New Holland D180 Service Manual

Copyright © New Holland
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 construc-
tion of any type of equipment, there are many condi-
tions 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 hydrauli-
cally, mechanically, and/or cable controlled equip-
ment (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 Before operating a machine, always ensure that any
or maintain this machine. unsafe condition has been satisfactorily remedied.
- Do not wear rings, wrist watches, jewellery, loose or - Check brakes, steering and attachment controls before
hanging apparels, such as ties, torn clothing, scarves, moving. Advise the proper maintenance authority of any
unbuttoned or unzipped jackets that can catch on mov- malfunctioning part or system.
ing parts. Wear proper safety equipment as recom-
mended for the job. Examples: hard hat, heavy gloves, - Be sure all protective guards or panels are in place, and
ear protection, safety glasses or goggles, reflector vests, all safety devices provided are in place and in good
respirator. Consult your employer for specific safety operating conditions.
equipment requirements.
- Be sure exposed personnel in the area of operation are
- Keep operator's compartment, stepping points, grab- clear of the machine before moving it or its attachments.
rails and handles clear of foreign objects, oil, grease, WALK COMPLETELY AROUND the machine before
mud or snow accumulation to minimise the danger of mounting. Sound horn.
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
- Do not jump on or off the machine. Keep two hands and machine.
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 - Obey all flag signals and signs.
climbing on or off machine. Hoses and controls are
movable and do not provide a solid support. Also, - Due to the presence on the machine of flammable fluids,
controls may be inadvertently moved causing accidental never check or fill fuel reservoirs or batteries near open
machine or equipment movement. flames, smoking materials or sparks.
- Never attempt to operate the machine or its tools from - REMEMBER THAT STARTING FLUID IS FLAMMABLE.
any position other than seated in the operator's seat. Follow strictly the recommendations printed on contain-
ers and in the Operation and Maintenance Manual.
- Keep head, body, limbs, hands and feet inside opera-
tor's compartment at all times, to reduce exposure to - DO NOT PUNCTURE OR BURN CONTAINERS.
hazards outside the operator's compartment.
- Containers must be stored in fresh, well ventilated plac-
- Be careful of slippery conditions on stepping points, es, out of reach of unauthorised persons. Follow strictly
hand rails, and on the ground. Wear safety boots or the instructions provided by the Manufacturer.
shoes that have a high slip resistant sole material.
- Never use these products near open flames, smoking
- Do not leave the machine until it is completely stopped. materials or sparks.
- Check the seat safety belt at least twice a year. If there

are signs of wear or fraying or other signs of weakness OPERATION
that could lead to failure, replace it.
- Do not run the engine of this machine in closed areas
without proper ventilation to remove deadly exhaust
STARTING gases.
- NEVER START NOR OPERATE AN UNSAFE MA- - Roll Over Protective Structures are required on loaders,
CHINE. dozers, graders, excavators.
I
SAFETY RULES
NEVER OPERATE machines without ROPS. Keep cab windows clean and repaired.
- Make sure the Operator's compartment is free of foreign - When machines are operating in tandem, the pusher (rear)
objects, especially if not firmly secured. Never use the must be equipped with the appropriate deflectors to protect
machine to transport objects, unless proper securing the unit in front from the air stream coming from the radiator.
points are provided.
- When pulling or towing through a cable or chain, do not
- Check monitoring instruments at start-up and frequently start suddenly at full throttle; take-up slack carefully.
during operations. in case the brake pressure gauge
shows a pressure lower than the minimum operating Inspect carefully for flaws or troubles before using.
pressure, stop immediately the machine .
- Avoid kinking chains or cables. Do not pull through a
- DO NOT CARRY RIDERS ON MACHINE kinked chain or cable to the high stresses and possibility
of failure of the kinked area. Always wear heavy gloves
- Study and familiarise with escape routes alternate to when handling chains or cables.
normal exit routes.
- Be sure chains and cables are anchored and the anchor
- Seat belts are required by current regulations to be provid- points are strong enough to handle the expected load.
ed with Roll Over Protection Structures or cabs. Keep Keep exposed personnel clear of anchor points and
safety belts fastened around you during operation. cables or chains.
- For your personal protection, do not climb on or off - DO NOT PULL UNLESS OPERATOR's COMPARTMENT
machine while machine is in motion. 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 - Be alert to soft ground conditions close to newly construct-
operating the equipment. Sound horn. Obey all indications ed walls. The fill material and weight of the machine may
provided by flags and signals. cause the wall collapse under the machine.
- NEVER COAST the machine down grades and slopes - In darkness, check area of operation carefully before
with the transmission in neutral or neutralised. 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
- Do not operate machinery in a condition of extreme fatigue or authority immediately. Do not continue to operate ma-
illness. Be especially careful towards the end of working shift. chine, until condition has been corrected.
- 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
- Operate the machine at speeds slow enough to ensure exhaust fumes are dangerous to the operator.
complete control at all times.
- In case of closed type cabs, always keep an opening with
- Travel slowly over rough terrain, on slopes or near drop- the outside, to ensure a constant air circulation.
offs, in congested areas or on ice or slippery surfaces.
- Operators must know thoroughly the performances of the
- When backing, always look to where the machine is to be machine they are operating. When working on slopes or
moved. Be alert to the position of exposed personnel. DO near sudden level drops of the terrain, avoid areas where
NOT OPERATE if exposed personnel enter the immediate ground is loose or soft since rolling-over or loss of control
work area. STOP THE MACHINE. of machine could result.
- Maintain a safe distance from other machines. Provide - Where noise exposure exceeds 90 dBA for 8 hours, wear
sufficient clearance for ground and visibility conditions. approved ear protection.
Yield right-of-way to loaded machines.
- When counterweights are provided, do not work machine
- Maintain clear vision of areas of travel or work. if they have been removed.
II
SAFETY RULES
- Overtaking manoeuvres must be performed only when - Avoid operating equipment too close to an overhang or
absolutely necessary and unavoidable. Beware of possi- high wall, either above or below the machine. Be on the
ble uneven terrains, poor visibility conditions, the pres- look-out for caving edges, falling objects and slides.
ence of other machinery or persons out of sight. Beware of concealment by brush and undergrowth of
these danger.
- Operate the machine at a speed adequate to the working
conditions in the site and slow enough to ensure complete - When pushing-over trees, the machine must be equipped
control at all times. with proper overhead guarding. Never allow a machine to
climb up on the root structure particularly while the tree is
- Never use the machine as a work platform or scaffolding, being felled. Use extreme care when pushing over any
nor other inappropriate operations (i.e. pushing railway tree with dead branches.
cars, trucks or other machines).
- When pushing trees with dead limbs, proceed with ex-
- Be alert of people in the operating area of the machine. treme care. Avoid brush piles, logs or rocks.
- When operating a machine, know in advance what clear- - NEVER DRIVE OVER THEM or other surface irregulari-
ances will be encountered, overhead doors, cables, pipes, ties that brake traction with the ground, especially when on
bearing load limitations of ground, bridges, floors or slopes or near drop-offs.
ramps.
- Be alert to avoid changes in traction conditions that could
- When roading, find-out what conditions are likely to be cause loss of control. DO NOT DRIVE on ice or frozen
encountered, clearances, traffic congestion, type of road ground conditions when working the machine on steep
surfacing, etc. Beware of fog, smoke or dust elements that slopes or near drop-offs.
obscure visibility.
- Working in virgin and rough terrains is characterised by
- When crossing gullies or ditches, move at an angle with the presence of all the perils and risks listed above. In
reduced speed after ensuring ground conditions will per- these conditions, it is emphasised the danger represented
mit a safe traverse. by large tree limbs (possibly falling on the machine), large
roots (acting as a leverage under the machine when up-
- Explore the working area to identify potential risks such as: rooted causing the roll-over of the unit) etc..
slopes, overhangs, pits, demolition rubble, fires, ravines,
ditches, soft terrain, heavy traffic, crowded parking areas,
closed ambients. In such conditions, proceed with ex-
treme care.
- Whenever possible, avoid going over obstacles such as

rough terrain, rocks, logs highly irregular ground, steps, STOPPING
ditches, railroad tracks. When obstructions must be
crossed, do so with extreme care at an angle, if possible. - When the machine is stopped for whatever reason, follow
Reduce speed, shift-down. Ease up to the break over the instructions of chapters "Stopping the machine" and
point, pass the balance point slowly on the obstruction and "Stopping the engine" of the Operation and Maintenance
ease down on the other side. Instruction Manual.
- In steep down-hill operation, do not allow engine to over- - Always remember to position the transmission drive control
speed. Select proper gear before starting down grade. in neutral and engage the control lock to secure the machine.
- Avoid side hill travel, whenever possible. Drive up and - The parking brake is automatically set, when the transmis-
down the slope. Should the machine slipping sideways, sion safety lever is lowered.
turn it immediately downhill.
- NEVER LEAVE THE MACHINE UNATTENDED with the
- The grade of slope you should attempt will be limited by engine running.
factors such as condition of the ground, load being han-
dled, type of machine, speed of machine and visibility. - Always, before leaving the operator's seat and after mak-
ing sure all people are clear of the machine, slowly lower
- There is no substitute for good judgement when working the attachments or tools flat to the ground in a positive
on slopes. ground support position.
III
SAFETY RULES
- Return the controls to rest position. Place the gearshift - Keep operator's compartment free of all loose objects
lever in neutral. Disconnect the master switch and extract that are not properly secured.
the key.
- Do not wear rings, wrist watches, jewellery, loose or
- Park in a non- operating and no-traffic area or as instruct- hanging apparels, such as ties, torn clothing, scarves,
ed. Park on firm level ground if possible. Where not unbuttoned or unzipped jackets that can catch on mov-
possible, position machine at a right angle to the slope, ing parts. Wear proper safety equipment as recom-
making sure there is no danger of uncontrolled sliding mended for the job. Examples: hard hat, heavy gloves,
movements. ear protection, safety glasses or goggles, reflector vests,
respirator. Consult your employer for specific safety
- If parking in traffic lanes cannot be avoided, provide equipment requirements.
appropriate flags, barriers, flares and signals as re-
quired. Also provide advance warning signals in the - Do not use controls or hoses as hand holds when
traffic lane of approaching traffic. climbing on or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
- Keep head, body, limbs, feet, fingers or hands away from controls may be inadvertently moved causing accidental
bucket, blade or ripper when in raised position. machine or equipment movement.
- Always disconnect the master switch before any inter- - Do not jump on or off the machine. Keep two hands and
vention (i.e. cleaning, repairing, maintaining, refuelling one foot, or two feet and one hand in contact with step
etc.). Do the same when parking for prolonged periods grab rails and handles at all times.
of time to avoid accidental or unauthorised starting.
- Do not perform any service operation on the machine
- Never lower attachments or tools other than seated in with a person seated in the operator's compartment,
operator's seat. Sound horn. Make sure area near the unless he is an authorised operator co-operating in the
attachment is clear. Lower the attachment slowly. DO operation to be performed.
NOT USE FLOAT POSITION of hydraulic system.
- Keep operator's compartment, stepping points, grab-
- Place master switch in OFF, securely block the machine rails and handles clear of foreign objects, oil, grease,
and lock it every time you leave it unattended. Return mud or snow accumulation to minimise the danger of
keys to authorised security. Heed all shut-down opera- slipping or stumbling.
tions 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 hydrau-
GENERALITIES lically operated attachments by means of machine's
hydraulic system remember that all manoeuvres must
- Before operating or performing any intervention on the be made only when seated in the operator's seat. Before
machine: starting machine or moving attachment or tools, set
brakes , sound horn and call for an all clear. Raise
• read carefully all the rules contained by this Manual; attachment slowly.
• read and obey all safety related plates and instructions - Always block booms or parts of the machine which must
located on the machine. be raised to perform interventions under them with
external devices. Do not allow persons to move into the
- Do not allow unauthorised personnel to perform any vicinities nor standing under equipment not being
maintenance operation. Do not perform maintenance blocked. Unless you are totally sure about your safety,
operation without prior authorisation. Follow all recom- avoid staying under raised equipment, even in case it is
mended maintenance and service procedures. blocked.
IV
SAFETY RULES
- Do not place the body, limbs or fingers into sharp - Never align holes with fingers or hands; always use
articulation uncontrolled openings of the machine and appropriate aligning tools.
without proper protections, unless they are blocked in a
safe manner. - 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 - Use only approved grounded auxiliary power sources for
jewellery near moving parts. 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 - Lift and handle heavy parts with a lifting device of proper
step platform that meet local and national regulations, to capacity. Be sure parts are supported by proper slings
reach the service point. If such ladder or platform are not and hooks. Use lifting eyes if provided. Watch-out for
available, use the machine hand holds and steps as people in the vicinity.
provided. Perform all service or maintenance carefully.
- Never pour gasoline or diesel fuel into open, wide and
- Shop and/or field service platforms or ladders must be low containers. Never use gasoline, solvent or other
constructed and maintained in accordance with local flammable fluid to clean parts. Use exclusively qualified,
and national regulations. non-flammable, non-toxic commercial solvents.
- Disconnect batteries and tag all controls according to - When using compressed air for cleaning parts, use
current regulations to warn that work is in progress. safety glasses with side shields or goggles. Limit pres-
Block machine and all attachments that must be raised sure to 2 bar, in accordance with local and national
according to current regulations. regulations.
Due to the presence of flammable fluids, never check or - Do not run the engine in closed areas without proper
fill fuel tanks, batteries, nor use starting fluid near lighted ventilation to remove deadly exhaust fumes.
smoking materials or open flames.
- Do not smoke or permit any open flames or spark near
- BRAKES ARE INOPERATIVE when manually released when re-fuelling or handling flammable materials.
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 - Make sure that all mechanic's tools are in good condi-
end of the fuelling operation to avoid the possibility that tions. NEVER USE tools with mushroomed heads or
sparks due to static electricity are generated. frayed. Always wear eye protections.
- Use only designated towing or attaching points. Use - Move with extreme care when working under the ma-
care in making attachments. Make sure pins and/or chine, its attachments and or on or near them. Always
locks are secure before pulling. Stay clear of drawbars, wear protective safety equipment as required, such as
cables or chains under load. hard hat, goggles, safety shoes, ear plugs.
- To move a disabled machine, use a trailer or a low-boy, - When performing operations requiring running of the
if available. In case towing is needed , use all necessary engine, have a qualified operator in the operator's seat
signals required by local and national regulations, and at all times with the mechanic on sight. Place the trans-
follow the directions provided in this Manual. mission in neutral and set the brakes and safety lock.
- To load/unload a machine from transporter, choose a - KEEP HANDS AND CLOTHING AWAY FROM MOVING
level surface ensuring firm support to the wheels of truck PARTS.
or trailer. Use strong access ramps, with adequate
height and angle. Keep surface free of mud, oil or - For field service, move machine to level ground, if
slippery materials. possible, and block it. If work on an incline is abso-
lutely necessary, first block machine and its attach-
- Anchor the machine securely to the bed of truck or trailer ments securely, than move it to level ground as soon
and block wheels or tracks with appropriate wedges. as possible.
V
SAFETY RULES
- Do not trust worn and /or kinked chains and cables: do - The load lifted by jacks is always dangerous: it is
not use them for lifting or pulling operations. To handle necessary to transfer loads to appropriate blocking
them, always use heavy gloves. as a safety measure, before proceeding with service
or maintenance work, according to local or national
- Be sure chains and cables are anchored and the anchor regulations.
points are strong enough to handle the expected load.
Keep exposed personnel clear of anchor points and - Steel cables are frayed after prolonged use; always wear
cables or chains. appropriate protections (heavy gloves, goggles etc.).
- No bystanders are allowed near the hooking points, - Handle all parts carefully. Keep hands and fingers away
chains or cables. from structures, gears or moving parts. Use and wear
always the appropriate protections
- DO NOT PULL UNLESS OPERATOR's COMPART-
MENT OF MACHINES INVOLVED ARE PROPERLY - Compressed air systems can have water deposits creat-
GUARDED AGAINST POTENTIAL CABLE OR CHAIN ed by moisture condensation due to changes of atmos-
BACKLASH. pheric conditions. If required, discharge deposits, as
instructed.
- Keep the area where maintenance operations are per-
formed 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 - Do not place head, body, limbs, feet, hands or fingers,
machine. Be sure exposed personnel in the area of near rotating fans or belts. Be especially alert near
operation are clear of the machine before moving it or its pusher fans.
attachments. Sound horn.
- Rust inhibitors are volatile and flammable Use only in

well ventilated areas. Keep open flames away - DO NOT ENGINE
SMOKE - Store containers in a cool well ventilated
place, secure against unauthorised personnel. - Loosen the radiator cap very slowly, to release pressure
from the system, before removing it. All coolant level top-
- Do not carry loose objects in pockets that might fall ups must be performed with engine OFF.
unnoticed into open compartments.
- Avoid that flammable materials touch exhaust parts.
- Wear proper protective equipment such as safety gog- Should this be possible, provide the necessary protec-
gles or safety glasses with side shields, hard hat, safety tions.
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
- Wear welders protective equipment such as dark safety fuel is spilled.
glasses, helmets, protective clothing, gloves and safety
shoes, when welding or burning. Wear dark safety - Never attempt to check or adjust fan belts when engine
glasses near welding zones. is running.
DO NOT LOOK AT ARC WITHOUT PROPER EYE - Do not adjust engine fuel pump when machine is mov-
PROTECTION. ing.
- Know your jacking equipment and its capacity. Be sure - Do not lubricate the machine with engine running.
the jacking point used on the machine is appropriate for
the load to be applied. Be sure the support of the jack at - Do not run the engine with air intakes, door or protections
the machine and under jack is appropriate and stable. open.
VI
SAFETY RULES
ELECTRICAL SYSTEM - Stop the engine and release all pressures in the system
before removing panels, housings, plugs or covers.
- Disconnect batteries prior to any intervention on ma-
chine or electrical system (cleaning, repair, mainte- - In case pressures must be measured, use instruments of
nance). 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 termi-
nals. Follow thoroughly the instructions of this Manual. TOOLS
- Before any intervention, make sure that the main switch is - Keep head, body, limbs, feet, fingers or hands away from
OFF. bucket, blade or ripper when in raised position.
- BATTERY GAS IS HIGHLY FLAMMABLE. Leave bat- Prior to any intervention, install all safety devices accord-
tery box open to improve ventilation when recharging ing to current rules and regulations.
batteries. Never check charge by placing metal objects
across the posts. Keep sparks or open flames away from - In case equipment on the machine must be operated
batteries. Do not smoke near battery to guard against the by hydraulic systems, remember to proceed only
possibility of causing an explosion. after seating in the operator's compartment. Make
sure that there are no persons in the operating area
- Before any intervention, make sure that there are no fuel of the machine. Alert people before operating using
or electrolyte leakages; eliminate them before proceed- the horn and by voice. Move the equipment very
ing with further work. When recharging batteries in carefully.
closed ambients, make sure that there is appropriate
ventilation to prevent possible accidental explosions due - Do not use machine to transport loose objects, unless
to the accumulation of gases generated during the proper devices for this purpose are provided.
recharge.
- Clutches and brakes of this machine and eventual aux-
iliary equipment and attachments (such as operating
cylinder or winches control valves) must always be
HYDRAULIC SYSTEM properly adjusted in accordance with the instructions
provided by the Manuals of the Manufacturer.
- Fluid escaping under pressure from a very small hole
can be almost invisible and can have sufficient force to - Never perform adjustments with engine running, except
penetrate the skin. Use a piece of cardboard or wood to when called for by the above instructions.
search for suspected pressure leaks. DO NOT USE
HANDS. If injured by escaping fluid, see a doctor at When changing work shift, check that wheel or rim
once. Serious infection or reaction can develop if proper securing screws and brackets are not loosen; if neces-
medical treatment is not administered immediately. sary, 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 con-
trolled 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) 2) identify the type of material of the seals, if they are
are used in systems operating at high temperatures, since VITON, performing the test illustrated below, on the
this materials resists the effects of heat. However, in the spare parts;
event this material is subject to heat exceeding 315 °C (599 3) in case it is verified, or there is a reasonable doubt that
°F) (in practice, only in case of fire or when using welding the components are made of VITON, the contaminated
flames) fluoridic acid is generated. This acid is highly area MUST be decontaminated before proceeding with
corrosive and could cause severe burns, if in contact further operations;
with the skin. 4) wear neoprene rubber or PVC gloves and protection
Every time it is necessary to intervene on components goggles or face screen, and wash accurately the con-
equipped with VITON rings, for which an exposure to taminated zone with a solution of hydraulic lime (found
excessive temperatures is suspected, the following proce- at building stores) and water, so that a milky liquid is
dures must be applied: obtained. Rinse carefully with steam or running water;
5) dispose of the materials removed and the protective
1) inspect visually, without touching them, all seals show- gloves in a safe manner, without burning them.
ing 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
TRICHLORO-
ETHYLENE
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)
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 MODELLO MARKING
On the right side of the transmission housing it is D180 LT (Power Steering) *FNH180LTN5HC24001*
possible to read the MARKING of the machine, com-
posed of: D180 XLT (Power Steering) *FNH180XTN5HC25001*
- manufacturer code (the first three digits) FNH;
- machine code; D180 LGP (Power Steering) *FNH180LPN5HC26001*
- check letter "N";
- - year of production “5” for 2005; D180 LT (Clutch) *FNH180B1N5HC27001*
- manufacturing plant H (Lecce Plant); D180 XLT (Clutch) *FNH180B2N5HC28001*
- product line “C” (Dozer);
- machine serial number (last 5 digits).
D180-0R001
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
TABLE OF FLUID CAPACITIES 0-4
ITEM QUANTITY Fluids and lubricants VISCOSITY Outdoor temperatures International

