRONT TRAMSISSION

124 124
Training Centre-Lecce
 HANDTRUCK SIDE SHAFTS-CLUTCH -
PACK SPRING-LUBRICATION LINES

CLUTCH PACK SIZE

BY-GO-NO-GO GAUGE
HANDTRUCK SIDE GEARS-HUBS
125 -PISTONS+COVER 1st 125
Training Centre-Lecce
 BEFORE ASSEMB. AFTER ASSEMB.

REVERSE
SPEED CLUTCH

CLUTCH DRUM + GEAR+SPRINGS+CLUTCH DISCS

126 126
Training Centre-Lecce
 3dr SPEED CLUTCH COMPONENTS

3dr SPEED CLUTCH +GEARS

127 127
Training Centre-Lecce
 PREPARATION OF THE FRONT COVER

OIL TRANSFER TUBE

OIL PRESSURE REGULATOR VALVE - 3bar

128 128
Training Centre-Lecce
HOUSING+COVER+HANDTRUCK PARTS READY FOR ASSEMBLING
129 129
Training Centre-Lecce
 ASSEMBLING FOR REVERSE ASSEMBLING 3dr SPEED+MANOV. TOOL
SPEED CLUTCH+GEARS +
INTERMEDIATE / (DRIVEN) SHAFT

REV
REV

3rd

SIDE RIGHT ACCESS

130 130
Training Centre-Lecce
 PREPARATION 2nd DRUM SPEED

MANEUVER TOOLS
2nd

131 131
Training Centre-Lecce
 INTERMED. SHAFT (DRIVEN)

REV

3rd

REV

TIGHTENING TORQUE 95 daNm

132 132
Training Centre-Lecce
 ASSEMBLING FOR 2nd SPEED CLUTCH
2nd SPEED CLUTCH COMPONENTS

SPRING

133 CLUTCH PISTON 2nd +QUICK DISCHARGE VALVE 133

Training Centre-Lecce
 1st SPEED CLUTCH COMPONENTS

COVER 1st - FWD SPEED CLUTCH

COVER FOR 3dr - 2nd SPEED CLUTCH

INTERMED. SHAFT“OUT” SIDE

134 134
P.T.O. SHAFT
Training Centre-Lecce
 2nd - 3dr
INTERMED. SHAFT
“IN” SIDE

Pressure REV

REV
FWD - 1st
Lubric. REV

OIL SUMP AND OIL PIPES

135 135
Training Centre-Lecce
 INTERFACE FOR TRANSM. CONTROL VALVE

MOUNTING
136
OF COVER+GASKET 136
Training Centre-Lecce
 MODULATING VALVES - SPEED

LUBE PRESSURE RELIEF VALVE -3 bar

1st 2nd 3dr MODULATING

REMOVE N. 7 SHIMS FOR D180PS VALVES (SPEED) MOUNTED
REMOVE
137 N. 3 SHIMS FOR D150PS T2 137
Training Centre-Lecce
 TRANSMISSION CONTROL VALVE BY VICKERS

III
P
REV T

P1
I
FWD

FWD REV
138 138
MODULATING VALVES (for direction) Training Centre-Lecce
 SECTION VIEW OF
TRANSMISSION HOUSING

IN OUT

139 139
Training Centre-Lecce
 DATA OF CLUTCH DISCS PACK ASSEMBLY

(*)140
Check by measuring the stroke of the mobile piston. 140
(**) Check pre-loading the clutch pack with a load of 197 daNm. Training Centre-Lecce
 TRANSM.OIL
DIPSTICK VENT

“IN” FRON
TORQUEC0NVERTER

FROM OIL
TRANSM.OIL FILTER SUCT. LINE
COOLER
141 141
Training Centre-Lecce
 “OUT” SHAFT TO REAR TRANSMIS.