(Litres) GRADE of reference Classification
Mixture of water and antifreeze at

Cooling system 28 (30) Agriflù Agriflù mixed with 50 % Down to - 35 °C
50%. The mixture provides
water protects down to (-31 °F) oxidation, foaming, corrosion,
- 35 °C (- 31 °F) scaling and freezing protection
properties down to - 35 °C (- 31 °F).
Fuel reservoir 400 – – – DIESEL FUEL ASTM No. 2D

Grade TT of reputable quality and make
Engine 16 (19) Super Gold SAE 15W - 40 - 15 to 40 °C (-5 to 104 °F) API CF-4/SG or
CCMC D4 or
SAE 10W - 30 - 25 to 20 °C (-13 to 68 °F) MIL-L-2104 E
TorqueconverterTransmission 31 (40) Hydropower SAE 10W All season ATF Type A Suffix A
SAE 15W - 40 - 15 to 40 °C (-5 to 100 °F)
Transmission housing 46 (60) Super Gold API CF-4/SG or
steering/brakes CCMC D4 or
SAE 10W - 30 - 25 to 20 °C (-13 to 68 °F)
MIL-L-2104 E
Hydraulic system
"BULLDOZER" equipment DIN 51524 PART - 1
D180 90 (110) - 20 °C to 50 °C
HI-TECH 46 ISO 46 DIN 51524 PART - 2
D180 Power Steering / 110 (130) (- 4 to 122 °F)
110 (130) ISO VG 46
D180 LGP
Final drives (each) 33 Hypoide 90 SAE 80W - 90 All season API GL5 or
MIL-L-2105
SAE 15W - 40 - 15 to 40 °C ( 5 to104 °F)
Idlers 7 Super API CE or
Rollers and track chains CCMC D4 or
SAE 10W - 30 - 25 to 20 °C (-13 to 68 °F)
MIL-L-2104 E
Grease fittings MG2 NLGI2 consistency All season –
Cab tilting pump 0.5 Hydropower SAE 10W All season ATF Type A Suffix A
If the content of sulphur of the fuel exceeds 0.5 %,
Note: Oil quantities indicated are those required for periodical changes.
change the engine oil as follows:
- ( ) First supply quantity.
Down to 0.5 % sulphur Periodical change
D180
from 0.5 to 1 % Half normal interval

Over 1 % One quarter normal interval
MAIN DIMENSIONS
D180
TRACTOR DIMENSIONS LT XLT LGP

A Cab height from the ground mm 3235 (127.4 in) 3235 (127.4 in) 3235 (127.4 in)
B Muffler height from the ground mm 3170 (124.8 in) 3170 (124.8 in) 3170 (124.8 in)
C Machine frame length mm 4210 (165.7 in) 4210 (165.7 in) 4210 (165.7 in)
D Pitch mm 2700 (106.2 in) 3205 (126.2 in) 3205 (126.2 in)
E Track mm 1900 (74.8 in) 1900 (74.8 in) 2082 (82 in)
F Shoe width mm 560-610 (22-24 in) 560-610 (22-24 in) 762-915 (30-36 in)
G Rib height mm 71.5 (2.8 in) 71.5 (2.8 in) 71.5 (2.8 in)
H Free space from the ground mm 390 (15.3 in) 390 (15.3 in) 390 (15.3 in)
I Carriage width with shoes 560 (22 in) mm 2460 (96.8 in) 2460 (96.8 in) –
Carriage width with shoes 610 (24 in) mm 2510 (98.8 in) 2510 (98.8 in) –
Carriage width with shoes 760 (30 in) mm – – 2844 (111.9 in)
Carriage width with shoes 915 (36 in) mm – – 2997 (118 in)
Shipping weight without blade **** kg 17290 (38117.9 lb) 18390 (40543 lb) 19410 (42791.7 lb)
BLADE DIMENSIONS Half-U (HSU) With angle (HA) Half-U (HSU) Half-U 3 m With angle (HA) Straight (HS)
Blade capacity SAE J1265 m3 5.6 (197.8 ft3) 3.18 (112.3 ft3) 5.6 (197.8 ft3) 5.0 (176.8 ft3) 3.18 (112.3 ft3) 3.7 (130.7 ft3)
L Blade width mm 3460 (136.2 in) 4000 (157.5 in) 3460 (136.2 in) 2990 (117.7 in) 4000 (157.5 in) 3900 (153.5 in)
L1 Width with angle blade** mm – 3650 (143.7 in) – – 3650 (143.7 in) –
M Blade height mm 1425 (56.1 in) 1030 (40.5 in) 1425 (56.1 in) 1425 (56.1 in) 1030 (40.5 in) 1110
N Max. tilt mm 850 (33.5 in) 550 (21.6 in) 850 (33.5 in) 800 (31.5 in) 550 (21.6 in) 836 (32.9 in)
O Max. pitch * 10° 10° 10° 10° 10° 10°
P Digging depth mm 472 (18.5 in) 452 (17.8 in) 550 (21.6 in) 550 (21.6 in) 452 (17.8 in) 535 (21 in)
Q Blade raising from the ground mm 1100 (43.3 in) 1148 (45.2 in) 1190 (46.8 in) 1190 (46.8 in) 1148 (45.2 in) 1160 (45.7 in)
R Machine length with blade*** mm 5487 (216 in) 5316 (209.3 in) 5878 (231.4 in) 5878 (231.4 in) 5316 (209.3 in) 5675 (223.4 in)
Operating weight with blade* kg 20530 (45260.9 lb) 19650 (43320.8 lb) 20800 (45856 Ib) 20700 (45635 lb) 21630 (17685.9 lb) 22730 (50111 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.
0-5
**** Includes ROPS cab, blade lifting cylinders, lubricants and 10% fuel (for Power Steering version add 330 kg) (727.5 lb).
0-6 D180
TECHNICAL DATA D180 Power Steering - D180 Steering Clutch
TECHNICAL DATAS LT/XLT LGP
Max. speeds
FORWARD
1st km/h (mph) 4.1 (2.6) 4.3 (2.7)
2nd km/h (mph) 7.1 (4.4) 7.0 (4.3)
3rd km/h (mph) 11.1 (6.9) 10.8 (6.7)
REVERSE
1st km/h (mph) 5.3 (3.3) 5.3 (3.3)
2nd km/h (mph) 8.5 (5.3) 8.6 (5.3)
3rd km/h (mph) 13.2 (8.2) 13.2 (8.2)
Max. towbar pulling effort

FORWARD
1st kN 282 (63.3) 297.0 (66.7)
2nd kN 160 (36) 168.7 (37.9)
3rd kN 90.5 (20.3) 95.8 (21.5)
REVERSE
1st kN 221.7 (49.8) 233.9 (52.6)
PERFORMANCES
2nd kN 124.7 (28.0) 131.8 (29.6)
3rd kN 69.5 (15.6) 73.7 (16.6)
Ground pressure
in operating conditions kPa 65
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) % 60
2nd 5 km/h (3.1 mph) 5,6 km/h (3.5 mph) % 30
3rd 9.0 km/h (5.6 mph) 10 km/h (6.2 mph) % 10
Front equipment cycle times (ref. semi-U blade)

Raising time (from ground to max. height) sec 2.9
Controlled lowering sec 1.4
Floating sec 1.4
Noise
Outside (2000/14/CE)LwA dB(A) 111
Back-up alarm
Left safety lever
SAFETY DEVICES 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
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) 114 x 135 (4.5x5.3)
Total displacement L (gal.) 8.3 (2.2)
Number of cylinders - 6
D180 LT/XLT kW 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 kW HP
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 deg 45
ENGINE AND Fuel consumption (MAX. POWER) kg/h (lb/h) 30.7 (67.7)
ACCESSORIES
Starting capacity
Standard configuration °C (°F) -12 (10)
With cold starting system °C (°F) -25 (-13)
Electrical system
System voltage Volt 24
Capacity of starter motor kW (HP) 7.8 (10.5)
Capacity of alternator Amp 70
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 - 6
Gauge of fins mm (in) 3.5 (0.1)
Cap pressure bar (psi) 1.0 (14.5)
Air radiator/air
Fan diameter mm (in) 500 (19.7)
N. hoses 32
Pitch 2.8
2 2
Radiant surface dm (in ) 31.3 (485.1)
Operating pressure bar (psi) 2 (29)
0-8 D180
TECHNICAL DATA D180
Water pump flow (at normal speed) L/min (US gpm) 270 (71.3)
Fan (Blowing) / Soundproof blowing fan TRUFLO ABB
Fan diameter mm (in) 762 (30) 704 (27.7)

Blade pitch deg 26 27
Number of blade - 6 6
Dimension of blades mm (in) 178x258 -
(7x10.2)
Drive ratio (fan/engine) - 0.87:1 0.87:1
Air cleaner
Brand Donaldson
Type FHG12-0345
Dry type, two stages with safety element

and centrifugal separator
Setting of clogging indicator bar in H2O 0.062 (25)
ENGINE AND
ACCESSORIES 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 g/CFM 21
Dimensions mm (in) 304.8 (12)
Pre-cleaner
Rotor/centrifuge assembly, it uses centrifugal force
to separate contaminants carried by the air efficiency 85%
Recommended operation range L/min (CFM) 9910.9 to 19821.8
(350 ÷ 700)
Silencer Donaldson
Horizontal type. Under hood.
Dimensions mm (in) 209x292x600
(8.2x11.5x23.6)
Max. counter-pressure (Cummins limit: 76 mmHg, 1.46 psi) bar (mmHg) 0.10 (75)
Total volume L (US gal) 400 (106)

FUEL TANK
Specifications of filler cap -
Brand: Twin Disc

Model: 15" MS 335
Type: Single stage, single phase
TORQUE
CONVERTER Stall ratio - 2.28 : 1
AND Nominal diameter mm (in) 381 (15)
HOUSING
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) L/min (US gpm) 116.0 (30.6)
Wet TC housing with scavenger pump
D180 0-9
TECHNICAL DATA D180
Type: countershafts
Model: TM 200
Make: NH
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) 169 (1246)
Max. speed @ 0 torque rpm 2183
Specifications:
Clockwise rotation (from rear of machine) driven by Torque Converter
Shaft specifications:
Number of teeth - 21
Module mm (in) 1.58 (0.06)
Outer diameter mm (in) 34.87 (1.37)
Filters:
TRANSMISSION
Suction:
Metal mesh + magnetic rod mesh 100
Line:
Screwed-on Micron 25 abs.
Setting of by-pass valve bar (psi) 3.44 (49.9)
Collecting capacity @ 3.44 bar (49.9 psi) (ISO 4572) g (lb) 50 (0.1)
2 2
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 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
Dimension of shaft
PROPELLER Mechanical 7C
SHAFT Nominal length mm (in) 425 (16.7)
0 - 10 D180
TECHNICAL DATA D180
Gleason type, modular pinion assembly. Forced lube pinion bearings

D180 D180
BEVEL GEAR Power Steering
GROUP Steering Clutch
Ratio: 17/36 13/40
Module: mm (in) 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) cc/rev 130
- hydraulic motor
Bent axis design, axial pistons, fixed displacement motor
STEERING (with bolt-on movement control valve)
SYSTEM
Displacement cc/rev 90
Max. operating pressure bar (psi) 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) 30 (435.1)
- Oil radiator
Aluminium body mm (in) 590x179x63 (23.2x7x2.5)
By-pass setting bar (psi) 5 (72.5)
Planetary modules
See "power train" diagram
Gear ratio
straight travel conditions - 1.44
Steering line
See "power train" diagram
D180 0 - 11
TECHNICAL DATA D180
Gear ratio
Hydraulic motor to sprocket - 1.92
Performance
STEERING
SYSTEM Min. steering radius m (in) 1.0 (39.4)
D180
POWER
Max. differ. track chain
STEERING
speed, no load condition km/h (mph) 4.0 (2.5)
Max. differ. track chain

torque at 350 bar 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 Steering clutches:

SYSTEM - Typology with multiple discs,
D180
oil bath
- Control through spring
electro-hydraulic
Number of clutch driven discs (sintered) 7 (per clutch)

Number of driving discs (sintered) 8 (per clutch)
Total area for one clutch 7612 cm3
Inner diameter 280 mm
Outer diameter 350 mm
Steering filters
Suction
Metal mesh + magnetic rod mesh 100
Aligned filters:
Screwed-on Micron 25 abs.
Setting of by-pass valve bar (psi) 3.44 (49.9)
Collecting capacity @ 3.44 bar (ISO 4572) g (lb) 50 (0.11)
2 3
Filtering area cm (m ) 3075 (476.6)
Loss of charge @ 80 L/min bar (psi) 0.71 (1029.7)
BRAKES
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 - 5
Outer diameter mm (in) 350 (13.8)
Inner diameter mm (in) 280 (11)
Total friction area cm2 (in2) 2771 (429.5)
Friction material - sintered
No of springs - 20
0 - 12 D180
TECHNICAL DATA D180
Max. braking torque daN (lb) 1016 (2284)

BRAKES Pump flow (@engine max. speed) L/min 50
System pressure bar (psi) 25 (362.6)
SECTION
STEER./BRAKES Fabricated housing
Countershaft, double reduction, modular assembly
FINAL DRIVE
Total ratio - 12.286
Segments. 9 Elements
SPROCKET No. of teeth - 27
Pitch diameter mm (in) 880.25 (34.6)
TRACK Fabricated structure with two sealed boxes

FRAME Sealed track tensioner compartment
LT XLT/LGP
Link pitch mm (in) 203 (8) 203 (8)

No. of links - 40 45
Link height mm (in) 128 (5) 128 (5)
Shoe height mm (in) 71.5 (2.8) 71.5 (2.8)
Weight of shoes per metre kg/m (lb/in) 38.2 (2.13) 38.2 (2.13)
Width of standard shoe mm (in) 560 (22) 915 (36)
UNDER- Width of optional shoes mm (in) 610 (24) 762 (30)
CARRIAGE
LT XLT/LGP
No. of track rollers - 7 8

Sequence of rollers from sprocket - SF-DF-SF-DF SF-DF-SF-DF
-SF-DF-SF SF-SF-DF-SF
Diameter of rollers mm (in) 210 (8.3) 210 (8.3)
No. of support rollers - 2 2
Diameter of rollers (support) mm (in) 187.5 (7.4) 187.5 (7.4)
Diameter of idler wheel mm (in) 690 (27.2) 690 (27.2)
Sliding idler guides with replaceable wear strips

Sealed track tensioner compartment. Grease piston for track tension adjustment
Single spring.
Nominal load of spring assembly daN (lb) 19509 (430173)

Outside diameter of spring mm (in) 245 (9.6)
TRACK TENSION Diameter of wire mm (in) 53 (2.1)
SYSTEM
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
D180 0 - 13
TECHNICAL DATA D180
Diameter of pivot shaft mm (in) 120 (4.7)

Thickness of cross-member mm (in) 80 (3.1)
TRACK TENSION
SYSTEM Swing travel (track chain) deg ± 3.5
Idler travel (total) mm (in) 255 (10)
Fabricated structure, with two main members.

Bolted to steering compartment housing.
TRACK
SUSPENSION
SYSTEM Width of frame mm (in) 1040 (40.9)
Width of longeron mm (in) 100 ÷ 145 (3.9 ÷ 5.7)
Fabricated structure, with two main members.
COUNTER With integrated mudguards.

FRAME
Total width mm (in) 1984 (78.1)
Bolted to steering compartment housing
Pin diameter mm (in) 45 (1.8)

HOOK
Shim of bar mm (in) 90 (3.5)
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 D180

Power Steering
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 30 ÷ 32
(435 ÷ 464) (435 ÷ 464)
Main pump: axial pistons D180 D180
Power Steering
Steering Clutch
HYDRAULIC
Variable Fixed
SYSTEM
displac. displac.
Governors:
constant power control kW (HP) 90 (120.7) -
@ 1950 rpm
Cut-off pressure bar (psi) 350 (5076) 250
Load sensing bar (psi) 20 ÷ 21
(290 ÷ 304)
Brand Rexroth Rexroth
Model A11V0130 A10V0100
Max. displacement cc/rev 130 88
Pump speed at max. engine speed rpm 1912 1912
Pump max. flow L/min (gpm) 249 (65.8) 170
Min. displacement cc/rev 15 15
Pressure stand-by bar (psi) 33 ÷ 37 28 ÷ 32
(478.6 ÷ 536.6)
0 - 14 D180
TECHNICAL DATA D180
Tool control valve: D180 D180

Piloted, Closed centre, flow partition, with unloading valve. Power Steering
Steering Clutch
4 spools 3 spools
Brand Rexroth Rexroth

Model 4M7 - 22 3M6 - 15
Nominal dimensions mm (in) 22 (0.86) 15 (0.59)
st
1 spool
Ripper (raising, lowering)
2nd spool
Blade tilt (left, right)
Max. delivery L/min (gpm) 70 (18.5) 70 (18.5)
rd
3 spool
Blade (raising, owering, float, with hook)
4th spool Does not
Steering motor exist
Pilot valve
Single lever for 2nd and 3rd spool
Brand Rexroth
Model 5THF6
HYDRAULIC
SYSTEM 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)
Tilt (bulldozer blade)

Bore mm (in) 140 (5.5)
Stroke mm (in) 126 (4.9)
Tilt (angledozer blade)

Bore mm (in) 110 (4.3)
Ripper
Bore mm (in) 100 (3.9)
D180 0 - 15
TECHNICAL DATA D180

Hydraulic tank D180 D180
Power Steering
Steering Clutch
Total tank capacity L (US gal) 90 (23.8) 90
Oil tank volume L (US gal) 70 (18.5) 70
Capacity oil circuit L (US gal) 130 (34.3) 110
Strainer
Media Metalic mesh
HYDRAULIC Filtration capacity micron 250

SYSTEM By-pass valve setting bar (psi) 0.2 (2.9)
Max. nominal flow L/min (gpm) 275 (72.6)
2 2
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) 10
By-pass valve setting bar (psi) 2.5 (36.2)
Differential switch setting bar (psi) 2.2 (31.9)
2 2
Surface cm (in ) 9000 (1395)
Max. nominal flow L/min (gpm) 440 (116.2)
Cab:
Fully enclosed cab, modular, tiltable to 60° 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:
Support for hydraulic joystick and 3rd function lever, adjustable armrest, horn, ashtray, ignition
OPERATOR'S key.
COMPARTMENT
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
0 - 16 D180
TECHNICAL DATA D180
Dom light (2)

FM-AM Radio (12 Volt)
Can holders
12 V jack for lunch box refrigerator
No. of air ducts - 10
Seat
Make Kab
Model 301
Adjustment range mm (in) 150 (5.9)
Height adjustment mm (in) 60 (2.4)
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) kW (HP) 10.4 (13.9)
Filter:
Media, inorganic glass fibre paper
Efficiency % > 65
Capacity micron 0.3
2 2
Size cm (in ) 19600 (3038)
Recirculation percentage:
OPERATOR'S
COMPARTMENT No. of fans (type: SPAL 006-839-22 3 speed - total free flow 1160 m3/h) 2
No. of fan speeds 3
Max. cab air flow (free total air flow 1160 m3/h) m3/h (ft3/h) 500 (17657)
Max. pressurization bar (psi) 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) 6 (8)
Re-circulation percentage % na
Compressor
Make Sanden
Model SD7H1SMD7948
Displacement (max. allowed speed 7000 rpm) cc/rev 160
Thermostat valve setting +1 °C (33.8 °F)
open: diff. temp.
setting 3.5 °C (38.3 °F)
Pressure switch (2 level type):

LOW LEVEL: open 2 bar, closed 2.1 bar
HIGH LEVEL: open 25 bar, closed 19 bar
Expansion valve 2 TON - 6000 kcal/h
D180 0 - 17
TECHNICAL DATA D180
Condenser
Size (front surface) mm (in) 690 x 200 (27.2x7.9)
No. of fans (type: SPAL VA 14-BP7/C-34A - 3
Fan diameter mm (in) -
Fan size kW (HP) -
Tilting system
OPERATOR'S
COMPARTMENT Tilt cylinder
Double stroke with stroke-end valves
Brand Weber
Diameter mm (in) 45 (1.8)
Hand pump
Double stroke with oil tank
Brand Weber
Nominal displacement 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 2
No. of connections series
ELECTRICAL Brand Magneti Marelli
SYSTEM
Capacity Amp h 160 - 12 Volt
Discharge 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 50 & 80
Fuse boxes 2 x 11 fuses
Four position key starter switch -
Monitor 24 Volt MC Elettronica
0 - 18 D180
TECHNICAL DATA D180
Engine rpm counter digital

Hourmeter digital
Fuel level level indicator
Coolant temperature level indicator
ELECTRICAL
SYSTEM 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)
Push beams
Beam height mm (in) 200 (7.9)
Diameter of front ball joint mm (in) 108 (4.2)
HS blade:
Width (blade) mm (in) 3350 (131.9)
Width (tip of corner bits) mm (in) 3385 (133.3)
Height mm (in) 1215 (47.8)
3 3
Nominal capacity m (ft ) 3.9 (137.7)
Max. raising mm (in) 1090 (38492)
Penetration into the ground mm (in) 450 (17.7)
BULLDOZER Max. tilt mm (in) 830 (32.7)

EQUIPMENT Max. pitch deg ± 5° 30'
Wear components:
Two corner bits + three reversible cutting edges
Thickness of cutting edges mm (in) 20 (0.8)
Break-up force (lift cylinders)
Break-up force (tilt cylinder)
Semi-U blade
Width (blade) 3460
Height mm (in) 1425 (56.1)
Nominal capacity mm (in) 5.62 (0.2)
Max. raising m3 (ft3) 1090 (38492)
Max. tilt mm (in) 850 (33.5)
Max. pitch deg ± 5° 30'
D180 0 - 19
TECHNICAL DATA D180
Wear components:
BULLDOZER Thickness of cutting edges mm (in) 20 (0.8)
EQUIPMENT
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 200 (7.9)

Diameter of front ball joint mm (in) 150 (5.9)
Angledozer blade
Width (blade) mm (in) -
Height mm (in) 1030 (40.5)
ANGLEDOZER
EQUIPMENT Nominal capacity m3 (ft3) 3.18 (112.3)
Max. raising mm (in) 1148 (45.2)
Max. tilt mm (in) 380 (14.9)
Max. pitch deg ± 5° 30'
Wear components:
Thickness of cutting edges mm (in) 20 (0.8)
Break-up force (lift cylinders) -
Break-up force (tilt cylinder) -
Parallelogram PD180 ripper

Two double-stroke cylinders
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)
MULTISHANKS Cylinder supports and equipment beams in welded boxed structure
RIPPER
LT/XLT H. D. semi-curved shanks with replaceable tips
No. of shanks 3
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)
0 - 20 D180
TECHNICAL DATA D180
Break-up force daN 15800

Penetration force daN 6250
MULTISHANKS
Mass kg (lb) 1600 (3527.4)
RIPPER
LT/XLT 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
No. of shanks 3
MULTISHANKS
RIPPER Dimensions (according to ISO 6746/2) -
LGP 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)
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) 5 (1.3)
D180 0 - 21
CONTROL DATA ON THE MACHINE
ENGINE
Net power flywheel power (ISO 9249) kW (HP) 196 HP/ 146 kW (196)
Low idle rpm 680 ÷ 820
High idle rpm 2140 ÷ 2160
Implem. stall rpm 2070 ÷ 2210
Torque converter/transmission stall rpm 1780 ÷ 1920
Full stall rpm 1700 ÷ 1900
Lubrication
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)
Temperature of thermostats °C (°F) 81 ÷ 83 (178 ÷ 181)
Max. temperature setting °C (°F) 95 (203)
Setting of BOSCH injectors bar (psi) 260 ÷ 270
TRANSMISSION
Pressure relief valve 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 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) 31.5 ÷ 35.0
(456.9 to 507.6)
Max. pressure (equipment/steering) bar (psi) 190/350 (2320.6/5076.3)
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)
UNDERCARRIAGE
0 - 22 D180
D180 Power Steering - Steering Clutch (LT/XLT)
ENGINE
Net flywheel power (ISO 9249) kW (HP) 182 HP/ 135 kW
Low idle rpm 780 ÷ 920
High idle rpm 2080 ÷ 2220
Implement stall rpm 2070 ÷ 2210
Torque converter/transmission stall rpm 1730 ÷ 1870
Full stall rpm 1675 ÷ 1875
Lubrication
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)
Temperature of thermostats °C (°F) 81 ÷ 83 (178 ÷ 181)
Max. temperature setting °C (°F) 95 (203)
Setting of BOSCH injectors bar (psi) 260 ÷ 270 (3771 to 3916)
TRANSMISSION
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
(239.9 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)
UNDERCARRIAGE
TABLE OF WEIGHTS D180 - D180 POWER STEERING
D180
OPER. COMP. EQUIPMENT SHOES mm (in) TRACK CHAIN FUEL TOTAL

BASIC WEIGHT
DOZER SEMI-U 560 610 OPERATOR
MACHINE CAB CANOPY ANGLE RIPPER (22.04) (24.01) STD LONG 10% 100%
BLADE BLADE kg lb
X X X X X X X 19920 43916
X X X X X X X 20150 44423
X X X X X X X 19760 43563
X X X X X X X X 22160 48854
X X X X X X X 19620 43254
X X X X X X X 19850 43761
O
X X X X X X X 19460 43299 P
X X X X X X X X 21860 48193 E
X X X X X X X 20070 44246 R
X X X X X X X 20300 44753 A
T
X X X X X X X 19910 43894
I
X X X X X X X 19770 43585 O
X X X X X X X 20000 44092 N
X X X X X X X 19610 43233 A
X X X X X X X 20670 45569 L
X X X X X X X 20900 46077
W
X X X X X X X 20510 45217 E
X X X X X X X 20370 44908 I
X X X X X X X 20600 45415 G
X X X X X X X 20210 44555 H
T
X X X X X X X 20840 45944
S
X X X X X X X 21070 46451
X X X X X X X 20680 45592
X X X X X X X 20540 45283
X X X X X X X 20770 45790
X X X X X X X 20380 44930
X X X X X 16910 37280
S
X X X X X 17060 37611
H
X X X X X 17660 38934 I
X X X X X 17830 39308 P
X X X X X 16610 36618 P
I
X X X X X 16760 36949 N
X X X X X 17360 38272 G
X X X X X 17530 38647
0 - 23
0 - 24 D180
TABLE OF WEIGHTS D180 - D180 Power Steering
WEIGHTS
BASIC CAB SEMI-U SHOES FUEL TOTAL
OPERATOR
MACHINE BLADE (mm) (in) 100% kg (lb)
LT(PS) X X 610 (24) X X 20380 (45260.9)
XLT(PS) X X 610 (24) X X 21480 (47686)
OPERATIONAL
LGP(PS) X X 915 (36) X X 22730 (50111)
WEIGHTS
LT(SC) X X 560 (22.04) X X 20050 (44203)
XLT(SC) X X 560 (22.04) X X 21150 (46628)
D180 0 - 25
LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS
kg lb
Engine assembly 861 1898
Engine (with air cleaner and silencer) 700 1543
Torque converter assembly (with pumps) 161 355
Torque converter + housing 91 201
Main pump (D180 Power Steering) 60 132
Main pump (D180) 50 110
Brake pump 10 22
Transmission & converter pump 10 22
Radiator assembly (empty) 120 265
Universal joint 16 35
Transmission assembly 530 1168
Steering compartment assembly (with final drives) 3060 6747
Steering compartment assembly 1654 3647
Bevel pinion assembly 30 66
Bevel gear set 25 55
Bevel gear shaft 30 66
Steering module assembly (each) 235 518
Starter housing 905 1995
Ring gear 19.1 42
Ring gear, support 12.2 27
Hydraulic motor (D180 Power Steering version) 41 90
Cover assembly (including gears) 122 269
Final drive assembly (each) 703 1550
Pivot shaft 65 143
Swing bar 160 353
Shoes (910 mm (35.82 in), each) 35 77
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) 21 46
Shoes (610 mm (24 in), each) 23 51
Carriage assembly - LT 1514 3330
Carriage assembly - XLT/LGP 1800 3960
Track roller (each) 53 117
Support roller (each) 32 71
Track chain tensioner assembly 233 514
Idler wheel assembly 212 467
Track guide (each) 20 44
Fuel tank (empty) 180 397
0 - 26 D180
LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS
kg lb
Hydraulic tank (empty) 120 265
Battery (each) 49 108
Battery box 20 44
Operator's compartment 950 2094
Operator's compartment (canopy) –
Upper frame 480 1058
Hood support 85 187
Hood 25 55
Side panel (upper) 25 55
Side panel (lower) 10 22
Front grill 30 66
Hydraulic control valve (D180 Power Steering) 73 160
Hydraulic control valve (D180) 40 88
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 80 176
Pivot pin (each) 35 77
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
D180 0 - 27
CENTRE OF GRAVITY TABLE
Machine configuration:
HG mm (in) LG mm (in)
Basic machine + HSU blade + Ripper
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)
Basic machine + HA blade + Ripper

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)
Basic machine + HSU blade

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)
Note: LG = Horizontal distance from C/L sprocket

HG = Ground clearance
F14320
0 - 28 D180
GENERAL INSTRUCTIONS
INSTALLATION OF SEALS FOR ROTATING REMOVAL AND INSTALLATION OF ELASTIC

SHAFTS RINGS FOR ROTATING SEALING
Please comply with the following advises: Remove the rings as follows:
- prior to installation, keep the seals half an hour - press the ring so that one end and part of the inner
dipped into the same oil they are going to seal; circumference contact the bottom of the relevant
seat (a);
- clean accurately the shaft and make sure that its
working surface is undamaged; - keep the ring in the position above and, acting with
a scriber on the other end, free the catches, as
- direct the sealing lip towards the fluid; in case of an indicated in the figure (a).
hydro dynamic lip, the grooves must be oriented
so that the rotating direction of the shaft, tend to
return the oil inside the seal;
- 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 en-

tered perpendicularly to its seat and once the press-
ing 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 installa-
tion of the two parts, to insert an appropriate seal.
Re-install the elastic rings as follows:

INSTALLATION OF O-RINGS
- Press the ring so as to have one end and part of
Lubricate the seals before placing them into the rel- the inner circumference touching the bottom of the
evant seats so as to avoid that, during the installa- relevant seat (b);
tion, they tend to roll, thus altering their correct posi-
tioning, being furled, causing prejudice to their seal-
ing function.
D180 0 - 29
- install the ring in the position describe above and CLEANING

lift the free end (b) moving it until the two catches
engage correctly (c). After disconnecting the electrical system, clean ac-
curately all the parts to be disassembled, preferably
using steam.
In many repair or service workshops, caustic com-

pounds 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 ef-
ficient 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 sensi-
tive 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 recom-
mended.
b
DISASSEMBLY
It is always recommended, for any intervention on
engines or other assemblies removed form the ma-
chine, 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.
When identical parts are disassembled, such as
valves, tappets etc., place them in appropriate con-
tainers to ensure the same mating order when reas-
c sembling.
RECOMMENDATIONS FOR THE DISASSEMBLY ASSEMBLY

AND REASSEMBLY OF GROUPS
Clean accurately all the components to be reassem-
bled, as described by the various chapters of the
The following information, of a general nature, are
Manual.
intended to facilitate the disassembly and reassembly
The use of the proper special tools shown in the
of groups.
Manual is recommended.
Consequently, read and heed them when performing
Note – When applying sealing adhesive compounds,
this type of operations.
comply with the instructions provided with commer-
cial products.
0 - 30 D180
The manufacturer, prescribes, unless differently HIGH PRESSURE PIPES, CONNECTIONS, HOSES
specified, the following adhesive compounds: AND PIPES
RHODOSIL CAF 1, or LOCTITE 510.
This chapter provides correct recommendations and
Whenever possible, press bushes into their correct procedures to be followed during the disassembly of
position using a press. pipes and relevant connections.
- Keep all internal and external threads clean;
In the event it is necessary to use a hammer to install
a bush, use an appropriate punch to avoid damaging - Remove the plugs just before connecting the pipes
the bush. and plug at once all open connections.
- Do not use or reuse semi flanges out of shape more
Lubricate ball bearings prior to their installation. Lu- than 0.6 mm in the centre (see figure).
bricate the sealing lip of all seals, prior to their instal-
lation. - Make sure that the seats of O-rings are undam-
aged.
Whenever possible, install new seals; in particular - Lubricate all O-Rings.
new gaskets must be used on engine cylinder heads.
- Make sure that O-Rings are in place in the relevant
Use screws with the dimensions and grade indicated, seat.
referring to the part number of the Spare Parts Cata- - Tighten regularly so as to avoid distortions or dam-
logue. ages to O-Rings.
When indicated, safety washers, split pins and lock- - Install pipes and support bands letting the latter
ing wires etc. must be used. slightly loosen (tighten the band only after tighten-
ing the connections).
Comply with the prescribed tightening torques indi- - Make sure that the hoses reach the corresponding
cated in the "Tightening torques" section of this part to be connected to without forcing their posi-
Manual, using an appropriate torque wrench. tion.
Self-locking nuts must be replaced at each disassem- - In the event a hose is mounted straight, let enough
bly, to ensure a constant good performance against space to absorb contractions caused by pressure.
loosening. - Hoses must not be rolled (see figure) or touching
one another or touching other parts, especially if
moving.
Wrong Correct
D180 0 - 31
- Make sure that the dimension of the bands is - Make sure that bands are installed in a correct po-
appropriate for the outer diameter of the pipe to be sition so that the hose is kept away from obstacles
tighten to avoid possible rubbings (see figure). (see figure).
Wrong 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
0 - 32 D180
O-RINGS Field of application
DESIGNATION BASE ELASTOMER TEMPERATURE FIELD OF APPLICATION

of OPERATION
(*)
MINERAL OIL AND GREASE, COOL-

- 40 to 120 °C ANTS, FUEL, WATER UP TO 70°C (158
(- 40 to 248 °F) °F), AIR UP TO 100 °C (212 °F)
NBR NITRIL BUTADIENE

SAME COMPATIBILITY OF NBR 60 "
- 30 to 125 °C 75 IRHD, BETTER RESISTANCE TO
(- 22 to 257 °F) EXTRUSION, USED ONLY AS STATIC
SEAL
GENERAL FUELS, NON FLAMMABLE

FLUOROCARBON FLUIDS, ACIDS, SOLVENTS, MIN-
FPM (VITON) - 40 to 200 °C ERAL OIL
(- 40 to 392 °F) TO BE USED WITH TEMPERATURES
> 100 °C (212 °F)
BRAKE FLUID (DOT 3), STEAM, HOT

WATER, SILICON OIL AND GREASE.
EPDM ETHYLENE PROPYLENE - 40 to 150 °C WARNING: NOT TO BE USED WITH
(- 40 to 302 °F) MINERAL OIL AND GREASE
AIR, GAS, WATER, HIGH ANILINE

POINT MINERAL OIL, STEAM USED
MVQ SILICON -60 to 200 °C AS STATIC SEAL ONLY
(- 76 to 392 °F)
NOTE:
(*) Temperature indicated for static applications, provided as indication only.
O-RING PROPERLY O-RING O-RING O-RING

INSTALLED PRESSURISED EXTRUDED BROKEN
D180 0 - 33
TROUBLESHOOTING
GENERALITIES
For a fast troubleshooting, we recommend the com- e) Diagnosis

pliance with the following rules:
Once the trouble is identified. prepare a list of the
possible causes with the help of the suggestions of
a) Knowing the machine. the chapter for the group involved and identify the
correct one, using practical tests, starting from the
It is impossible to research the causes and formula most probable causes and the easiest tests.
te a diagnosis of troubles without having a good knowl-
edge 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.
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 instrumen-
tation;
- the performance of the machine;
- eventual odours or signs of overheating;
- noises different from normal operation noises; iden-
tify 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 de-
formations etc.
0 - 34 D180
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.) supersed-
ing those previously used by the M.K.S. system. Note – In case, in the different sections, the tighten-
ing torque is not listed, refer to the table "TIGHTEN-
Force: decanewton (daN) supersedes ING TORQUES", only after identifying exactly the
kilogram (kg) component.
Pressure: bar, supersedes kg/cm2
Torque: decanewton x meter (daN meter) The latter is identified by a coded eight digit number,
supersedes kg-m allowing a complete description of the item.
To convert the units of measure, the following table

applies: Example:
I / a b c d e / f g
multiply by to obtain
I - Standard index digit
Force kg 0.9807 daN
It is always represented by the digit 1. This number
Pressure kg/cm2 0.9807 bar indicates that the item can be fabricated in different
versions, differing for the material and coating.
Torque kgm 0.9807 daNm
a - b - c - d - e - Standard base digit
Note – For current repair needs, the following equiva- It is a number always composed of five digits identi-
lencies can be considered valid: fying the dimensional specifications of the item
kg = daN; kg/cm2 = bar; kgm = daNm.
f - Material index digit

To convert the units of measure of the International
System into an Anglo Saxon system, please refer to This digit indicates the material used fro a defined
the following table: item. Its meaning is indicated in the table to follow.
multiply by to obtain
Mass kg 2.205 Ib
g - Coating index digit
Length mm 0.03937 in
It indicates the coating applied to a defined item.
Pressure bar 14.5 psi
Torque daNm 7.373 lbf.ft
Flow L/min 0.2642 US gal/min
Temperature °C °C + 32 °F
9
Power kW 1.341 HP
5
Capacity L 0.2642 US gal
Speed km/h 0.6213 mph
D180 0 - 35
Class of strength and type of material

Index no. of
material ( f )
FIAT UNI DIN SAE BSI BNA
0 R 40 D - 4S - 4A 1 A 42
1 R 50 5S - 6S 3 P 56
2 R 80 8G 5 T 80
3 R 100 100 10K 8 V 100
4 Ottone Ottone Messing Brass Brass Laiton
5 Alluminio Alluminio Aluminium Aluminium Aluminium Aluminium
6 Rame Rame Kupfer Copper Copper Cuivre
7 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 ± 5%.
- The strength classes R80, R100, R120, must be

intended as follows:
10.9 supersedes R 100
12.9 " R 120 } for screws
}
10 supersedes R 80
for nuts
12 supersedes R 100
CDT = cadmium plated; FOSF = phosphatised;

ZNT = zinc plated.
0 - 36 D180
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:
NUTS (ZNT) SCREWS (ZNT / DEIDR)
Class of strength: 10 (R 80) Class of strength: 10.9 (R 100)
Diameter Normal Low type With polyamaide ring Diameter normal autoblocc.
and pitch and pitch ZNT ZNT
Normal Low type daNm daNm
mm daNm (lbf.ft) daNm (lbf.ft) daNm (lbf.ft) daNm (lbf.ft) mm (lbf.ft) (lbf.ft)
M6 x 1 1.3 (9.6) 1.2 (8.8) - - M6 x 1 1.3 (9.6) -
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)
M16 x 2 - - - - M16 x 2 - -
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 - - - - 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 - - - - 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 - - - - 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 - - - - 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) -
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 ENGINE 1-3
1.1 GENERAL SPECIFICATIONS
1. The Series C engine is a diesel for heavy duty

applications characterised by several design con-
cepts tending towards simplicity and a high com-
pactness.
F14321
Series C
Length Width Height Weight
mm in mm in mm in kg lb
1118 44 679 26.7 694 27.3 606 1336
2. The engine incorporates, in a single solution, all

the most important characteristics and advantag-
es of modern diesel technology. Technology
• In-line cylinders
• Water cooled
• 4 stroke
• Turbocharged
• Afterc-ooled
• Direct injection
• Metric dimensions
• Air flow cooling
3. The engine has been entirely designed with met-

ric dimensions. the only discrepancy with these
specifications involves the use of connections for
pipes and plugs with SAE standards. The speci- Engine components
fications of accessories change depending upon • Metric specifications
the Supplier. Technical publications list metric
values with the equivalent SAE values.
Pipes connections and
plugs
• SAE standards
1-4 ENGINE D180
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 con-

tacting 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 – Do not change the engine data plate unless

authorised by Cummins Engine Company, Inc.
2 1
4. The engines are designated as follows: Nomenclature

Model of industrial engine
The first digit indicates the number of cylinders, 6 C T A 8.3
the letter to follow indicates the series of the en-
gine, the remaining letters indicate the air intake No. of cylinders
(T = turbocharged) and the last numbers indicate Series C
the total displacement in litres. Turbocharged
After-cooled
Total displacement in litres
5. The total displacement of the engine is 8.27 litres Specifications of engine series
(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 in- Total displacement 8.27 L (504.5 in)
line, 6 cylinder Cummins engines, 1-5-3-6-2-4. Bore 114 mm ((4.5 in)
Stroke 135 mm (5.3 in)
Firing order 1-5-3-6-2-4
D180 ENGINE 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]
1-6 ENGINE D180
Cooling system
Thermostats
Beginning of opening: ................................................................. From 81 to 83 °C [170° to 182 °F]
Fully open: ................................................................................................................. 95 °C [203 °F]
Temperature of upper tank
Maximum allowed: ................................................................................................... 100 °C [212 °F]
Minimum recommended: ........................................................................................... 70 °C [158 °F]
Cap pressure with system at 99 °C (210 °F) .................................................... 0.42 bar (50 kPa) [7 psi]
Cap pressure with system at 104 °C (220°F) ................................................. 1.3 bar (103 kPa) [15 psi]
Coolant pressure (Upper manifold) at rated speed of 2000 rpm ............................................................
....................................................................................... 1.3 ÷ 2.7 bar (103 ÷ 276 kPa) [15 ÷ 40 psi]
Coolant flow (thermostats fully open, at rated speed of 2000 rpm) .................... 258 L/min [68 US gpm]
Coolant capacity ............................................................................................................ 9 L [10.5 US qt]
Intake and exhaust
Maximum restriction allowed at rated speed and nominal load (with dry air cleaner element)
................................................................................................................... 63.5 cm H2O [25 in H2O]
Maximum restriction allowed at turbocharger outlet at rated speed and nominal load
........................................................................................................................76.2 mm Hg [3 in Hg]
................................................................................................................. 101.6 cm H2O [40 in H2O]
Fuel system
Maximum restriction at fuel pump inlet ............................................................... 100 mm Hg [4.0 in Hg]