SHAFT REVERSE+PTO

142 142
Training Centre-Lecce
 FRONT TRANSMISSION ASSEMBLYED

SUCTION FILTERS

TRANSMISSION CONTROL VALVE

143 143
Training Centre-Lecce
 FILLING THE TRANSMISSION WITH OIL
HYDROPOWER ATF Type A Suffix A

2,5 Kg

144 144
Training Centre-Lecce
145 145
Training Centre-Lecce
 TORQUE
CONVERTER
15”MS 335
TWIN-DISC
146 146
Training Centre-Lecce
 ITEMS FOR ASSEMBLING TORQUE CONVERTER:
BUCHING-GEAR-SPACER

TORQUE at 7.1 daNm

147 147
Training Centre-Lecce
 ASSEMBLING TORQUE CONVERTER ON ENGINE

TORQUE at 7.1 daNm

148 148
Training Centre-Lecce
 TORQUE CONVERTER+PUMPS

Varioable Transmission pump

displacement
Hydraulic pump

Converter pump

Brake pump
Scavenge pump

149 149
Training Centre-Lecce
 DISASSEMBLY SEQUENCEOF THE COMPONENTS

REMOVE BEARING RETAINING PLATE

CONVERTER ON WORK BENCH

150 150
Training Centre-Lecce
 REMOVAL ASSY FROM HOUSING

REMOVE IMPELLER CAPSCREWS

151 151
Training Centre-Lecce
TORQUE CONVERTER DISASSEMBLED

STATOR

TURBINE IMPELLER

152 152
Training Centre-Lecce
ASSEMBLING SEQUENCEOF THE TORQUE CONVERTER HOUSING

BEARINGS+SNAP RING NEW SYSTEM WITH OLDHAM JOINT

153 153
Training Centre-Lecce
 ASSEMBLING FOR THE SPLINE SHAFT SUPPORT+ OLDHAM JOINT

154 154
Training Centre-Lecce
 FLUID OUTLET

FLUID INLET

OIL BAFFLE
TORQUE CONVERTER HOUSING THREE GEARS TO PUMPS DRIVEN
155 155
Training Centre-Lecce
 ASSEMBLING SEQUENCEOF THE CONVERTER
ANTICLOCKWISE

156 3 156
Training Centre-Lecce
 TIGHTENING TORQUE 7.1 daNm TIGHTENING TORQUE 7.7 daNm

157 157
Training Centre-Lecce
 ASSEMBLING SEQUENCE OF THE PUMPS

TIGHTENING TORQUE 34 daNm

VARIABLE DISPLACEMENT HYDRAULIC PUMP

158
A11VO 130 LRDS/10L 12 N00 158
Training Centre-Lecce
 FLANGE FOR CARDAN SHAFT
1

159 3 TIGHTENING TORQUE 3.5 daNm 159

Training Centre-Lecce
 17 bar

10.7 bar

TRANSMISSION PRESSURE RELIF VALVE and TORQUE CONVERTER SAFETY

160 160
Training Centre-Lecce
NEW SYSTEM WITH OLDHAM JOINT TORQUE 3.5 daNm

3
Transmission and Converter pump

161 161
Training Centre-Lecce
 FINAL ASSEMBLY OF THE SERVICES PUMPS

Transmission and Converter pump

BRAKE and SCAVENGE PUMP

TIGHTENING TORQUE 3.5 daNm

162 162
Training Centre-Lecce
 CONVERTER READY FOR ASSEMBLY LINE

ASSEMBLING OF THE
163 PIPELINES+VENT 163
Training Centre-Lecce
164 164
Training Centre-Lecce
 BRAKES
SYSTEM
D180 PS
165 165
Training Centre-Lecce
ENGINE ON
SAFETY LEVER ON (RAISED)
PARKING BRAKE ON

DR

SUCTION LINE
LUBRICATING LINE (1 ÷ 2 bar)

DISCHARGE LINE WITH SAFETY LEVERS

ON

166 166
Training Centre-Lecce
ENGINE ON
SAFETY LEVER OFF (LOWERED)
PARKING BRAKE OFF BRAKE ACTION

DR

Brake pressure
to diagnostic panel

SUCTION LINE

LUBRICATING LINE (1 ÷ 2 bar)

DISCHARGE LINE AFTER BRAKE ACTION

PRESSURE LINE TO REMOVE THE BRAKE 20bar
PILOTE LINE 25bar

167 167
Training Centre-Lecce
BRAKE PUMP

SCAVENGE PUMP

168 168
Training Centre-Lecce
 BRAKE VALVE BLOCK
HYDRAULIC DIAGRAM

BRAKE POWERING VALVE BLOCK

169 169
PILOT OIL SUPPLY Training Centre-Lecce
Brake pedal valve

Porta A

Porta B

170 170
Porta T Training Centre-Lecce
 BRAKE OIL FILTERS

Delivery filter Suction filter

(ref .2 brake hydraulic diagram) (ref .10 brake hydraulic diagram)
171 171
Training Centre-Lecce
D180PS BRAKE DISENGAGEMENT

3)From the left side of the machine, open the panel under the
cab to reach the diagnostic panel. Rotate the igniction key in
(ON) and safety levers down. Connect hand pump to
pressure pick-up point (1) (see next slide), and actuate it
until
172 disingagement screws M16x2 (A, fig. E) protrudes, 172
indicating the disengagement of piston (S) of about 4.5mm. Training Centre-Lecce
BRAKES DISENGAGEMENT ON D180PS WITH ENGINE INOPERATIVE
and ACCUMULATOR BRAKE VALVE BLOCK UNLOADED

173 173
Training Centre-Lecce
 STEERING
SYSTEM
D180 PS
174 174
Training Centre-Lecce
STEERING HYDRAULIC CIRCUIT DIAGRAM Dozer tier3
The Steering circuit and that of the EQUIPMENT are only one hydraulic circuit and use the same oil (HI-TECH 46). Although the two
circuits have parts of the system in common, they operate at separate operating pressures, and precisely:
- max. steering circuit pressure 350 bar ± 5 bar
- max. equipment circuit pressure 160 bar± 5 bar
The steering circuit mainly comprises :
- A 130 cc variable displacement AXIAL PISTON PUMP for steering/equipment circuits (ref. P hydraulic diagra);
- A Hydraulic motor for the for the steering functions (ref. M)
- A Control Block (load sensing closed center) controlling the steering/equipment (ref. D),with included a series of valves, in
particularly: the pilot supply valve (21), the unloading valve( 22), the quick blade lowering solenoid valve (20), the pilot
supply solenoid valve (23), one pressure switch 17 bar (18), one steering pressure transducer for priority function (19), one
dual stage LS relief solenoid valve (24), one dual stage LS relif valve (25), one PUMP RELIEF VALVE (27) 380 bar.
- Two steering levers, on the Armerest (rif.Mt)
- one oil radiator (ref. 29)
-One Microcontroller (rif. Transmission Control Unit)
- One blade control valve (rif. Ma) and one ripper control pilot valve (rif. Mr)
The D180PS is provided with a steering differential enabling the dozer to transmit power to both tracks (even differently) in a bend,
changing their speed at tracks, and then to push and steering at the same time.

When the operator pull one steering lever, one electrical signal will be processed by the microcontroller Rexroth, to be sent at the
electro-solenoid proportionaly valve located on the end caps of the steering spool, after to be intercept by the TRASDUCER (rif.19)
it reaches the blade joystick , that thanks to its software, allows to energize the elettoro-solenoid valve (rif. 24) in order to permit
the commutation of the dual stage valve (25) at 350 bar, and in the same time via sofware to give priority at steering system in
comparison to the other utility.
By acting on the steering lever (L) left (or Right) but with the transmission in neutral and without touching the equipment, the
pump hydraulic flow rate will flow into the hydraulic motor (M), the latter, through a steering bevel pair+a transmission shaft+a
gear will enable tracks to move at the same speed, but in opposite direction, causing the machine to countertun. When the
transmission is engaged (machine moving) there is a summation of the effects, i.e. the translation speed (coming from the bevel
gear) is summated to the differential effect which is entered instead through the hydraulic engine.
175 175
Training Centre-Lecce
 1850 TIER III D 180 PS TIER III

Steering
Transmission 1..2,95V steer. Joystick
MH4-4 Controller &dig. Signals Transmission
forw/backw
turtle/rabbit CASE
Armrest
Fingerpotis NH
Display
Error code
CIAM
Error code from all controllers
PWM 2x are displayed directly
PWM 6x

PWM 2x
Joystick Blade
Priofunction
dig. Out
Steering (24V, 1A) Pressure inc.

Section
Ripper
Angle

Inlet-
160/350 bar

Lift
Tilt
Detection
RS232 for EST –
Pilot Pressure
communication and
35 bar max
Implement Error code via
Supply Solenoid Blade Joystick
p dig. Signal (24V, 1A)
p
i
Joystick
Detection Lowering Ripper
dig. Signal (24V, 1A)
for tank pressuration

Detection Steering
176
Analog Signal (4..20 mA)
176
Training Centre-Lecce
 D180PS-1850K POWERLINE & D.S.D.