Minimum output pressure of fuel pump at rated speed
low delivery ................................................................................................. 0.7 bar (83 kPa) [12 psi]
high delivery ........................................................................................... 1.68 bar (172 kPa) [25 psi]
Restriction of fuel filter (maximum pressure drop through the filters) ............. 0.345 bar (35 kPa) [5 psi]
Minimum pressure in pump duct at rated speed and high flow .................... 1.37 bar (140 kPa) [20 psi]
Minimum pressure in pump duct at rated speed and low flow ...................... 0.42 bar (48 kPa) [7.0 psi]
Restriction on fuel return (maximum) ................................................................ 518 mm Hg [20.4 in Hg]
D180 ENGINE 1-7
Electrical system
Minimum capacity of recommended batteries

12 Volt system
18 °C (64.4 °F) Cold starting current................................................................................. 1800 Amp
(Reserve capacity)* .......................................................................................................... (640 Amp)
0 °C (32 °F) Cold starting current ..................................................................................... 1280 Amp
24 Volt system**
18 °C (64.4 °F) Cold starting current................................................................................... 900 Amp
0 °C (32 °F) Cold starting current ....................................................................................... 640 Amp
* The quantity of plates for a given dimension of batteries determines its capacity. The reserve capacity
determines the length of the period during which a sustained starting is maintained.
** Per battery (two 12 Volt batteries in series). CCA specifications are based upon - 18 °C (-0.4 °F)
Batteries (Specific gravity)
Specific gravity at Charge status

27 °C [80 °F]
1.260 - 1.280 100%

1.230 - 1.250 75%
1.200 - 1.220 50%
1.170 - 1.190 25%
1.110 - 1.130 Exhausted
1-8 ENGINE D180
1.3 DIAGRAMS OF SERIES "C" ENGINE
The illustrations here below provide information on The illustrations and the configuration of the compo-
the engine components, the location of filters, the nents shown in these diagrams are of a general na-
draining points and the access locations for engine ture. The locations of some components change de-
instrumentation and controls. pending upon the application and the installation.
For the removal, testing, overhaul and installation of the engine,

please refer to the Workshop Manual Print Number 604.06.901.
Front lifting
bracket High pressure fuel pipes 1/4 " NPTF (air) M22 x 1.5 (air)
Rear lifting
bracket
Fuel/water
separator
Fuel injection
pump Fuel pump
Oil filler 3/4 " x 16 " UNF point

neck for magnetic sensor
Arrangement for
sump oil heating
Engine front Oil draining plug

mounting bracket
F14322
Fig. 1-1 View from injection pump side
D180 ENGINE 1-9
Turbocharger
exhaust outlet
Cylinder block
breather pipe
Flywheel
Centring bearing
housing
Flex disc
mounting holes
Flywheel
F14323
Fig. 1-2 Rear view
Turbocharger
air intake Turbocharger air outlet Engine air intake
Coolant filter Fan pulley
Belt tensioner Fuel pump drive cover
Alternator Drive belt
Water pump
Vibration damper
Fig. 1-3 Front view
1 - 10 ENGINE D180
Turbocharger Westgate Turbocharger

exhaust outlet actuator air outlet
Water
outlet connection
Arrangement
Lube oil temperature
for coolant
thermostat
heater
Lube oil pressure

(after the filter)
Arrangement
for cab heater Lube oil pressure
(before the filter)
Arrangement
for coolant 1/2" NPTF
temperature (coolant)
sensor
Coolant inlet
Turbocharger
oil draining Lube oil
temperature sensor
Lube oil filter Lube oil heat

exchanger
F14325
Fig. 1-4 View from turbocharger side
D180 ENGINE 1 - 11
1.4 MOUNTING OF ENGINE ON FRAME
F14325
Tightening torques
C1. Self-locking nut M24 x 2 .............. 108 daNm (796.3 lbf.ft)

C2. Screw TE M12 x 1.75 ...................... 11 daNm (81.1 lbf.ft)
C3. Self-locking nut M16 x 1.5 ............... 30 daNm (22.1 lbf.ft)
1 - 12
38±2 bar (551±29 psi) Sequence valve
with 5 L/min (1.3 US gpm)
Gear motor 8 cc/turn

Gear 8 cc/turn
pump
ENGINE
PT0 speed
1.13 engine speed
16±2 bar (232±29 psi)

with 19 L/min (5 US gpm)
Back
1.5 AFTERCOOLER FAN DRIVE SYSTEM
pressure
valve
Tank
F14454
D180
D180 ENGINE 1 - 13
7
1
Tank
F14455
1. Gear pump - 2. Sequence valve - 3. Gear engine - 4. Counterpression valve - 5. Radiator - 6. Turbo -
7. Support
1 - 14 ENGINE D180
1.6 THROTTLE LINKAGE
Adjustment procedure at one end of rod (1) until the securing holes corre-
sponding with the one of cam “D” is found.
Connect adjustable link (1) to lever “A” using pin, Insert the pin and hook the stopper.
washer and split pin. Hook spring “E” to the to pins.
With throttle lever “B” in low idle position, position Connect lever “C” to the injection pump using the
lever “C” at the dimension indicated. adjustment of the forks located at the ends of rod (2)
Adjust the fork complete with pin and stopper located and install the relevant pins, washers and split pins).
SECTION 2
TRANSMISSION
TABLE OF CONTENTS
2.1 GENERAL DESCRIPTION ............................................................................................... 2-3

2.1.1 Transmission torque converter hydraulic diagram ............................................................ 2-3
2.1.2 Transmission housing /propeller shaft/torque converter ................................................... 2-5
2.2 TROUBLESHOOTING ..................................................................................................... 2-6
2.3 TESTS ............................................................................................................................ 2-10

2.3.1 Torque converter stall test ............................................................................................. 2-10
2.3.2 Delivery pressure test procedure .................................................................................. 2-10
2.3.3 Transmission gearshifting electric control valve ............................................................ 2-11
2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER .......................... 2-13
2.4.1 Removal ....................................................................................................................... 2-13
2.4.2 Re-Installation ............................................................................................................... 2-14
2.4.3 Disassembly ................................................................................................................. 2-15
2.4.4 Reassembly .................................................................................................................. 2-24
2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION ...................................... 2-25

2.5.1 Removal ....................................................................................................................... 2-25
2.5.2 Re-Installation ............................................................................................................... 2-26
2.5.3 Disassembly ................................................................................................................. 2-27
2.5.4 Overhaul of the forward speed clutch ........................................................................... 2-41
2.5.5 Overhaul of the 3rd speed clutch ................................................................................... 2-43
2.5.6 Overhaul of the reverse speed clutch ........................................................................... 2-48
2.5.7 Modulating valves (disassembly/assembly) .................................................................. 2-52
2.5.8 Pressure relief valve (disassembly/assembly) .............................................................. 2-53
2.6 SPECIFICATIONS AND DATA ......................................................................................... 2-56

2.6.1 General data .................................................................................................................. 2-56
2.6.2 Tightening torques (Torque converter) ........................................................................... 2-57
Transmission housing .................................................................................................. 2-58
2.6.3 Transmission Data ......................................................................................................... 2-59
Transmission Clutch .................................................................................................... 2-59
Transmission clutch discs ............................................................................................ 2-61
1st - 2nd - 3rd speed Transmission Clutch modulating valves ......................................... 2-61
Lube oil pressure relief valve ....................................................................................... 2-62
Forward/reverse modulating valves ............................................................................. 2-63
Transmission pressure relief and torque converter safety valve ................................... 2-64
Torque converter - transmission feeding pump ............................................................ 2-65
Oil filters ....................................................................................................................... 2-66
2.7 SPECIAL TOOLS ............................................................................................................ 2-67

D180 TRANSMISSION 2-3
2.1 GENERAL DESCRIPTION
2.1.1 TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM
The transmission is of a "power-shift" type with three forward and three reverse speeds. The system is powered
by a dual pump feeding the transmission and the torque converter (1).
The pump sucks oil from the transmission housing through filter (6) and circulates it purifying further through
filter (2). A valve (set at 2.5 bar 36.2 psi) protects filter (2) against over pressures due to the clogging of the
cartridge or excessively thick oil.
The feeding pump of the hydraulic system steering clutches sucks the oil accumulated in the torque converter
support housing, through a mesh filter (14) and returns it to the transmission housing.
The oil delivered by feeding pump (1) after being purified by filter (2) reaches pressure relief valve (3) establish-
ing and maintaining the pressure setting of the oil controlling the transmission clutches.
Safety valve (16) protects the torque converter and the heat exchanger against accidental pressure increments,
normally due to cold and excessively thick oil, discharging the flow excess into the pump delivery line (1).
The oil flowing out the torque converter, passes through the heat exchanger, the manifold and it is distributed to
the lube and cooling ducts of the transmission clutches.
The maximum lube pressure is limited by valve (15) set at 3 bar. (43.5 psi)
Modulating valves (9) make the engagement of the clutches progressive, regulating the pressure increment in
the control circuits.
A low engine lube oil pressure or an excessive lube oil temperature are indicated on the dashboard in the cab.
Quick discharge valves on the 2nd and 3rd speed clutches, during the speed engagement phase, are in closed
position, under the action of pressurised oil. When shifting from one speed to another, the relevant control
cylinder is connected to the discharge and the pressure drop causes the centrifugal force to prevail over the
action of the oil, moving the balls outwards, facilitating a quick discharge.
2-4 TRANSMISSION D180
N
F
AS
P
AL
R
MICROCONTROLLER
12
9
11
10
18
17
7
16
1
10.5 bar
(152.3 psi)
26
4 25
17 bar
(246.6 psi)
3.5 bar (50.8 psi)
8
To brakes feeding
valve β 25 ≥ 75 1.33 ENGINE RPM B
3
IND
AV
B 25 cc
rev.
19 cc
rev.
0.3 bar (4.3 psi)
23
1 2 6
22
1.33 ENGINE RPM 14 2 100 µm 24
13
19 cc
rev.
8 cc
rev.
21
1 2
24 24
From transmission housing Transmission
20
5 15 lubrication
19 F14327
Fig. 2-1 Torque converter hydraup diagram
B. To transmission housing - F. Forward speed - R. Reverse speed - P. Upshifting - S. Downshifting - N. Neutral - AS. Auto-shift function - AL. Auto kick-down function - 1. Transmission/torque converter pump - 2. Oil filter (delivery) - 3. Pressure relief valve (17 bar, 246.5 psi) -
4. TWIN-DISC torque converter - 5. Heat exchanger - 6. Oil filter (suction) - 7. Control valve - 8. Transmission housing - 9. FORWARD speed solenoid - 10. REVERSE speed solenoid - 11. 1st speed solenoid - 12. 3rd speed solenoid - 13. Brake/scavenge pump - 14. Mesh filter -
15. Lube oil pressure relief valve (3 bar, 43.5 psi) - 16. Torque converter safety valve (10.5 bar, 152.3 psi) - 17. FORWARD/REVERSE control valve spool - 18. 1st - 3rd control valve spool - 19. To 1st speed clutch pack - 20. To 3rd speed clutch pack - 21. 2nd speed clutch pack -
22. To FOR speed clutch pack - 23. To REV speed clutch pack - 24. 1st - 2nd - 3rd speed modulating valves - 25. Filter clogging valve - 26. FOR/REV modulating valves.
Brakes/steering
Transmission clutches oil
oil filler neck suction filter
and oil dipstick
Control valve
solenoid
Transmission
oil suction filter Transmission
control valve
Transmission oil
level sensor
SM9008
Fig. 2-2 Transmission housing
Transmission
Torque
Transmission/torque converter
converter propeller shaft
SM9006
Fig. 2-3 Propeller shaft

Oil inlet
Pressure relief valve (it
provides 17 bar (246.5
Torque converter safety valve,
psi) for the operation of
setting: 10 bar (145 psi)
the transmission)
Oil outlet at 17 bar,
Equipment/steering pump (246.5 psi) actuating
the transmission
Brakes pump Transmission pump
(50 L/min 13.2 US gpm) (67 L/min 17.7 US gpm)
Scavenger pump Torque converter pump
(22 L/min 5.8 US gpm) (50 L/min 13.2 US gpm)
It recovers the oil at the
Torque converter
bottom of the torque
discharge
converter cover and flows it
into the transmission
Lube pressure switch
SM9009
Fig. 2-4 Torque converter
2.2 TROUBLESHOOTING
PROBABLE TOOLS
TROUBLE CAUSE REQUIRED TEST SOLUTION
Low lube oil Transmission oil Instruction Manual Pull-out the dip- Top-up oil up to
pressure. level low stick and check prescribed level
The indicator the level
light is ON with
engine running. Torque converter Clean the filter
pump suction filter
clogged
Outer crack allowing If the oil is foam- Eliminate the crack

the seeping of air ing, check if a
into the pump crack is present
Hose defective Suction pipe clog- Change or clean the

ged pipe
Oil of a wrong type Instruction Manual Check oil speci- Drain the oil and
fications with data change it with oil of
provided by Manu- the prescribed type
facturer
PROBABLE TOOLS
TROUBLE CAUSE TEST SOLUTION
REQUIRED
Control oil pres- Transmission oil Instruction Manual Check oil level on Top-up with pre-
sure low at al level low dipstick scribed oil to correct
speeds with level
transmission in
neutral Transmission pump Clean the filter
suction filter clogged
Outer crack allowing If the oil is foam- Eliminate the leakage

the seeping of air ing, check if a
Suction pipe Suction pipe clog- Change or clean the

ged pipe
Pressure relief valve Check pressure of Correct the pressure

out of setting system setting
Feeding pump deli- Check delivery of Replace pump, if

very insufficient pump defective
Control oil pres- Transmission pump Check and wash the

sure low at high suction filter clogged mesh filter
engine speed
with transmis- Outer crack allowing If the oil is foam- Eliminate the
sion in neutral the seeping of air ing, check if a leakage
Transmission Orifice of direction Clean the orifice

pressure is nor- modulating valve
mal in neutral plunger clogged
and low with
speeds en- Direction modulating Eliminate condition
gaged. The valve plunger seized for seizure between
machine starts plunger and seat
with difficulty in
one direction
and the torque
is insufficient
PROBABLE TOOLS
TROUBLE REQUIRED TEST SOLUTION
CAUSE
High transmis- Pressure relief valve Eliminate seizure

sion oil pressure seized open
at all engine
speeds
High transmis- Transmission oil level Instruction Manual Check level on dip- Top-up with pre-scribed
sion oil tempera- low stick oil to cor-rect level
ture
Transmission heat Measure tempera- Clean or replace the
exchanger clogged ture differential bet- heat exchanger
keeps the safety ween inlet and out-
valve open let of heat exchang-
er. With a clogged
unit, the differential
is marginal
Operation pressure Measure operating Refer to remedies for

low pressure of trans- low oil pressure fault
mission
Clutch discs burnt, Replace defective com-

seized with clutches ponents
disengaged
Transmission oil Oil pump delivery in- Test pump

is normal, but sufficient
the machine
moves only at
high engine
speed
PROBABLE TOOLS
TROUBLE CAUSE REQUIRED TEST SOLUTION
Transmission Discs worn or war- Replace defective com-

pressure normal; ped ponents
low power in cer-
tain speeds and
oil overheating
Transmission Leakages in piping Check if seals or Overhaul the trans-mis-

pressure low in a of defective speed pipes are damaged sion and re-place de-
given speed fective parts
Engine oil level Together with trou- Clean scavenger filter

increases and ble for low power
transmission oil output
level drops
Crankshaft sealing Replace crankshaft

ring damaged sealing ring
Replace pump
2 - 10 TRANSMISSION D180
2.3 TESTS
2.3.1 TORQUE CONVERTER STALL TEST RESULT: Under stall test conditions, a comparison
between the effective engine speed and the normal
The stall test must be performed when the power one prescribed for such conditions, indicates that the
group (engine and transmission) do not operate sat- trouble is in the engine or in the transmission.
isfactorily. The scope of the test is to determine if the
transmission is defective. It is performed with the Note – Ambient conditions, such as ambient tem-
engine running at maximum speed and the transmis- perature, elevation, variations in the loss of engine
sion output stalled. Perform the torque converter stall accessories, influence the power transferred to the
test proceeding as follows: torque converter: These conditions can cause varia-
tions in the stall speed of 50 rpm, with respect to the
normal value. When the difference can be assigned
to such causes, the effective speed can be accepted
WARNING as normal.
Do not run the engine of this machine in closed
areas without proper ventilation to remove deadly
exhaust gases.
2.3.2 DELIVERY PRESSURE TEST
Be sure exposed personnel in the area of opera-
tion are clear of the machine before moving it or PROCEDURE
its attachments. WALK COMPLETELY AROUND Prior to measuring the pressures and the oil flow of
the machine before mounting. Sound horn. Obey the torque converter and transmission, it is neces-
flag man, safety signals and signs. sary to proceed with the following preliminary check.
Comply with all procedures for the starting and
stopping of the machine and the "NOTICES" Check the oil level of the transmission, with the oil at
listed in the Operation and Maintenance Manual. normal operating temperature: DO NOT perform this
test with cold oil: To bring the oil temperature to the
prescribed value, it is necessary to operate the ma-
chine or stall the converter.
1. Connect a precision revolution counter to the en-
gine and bring the transmission housing to the
operating temperature: DO NOT PERFORM this WARNING
test with cold oil. Record the engine speed (rpm).
Keeping the stall speed too long, overheats the
torque converter.
Note – The stall conditions must not be kept for
over 30 seconds, in any case, to avoid excessive
temperatures.
areas without proper ventilation to remove deadly
exhaust gases.
2. Block the transmission output shaft, keeping the
brake pedal pressed, then engage the forward high
Prior to starting the engine, warn all persons
speed range checking that the engine is at full
nearby the machine.
speed. Record the engine speed. DO NOT let the
temperature on the outlet of the torque converter
NEVER LEAVE THE MACHINE UNATTENTED with
exceed 120 °C (250 °F).
the engine running.
Note – Let the transmission operate in neutral for
an interval of about 2 minutes between the vari-
Check the temperature and pressure gauges on the
ous stall tests, to avoid overheating. During these
instrument panel. If the main pressure stays within
two minutes do not let the engine speed drop, ex-
the limits (or in case the trouble persists after inter-
cept when shifting through the neutral.
ventions to correct the main pressure) measure and
record all pressures for a comparison.
3. Engage the other speeds and check that the en-
gine speeds drops the same value, independently
from the speed being engaged. In the event the The pressure gauge pick-up points of the pressures
engine speed does not drop with a given speed of the entire system are located on the control valve
engaged, it is probable that the relevant clutch slips. illustrated at page 2-11. All connections can be made
In the event the engine speed does not drop with simultaneously. The pressure gauge connected to
all speeds, as indicated, this could be due to: each point must have a capacity sufficient to meas-
- the transmission, if the shaft between torque ure the pressure involved; however it must not by so
converter and transmission is operating, or high to make the reading of the correct pressure dif-
- the torque converter, if said shaft is inoperative ficult.
D180 TRANSMISSION 2 - 11
2.3.3 TRANSMISSION GEARSHIFTING ELECTRIC CONTROL VALVE
Specifications and data D180 LT/XLT D180 LGP
- Normal operating temperature From 50 to 120 °C (122-250 °F) From 50 to 120 °C (122-250 °F)
- Engine low idle speed From 780 to 920 rpm From 680 to 820 rpm
- Engine max. rated speed (idle) From 2080 to 2220 rpm From 2140 to 2160 rpm
- Torque converter stall engine speed From 1710 to 1850 rpm From 1780 to 1920 rpm
- Total stall engine speed From 1640 to 1840 rpm From 1700 to 1900 rpm
P - Main pressure From 16.5 to 17.5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
1 - 1st speed clutch pressure From 16.5 to 17.5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
2 - 2nd speed clutch pressure From 16.5 to 17.5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
3 - 3rd speed clutch pressure From 16.5 to 17.5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
F - Forward speed clutch pressure From 16,5 to 17,5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
R - Reverse speed clutch pressure From 16.5 to 17.5 bar From 16.5 to 17.5 bar
(239.3 to 253.8 psi) (239.3 to 253.8 psi)
L - Lube pressure 3 bar (43.5 psi) 3 bar (43.5 psi)
F14328
Fig. 2-5 Transmission pressure pick-up points on diagnostic panel
Positioning of diagnostic hoses
2nd GEAR
FORWARD
GEAR
LUBRICATION
TRANS-
MISSION
CONTROL
VALVE
SLOW
FAST SPEED
SPEED
REVERSE GEAR
F14392
2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER

2.4.1 REMOVAL
Turn the main switch into position "OFF". Place a "DO Travel
NOT OPERATE" warning signal on the machine. direction
please refer to the Section "CAB" of this Manual to
tilt the cab.
ON
OFF
DO PER
O
NO ATE
T
SM1601
Remove the central lower guard.
SM9012
Drain the transmission oil through the draining plug.
SM9013
Drain the oil from the torque converter housing

through the draining plug.
SM9014
Tilt the cab and perform the following operations.