177 177
Training Centre-Lecce
 Pressure flow
D180 PSasCaratteristica
a function stroke of the-steering
Pressione levers
Corsa Leve

40

30
-bar
pressione (bar)
Pressure

20 pressione

10

0
0 20 40 60 80 100

Leve stroke
Corsa %
(%)

178 178
Training Centre-Lecce
179 179
STEERING/EQUIPMENT HYDRAULIC DIAGRAM D180PS Training Centre-Lecce
 EQUIPMENT CONTROL VALVE REXROTH M6-1234

180 180
Training Centre-Lecce
 5th SPOOL – STEERING SECTION – M6-1234

STEERING ELETTROV.
PROPORTIONALY
181
SOLENOID VALVE 181
Training Centre-Lecce
 DUAL STAGE LS RELIEF VALVE 160/350 bar
+ items for his activation
Joystick
Transmission
CASE
Armrest
Fingerpotis NH

Steering
25
Transmission
MH4-4 Controller

Joystick Blade

Pressure inc.

RS232 for EST –

communication and
Error code via
Blade Joystick

Joystick
Ripper
182 182
Training Centre-Lecce
 STEERING LEVERS

A RD
I GHTWING
R ER
S TE

ARD
FTW G
LE ERIN
STE

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

HYDRAULICS
SYSTEM
186 186
Training Centre-Lecce
EQUIPMENT CIRCUIT DESCRIPTION AND OPERATION D180PS Tier3
The equipment hydraulic system is common to the steering system due to the sharing of some units to the hydraulic oil itself, but
they respectively have separate circuits and operating pressures:
Equipment system with operating pressure of 160 bar ± 5 bar;
Steering system with operating pressure of 350 bar ± 5 bar.
The equipment hydraulic system shown in the next slide, is featured by being fitted with a variable displacement piston pump (ref.
P), having a max.flow rate of 248 liters/min, fitted with three regulators : LS (ref.14) CUT-OFF(ref.15) and POWER REGULATOR
(ref. 16) supplying contemporarily (after sucking oil from the 110 liter tank (ref. 7):
a control block M6-1234 (ref.D) Load Sensing-flow sharing “Closed Center” with pressure compensator (ref.28) through port
P located on the block. While a connection between power pump (port X) and control block (port LS) allows the sending of a
signal from the control block to the pump regulating the oil flow according to the effective requirements of the actuators, changing
the pump flow up to maximum delivery at max speed (248 lt/min.
The Control Block (ref. D), included also a series of valves, in particularly: the pilot supply valve (21), the unloading valve( 22),
the quick blade lowering solenoid valve (20), the pilot supply solenoid valve (23), one pressure switch 17 bar (18), one
steering pressure transducer for priority function (19), one dual stage LS relief solenoid valve (24), one dual stage LS relif
valve (25), one PUMP RELIEF VALVE (27) 380 bar.
- The equipment system include also:
- one oil radiator (ref. 29)
One Microcontroller (rif. Transmission Control Unit) + Armerest for stering system
- One blade control valve (rif. Ma) and one ripper control pilot valve (rif. Mr)
The blade TILT hydraulic control, is achieved by moving side-ways the equipment manipulator lever (ref.Ma, it is supplied at 65
liters/min thanks to the adjustment system of the rod stroke available on the section.

187 187
Training Centre-Lecce
188 188
STEERING/EQUIPMENT HYDRAULIC DIAGRAM D180PS Training Centre-Lecce
 12 21
8 9 10

28

22

8 9 10 12

189 189
EQUIPMENT/STERING CONTROL VALVE REXROTH M6-1234 Training Centre-Lecce
EQUIPMENT/STERING CONTROL VALVE REXROTH M6-1234

View side PORT: Pst1 – Pst8+L1-L8

PORT L1 – L8

190 190
PORT Pst1 – Pst8 Training Centre-Lecce
 PORTS ON CONTROL VALVE
22
21

Pst

23 AC

X
24

191 191
Training Centre-Lecce
EQUIPMENT/STERING
192 CONTROL VALVE 4 SPOOL ON THE MACHINE 192
Training Centre-Lecce
EQUIPMENT/STERING CONTROL VALVE 4 SPOOL
4 SPOOL CONTROL VALVE LOAD SENSING-REXROTH –M6-1234
DESCRIPTION:
IN
The D180PS EQUIPMENT/STEERING control block is a high pressure
closed center, capable of satisfying the requirements of 2 systems,
which even if separate, share some main hydraulic components.
The main control valve M6-1234 consist of 4/5 Spool (WHEN THE
ANGLE IT IS PRESENT) that respectively supplying:
TILT the 1st spool controls tilt, with a flow rate of 65 liters
the 2nd spool controls the blade with a flow rate of 180/240 liters the
3rd spool control the ripper with a flow rate of 165/170 liters;
the 4th spool control the angle with a flow rate of 240 liters
BLADE the 5th spool control the steering hydraulic motor with a flow rate of
225 liters.
A 2-stage valve with 160/350 bar controls the feed pressures of the
equipment/steering systems.