Disconnect the transmission temperature sensor wire.
Disconnect the return piping between heat exchanger

and torque converter.
Disconnect the inlet piping to the radiator.
Disconnect the piping between the main pressure

relief valve and gear/converter control valve.
Disconnect the piping on recovery/brake pump and

steering and gear/converter pump.
Remove the propeller shaft between transmission

housing and torque converter.
Disconnect the suction and inlet piping on tool pump.
Make a lifting bracket and secure it to the propeller

shaft flange on the torque converter. Holding the
torque converter with an appropriate lifting device,
remove the securing screws to the flywheel housing
and remove the torque converter.
WARNING
Lift and handle all heavy parts with a lifting de-
vice of appropriate capacity.
Make sure that the parts are secured by appro-
priate slings and hooks.
2.4.2 RE-INSTALLATION
The re-installation of the torque converter is per-
formed reversing the removal operations, with the
following exceptions.
Install the dowels on the flywheel housing.
SM9016
Smear with sealant the mating surfaces between

torque converter and flywheel housing.
Install the torque converter securing screws, tighten-

ing them at a torque of 6.8 to 7.4 daNm (50.1 to
54.5 lbf.ft).
SM9018
2.4.3 DISASSEMBLY
Remove the engine/torque converter adapter ring.
WARNING
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
or non ferrous metals. When these components
are remove or installed, always wear safety
glasses with side shields, heavy gloves etc., to
reduce the chances of injuries. SM9020
Place the torque converter on a rotary stand.
SM9021
Remove the hub.
SM9022
Loosen and remove the screws securing the retain-

ing plate, then pull-out the plate, the O-Ring and the
shaft flange.
SM9023
Remove the pressure relief valve assembly.
SM9024
Loosen the support securing screws, then turn the

torque converter with its bottom side upwards, so that
the securing screws can me removed from the sup-
port.
SM9025
Remove the oil deflector.
SM9026
Remove the screws securing the equipment pump

driven gear, lift the gear from the shaft nose and put
it aside.
SM9027
Secure a lifting chain to the torque converter; lift just

enough to rotate the support so that the remaining
gears are free, then pull the torque converter out the
housing.
WARNING
SM9028
Pull the equipment pump driven gear out the housing.
SM9029
Remove the circlips from the driven gears, then re-

move the gears from the shaft.
SM9030
Loosen the securing screws and remove the bearing

retaining plate.
WARNING
reduce the chances of injuries.
SM9031
Using an appropriate punch and a soft metal ham-

mer, pull-out the pump drive shafts from the bear-
ings.
WARNING
SM9032
Pull-out the bearings and spacers from the housing.
WARNING
SM9033
Remove the equipment pump drive shaft circlip.
SM9034
Pull-out the shaft and bearing from the housing.
SM9035
Pull-out the bearing left in the housing.
SM9036
Pull-out the seal assembly from the housing.
SM9037
Remove the bearing circlip from the equipment pump

drive, and pull-out the spacer and the bearing from
the shaft.
SM9038
Place the equipment pump drive shaft on a vertical

press of appropriate capacity to remove the inner race
of the bearing from the shaft.
SM9039
Place the torque converter assembly on an appropri-

ate work bench.
SM9040
Remove the front bearing retaining plate.
SM9041
Remove the screws securing the wheel.
SM9042
Using puller screws, separate the turbine from the

housing, then lift the turbine.
WARNING
SM9043
Separate the turbine from the shaft prying it, in case

the turbine comes out with the shaft.
SM9044
Otherwise, in case the turbine is not coming out with

the shaft, lift it from the housing.
SM9045
Remove the shoulder disc from the housing.
SM9046
Pull-out the front bearing from the housing, hammer-

ing it.
WARNING
SM9047
Place the pump wheel over blocks, remove the circlip

and pull-out the shaft from the wheel.
SM9048
Remove the screws securing the stator.
SM9049
Separate the stator from the pump wheel.
SM9050
Disassemble the bearing support from the pump

wheel and remove the sealing rings from the sup-
port.
Remove the bearing race from the support only in
case its replacement is required.
SM9051
Remove the pump drive gear from the wheel.
SM9052
Using a proper punch and a soft hammer, pull-out

the bearing support from the pump wheel.
WARNING
SM9053
Remove the sealing ring from the shaft.
SM9054
Pull-out the rear bearing from the shaft, using an

appropriate press.
SM9055
2.4.4 REASSEMBLY
To reassemble, reverse the disassembly procedures,
with the following modifications:
In case the dowels, the sleeve or the sealing ring

have been removed, install new parts.
Always install new O-Rings and seals.
In the event the heating of a bearing is required, use an

appropriate heater and warm-up at 121 °C (250 °F).
In the event the freezing of a bearing of its compo-

nents is required, place the part in dry ice 4 hours
prior to the installation.
Pay attention to the correct installation of the oil de-

flector.
2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION
2.5.1 REMOVAL
Turn the main switch into position "OFF". Place a "DO ON (connect)
NOT START" warning signal on the machine. Please Key
refer to the Section "CAB" of this Manual to tilt the OFF
cab. Drain the transmission oil through the draining (disconnect) NON AVVIARE
plug. DO NOT OPERATE
Remove the central lower guards.
Drain the oil from the torque converter housing

through the draining plug.
Remove the propeller shaft between torque converter SM9261
and transmission housing.
Disconnect the hydraulic pump pipes (delivery and

SM9057
return) to the distributor.
Disconnect the forward and 2nd speed pressure test

pipes between transmission and test panel.
Disconnect and label the three pipes between the

upper part of the control valve and the pilot valve.
Disconnect and label the 4 pipes on the rear side of

the transmission control valve: 2 run to the test panel,
one runs to the manual pilot valve and one runs to
the brake unlocking valve.
SM9058
Hold the transmission housing with an appropriate

winch: its mass is about 450 kg (990 lb).
Remove the screws and nuts retaining the transmis-

sion housing.
Note – It could be necessary to disconnect the cylin-

der pipe on the hydraulic control valve to be able loos-
ening the nuts on the right upper side of the trans-
mission housing.
SM9059
Remove the transmission housing from the pinion

support and lift it away from the machine.
WARNING
SM9060
2.5.2 RE-INSTALLATION
The installation is done reversing the removal proce-
dure.
2.5.3 DISASSEMBLY
Place the transmission assembly on a rotary stand.
WARNING
SM9061
Remove the lube manifold cover.
SM9062
Remove the modulating valves cover.
SM9063
Remove the modulating valves from the housing.
SM9064
Remove the covers of the forward and medium range

clutch spools.
SM9065
Pull-out the clutch spools from the shafts.
SM9066
Remove the input shaft drive flange.
SM9067
Turn the transmission assembly and remove the

transmission control valve assembly, loosening the
screws (q.ty 5).
SM9010
Remove the side covers.
SM9068
Remove the screws securing the front cover (please

Note that 2 screws must be removed from the bot-
tom).
SM9069
Remove the front cover of the housing, lifting it with

an appropriate winch.
WARNING
priate slings and hooks. Use the lifting eyes pro-
vided for this purpose.
SM9070
Turn the housing and remove the high range control

and lube pipes.
SM9071
Remove the low and high range clutches distribution

spools and pull them out from the shafts.
SM9072
Remove the low range clutch housing cover.
SM9073
Remove the rear cover.
SM9074
Remove the reverse clutch pipe holder.
SM9075
Pull-out the reverse clutch distribution spool.
SM9076
Remove the reverse clutch shaft bearing holder.
SM9077
Remove the oil sump and the oil pipes with the
bracket, recording the position of the pipes for the
installation.
SM9078
Loosen the nuts securing the forward and medium

range clutch shafts.
WARNING
SM9079
Block the transmission gears through the access

panel to prevent the shaft from turning, then loosen
the forward speed clutch shaft securing nut.
SM9080
Remove the forward speed piston assembly.
SM9081
Remove the forward speed clutch hub-pack assem-

bly.
SM9082
Loosen and remove the low range clutch shaft se-

curing nut (blocking the transmission gears to pre-
vent the rotation of the shaft).
SM9083
Remove the low range clutch piston assembly.
SM9084
Remove the low range clutch hub-pack assembly.
SM9085
Remove the low range clutch drum-stop assembly.
SM9086
Pull-out the clutch shaft taper spacer.
Please keep in mind that when reassembling, the

taper part of the spacer must be placed in front of the
bearing.
SM9087
Lift the low range and forward speed clutches shaft

from the transmission housing.
SM9088
Remove the gears and spacers through the access

panel.
SM9089
Remove the circlip from the driven gear of the for-

ward speed clutch drum.
SM9090
Remove the drum and the forward speed clutch gear,

using an appropriate punch, extracting the drum
through the gear and the housing.
SM9091
Install three clamps (P/N 380001346) on the high

range clutch assembly.
SM9092
Remove the medium range clutch shaft securing nut.
SM9093
Remove the medium range clutch piston.
SM9094
Remove the medium range clutch hub-pack assem-

bly.
SM9095
Remove the medium range clutch hub circlip.
SM9096
Remove the medium/high range clutch shaft.
SM9097
Remove the medium range clutch drum.
SM9098
Remove the medium range clutch gear.
SM9099
Remove the medium range clutch assembly.
SM9100
To pull-out the medium range clutch drum bearing,

use an appropriate punch, after removing the two
screws with retaining nut.
WARNING
SM9101
Remove the screws securing the input drive gear seal

and the bearing support, then extract the shaft prying
it.
SM9102
Remove the input drive gear using a pry bar and ham-
mering the shaft.
WARNING
SM9103
Remove the bearing and the retaining wing of the

relevant spacer.
SM9104
Remove the bearing spacer using a securing screw.
SM9105
Remove the output shaft nose bearing circlip.
SM9106
Remove the output shaft gear circlip.
SM9107
Remove the output shaft and the bearing using an

appropriate punch.
WARNING
SM9108
Using an appropriate punch, pull-out the output shaft

through the bearing and the gear.
WARNING
SM9109
Remove the output shaft gear.
SM9110
Remove the PTO shaft securing screws and seal

holder.
SM9111
Install two clamps (P/N 380001470) on the reverse

clutch.
SM9112
Loosen and remove the reverse clutch shaft locking

nut.
WARNING
SM9113
Pull-out the reverse shaft/PTO shaft through the clutch

and the housing.
SM9114
Remove the input gear and the reverse spacer.
SM9115
Pull-out the reverse clutch assembly.
SM9116
Remove the bearing remaining in the housing.
WARNING
SM9117
2.5.4 OVERHAUL OF THE FORWARD

SPEED CLUTCH
Note – The procedures for the overhaul of the low

and medium range clutches are the same as for the
forward speed clutch.
Remove the piston from the housing, then check that

these two elements are satisfying the prescribed re-
quirements. Reinstall the piston into the housing with
new sealing rings.
SM9118
Remove the clutch pack from the hub.
SM9119
Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.
SM9120
Press the spring using a long threaded stud.
SM9121
Remove the circlip.
SM9122
Remove the spring cup and the spring from the hub;
check that the spring complies with the prescribed
requirements.
SM9123
Reinstall the spring and the relevant cup on the hub;

press the cup and install the circlip.
SM9124
Reinstall the friction discs, the spacer springs and

the steel discs, alternatively, on the hub.
SM9125
To measure the height of the clutch pack, place the

clutch assembly on a press and load it at 197 daNm
(1450 lbf.ft), measuring as illustrated.
SM9126
2.5.5 OVERHAUL OF THE 3rd SPEED CLUTCH

Remove the blocks holding the high range clutch.
SM9127
Separate the high range gear housing and the piston

from the clutch assembly.
SM9128
Remove the high range piston from the relevant hous-

ing.
SM9129
Check that the piston and housing satisfy the pre-

scribed requirements. Install a new sealing ring on
the piston and housing hub, then reinstall the piston
into the relevant housing.
Remove the hub and the high range clutch pack from
the clutch drum.
Note – In the event it is necessary to replace the

bearings in the clutch drum assembly, it is imperative
that the shoulder washer with lube holes is properly
mounted, with the inner taper side on the opposite
side of the bearings.
SM9130
SM9131
Measure the thickness of all friction and steel discs;

replace them if not within the prescribed requirements.
SM9132
Press the return spring using a long thread screw.

(P/N 380000972).
SM9133
Remove the circlip.
SM9134
Remove the spring and the relevant cup from the hub;
check that the spring complies with the prescribed
requirements.
SM9123
Insert the spring cup and the spring into the hub; press
the spring and install the circlip.
SM9124
Reinstall the friction discs, return springs and steel

discs, alternatively on the hub.
SM9125

SM9126
Install the central hub assembly and clutch pack on

the high range clutch drum.
SM9135
Install the alignment tool (P/N 380001347) in the hub

grooves.
SM9136
Arrange the gear assembly on the hub assembly and

align the relevant grooves with the grooves on the
hub.
SM9137
Check the alignment of the grooves using the high

range shaft, prior to introducing the high range clutch
assembly into the transmission housing.
Note – It is important that the grooves are perfectly

aligned, otherwise they could be damaged during the
installation of the shaft.
SM9138
Install three brackets (P/N 380001346) on the high

range clutch assembly.
SM9139
2.5.6 OVERHAUL OF THE REV SPEED

CLUTCH
Remove the locking tools from the reverse clutch
assembly.
SM9140
Separate the reverse clutch drum from the clutch

assembly.
SM9141
Remove the clutch pack-hub from the piston-hous-

ing assembly.
SM9142
SM9131
Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.
SM9132
Press the return spring using the special tool

(P/N 380000972).
SM9133
Remove the circlip.
SM9134
Pull-out the spring stop and the return spring from

the hub; check that the spring complies with the pre-
scribed requirements.
SM9123
Insert the return spring and the relevant stop in the

hub; press the stop and install the circlip.
SM9124
Install the friction discs, the spacer springs and the

steel discs, alternatively, on the hub.
SM9125

SM9126
Pull-out the piston from the housing and check that

the two components comply with the prescribed re-
quirements. Install new sealing rings on the piston
and reinstall the piston into the housing.
SM9143
Install the hub-clutch assembly on the reverse clutch

hub-housing assembly. Check that the outer steel ring
is correctly oriented with respect to the housing.
SM9144
Install the reverse clutch drum on the clutch assem-

bly.
SM9145
Install two brackets (P/N 380001470) on the reverse

clutch assembly.
SM9146
2.5.7 MODULATING VALVES

Disassembly
Note – The three modulating valves are identical.
Remove the circlip from the modulating valve.
SM9147
Pull-out the cup, the springs, the plunger and the valve
from the valve body.
Check that the springs comply with the prescribed

requirements.
SM9148
Assembly
Insert the valve, the plunger, the springs the cup into
the valve body; block with the circlip.
SM9147
2.5.8 PRESSURE RELIEF VALVE

Disassembly
The pressure relief valve is located on the torque
converter. It is equipped with two spools: one con-
trols the main pressure, the other operates as a safety
valve, protecting the torque converter against pres-
sure overloads, which could occur with oil cold or
too thick.
Disconnect the pressure sender.
Note – Record the number of shims located under

the sender, which shall be the same when reinstall-
ing it.
SM9160
Remove the plug.
SM9151
Pull-out the spool assembly from the valve body.
SM9159
Disassemble the spool assembly.
Check that the spring complies with the prescribed

requirements.
Reinstall the spool assembly as illustrated in figure.
For the moment, do not tighten the setting ring.
SM9158
Remove the valve seat from the valve body.
SM9154
Push the plunger retaining ring out its seat.
SM9155
Pull-out the plunger, the spring and the shims from

the seat.
Check that the spring complies with the prescribed

requirements.
Assembly
Install the shims, the spring and the plunger into the
seat, press the spring and secure the pin.
SM9157
Install a new O-Ring and a new washer on the seat.
SM9156
Place the seat assembly into the valve body.
SM9158
Place the spool assembly into the valve body.
SM9152
Install the plug on the valve body.
SM9160
Set the pressure, actuating the valve, as indicated.
SM9161
2.6 SPECIFICATIONS AND DATA
2.6.1 GENERAL DATA
15" TORQUE CONVERTER
Make ....................................................................................................................................... TWIN-DISC

Model .......................................................................................................................... PX-1728 - C MS335
Number of elements ............................................................................................. 3 (pump, turbine, stator)
Torque ratio at stall ......................................................................................................................... 2.280:1
TORQUE CONVERTER AND TRANSMISSION PROPELLER SHAFT
Type ............................................................................................. Tubular with universal joints at the ends

Technical description .......................................................................................................... Universal 778/1
Working angle ................................................................................................................................... 8° 48'
Lube fittings .............................................................................................................................................. 2
Tightening torque of universal joint screws ........................................... 10.8-11.75 daNm (79.6-86.6 lbf.ft)
TRANSMISSION HOUSING
Type .................................................................................................................................. Full Power Shift

No of speeds ............................................................................................................... 3 forward, 3 reverse
No of clutches ........................................................................................................................................... 5
SPEED POWER-SHIFT CLUTCHES ENGAGED RATIO
1st Forward Low - Forward 1: 2.531

2nd Forward Medium - Forward 1: 1.484
3rd Forward High - Forward 1: 0.888
1st Reverse Low - Reverse 1: 2.016

2nd Reverse Medium - Reverse 1: 1.182
3rd Reverse High - Reverse 1: 0.707
QUANTITY
CLUTCH DISCS Forward 3rd 2nd 1th Reverse

Bimetal discs with outer toothing 10 6 8 8 8
Intermediate toothed steel discs 9 5 7 7 7
Shoulder toothed steel discs 1 1 1 1 1

Spacer springs 10 6 8 8 8
2.6.2 TIGHTENING TORQUES (TORQUE CONVERTER)

DESCRIPTION daNm (*) lbf.ft
1. Securing screws, front bearing stop From 4.1 to 4.9 From 30.2 to 36.1
2. Securing screws, shaft hub stop From 4.1 to 4.9 From 30.2 to 36.1
3. Securing screws, drive shaft From 10.8 to 11.7 From 79.6 to 86.2
4. Securing screws, torque conv. housing From 6.8 to 7.4 From 50.1 to 54.5
5. Securing screws, rear wheel From 2.3 to 2.8 From 16.9 to 20.6
6. Securing screws, stator From 3.4 to 3.9 From 25 to 28.7
7. Securing screws, pump drive gear From 4.1 to 4.9 From 30.2 to 36.1
8. Securing screws, steering-brakes pump From 1.2 to 1.4 From 8.8 to 10.3
9. Securing screws, pressure relief valve From 6.8 to 7.4 From 50.1 to 54.5
10. Securing screws, rear bearing support From 8.0 to 8.8 From 59 to 64.9
11. Securing screws, rear output flange stop From 4.1 to 4.9 From 30.2 to 36.1
12. Securing screws, oil deflector From 3.0 to 3.3 From 22.1 to 24.3
13. Securing screws, oil deflector support From 6.8 to 7.4 From 50.1 to 54.5
Screws, equipm. pump driven gear From 7.5 to 8.3 From 55.3 to 61.2
Sec. screws, trans./torque conv. pump From 6.8 to 7.4 From 50.1 to 54.5
Nut, pump drive hub From 2.1 to 2.3 From 15.5 to 17
Secur. screws, hydraulic pump
SM9259
Fig. 2-6 Section view of torque converter housing
TRANSMISSION HOUSING
DESCRIPTION Thread daNm (*) lbf.ft
1. Nuts, rear cover studs 10 x 1.25 From 6.1 to 7.7 From 45 to 56.8
2. Screws and nuts, low range clutch
cover and housing 10 x 1.25 From 6.1 to 7.7 From 45 to 56.8
3. Screws, reverse clutch front bearing cover 10 x 1.25 From 6.2 to 6.8 From 45.7 to 50.1
4. Screws, reverse clutch spool 10 x 1.25 From 5.7 to 6.3 From 42 to 46.5
5. Screws, reverse clutch seal 10 x 1.25 From 4.8 to 6.0 From 35.4 to 44.2
6. Screws, side cover 10 x 1.25 From 4.8 to 6.0 From 35.4 to 44.2
7. Screws, clutch spool cover 10 x 1.25 From 3.4 to 5.7 From 25 to 42
8. Screws, rear bearing holder 10 x 1.25 From 5.4 to 6.8 From 39.8 to 50.1
9. Self-locking screws, high range driven gear
and medium/high ranges drive gear 12 x 1.25 From 11 to 12 From 81.1 to 88.5
10. Nuts and screws, securing the transmission
housing to bevel gear pinion housing 16 x 1.5 24 177
11. Nuts, transmission shafts locking 40 x 1.5 From 92 to 95.5 (**) From 678.3 to 704
(*) Lubrificate with engine oil

(**) Apply Loctite 242
8 1
7 11
6 11
11
7
3
2
4
5
10
SM9260
Fig. 2-7 Section view of transmission housing
2.6.3 TRANSMISSION DATA

TRANSMISSION CLUTCHES
A Ø Out. diameter of forward-reverse speeds and 169.894 to 169.957 mm (6.68 to 6.69 in)
1st - 2nd ranges clutches fixed piston (large)
Ø Inner diameter forward speed mobile piston (large) 170.000 to 170.063 mm (6.69 to 6.695 in)
Piston play 0.043 to 0.169 mm (0.0016 to 0.006 in)
B Ø Out. diameter of forward-reverse speeds and 59.924 to 59.970 mm (2.35 to 2.36 in)
1st - 2nd ranges clutches fixed piston (small)
Ø Out. diameter of forward-reverse speeds and 60.000 to 60.046 mm (2.36 to 2.37 in)
1st - 2nd ranges mobile piston (small)
C Ø Outer diameter of 3rd range drive piston 194.600 to 194.700 mm (7.62 to 7.64 in)
Ø Inner diameter of high range on 1st range gear piston 195.000 to 195.072 mm (7.66 to 7.68 in)
D Ø Inner diameter of 3rd range drive piston 80.036 to 80.066 mm (3.15 to 3.152 in)
Ø Out. diameter of high range on 1st, 2nd and 79.940 to 79.970 mm (3.14 to 3.15 in)
3rd ranges drive gear hub
E Ø Outer diameter of clutch control spools 19.770 to 19.800 mm (0.78 to 0.79 in)
Ø Inner diameter of clutches control spools 20.016 to 20.020 mm (0.79 to 0.791 in)
Clearance between seat and spool 0.22 to 0.25 mm (0.008 to 0.009 in)
G Specifications of clutch springs
Spring free length (3rd speed) 83.5 mm (3.3 in)
Spring free length (1st, 2nd, FOR, REV) 83.0 mm (3.3 in)
Press. load at 35 mm (1.378 in) 3rd 65.5 to 72.5 daNm (483 to 534.5 lbf.ft)
Press. load at 65 mm (2.559 in) (1st - 2nd - FOR - REV) 315.5 to 348.5 daNm (2326.2 to 2570 lbf.ft)
DATA OF CLUTCH DISCS PACK ASSEMBLY
Clutch (X) Piston stroke (*) (Y) Clutch pack dimens. (**)
mm mm
FORWARD From 4 to 5 From 60.4 to 60.8
REVERSE From 3 to 4 From 48.25 to 48.65
1st SPEED From 3 to 4 From 48.25 to 48.65
2nd SPEED From 3 to 4 From 48.25 to 48.65
3rd SPEED From 2 to 3 From 36.1 to 36.5
(*) Check by measuring the stroke of the mobile piston.
(**) Check pre-loading the clutch pack with a load of 197 daNm. When the discs are worn, spare discs are
available to reastablish the setting, to be used in lieu of as many inner toothed discs.
Section 1st Speed Section 3rd Speed Section FORWARD

2nd Speed
REVERSE
SM9163
Fig. 2-8
TRANSMISSION CLUTCH DISC
C D
B
SM9164
Fig. 2-9 Section view of clutch discs
A Thickness of inner toothed intermediate discs From 2.42 to 2.58 mm (0.09 to 0.1)
B Thickness of inner toothed driving discs From 2.42 to 2.58 mm (0.09 to 0.1)
From 3.4 to 3.6 mm (0.13 to 0.14)
C Thickness of outer toothed friction discs

wear tolerance of syntherised friction discs From 0.90 to 1.20 mm (0.03 to 0.04)
D Length of return springs without permanent deformation From 3.8 to 4.2 mm (0.15 to 0.16)
1st - 2nd - 3rd SPEED TRANSMISSION CLUTCH MODULATING VALVES
C B A
SM9165A
SM9165B
Fig. 2-10 Section view of modulating valve
A Ø Outer diameter of piston 19.987 to 20.000 mm (0.78 to 0.79)

Diameter of piston seat in valve body 10.020 to 20.033 mm (0.39 to 0.79)
Installation tolerance between piston and seat 0.020 to 0.046 mm (0.0007 to 0.001)
B Specifications of outer spring:

Free length 65 mm (2.6)
Load for spring compressed at 47 mm (1.85 in) 2.47 to 2.73 daNm (18.2 to 20.1 lbf.ft)
C Specifications of outer spring:

Free length 48 (19)
Load for spring compressed at 32.5 mm (1.28 in) 9.11 to 10.11 daNm (67.2 to 74.5 lbf.ft)
LUBE OIL PRESSURE RELIEF VALVE
A Specifications of outer spring:

Free length 40 mm (1.57 in)
Load for spring compressed at 14 mm (0.55 in) 7.31 ÷ 8.09 daN (53.9 to 59.6 in)
B Valve pressure setting 3 bar (43.5 psi)
Lube pressure
relief valve
Valve
section
SM9166
Fig. 2-11 Pressure relief valve
FORWARD REVERSE MODULATING VALVES
Transmission control valve
FORWARD REVERSE B A
C
MODULATING VALVES VALVE SECTION
SM9167
Fig. 2-12 Transmission control valve and modulating valves
A Specifications of modulating valve inner spring:

Load for spring compressed at 22 mm (0.866 in) From 4.44 to 4.90 daNm (32.7 to 36.1 (lbf.ft)
B Ø Outside diameter of plunger From 23.987 to 24.000 mm (0.94 to 0.944 in)

Ø Inner diameter of modulating valve body From 24.020 to 24.041 mm (0.945 to 0.95 in)
Clearance between plunger and seat From 0.020 to 0.054 mm (0.0008 to 0.002)
C Specifications of modulating valve outer spring:

Load for spring compressed at 46 mm (1.811 in) From 2.05 to 2.25 daNm (15.11 to 16.6 lbf.ft)
TRANSMISSION PRESSURE RELIEF VALVE AND TORQUE CONVERTER SAFETY
A C E P B D S
Q
Q P
Section of pressure relief valve Section of torque converter safety valve
SM9168
Fig. 2-13
DATA mm (in)
A Ø Outside diameter of valve spool From 19.979 to 20.000 (0.78 to 0.788)

Ø Inner diameter of spool seat in body From 20.020 to 20.041 (0.789 to 0.79)
Clearance between spool and seat From 0.020 to 0.062 (0.0007 to 0.002)
B Ø Outside diameter of piston From 13.982 to 14.000 (0.55 to 0.56)

Ø Inner diameter of piston seat From 14.016 to 14.043 (0.56 to 0.57)
Clearance between piston and seat From 0.016 to 0.061 (0.0006 to 0.002)
C Specifications of spool return spring:

Free length 48 (1.89)
Load for spring compressed at 37 mm (1.46 in) 45.6 daN (336.2 lbf.ft)
D Specifications of spool return spring:

Free length 43.5 (1.71)
Load for spring compressed at 32 mm (1.26 in) From 15.64 to 17.30 daN (115.3 to 127.5 lbf.ft)
E Pressure change setting ringnut
Setting of transmission pressure relief valve
- Adjust ringnut (E) so that the valve opens under a pressure in "Q" of 13.75 ± 0.5 bar (-199.4 ± 7 psi)
with an oil flow at 40 °C (104 °F) of 10 L/min (2.64 US gal/min)
- Each turn of the ringnut changes the pressure 1.5 bar (21.7 psi)
- Operating pressure: 17 bar with a flow of 66 L/min (17.45 US gal/min)
Setting of torque converter safety valve
- Shim spring (D) so that the valve opens under a pressure in "P" of 10.5 ± 0.5 bar (152.3 ± 7 psi) with
an oil flow at 40 °C (104 °F) of 10 L/min (2.64 US gal/min)
- Each shim changes the pressure 0.7 bar (thickness 1 mm 0.04 in)
TORQUE CONVERTER / TRANSMISSION FEEDING PUMP (Ref. 1 - Hydraulic diagram)
Twin gear pumps, one feeding the transmission, the other feeding the torque converter.
Maximum speed .......................................................................................... 2650 rpm

Bench test of transmission/torque converter pumps:
- Nominal output (at max. speed) ................................... 117 L/min (30.9 US gal/min)
- Nominal output of transmission feeding section ............. 67 L/min (17.7 US gal/min)
- Nominal output of torque converter feeding section........ 50 L/min (13.2 US gal/min)
- Oil temperature ............................................................. 45 to 55 °C (113 to 131 ° F)
(*) The torque converter oil scavenger pump is connected to the steering clutches pump,
thus it is described in the Steering Clutch Section.
Torque converter Transmission feeding

feeding section section
The arrow indicates the rotation direction

of the shaft and the delivery side
SUCTION SUCTION
DELIVERY DELIVERY
SM9169
Fig. 2-14 Torque converter - transmission feeding pump
OIL FILTERS
Filter F on the total flow transmission torque converter 500 hours work (25 µ - nominal tightening torque 4
delivery with paper filtering element, replaceable every daNm and by-pass valve set at 2.5 bar 36.3 psi)
Fa
F14334
Fig. 2-15 F. Oil filter on delivery line

F. Transmission/torque converter oil filter - 1. Filter support - 2. Filter cartridge - 3. Filtering element - 4. Cover -
5. O-Ring.
2
1 4
6 7
3
Fa
Total flow filter Fa on torque converter-transmission 8

pump suction line, with steel mesh filtering element
9
(to be cleaned every 1000 hours work) and magnetic
plug (100 µ nominal, without by-pass)
7
Fig. 2-16 Fa. Oil filter on suction line
Fa. Steel mesh filtering element - 1. Cover locking

nut - 2. O-Ring - 3. Cover - 4. Stud - 5. Magnetic rod
- 6. Filtering element retaining spring - 7. Circlip -
8. Gasket - 9. Support. SM9172
2.7 SPECIAL TOOLS
380000972 Clutch spring pack compression
380001303 BB3
380001319 Tool, torque converter bearing

installation
380001346 Tools bearings high

speed retainer
380001347 Tool, drum positioning
380001470 Tool, reverse clutch packs

retaining
380001471 Connecting cable w/ adapter

for BB3
SECTION 3
FINAL DRIVES
TABLE OF CONTENTS
3.1 GENERAL DESCRIPTION ........................................................................................................ 3-3

3.1.1 Final drive ............................................................................................................................... 3-4
3.2 REPAIR PROCEDURES ........................................................................................................... 3-6

3.2.1 Final drive (removal / disassembly) ......................................................................................... 3-6
3.2.2 Pulling the housing cover ...................................................................................................... 3-10
3.2.3 Driven gear (bearing removal) .............................................................................................. 3-11
3.2.4 Driving gear shaft (bearing removal) ..................................................................................... 3-11
3.2.5 Description of installation of front seals (long life) ................................................................. 3-12
3.2.6 Final drive (assembly) ........................................................................................................... 3-13
3.3 SPECIFICATIONS AND DATA ................................................................................................. 3-22

3.3.1 Final drive shaft and bearing fittings ...................................................................................... 3-22
3.4 SPECIAL TOOLS .................................................................................................................... 3-25

D180 FINAL DRIVES 3-3
The final drives are of a double reduction type, with straight spur gears and a 1 : 12.286 reduction ratio.
Specifications of final drive oil: must meet MIL-2105 or Api Service GL5 (SAE 80W-90).
Quantity to fill with oil final drives: 18 L (4 3/4 US gal).
The D180 Power Steering/D180 Steering Clutch final drives have two features, one of a technical type, the
other service oriented.
The technical feature consists of a different arrangement of the final drives, being isolated from the stress
generated by the undercarriage, which, on the other hand, is directly connected to the transmission housing,
absorbing the majority of the loads on the track chains through the hinging on the two shafts (PIVOT - SHAFTS).
The service feature consists of the reduction of the service time required to intervene on the machine, since the
modular type final drives are individually removable from the unit, without involving the transmission housing.
4 2
5 3
SM9300
Fig. 3-1 Final drive installed
1. Final drive - 2. Sprocket - 3. Track frame -

4. Transmission housing - 5. Pivot shaft
3-4 FINAL DRIVES D180
3.1.1 FINAL DRIVE
174
185 173 172
168
179
175 176
168 169
178
170
159 190
181 G 182
172 165 R
167
158 193
192 V1
194 157
V2 184
C
171
161 166
180 162 183
187 C1
164
186
S
V1
V2
197 188 163
189
195
198 200/199 160 M V
SM9336
Fig. 3-2 Final drive exploded view
157. Housing - 158. Cover - 159. Bearing housing - 160. Sprocket shaft - 161. Driven or idle gear - 162. Bearing -
163. Housing - 164. Spacer - 165. Spacer - 166. Spacer - 167. Sprocket gear - 168. Plate - 169. Driving gear -
170. Bearing housing - 171. O-Ring 3.53x171 - 172. O-Ring 3.53x142.50 - 173. O-Ring 3.53x183.7 - 174. O-Ring
3.53x190.1 - 175. Screw TE M16x1.5x65 - 176. Washer 16x30x3 - 178. Roller bearing 40x90x33 - 179. Roller
bearing 70x150x35 - 180. Roller bearing 70x150x51 - 181. Roller bearing 55x120x43 - 182. Bearing - 183. Plug
M27x2x16 - 184. O-Ring 3x24 - 185. Seal - 186. Screw TE M12x50 - 187. Washer 12x24 - 188. O-Ring
3.53x215.5 - 189. Front seal - 190. Ring nut 170 to 190 daNm - 192. Safety plate - 193. Circlip 90 - 194. Circlip
170 - 195. Track chain guard - 197. Nut E M14x1.5 - 198. Washer 14x32 - 199. Screw TE M14x1.5x45 -
200. Screw TE M14x1.5x55 - C. Final drive cover - G. Dowel - R. Final drive upper guard - V. Sprocket hub
securing screw (M20x1.5) - V1. Final drive securing screw to PIVOT SHAFT (M24x2x260) (M24x2x130) -
V2. Final drive securing screw to transm. housing (M16x1.5) - C1. Segment securing screws (M22x1.5) -
S. Sprocket segments - M. Sprocket hub
168
169 175, 176 173, 174
157, 183, 184

170, 185
Driving
178
161
179
180 181
Idle
167
159, 168, 172
189
164
158, 171
160
190, 192, 193
TIGHTENING TORQUE
162 From 170 to 190 daNm
182
194
165
187, 186, 163 188 166
197, 198, 199

195, 196
197, 198, 200

SM9000
Fig. 3-3 Final drive sectional view (For the components, refer to fig. 3-2)
3.2 REPAIR PROCEDURES
3.2.1 FINAL DRIVE (removal / disassembly)

A
Removal
To remove the final drive, proceed as follows:

Drain the oil from the final drive through draining plug
B (fig. 3-4). Remove plug A to facilitate the draining.
Remove the guard on the track frame and relieve the

chain pressure, loosening track tension valve VR
(fig. 3-5) a few turns.
B
SM9337
Fig. 3-4
A. Oil filler plug - B. Oil draining plug
DANGER
Fluid under pressure. Do not relieve the track ten-
sion by loosening pressure relief valve Vs. Do
not remove grease fitting (I) installed on adjust-
ing valve VR.
VS VR I C
SM9352
Fig. 3-5 Adjustment of the track chain
VR . Tension adjusting valve - VS. Pressure relief valve - I. Grease fitting - C. Cover
Remove the track chain as described in SECTION 5

- UNDERCARRIAGE.
M
R
WARNING V
Never work under or in the vicinity of equipment
or parts of the machine not adequately supported
and blocked.
Lift and handle all heavy parts with lifting devices

of adequate capacity. Make sure that parts are
properly slinged and hooked. Use the lifting eyes
provided for this purpose. Pay attention to per-
sons in the vicinity of the parts to be lifted. T C1 S
SM9301
Fig. 3-6
To disassemble the final drive assembly, it is advis-
able to remove first the sprocket, then proceed as C 1 . Sectors securing screws - M. Sprocket -
follows: S. Toothed sectors - V. Sectors securing screws -
T. Track frame housing
- Remove at least three tooted sectors S from the
upper part of the sprocket, removing screws C1
(fig. 3-6).
- Move the machine just enough to place the sprocket
without toothed sectors corresponding to the inter-
ference with track frame T, so that the sprocket can
be removed form the final drive.
- Hold sprocket M using a hoist a lifting hook and
remove it, loosening the screws securing V it to the R
hub.
V1
157
V2
Remove the final drive upper guard R (fig. 3-7)
V1 C1
from lower cap of Pivot - Shaft A. Remove the tow
securing screws V1. Remove the cap. Sling and
hold the final drive assembly for the disassembly S
(weight of the final drive complete with sprocket is
about 530 kg - 1168 lb). Loosen screws V2 retain-
ing the final drive and remove it from the trans-
mission housing.
Place the final drive on a bench for the disassembly. A
195
197 V2
M V
198 199/200
SM9345
Fig. 3-7 Final drives, sprocket and guards
Disassembly
168 169 170
Remove the two seals (185) (fig. 3-8) from driving
shaft (169).
Pull out safety plates (168) from the seat on the cover
and bearing housing.
Remove bearing housing (170).
185 SM9303
Fig. 3-8
Install two eye screws A into holes B of bearing
A 170
housings (158 and 159) and remove them complete
with bearings and O-Rings.
B 158
159
SM9304
Fig. 3-9
Remove screws (175) on the final drive cover; re-
move the dowels.
SM9305
Fig. 3-10
Tighten three eye screws on cover (C) and remove
it as indicated in fig. 3-11.
SM9315
Fig. 3-11
Remove retaining circlip (193) on the sprocket shaft.

193
Remove safety plates (192) from the ring nut and
loosen it using a torque wrench and the ring nut re- 192
moval tool.
Remove the ring nut.
SM9318
Fig. 3-12
Remove driving gear (169) and driven gear (161)
from the final drive housing, as illustrated in the
figure.
SM9316
Fig. 3-13
Separate the components and place them on a proper

supporting surface, sufficient for all the parts to be
removed.
SM9339
Fig. 3-14
Install tool (P/N 380001349) A as indicated in fig.
3-15, to block the driven gear on the final drive hous-
ing. A
SM9319
Fig. 3-15
3 - 10 FINAL DRIVES D180
Turn the final drive upside down and remove screws

(186) retaining the sprocket shaft and remove the
assembly from the final drive housing, as indicated
in fig. 3-16.
SM9354
Fig. 3-16
Turn the final drive upside down, remove the block-
ing tool and remove the driven gear, as indicated
in fig. 3-17.
SM9307
Fig.3- 17
3.2.2 PULLING THE HOUSING COVER
Remove the outer straight roller bearings from the

cover with the appropriate puller, only in the event
they must be replaced.
SM9340
Fig. 3-18
D180 FINAL DRIVES 3 - 11
3.2.3 DRIVEN GEAR
Bearing removal E
Pull-out the bearing races from each end of the gear

shaft, using puller E, as illustrated in the figure.
SM9331
Fig. 3-19
Warm-up races P of the new bearings and install them

P
on the shaft as illustrated.
SM9332
Fig. 3-20
3.2.4 DRIVING GEAR SHAFT
Bearing removal P P E
Using an appropriate puller E, remove the bearing

races from the driving gear shaft, as illustrated in
the figure.
SM9333
Fig.3-21
Warm-up the races of the new bearings and install

them on the shaft as illustrated. P
SM9334
Fig. 3-22
3.2.5 DESCRIPTION OF INSTALLATION

OF FRONT SEALS (LONG LIFE)
Examine accurately the metal rings, checking that

the relevant faces are free from scratches, dents
and signs of wear, due to misalignment or planarity
errors.
Replace both metal rings 1, fig. 3-23 and rubber

rings 2, even if one only is defective.
Absolutely avoid mating a used metal ring with a

new one and rings salvaged from different seal
pairs.
To install the seals, comply with the following rules:

1. Eliminate all sharp corners and burrs; clean ac-
curately the rubber ring seats.
2. Clean accurately the rubber rings. SM9335
3. Press each metal ring 1 onto the relevant rubber
ring 2 (see detail a) Fig. 3-23
4. Make sure that the metal ring is properly installed,
by checking that dimension 3 (detail b) isconstant
on the entire circle.
5. Install manually each pair of rings into the rel-
evant seats on the rubber ring, as illustrated
(see detail c).
6. Before completing the assembly (detail d) clean
with a lint free rag sealing faces 4 and smear a
thin film of fluid oil on them.
3.2.6 FINAL DRIVE
Assembly
Clean and wash with an appropriate solvent all the

components prior to reassemble. 157
WARNING
provided for this purpose. Pay attention to per-
sons in the vicinity of the parts to be lifted.
Place final drive housing (157) on an appropriate

SM9308
bench, facing the inner side upward, as illustrated in
the figure. Fig. 3-24
Install the outer race of bearings (178) and (180) us-

ing an appropriate punch.
169
167
178 161 180

SM9341
Fig. 3-25
169. Driving gear - 161. Idle gear - 167. Driven gear

- 178. Bearing - 180. Bearing
Lift with a tool as illustrated and install driven gear

(161) into the final drive housing.
161
SM9307
Fig. 3-26
Arrange sprocket shaft (160) and install long-life seal

(189) in the relevant seat on the shaft.
160
Prepare housing (163) and install the second long-
life seal.
Note – Prior to the installation, lubricate adequately

the seals with oil or vaseline.
163
189
SM9309
Fig. 3-27
Install he housing onto the shaft and insert spacer
(164). 164
SM9311
Fig. 3-28
Block the housing - sprocket shaft assembly prop-
erly, as per fig. 29 and warm-up twin bearing (162) to 162
about 110 °C (230 °F).
Install the bearing on the shaft.
SM9310
Fig. 3-29
Install a tool (A) 380001349 on the housing to secure
the driven gear, as illustrated in the figure, and turn A
the final drive housing upside down.
SM9312
Fig. 3-30
Lubricate adequately with oil or vaseline the con-

tact surfaces of the sprocket shaft assembly.
SM9313
Fig. 3-31
Install O-Ring (188) in its seat.
188
SM9314
Fig. 3-32
Install spacer (166) and insert the shaft into the hous-
ing, paying attention, during the centring phase, that
the assembly sets-in in a uniform manner.
Install the 8 securing screws (M12x50) and tighten
them to the prescribed torque (see Torque Tighten- 166
ing Table of SECTION 0 at the beginning of this
Manual).
SM9320
Fig. 3-33
Turn the housing upside down and remove the driven

gear retaining tool.
Install spacer (165) on the shaft.
SM9319
Fig. 3-34
Prepare bearing housing (159) of idle shaft (161) and

install bearing (181) using a press.
181
159
SM9344
Fig. 3-35
Warm-up inner races (P) of bearings (179) of driving P
gear (169) at about 110 ÷ 120 °C (230 ÷ 248 °F).
SM9322
Fig. 3-36
Install races (P) onto the relevant seats on both
sides of the shaft.
P
SM9317
Fig. 3-37
Hold the shaft and idle gear (161) assembly and

install it inside bearing housing (159) inside the
final drive.
161
SM9316
Fig. 3-38
Also, install driving gear (159) matching it with idle

shaft (161). Rotate the gear train a few turns, to set 161 159
in the movement of the components.
SM9330
Fig. 3-39
Warm-up the bearing inner race (182) to 110 °C 182

(230 °F) and install it on the seat on sprocket bear-
ing (160).
SM9332
Fig.3- 40
Prepare bearing housing (158) for reassembly.