One elettr. Solenoid valve present on the system (item 23) energised by
RIPPER the security levers allows at pilot oil coming fron the valve (21) at 30 bar
to supply oil at all spool.
In the control valve there is also available an unloading valve(22), 34 ± 2
bar-and 15 liters/min (at min.RPM). This guarantees different functions
STEERING in the D180PS steering/equipment hydraulic circuit with the manipulator
in neutral.
Finally gate LS is located always on the distributor body, in direct
connection with pump gate X.

193 21 22 193
Training Centre-Lecce
EQUIPMENT/STERING
194 CONTROL 5 SPOOL FOR P.A.T. CONFIG. 194
Training Centre-Lecce
 195 195
A11VO 130 LRDS/10L-NSD 12N00-EQUIPMENT/STEERING PUMP
Training Centre-Lecce
 POWER CONTROL VALVE (16)
PORT- X

Load Sensing VALVE (14)

CUT-OFF VALVE (15)

VARIABLE DISPLACEMENT PUMP A11VO 130 LRDS

196 196
Training Centre-Lecce
 1. 3-regulator variable displacement pump.
2. Displacement control servopiston.
3. Cut-off regulator (350 bar).
4. Flow regulator LS (20 - 21 bar).
5. Power regulator (90 Kw a 1950 RPM)

4
20 -21 bar

1
3

350 bar
5
2

90 Kw a
1950 RPM

1 AXIAL PISTON PUMP

2 4

5
3

197 197
Training Centre-Lecce
 SECTION OF THE BLADE CYLINDER

BLADE LIFTING CONTROL CYLINDER

198 198
Training Centre-Lecce
199 199
ASSEMBILNG OF THE BLADE LIFTING Training
CYLINDER Centre-Lecce
 TILT CYLINDER
Bulldozer Version

SECTION OF THE TILT CYLINDER

FOR VERSION ANGLEDOZER :

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

200 200
Training Centre-Lecce
 SECTION OF THE RIPPER CYLINDER

RIPPER CYLINDER

201 201
Training Centre-Lecce
 BLADE JOYSTICK & RIPPER JOYSTICK

HYDRAULIC PILOT CONTROL DEVICES

202 202
Training Centre-Lecce
 BLADE JOYSTICK 5 SPOOL WITH TWIST FUNCTION FOR ANGLE
& RIPPER JOYSTICK
203 203
HYDRAULIC PILOT CONTROL DEVICES
Training Centre-Lecce
 HYDRAULIC PILOT CONTROL DEVICES

L R
neutral
BLADE JOYSTICK 5 SPOOL WITH TWIST FUNCTION FOR ANGLE
204 204
Training Centre-Lecce
 BLADE JOYSTICK 4 SPOOL & RIPPER JOYSTICK
205
HYDRAULIC PILOT CONTROL DEVICES 205
Training Centre-Lecce
 VALVE - 5 bar-+HYDRAUL. CONNECTION
To port S
From radiator To radiator
To tank

From T port
steering
hy.mototr

Port P from pump

PUMP Pressure
port -MP-

To pump
206 From port L on equip.stering valve. 206
Training Centre-Lecce
207 207
Training Centre-Lecce
 REAR
TRANSMISSION
ASSEMBLING

208 208
Training Centre-Lecce
209 REAR TRANSMISSION HOUSING 209
Training Centre-Lecce
 APPROACH OPERATIONS FOR BEARINGS CASES+PINION
210 210
Training Centre-Lecce
 ASSEMBLING EPICYCLOIDAL CROWN +GEAR WITH WIRE
211 211
Training Centre-Lecce
 DETAILS PINIONS+SHAFT+EPICYCLOIDAL CROWN GEAR
212 212
Training Centre-Lecce
 EPICYCLOIDAL ASSY DISASSEMBLED
213 213
Training Centre-Lecce
 SPIDER ASSY

PLANETARY GEAR DISASSEMBLED

214 214
Training Centre-Lecce
 ASSEMBLING FOR EPICYCLIC REDUCTION GEAR ASSY
215 215
Training Centre-Lecce
 TORQUE 12.5 daNm + VALIDATION

216 216
Training Centre-Lecce
 ASSEMBLING FOR RIGID PIPELINES
217 217
Training Centre-Lecce
 REAR TRANSMISSION BEFORE THE TOP COVER

218 218
Training Centre-Lecce
 REAR TRANSMISSION AFTER THE TOP COVER
219 219
Training Centre-Lecce
 63 lit.
33 lit.

33 lit.

220 220
TEST 1,5 bar X 2 min. + FILLINGS OF THE FLUID Training Centre-Lecce
 TESTING PROCEDURES FOR THE REAR
221 TRANSMISSION 221
Training Centre-Lecce
 Port S
Port A
Port T-to tank

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

Discharge line
Brake
linea control
comando line
freni
R+LR+L
side DR port valve block

Brake disc COVER + PIPELINES

Lubrication
222
C line 222
Training Centre-Lecce
 FRONT+REAR TRANSMISSION

223 223
Training Centre-Lecce
 REAR
TRANSMISSION
COVER
ASSEMBLING
224 224
Training Centre-Lecce
 PREPARATION AND ASSEMBLING FOR SHAFT ASSY (BEARINGS)

225 225
Training Centre-Lecce
 PREPARATION AND ASSEMBLING FOR SHAFT ASSY-
(GEARS)

226 226
Training Centre-Lecce
 PROCEDURE FOR ASSEMBLING
THE DOUBLE GEARS

227 227
Training Centre-Lecce
 1 2 3

ASSEMBLING FOR SHAFT ASSY- OF THE DOUBLE GEARS

228 228
Training Centre-Lecce
 2

MOUNTING OF TUBE FOR LUBRIFICATION OF THE DOUBLE GEARS

229 229
Training Centre-Lecce
 SPECIAL TOOL x assembling

PRE-TORQUE
TORQUE-45 daNm
PROCEDURE FOR ASSEMBLING
THE HYDRAULIC MOTOR

230 230
Training Centre-Lecce
 FILLING WITH HYDRAULIC
OIL HI-TECH 46-(2,5 Kg)
TORQUE-28 daNm
231 231
Training Centre-Lecce
 COVER – TOP VIEW

232 232
COVER – BOTTON VIEW Training Centre-Lecce
 PREPARATION AND
ASSEMBLING OF THE COVER

233 233
Training Centre-Lecce
234 234
Training Centre-Lecce
 ELECTRICAL
SYSTEM
D180PS
235 235
Training Centre-Lecce
 1850 TIER III D 180 PS TIER III

RS232

Gear Steering
box Transmission 1..2,95V steer. Joystick
MH4-4 Controller &dig. Signals Transmission
forw/backw
turtle/rabbit CASE
Engine TIER III
K-Line
Electr. Controlled Armrest
EDC 7 Fingerpotis NH
Engineering Display
Error code
Tool CIAM
RS232 Error code from all controllers
PWM 2x are displayed directly
PWM 6x

Pedal PWM 2x
Joystick Blade
Rexroth Priofunction
dig. Out
BB3 Steering (24V, 1A) Pressure inc.

Section
Ripper
Angle

Inlet-
160/350 bar

Lift
Tilt
Blade Detection
RS232 for EST –
Pilot Pressure
Service 35 bar max
communication and
Implement Error code via
Supply Solenoid Blade Joystick
p dig. Signal (24V, 1A)
EST-CNH p
i
Joystick
Servicetool Detection Lowering Ripper
IVECO dig. Signal (24V, 1A)
for tank pressuration

Detection Steering
236
Analog Signal (4..20 mA)
236
Training Centre-Lecce
 1850 - D180 TIER III Communication structure

Engineering Tool
EST
BB3

Blade control
9600 Baud Error management
(master unit)
Parameter, Error codes, RS232 (1) RS232 (2) RS232 (3)
Diagnostics, Cluster
Software update
(for both joysticks)

Transmission data, Error codes from all

(both joysticks and rexroth controller)

2500 Baud
9600 Baud

Transmission data, Error codes

Parameter, Error codes,
Diagnostics,
Ripper control Software update
(slave unit) (via master unit) Rexroth Controller

RS232 (2) RS232 (1) RS232 (3)

237 237
Training Centre-Lecce
 1850 TIER III (Main valve) D 180 PS TIER III

Send all informations

PWM from controller, ripper
joystick and blade
PWM joystick to display

Y302 Y304 Y306 Y308 Plug X2

Implement
Armrest Supply Solenoid Joystick Blade
dig. Signal
24V, 1A) Priofunction

Pressure inc.
Plug X1
Steering

Section
Ripper
Angle dig. Out

Inlet-
Lift
Tilt

(24V, 1A) Power sup.