Press mount bearing (182) outer race into the 182
housing complete with O-Ring.
Install the assembly on the cover and drive it with
a soft metal hammer until fully mounted.
158
SM9333
Fig. 3-41
Install circlip (194).
194
SM9334
Fig. 3-42
Screw ring nut (190) retaining the sprocket shaft.
190
SM9328
Fig. 3-43
Block the gear train and install the ring nut locking
tool (P/N 380001475), complete with torque B
wrench (A) and multiplier (B).
Tighten the ring nut from 170 to 190 daNm (1253.4 to A
1440.8 lbf.ft.).
Note – The tightening range (from 170 to 190 daNm

(1253.4 to 1440.8 lb.ft.)) allow orienting the ring nut,
so that the two safety plates can enter the seats.
Install two safety plates (192).
SM9326
Fig. 3-44
Then, install circlip (193).
193
SM9318
Fig. 3-45
Smear a film of sealing compound (LOCTITE 518)
on the mating face with the cover.
Install the cover on the final drive housing, lifting it as
shown in the figure 3-46.
SM9315
Fig. 3-46
Install two guide screws (V) to centre the cover on

the housing and insert dowels (G). V
Drive the dowels until fully seated.
WARNING
Use a soft non ferrous hammer.
SM9325
Fig. 3-47
Install the cover securing screws and tighten them

(12 daNm (88.5 lbf.ft.)).
SM9305
Fig. 3-48
Lubricate with oil or petroleum jelly, driving shaft bear- 170

ing housing (170), complete with bearing (179) and
O-Ring (172).
Install the housing into the seat oriented in such a
manner to coincide the seat for the installation of the
key.
SM9353
Fig. 3-49
Lubricate the idle shaft housing with oil or vase-
line and install it into the set on the cover.
SM9324
Fig. 3-50
Adjust the seat, if required to install the key.

Repeat the same operations for the sprocket shaft
bearing housing, as well.
SM9323
Fig. 3-51
Smear LOCTITE 518 on the lock race seats and in-

stall them.
SM9303
Fig. 3-52
Install the two seals on the driving shaft, using the

special tools P/N 380001320 - 380001323 (B), with B
the faces oriented as indicated in detail A for the
installation of the seals.
SM9306
Fig. 3-53
Seals
Driving
shaft
Bearing
housing
SM9324
Fig. 3-54 Detail A - Seal installation

NOTES:
3.3.1 FINAL DRIVE SHAFT AND BEARING FITTINGS
Driving
shaft
N M A B
Idle
shaft
L I C D
Sprocket
shaft
H G E F
Fig. 3-55 Sectional view of final drive
BEARING INSTALLATION SPECIFICATIONS AND DATA

(mm) (in)
Min. Max. Min. Max.
A.
- Bearing inner diameter 69.985 to 70.000 2.755 to 2.756
- Driving gear outer diameter 70.002 to 70.021 2.756 to 2.757
- Mounting interference 0.002 interf. to 0.036 interf. 0.00008 interf. to 0.0014 interf.
B.
- Bearing outer diameter 149.985 to 150.000 5.904 to 5.905
- Housing inner diameter 149.960 to 150.000 5.904 to 5.905
- Mounting interference 0.025 clear. to 0.040 interf. 0.0009 clear. to 0.0016 interf.
C.
- Idle gear diameter 55.002 to 55.021 2.165 to 2.166
- Mounting interference 0.002 interf.to 0.036 interf. 0.00008 interf. to 0.0014 interf.
D.
E.
- Bearing inner diamete 94.980 to 95.000 3.739 to 3.740
- Sprocket shaft diameter 94.978 to 95.000 3.739 to 3.740
F.
- Bearing housing diameter 169.975 to 169.992 6.692 to 6.693
G.
H.
- Mounting interference 0.046 clear. to 0.046 interf. 0.0018 interf. to 0.0018 interf.
I.
L.
- Housing diameter 149.960 to 150.000 5.904 to 5.905
- Interference 0.018 clear. to 0.04 interf. 0.0007 clear. to 0.0016 interf.
M.
- Driving gear diameter 40.002 to 40.018 1.575 to 1.576
- Interference 0.002 interf. to 0.030 interf. 0.00008 interf. to 0.0012 interf.
N.
- Interference 0.015 clear. to 0.035 interf. 0.0006 clear. to 0.0014 interf.
NOTES:
3.4 SPECIAL TOOLS
380001317 Tool, reduction unit pinion

bearing installation
380001320 Installation of reduction unit

housing seal
380001321 Tool, reduction unit housing

bearing installation
380001323 Installation of reduction unit

housing seal
380001349 Tool, reduction gear holding
380001472 Hook, final drive crown

gear lifting
380001475 Tool, final drive ring nut holder
380001348 Final drive lifting tool
SECTION 4
BRAKES AND STEERING CLUTCHES
D180 POWER STEERING

TABLE OF CONTENTS
4.1 GENERAL DESCRIPTION .................................................................................................... 4-3

4.1.1 Brakes hydraulic diagram ...................................................................................................... 4-3
4.1.2 Brake circuit main components ............................................................................................. 4-4
Brake powering pump ........................................................................................................ 4-4
Brake powering valve block ................................................................................................ 4-5
Brake pedal valve ............................................................................................................... 4-6
Brake oil filter ..................................................................................................................... 4-8
4.1.3 Steering hydraulic circuit diagram .......................................................................................... 4-9
4.1.4 Steering circuit main components ........................................................................................ 4-11
Hydraulic motor ................................................................................................................ 4-11
Steering piloting valve block ............................................................................................. 4-12
4.2 TROUBLESHOOTING ........................................................................................................ 4-13

4.2.1 Diagnosis on the display ...................................................................................................... 4-13
4.3 TESTS ................................................................................................................................ 4-15

4.3.1 Test of circuit pressures on diagnostics ............................................................................... 4-15
4.3.2 Positioning of diagnostic hoses ........................................................................................... 4-16
4.3.3 Brake pedal adjustment ...................................................................................................... 4-17
4.3.4 Test and setting of brake powering valve block ................................................................... 4-18
4.3.5 Calibration of steering levers ............................................................................................... 4-19
4.4 REPAIR PROCEDURES ..................................................................................................... 4-21

4.4.1 Brake pedal valve (removal / disassembly) ......................................................................... 4-21
4.4.2 Brake power pump .............................................................................................................. 4-22
4.4.3 Brakes and steering differential ........................................................................................... 4-23
Removal (preliminary operations) ..................................................................................... 4-23
Removal of the ring gear .................................................................................................. 4-27
Disassembly of the planet carrier differential assembly .................................................... 4-29
Disassembly of the sun gear ............................................................................................ 4-29
Disassembly of the brake assembly ................................................................................. 4-30
Re-assembly of the brake drum assembly ....................................................................... 4-34
4.4.4 Check and inspection of brake packs .................................................................................. 4-40
Re-assembly of the sun gear ........................................................................................... 4-41
Re-assembly of the planet carrier assembly ..................................................................... 4-42
Re-assembly and re-installation of the ring gear assembly .............................................. 4-44
Re-installation of brake/steering differential group into the transmission housing ............. 4-45
4.4.5 Bevel gear set (Removal/disassembly of pinion and bevel gear) ......................................... 4-47
4.4.6 Procedure for the setting of the bevel pinion bearings pre-load ........................................... 4-57
4.4.7 Procedure for the setting of the bevel gear crown ............................................................... 4-58
4.4.8 Re-installation of housing cover .......................................................................................... 4-59
4.5 SPECIFICATIONS AND DATA ............................................................................................ 4-60

4.5.1 Bevel gear reduction unit (general data/dimensions) ........................................................... 4-60
4.5.2 Brakes ................................................................................................................................. 4-62
4.5.3 Brake pedal valve ................................................................................................................ 4-63
4.5.4 Rear transmission (Transmission side sectional view) ........................................................ 4-65
4.6 SPECIAL TOOLS ................................................................................................................ 4-67

D180 BRAKES AND STEERING CLUTCHES 4-3

4.1.1 BRAKES HYDRAULIC DIAGRAM
The brake hydraulic system is totally separated from the steering circuit and it is mainly composed of:
- A dual pump powering the brakes circuit and the transmission (ref. 1 hydraulic diagram)
- A suction oil filter (10) (metal) and one on the delivery (paper) (ref. 2) A powering valve block (ref. 3)
- A brake pedal valve (ref. 4)
- A rear transmission housing (ref. 8)
Power pump (1) sucks oil from transmission housing (8) through a metal mesh filter (10) and sends it to port (P)
of powering valve block (3), through filter (3).
Power valve (P) provides the circuit with a pressure of 25 ± 2 bar (362 ± 29 psi). Accumulator (5) provides the
pressure to the circuit in case of engine failure.
A brake pedal valve (actuated directly by the central pedal in the cab) actuates directly the brakes, removing
pressure from the circuit.
Transmission housing (8) is composed of the bevel gear set (driven directly by the transmission), the brake
discs (oil-bath) and the steering differential. The transmission housing provides the collection of the oil being
used both to pilot the packs and to lubricate all the components of the housing.
the engagement of the brakes occurs when the brake pedal is pressed, so that pressure is removed from the
circuit, then the force of the springs blocks the braking device actuating the brake disc pack.
The machine brakes under the following conditions:
- with machine inoperative and engine cut-off (parking brake);
- with machine inoperative, engine started and safety levers in raised position;
- with machine in operation, when pressing the central brake pedal (service brake).
F14335
Brake hydraulic system
1. Power dual pump - 2. Oil filter (delivery) - 3. Powering valve block - 4. Brake pedal valve - 5. Accumulator
- 6. Pressure relief valve - 7. Directional solenoid valve - 8. Transmission housing - 9. Brake discs - 10. Oil filter
(suction) - 11. Pressure pick-up - A From torque converter - B To transmission housing
4-4 BRAKES AND STEERING CLUTCHES D180
4.1.2 BRAKE CIRCUIT MAIN COMPONENTS
Brake powering pump

(Ref. 1, hydraulic diagram)
Pump type ....................................................... gear

Make ................................ SAUER SUNDSTRAND
Model .........................................PNN 19+8S SC 41
Gear dual pump mounted on the converter cover;

one section powers the brakes, the other scavenges
the oil form the converter and returns it to the trans-
mission.
Flow at max. speed (2650 rpm) with engine max. rated
power speed of 2000 rpm.
Delivery of section 1 feeding brakes / clutches:
50 L/min (13.2 US gpm).
Delivery of section 2, scavenging the torque converter
oil: 22 L/min (5.8 US gpm).

SUCTION
DELIVERY
2.650 RPM
2650 rpm
Sez.1
Sec. 1 19.2
19.2 CC/REV
cc/rev
50 L/min
l/min
2.650 RPM
2650 rpm
Sez.2
Sec. 2 8.4 CC/REV
cc/rev
22 L/min
l/min
SUCTION
DELIVERY
Section 1: Brake Section 2:

circuit powering pump Torque converter oil
scavenger pump C
2 1
SM9174 P
P1
SM1405
P. Brake pump
C. Torque converter
P1. Equipment/steering piston pump
Brake powering valve block

(Ref. 3 brake hydraulic diagram)
The feeding valve block is mounted on the left side,

under the cab. To reach it is just enough to open the
left panel under the cab.
1. Brake powering pump

3. Powering valve block
5. Accumulator (pre-charge 13 bar) (188.5 psi)
6. Pressure relief valve (setting 25 bar) (362.6 psi)
7. Directional solenoid valve F14336
3
6
PP 2
1
DR P
SM1407
Ports on block:
DR. Drainage
P. From power pump
C. Brakes lubrication
PP. Pressure pick-up
1. To brake pedal valve
Brake pedal valve

(Ref. 4, brake hydraulic diagram)
The brake pedal valve is mounted in the lower part of

the cab and it is actuated by a linkage, directly by the
brake pedal.
Item on the valve
P. To brakes (delivery)
DR. To brakes (draining)
T. To housing (discharge)
A. To powering valve block (pos. 1) DR
B. From powering valve (pos. 2)
DR SM9181
(M12X1,5)
T
(M22X1,5)
A
(M16X1,5) P
(M22X1,5)
B
(M14X1,5)
SM9186
Brake oil filter
T SM9187
25 1 2 3 4 5 6 7 8 9 10 28
P 11
12
13
14
34
20 19 B 18 17 33 16 15 23
A SM9188
21
37 30 30 32 31
25
36
35
T
22
SM9189
Section of brake pedal valve
1. Cover 17. Piston spring

2. Spring 18. Piston
3. Washer 19. Spacer
4. Piston 20. Gasket
5. Body ass.ly 21. Pin
6. Rod 22. Dowel
7. Inner cup 25. Shaft seal
8. Washer 28. O-Ring 2.62x34.59
9. Spring 30. Spring washer
10. Outer cup 31. Screw M8x55
11. Guide 32. Screw M8x35
12. Pushing pin 33. O-Ring 2.62x20.29
13. Cover 34. O-Ring 2.62x18.72
14. Cam 35. Gasket
15. Washer 36. Plug M10x1.25
16. Gasket 37. Screw M8x75
Brake oil filter
Delivery filter (2)

(Ref. 2 brake hydraulic diagram)
The filter on the delivery line of the brakes / steering

clutches circuit is reached by opening the panel of 5
the engine compartment on the left side of the ma-
chine.
Total flow, with paper filtering element, replaceable

3
(µ) every 500 hours work (30 µ nominal and by-pass 1
valve set at 2.5 bar) (50.7 psi).
Tightening torque 4 daNm (29.5 lbf.ft). 4
Fa
F
SM9171
F14338
F14338
1. Filter support
2. Filter cartridge
3. Filtering element
4. Cover
5. O-Ring 2
F. Transmission / torque converter oil filter
1 4
Suction filter 6 7
(Ref. 10 hydraulic diagram)
3
The filter on the suction line of the brakes / steering Fa
clutches circuit is reached when lifting the cab.
Total flow, with steel mesh filtering element (non re- 5
placeable, to be cleaned every 1000 hours work) and
magnetic plug (100 µ nominal, without by-pass). 8
9
Fa. Steel mesh filtering element
1. Cover securing nut
2. O-Ring
7
3. Cover
4. Stud
5. Magnetic rod
6. Filtering element retaining spring
7. Circlip
8. Gasket
9. Support SM9172
4.1.3 STEERING HYDRAULIC CIRCUIT DIAGRAM
The steering diagram circuit and the equipment one are a single hydraulic system and use the same oil.
The two circuits, although sharing some hydraulic components, are described separately.
The equipment circuit is described in SECT. 6 - DOZING EQUIPMENT HYDRAULIC SYSTEM.
The two circuits are separated by the operating pressures and they operate at:
- steering circuit max. pressure 350 ± 5 bar (5076 ± 72 psi)
- equipment circuit max. pressure 190 ± 5 bar (2755 ± 72 psi).
The steering circuit is mainly composed of:

- A piston pump powering the steering/equipment circuits (ref. P)
- A hydraulic motor (ref. M)
- A steering/equipment control valve (ref. D)
- A steering piloting valve block (ref. Vp)
- A powering valve block (ref. Va)
- Two steering levers (ref. L)
- An oil radiator (ref. S)
- A micro-controller (ref. C)
The D180 Power Steering is equipped with a steering differential allowing the dozer to provide constant power
when steering to both track chains, changing the speed without ever blocking the track chain. The speed of one
track chain increases or decreases of the same value with respect to the other, without any loss of pushing
power. It becomes particularly advantageous also during finishing jobs, especially in particularly restricted spaces.
When steering levers (L) are actuated, their movements is transformed into an electric signal, that reaches,
through controller (C) steering piloting valves (Vp), which operate piloting directly steering spool (1) on control
valve (D).
Piston pump (P) mounted on the torque converter, power both steering and equipment circuits, through the
control valve. The regulation of the flow distribution system operates with a logic priority for the steering, through
the Load Sensing signal between control valve and pump.
When high performances are demanded to the steering, during the simultaneous operation of both steering and
equipment, it occurs that at the pressure of 190 bar (2756 psi), the delivery on the equipment is zeroed, since it
is totally taken by the hydraulic motor.
Thus, the travel speed remains unchanged, since the power taken away from one track chain is added , at the
same value, to the other one, providing a constant steering, without any blocking of the track chain, with a
precise control of the trajectory.
When the travel direction is straight, without using the equipment, the power flows entirely to the bevel gear set,
thus to the track chains which are forced to move at the same speed, since under this condition, the hydraulic
motor is inoperative.
When the steering levers are actuated with the transmission in neutral, the pump delivery flows entirely (without
using the equipment) toward the hydraulic motor.
The latter provides that the two track chains are obliged to travel at the same speed (from 0 through 2 km/h) but
in an opposite counter rotation direction. Thus the machine is capable of turning on its own turning rightward if
the right lever only is actuated, or viceversa leftward, when actuating the left lever only.
A heat exchanger (S) on the oil return circuit, constantly diminishes the oil temperature, to ensure an appropriate
operation of the hydraulic system.
4 - 10 BRAKES AND STEERING CLUTCHES D180
Ma
STEERING HYDRAULIC DIAGRAM
L
M T 380±5 bar
(5511±72 psi)
MA MB
C
T 3
MICROCONTROLLER A1 S B1
P
2 2
19
D
4
R S X L
A b1 B1 A1 b4 X1 B4 A4 Y1 K
40 bar
TR (580.1 psi) TL 210±5 bar 210±5 bar
T P
16 3045.8±72.5 psi) 3045.8±72.5 psi)
13
C
Vp
A
B
STEERING
PS
SECTION
B 3 34 ± 2 bar 12
C 1 18 (493±29 psi) 10
PM A
D 5 bar (72.5 psi) (160/350) ± 5 bar
A 14 11 2320.5/5076.3±72.5 psi)
9
T
17 P T
P
Q = 0.7 l/min
3
380 ± 10 bar
(5511.4±145 psi)
P T
15
a1 Mp a4 P MLS T
15
BLADE
5 SECTION
LS
5 bar
(72.5 psi)
P1
Va
6 P
8
X S
F S
35 bar
(507.6 psi)
45 bar
(652,7 psi)
7
P2 T PR
SM1400
Fig. 4-12 Steering hydraulic diagram
C. Controller - F. Oil suction filter - M. Steering hydraulic motor - D. Equipment/steering control valve - P. Variable displacement piston pump - S. Heat exchanger - Ma. Blade control pilot valve - Va. Supply block - Vp. Steering pilot valve - L. Steering control - 1. Steering control
spool - 2. Steering spool safety valves - 3. Electro-proportional valves - 4. Priority valve (40 bar, 580.1 psi) - 5. Accumulators - 6. Reduction valve (35 bar, 507.6 psi) - 7. Power cut-off solenoid valve - 8. Supply block pressure relief valve (45 bar, 652.7 psi) - 9. Line LS
decompression valve (0.7 L/min, 0.2 US gpm) - 10. Load Sensing relief valve - 11. Pressure relief valve - 12. Blade control spool - 13. Blade control spool safety valves - 14. Unloading valve - 15. Pressure compensator - 16. Selector valve - 17. Piloting valve - 18. Plug -
19. Hydraulic breaking valve.
D180 BRAKES AND STEERING CLUTCHES 4 - 11
4.1.4 STEERING CIRCUIT MAIN COMPONENTS
Note – For the following components.
- Variable displacement piston pump (ref. P)

- Control valve (ref. D)
- Powering valve block (ref. Va).
Please refer to SECT. 6 - EQUIPMENT HYDRAULIC
SYSTEM DIAGRAM page 6-5.
Hydraulic motor
Brand .......................................................... Rexroth
Type ................. fixed displacement AZ FE 90/61W
SM1409
A' B' G
A S B
A. To steering/equipment control valve

B. To steering/equipment control valve Motor hydraulic diagram
S. To heat exchanger SM1498
Steering piloting valve block

(Ref. Vp hydraulic diagram)
It is mounted on the frame on the left side of the

machine. To reach it, it is necessary to tilt the cab.
Steering lever
P
ML MR
SM1412
Micro-controller
PM
4
R S X L
A PS
TR 40 bar (580.1 psi) TL
T P
16
C A Vp
B
PS
B
C
3
T
PM A
D 5 bar
A
17
(72.5 psi) X
P T P T
3 S
P T
SM1411
Hydraulic diagram
Vp. Piloting valves block L R
3. Electro proportional valves
4. Pressure relief valve (40 bar (580.1 psi))
16. Selector valve
SM1410
17. Piloting valve
Ports on the piloting valves block
P. From powering block
T. To reservoir
L. To b1 of control valve
R. To a1 of the control valve
X. To y1 of the control valve
S. To b4 of the control valve
4.2 TROUBLESHOOTING
4.2.1 DIAGNOSIS ON THE DISPLAY 5 text field digits
The display has 5 text field digits signalling the fol-

lowing messages:
A. Work hourmeter signal

The engine hours are signalled by coming ON for
about 1 second when the general test of the in-
strument panel is performed. To repeat the read-
ing of the engine hours, it is necessary to cut-off
SM9191
and to energise again the system with the starter
switch key. The hours stay ON until the engine is
started. Failure code E = Failure
or
Speed engaged Code failure
B. Speed engaged + failure code signal 1st speed
- The first digit indicates the speed engaged
- The second digit indicates E in the event of a
failure.
- The 3rd - 4th and 5th digits indicate the code of the
type of failure and they are distinguished by two
types.
Failure codes of a single component of the brakes/
clutches and transmission control system
(see table 4-1).
Failure codes for more than one component
(see table 4-2). Failure example SM9192
When the display shows one of the failure codes here below, identify the corresponding failed component,
as per table 4-1.
TABLE 4-1
Failure
Failed component
code
Solenoid of the left proportional solenoid valve 001
Solenoid of the right proportional solenoid valve 002
Forward speed "F" solenoid 004