Y309 160/350 bar (24V, 7A)
Power sup.
Y310 (24V, 5A)

Detection Receive all

Pilot Pres.
Plug X1 informationf
RS232
35 bar max rom Rexroth
Joystick controller
Y301 Y303 Y305 Y307 Ripper
p
i PWM Plug X2
PWM
p
Detection Lowering RS232
dig. Signal (24V, 1A) to service tool
for tank pressuration
Detection Steering
Analog Signal (4..20 mA)
238 238
Training Centre-Lecce
 D180 PS Caratteristica Corrente - Corsa

800
700
550
600
Corrente (mA)

500
400 Corrente

300

200
150
100

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

COURRENT (mA) V/S STEERING LEVERS STROKE

239 239
Training Centre-Lecce
 PRIMARY DIAGNOSTIC CODES
DEFECT CODE
LEFT STEERING SOLENOID VALVE SHORT CIRCUIT OR INTERRUPTION E001

RIGHT STEERING SOLENOID VALVE SHORT CIRCUIT OR INTERRUPTION E002

FORWARD SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E004

REVERSE SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E008

FIRST GEAR SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E016

THIRD GEAR SOLENOID CONNECTION SHORT CIRCUIT OR INTERRUPTION E032

LEFT STEERING LEVER POTENTIOMETER CONNECTION SHORT CIRCUIT OR INTERRUPTION E064

RIGHT STEERING LEVER POTENTIOMETER CONNECTION SHORT CIRCUIT OR INTERRUPTION E128

240 240
Training Centre-Lecce
 SECONDARY DIAGNOSTIC CODES
E001 E002 E004 E008 E016 E032 E064 E128
E001 E001 E003 E005 E009 E017 E033 E065 E129

E002 E002 E006 E010 E018 E034 E066 E130

E004 E004 E012 E020 E036 E068 E132

E008 E008 E024 E040 E072 E136

E016 E016 E048 E080 E144

E032 E032 E096 E160

E064 E064 E192

E128 E128
241 241
Training Centre-Lecce
242 242
ELECTRICAL SYSTEM -1°- :START & SECURITY (A) Training Centre-Lecce
243 243
ELECTRICAL SYSTEM -1°- : START & SECURITY (B) Training Centre-Lecce
 ELECTRICAL SYSTEM
2°-area MANAGEMENT

FG. 2/2

244 244
Training Centre-Lecce
 FG. 1/2
FG. 2/2

ELECTRICAL
SYSTEM
area-3°-MONITOR

245 245
Training Centre-Lecce
ELECTRICAL SYSTEM-4°-SERVICES area (LIGHTS)
246 246
Training Centre-Lecce
 ELECTRICAL SYSTEM-5°-area ENGINE UNIT (CPU)
247 247
Training Centre-Lecce
 ELECTRICAL
SYSTEM-6°(A)-
area
JOYSTICK
BLADE

248 248
Training Centre-Lecce
 ELECTRICAL
SYSTEM-6°(B)-
area
JOYSTICK
249 RIPPER 249
Training Centre-Lecce
 ELECTRICAL
SYSTEM-6°(C)-
area
JOYSTICK
250 TRANSMISS. 250
ONLY for CASE Training Centre-Lecce
 ELECTRICAL SYSTEM-
7°- (A)
SERVICES
area (windsheld wiper)

251 251
Training Centre-Lecce
 ELECTRICAL SYSTEM-
7°- (B)
SERVICES
area HEATER

252 252
Training Centre-Lecce
 ELECTRICAL SYSTEM-
7°- (C)
SERVICES area
CLIMA+RADIO..

253 253
Training Centre-Lecce
 MONITOR SENDERS 1
LOCATION ON ENGINE
5
1. Air cleaner clogging sensor

2. Engine coolant max temperature switch 2

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

7. Hydraulic oil filter clogging sensor

D180PS
LOCATION ON TORQUE CONVERTER
8. Brake-clutches low oil pressure sensor (set
at 11.5 bar) 8
9. Transmission oil low pressure sensor (set at 10
11.5 bar) 9
10. Transmission oil temperature sensor (set
at254
119°C) 254
Training Centre-Lecce
Sul telaio
 MODULES RELAY & DIODE
DOZER BASE/STANDARD
Resistance from 1komh
MODULE POWER RELAY

MODULE BUSSMANN FOR

MINI RELAY+DIODE
255 255
Training Centre-Lecce
 MODULES RELAY & DIODE
DOZER BASE/STANDARD

MODULE BUSSMANN RALAY+DIODI MODULE POWER RALAY

256 256
Training Centre-Lecce
 MODULE RELAY & DIODE
(WITH COLD START& AIR CONDITIONED

RELAY COLD START 150Amp

FUSE COLD START 150 Amp

257 257
Training Centre-Lecce
 MODULE BUSSMANN RELAY + DIODE + FUSE
(WITH COLD START & AIR CONDITIONED

MODULE UPPER COMMON AT

D180 E 1850K

MODULE LOWER FOR D180 T3 ONLY

258 258
Training Centre-Lecce
 MODULE RELAY & DIODE
(WITH COLD START & AIR CONDITIONED)

MODULE ASSEMBLED ON THE MACCHINE

259 259
Training Centre-Lecce
 MODULE RELAY & DIODI
(WITH AIR CONDITIONED ONLY)

MODULE POWER RELAY +FUSE from 20 Amp for A.C.

260 260
Training Centre-Lecce
 MODULE RELAY & DIODI
(WITH AIR CONDITIONED ONLY)

MODULE BUSSMANN RALAY+DIODI FOR A. C. CONFIGURATION

261 261
Training Centre-Lecce
 STARTER MOTOR
262 262
Training Centre-Lecce
 ALTERNATOR
263 263
Training Centre-Lecce
264 AIR CONDITIONED COMPRESSOR 264
Training Centre-Lecce
 FUSE LINK

80A 80A
80A 80A

Alternator Machine

265 265
Training Centre-Lecce
ROPS CANOPY - CONFIGURATION

ROPS CAB CONFIGURATION

PLUG CONNECTOR 12 WAY+

MAIN CONNECTORS 19-21-23 WAYS
266 266
Training Centre-Lecce
 DEUTCH CONNECTOR FOR MODULE POWER RELAY-CABLE MACHINE
267 267
Training Centre-Lecce
 DASHBOARD ON ROPS CANOPY DASHBOARD ON ROPS CAB
CONFIGUR-D150 - D180PS CONFIGUR-D150-D180PS

BOX FUSE ON CANOPY CAB

268 268
Training Centre-Lecce
 BOX FUSE FOR STANDARD CAB

269 269
Training Centre-Lecce
 BOX FUSE FOR ROPS CANOPY

A
B

270 270
Training Centre-Lecce
 ELECTRONICS STOPCOCK WIT TIMER + BLOW-BY MOTOR
271 271
Training Centre-Lecce
 CONTROL PANEL FOR AIR CONDITIONER

272 272
Training Centre-Lecce
 OPERATOR SAFETY PROXIMITY SWITCH

273 273
Training Centre-Lecce
 BREAK OIL LOW
PRESSURE SWITCH

SOLENOID VALVE
274 274
Training Centre-Lecce
 BACK-UP ALARM + HORN

275 275
Training Centre-Lecce
 MASTER SWITCH IGNICTION KEY

276 276
Training Centre-Lecce
 RS 232 CONECTOR FOR
9 PIN DEUTCH PER
DOWNLOAD PARAMETERS
DIAGNOSIS ON NEF ENGINE
JOYSTICK LAMA+RIPPER

LED-ENGINE ERROR CODE

BUTTON FOR ACTIVATE

LED FLASHING

277 277
Training Centre-Lecce
 BATTERY BOX
278 278
Training Centre-Lecce
 Pedal brake pressure switch+decelerator pedal proximity swtich
for inhibition of the AUTO-KICK DOWN

279 279
Training Centre-Lecce
 280
280
MICRO CONTROLLER REXROTH MHDA-4
Training Centre-Lecce
 ENGINE IDLE SWITCH SENSOR

281 281
Training Centre-Lecce
 END OF THE PRESENTATION

282 282
Training Centre-Lecce