Reverse speed "R" solenoid 008
1st speed solenoid 016
3nd speed solenoid 032

Solenoid of the left steering lever 064
Solenoid of the right steering lever 128
TABLE 4-2
Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of
left prop. right prop. Forw. Rev. 1st 3rd left right
Failed component
solen. solen. speed speed speed speed steer. steer.
valve valve "F" "R" lever lever
Solenoid of the left proportional

valve 001 003 005 009 017 033 065 129
Solenoid of the right proportional
valve 002 006 010 018 034 066 130
Forward speed "F" solenoid 004 012 020 036 068 132
Reverse speed "R" solenoid 008 024 040 072 136

1st speed solenoid 016 048 080 144
3rd speed solenoid 032 096 160
Solenoid of the left steering lever 064 192

Failure code of reverse speed "R" solenoid = 008

Failure code addition on display Failure code of 1st speed solenoid = 016
In the event the failed components are two, refer to The crossing in TABLE 4-2 of the two components
TABLE 4-2 where the code is determined by the determines the failure code given by the addition of
addition of the two single failure codes listed in the two single codes 024.
TABLE 4-1. As an example, code 024 indicates
that the failed parts are two: the top digit of the col- Reverse speed "R" failure code = 008 +
umn identifies the solenoid of the "1st speed", 1st speed failure code = 016
whereas the left digit identifies the solenoid of the
"reverse speed R". Failure code for both on the display = 024
4.3 TESTS
4.3.1 TEST OF CIRCUIT PRESSURES

ON DIAGNOSTICS
Loosen the plugs on the diagnostic panel. WARNING

Connect a pressure gauge with engine inoperative, to
Prior to operating the machine or its equipment,
pressure pick-ups (1-2-3-4-5) indicated in the figure.
make sure that there are no bystanders within the
range of operation. Make an inspection around the
When proceeding with the test of the circuits, make
machine prior to mounting on it. Sound the horn.
sure that the single pressure gauges are adequate
for the pressures to be measured.
Bring the engine to max. speed (2100 to 2200 rpm)
and read the relevant pressure that must coincide
Start the engine and make a few forward/reverse
with the values of the nominal pressures listed in the
manoeuvres, actuating, at the same time, the steer-
table here below.
ing levers to warm-up the oil.
Table of nominal pressures
WARNING 1. Brake pressure 18 ÷ 22 bar

Do not operate the engine of this machine in en- (261 ÷ 319 psi)
closed ambient without enough ventilation en- 2. Pressure A1 on hydr. motor 350 ± 5 bar
suring the dissipation of toxic fumes. (5076 ± 72.5 psi)
3. Pressure B1 on hydr. motor 350 ± 5 bar
(5076 ± 72.5 psi)
4. Piloting pressure a1 30 ± 2 bar
(435 ÷ 29 psi)
5. Piloting pressure b1 30 ± 2 bar
(435 ± 29 psi)
1 2 3 4 5
1 - BRAKE PRESSURE 4 - STEERING PILOT "a1"

2 - HYD. MOTOR "A1" 5 - STEERING PILOT "b1"
3 - HYD. MOTOR "B1"
SM1413
Pressure pick-ups on diagnostic panel
4.3.2 POSITIONING OF DIAGNOSTIC HOSES
- PUMP PRESSURE - STEERING PILOT "a1"

- HYD. MOT OR "A1" - STEERING PILOT "b1"
- HYD. MOT OR "B1"
5
4
3
2
1
F14339
F14339
4.3.3 BRAKE PEDAL ADJUSTMENT
Position brake pedal (1) at dimension L = 175 mm

(6.9 in) from the cab floor, actuating stop 2.
Connect link (3) to fork (4).

4
Adjust the length of link (3) until it connects with lever
(5) positioned at stroke end. 2
1
Tighten locknut (6). 6
Loosen stop (2) until the pedal play is almost totally

eliminated and lock it with the relevant nut.
Actuate brake pedal (1) full stroke avoiding forcing it

beyond the lever stroke end (5). CAB FLOOR
Bring screw (7) against brake pedal (1). 7
Release the brake pedal, loosen screw (7) two turns

and lock the nut.
3
SM9198
2
3
SM1414
4.3.4 TEST AND SETTING OF BRAKE

POWERING VALVE BLOCK
(ref. 3 on brakes hydr. diagram)
Open the left side panel as indicated, and connect a WARNING

pressure gauge (30 bar (431.1 psi) scale capacity) to
Disconnect and connect all connections with the
the quick release pressure pick-up PP on the feed-
engine inoperative. The flowing of pressurised oil
ing valve block.
from loose connections could cause personal inju-
ries and property damages.
Start the engine at max. power speed (2100 to
Wear protection glasses with side panels or goggles.
2200 rpm) and measure the pressure setting of the
pressure relief valve on the pressure gauge, which
should be 22.5 ± 27.5 bar (326.3 to 398.8 psi), at a
flow of 50 L/min (13.2 gpm).
In the event the pressure differs from the prescribed

value, proceed as follows:
- Loosen locknut (2) and loosen or tighten screw (1)

so that the pressure is changed, setting it at
22.5 ± 27.5 bar (326.3 to 398.8 psi).
- Retighten locknut (2).
Pressure
relief valve
2
SM9205
PP
Pressure quick Left side
release pick-up under
point cab door
F14340
4.3.5 CALIBRATION OF STEERING LEVERS
The calibration procedures is performed on the machine every time a replacement or repair intervention occurs,
involving the steering levers or the transmission/steering controller.
It is possible to perform the calibration of the steering levers on the machine in two manners.
Either using only harness BB3 and the controls in the cab, or using, besides these, instrument BB3 as well.
To perform the calibration, the following special tools are required:
380001303 Wire with setting box
380001471 Instrument BB3
Under a functional point of view, the two procedures are equivalent, but the procedure using the BB3 as well,
provide a test of the correctness of the parameters set by the manufacturer, thus it is suggested that it is always
implemented.
3 4
Harness BB3
2
B CAL LEVE A
BASE ON
SM9409A
DSD OFF
Setting box Harness BB3
CAB
7 8 9 MENU
4 5 6 TEACH BB3
1 2 3 PROC
- 0 - F1
ALT CLEAR ENTER F2
SM9409B
SM9409C
Connection diagram
1. Plate on cab post - 2. Plug - 3. cab connector - 4. Harness BB3 connector - A. Calibration switch - B. BASE/
DSD switch
(*) For the version equipped with ROPS structure, open the side panel on the left side of the operator's compart-
ment and reach the controller compartment.
Calibration of the levers without instrument BB3
To make the connection, follow the diagram as in the figure, proceeding as follows
Remove from the left post of the cab, remove plate (1) and extract plug (2) installed on electric connector (3),
then connect connector (4) to connector (3).
1. Arrange the two switches on the setting box as follws:
Switch A in position "CAL"
Switch B in position "DSD"
2. Lower the safety levers.
3. Place the starter key in "ON" second click of the key) and the display shall show "0".
ON START
ACC.
OFF
Starter key
SM9409F DISPLAY SM9409E
4. Press button “N” on the arm; the display shows “CAL0”.

5. Press button “N” again; the display shows “00”, then “0” (calibration of levers at rest performed).
6. Press neutral button “N”; the display shows “CAL1”.
7. Actuate the two levers simultaneously indicated to stroke-end.
8. With the levers actuated at stroke-end, press neutral button “N; the display shows “FF” then “0”.
9. Release the levers in rest position (calibration of levers at stroke-end performed).
10.Position the starter key in “OFF” and disconnect connector (4) from connector (3).
11. Install plug (2) on connector (3) and re-install plate (1) on the cab post.
12.Calibration of the steering levers completed.
Calibration of the steering levers with BB3

1. Connect harness BB3 to the machine connector, as
indicated
in the connection diagram. N
2. Starter key in “ON” (second click).
3. After checking the monitor, move the switch in “CAL”.
4. Press button “F1” on BB3.
5. Then, “GO ON ENTER” appears on the BB3 display.
6. Press button ENTER on the BB3 (setting of 0).
7. Then, the BB3 display shows: PUT T1 & T2 TO MAX
START Þ ENTER.
8. Move the steering levers to stroke-end and, keeping
them in this position, press button ENTER on the BB3.
9. The display shows: ADJUSTED then the window
MANNESMAN REXROTH appeared previously af-
ter the checking phase.
Setting test
1. Press the button with Þ arrow.
2. The display shows the window INPUT SIGNALS.
3. T / % indicates the stroke of the steering levers.
4. With the levers in rest position, T / % must be zero for both sides (L, R).
5. At the hardening point, it must be 43 % ± 1.
6. At stroke-end it must be 100 %.
4.4.1 BRAKE PEDAL VALVE

(Removal / Disassembly)
Removal
Disconnect and label the hoses of the control valve,
remove the two screws (2) and washers securing the
control valve to support (3).
Remove brake valve (1). SM9208
Disassembly Valve (5) cover section

Disconnect all connections and washers, remove
screws (4) and the relevant washers. Remove cover 6. Seal - 7. Plug M10 x 1.25 - 8. Gasket 10 x 16 x 1-
(5) from the valve body. 9. Dowel - 10. Shaft.
Remove plug (7) and copper gasket (8) from cover

(5) to reach pin (23) retaining cam (14). Pull-out the
lever using a punch and the relevant shaft. Remove
the key and the seal from the shaft.
From the other side of the valve, remove screws (25)

from cover (1). Hold the cover while loosening the
last two screws, since shaft (4) is spring loaded. Then,
remove the cover and the O-Ring; spring (2) and cup
(3).
From the opposite side, remove guide (11) pushrod

(12) and O-Ring (24), then remove pushrod assembly
(6). Press spring (9) and extract the pushrod retaining
washer (8), remove the spacer, spring (9) and cup (10).
SM9207
Extract washer (15) O-Ring (22), extract spring (17)
and the large and small plungers (18 and 19).
Brake pedal valve linkage
1. Brake control valve - 2. Valve securing screws
M10 x 1.5 - 3. Valve support - 4. Upper cover screws
M 8 x 1.25 - 5. Cover. 1. Cover
2. Spring
Remove dowel (9) securing shaft (10) using an ap-
3. Cup
propriate screw (diam. 4 mm (0.16 in) - pitch
4. Shaft
0.75 mm (0.03 in).
5. Body ass.ly
6. Pushrod
25 1 2 3 4 5 6 7 8 9 10 28 7. Inner cup
P
8. Washer
11
9. Spring
10. Outer cup
12 11. Guide
12. Pushrods
13 13. Cover
14. Cam
14 15. Washer
16. Gasket
17. Piston spring
18. Piston
19. Spacer
20. Gasket
21. O-Ring 2.62 x 18.72
34 22. O-Ring 2.62 x 20.29
23. Pin
20 19 18 17 33 16 15 23 24. O-Ring 2.62 x 34.59
B A SM9188 25. Cover securing screw M8 x 75
4.4.2 BRAKE POWER PUMP Inspection of components

(Removal / Disassembly / Reassembly)
For the disassembly operations of he pump powering WARNING

the steering differential circuit and the equipment hy-
Never use gasoline, solvents or other flammable
draulic pump, please refer to SECT. 6 – DOZING
fluids to clean the components. Use approved
EQUIPMENT HYDRAULIC SYSTEM of this Manual. commercial non flammable and non toxic sol-
vents only.
Removal
To remove the pump from the torque converter cover Clean accurately all components and blow them with
it is necessary: dry compressed air.
- to tilt the cab and disconnect the pump (1) pipes; Check the pump gear support bushes; in the event
- to remove the screws securing the front cover to they are scored, pitted or excessively worn, replace
converter housing (C) and remove the pump. them. Check that pump body (5) in correspondence
with the zone near the gears is not worn. Replace
Disassembly the parts if damaged. Replace all seals and gas-
kets.
To disassemble the components of the pump, it is
necessary to remove screws (1), remove the front Reassembly
and rear covers and extract supports (7) complete
with gears (8 and 9). Reassemble the pump reversing the sequence for
the disassembly. Lubricate generously all inner
parts and make sure that gears (8 and 9) turn freely,
without hesitation.
Secure the pump to the torque converter cover,
smearing the mating surfaces with an adequate
sealing compound.
3 5 8 6 7 Connect the pipes.
9
10
C
C2
11
C1 2 1
SM9209
Steering clutch / brake feeding pump P
1. Pump holding screw - 2. Rear cover - 3. O-Ring - SM1415

5. Pump body - 6. Dowel - 7. Supports - 8. and 9.
Pump gears - 10. Key - 11. Front cover - 12. Centring Torque converter cover
ring -13. Circlip -14. Spring washer - 15. Drive ring
locking nut -16. Bushes - 17. Seal - 18. Circlip. C1. Pump securing screw, tightening torque 5 to 10 Nm‘
C1. Screw tightening torque 5 to 10 Nm (36.9 to 73.7 lbf.ft) (36.9 to 73.7 lbf.ft)
C2. Nut tightening torque 44 to 54 Nm (324.4 to 398.1 lbf.ft) C2. Nut, tightening torque 44 to 54 Nm (324.4 to
398.1 lbf.ft)
P. Brake pump
C. Torque converter.
4.4.3 BRAKES AND STEERING

DIFFERENTIAL
Removal (preliminary operations)
Prior to each removal operation, turn the main switch

into "OFF" and place a sign "DO NOT START" on
the engine starter key in the cab.
Moving
direction
WARNING
ON
ON
Make sure that the cables are properly secured
and that the securing point is strong enough to
lift the load. Keep all bystanders away from the
lifting point, the cables or chains. OFF
F14341
F14341
Drain the fuel from draining pipe T indicated, actuating T

valve R. Drain completely the fuel before removing it.
Capacity of full fuel reservoir: 400 L (105 US gal).
Disconnect the fuel feeding pipe to the injection pump R
and remove the four securing screws (1) at the base
of the reservoir.
Hold the tank with a hoist equipped with lifting eyes,
using the eyes as indicated in fig. SM9287. Remove
the two side securing screws (2) with the hydraulic
tank, that it is not necessary to remove.
WARNING
Avoid twisting chains or steel cables. Always wear
heavy gloves when handling cables or chains. SM9284
Remove the fuel reservoir.
1
1
1
1
SM9287
- Drain the oil from the transmission housing, remov-

ing plug A from the bottom of the machine and let
the oil drain completely (housing oil capacity about
50 L - 13.25 US gal).
- Remove the track chain, as described in SECTION

5 - UNDERCARRIAGE of this Manual.
- Remove the final drive, as described in SECTION

3 - FINAL DRIVES of this Manual.
Tilt the cab, as described in the Operation and Main-

tenance Manual. A
SM9286
Disconnect all pipes connected to the housing cover 1

and remove guard (1) of hydraulic motor (9) and the
relevant control pipes (2 - 3 - 4 - 5). 2
Also, remove the two side inspection covers (6) re-

moving retaining screws (7).
3
Remove all retaining screws (8) of housing cover (10).
5
7 9
4
8
6
6
10
4-22
Arrange a hoist, to remove the cover, equipped with

appropriate lifting hooks.
Install the two eyes in the holes, as indicated in the fig-
ure, and lift the transmission hosing cover assembly.
SM1416
Disconnect the lube piping from the connector indi-

cated.
SM1417
Disconnect the brake control and lube pipes from

the connectors indicated.
SM1418
Remove the pipe assemblies from the connectors

indicated on the housing.
SM1419
Loosen screws (C2) securing the brakes/differential

from the transmission housing.
C2
SM9214
SM1502
Section view of transmission housing
Install special tool (P/N 380001348) as indicated in

the figure and pull-out the brakes/differential assem-
bly from the housing.
Place the brakes/differential assembly on a bench

equipped with an adequate support to disassemble
the components.
SM9216
Removal of the ring gear
Pull-out the circlip from the ring gear support.
SM1420
Pull-out the ring gear support from the upper part of

the transmission housing.
SM1421
Pull-out the circlip from the seat of the ring gear.
SM1422
Pull-out the ring gear support from the ring gear.
SM1423
Items removed from the ring gear group

1. Ring gear - 2. Circlip - 3. Circlip - 4. Ring gear sup- 4 1
port
Clean and wash accurately all components.
WARNING
Never use gasoline, solvents or any other flam-
mable fluid to clean components. Use approved
commercial non flammable and non toxic sol-
vents only. 3 2
SM1424
Disassembly of the planet carrier assembly

1
Remove the two screws (1) securing the assembly.
SM1425
Using a hoist equipped with two lifting hooks, remove

the planet carrier assembly as illustrated in the figure.
SM1426
Disassembly of the planet carrier differential as-

sembly.
Lift the wings on the securing plates and remove the

retaining screws from each pin.
SM1427
Then, pull-out the pins and all the components of the

planet carrier assembly.
SM1428
Exploded view of planet carrier assembly.

1
1. Planet carrier 2
2. Pin - q.ty 3
3. Planetary gear - q.ty 3
4. Needles - q.ty 29
5. Thrust washer - q.ty 2
6. Pin securing plate - q.ty 3
7. Safety plate - q.ty 3
6
Clean and wash accurately all components.
5 4 7 3 SM1429
WARNING
mable fluid to clean components. Use approved
commercial non flammable and non toxic sol-
vents only.
Disassembly of the sun gear
Pull-out the spacer from the drum of the brake as- SM1430
sembly.
Pull-out the sun gear from the brake assembly.
SM1431
Pull-out the retaining ring.
SM1432
Also, remove the bearing from inside the sun gear.
SM1433
Disassembly of the brake assembly
Remove the securing screws (q.ty 12) of the thrust

plate and remove it from the brake assembly.
SM1468
SM1435
Remove the discs from the outer drum, paying atten-

tion to keep the sequence during the re-assemly
phases.
SM1464
Pull-out the toothed hub of the planet carrier from the

outer drum.
SM1437
Turn the drum assembly upside down to proceed with

the disassembly of the componets.
Loosen the securing screws and remove them.
SM1461
Install two lifting eyes on the outer disc as illustrated

and, using a hoist equipped with lifting hooks, remove
it.
SM1439
Pull-out the brake disengagement springs from the

piston.
SM1440
Pull-out the piston from the brake drum.
SM1441
Remove the inner and outer O-Ring from the brake

drum.
SM1442
Loosen the bearing housing from the outer disc, loos-

ening the securing screws.
SM1453
Pull-out the 1st and 2nd safety rings, then pull-out the
1st half-bearing from the housing.
SM1444
The, proceed with the removal of the 2nd half-bearing

from the housing.
SM1445
Wash accurately all the parts removed from the brake 4

drum assembly. 3
5
Parts removed from the brake drum assembly
1. Brake drum - 2. Outer disc - 3. Thrust disc -
4. Bearing housing - 5. Piston - 6. Springs q.ty 20
WARNING
mable fluid to clean components. Use approved 2
6
commercial non flammable and non toxic sol- 1
vents only. SM1446
Re-assembly of the brake drum assembly 4

5 3
Parts disassembled
1. Brake drum - 2. Outer disc - 3. Thrust disc -
4. Bearing housing - 5. Piston - 6. Springs q.ty 20
2
6
1
SM1446
Install the 1st bearing into the housing using an hy-

draulic press.
SM1445
Install the 1st and the 2nd ring into the bearing housing.
WARNING
Handle all parts with great care. Do not place
hands or fingers between one part and another.
Wear approved safety clothing such as goggles,
gloves and safety shoes.
SM1449
Then insert the 2nd bearing.
SM1450
Install the safety ring to block the bearings in their

seats.
SM1451
Install the housing assembly on the disc.
SM1452
Insert the screws complete with washer helping with

a centring drive and tighten with a torque wrench to
11 daNm.
Note – lubricate adequately prior to the installation of

all O-Rings and all parts in contact.
SM1453
Insert first the outer O-Ring in the drum seat.
SM1454
Then, insert the inner O-Ring in its seat.
SM1442
Insert the outer O-Ring in the seat of the piston.
SM1456
Install the 2nd outer O-Ring in the seat of the piston.
SM1457
Turn the piston upside down and install it into the disc
complete with O-Ring.
SM1458
Insert the 20 springs into the seats of the piston.
WARNING
Lift and handle all items with a hoist of appropri-
ate capacity.
Make sure that all parts are held by appropriate
slings and hooks.
SM1440
Secure two eyes as illustrated, on the outer disc and,

using a hoist equipped with hooks, lift the disc and
place it on the piston assembly.
Guide the disc for a correct insertion, during the in-
stallation phase.
Note – During the installation, pay attention that the

lube holes of the thrust disc and the piston coincide.
SM1439
Initially, tighten the 3 longer screws so that the piston

is hooked and press the springs.
Then, insert the other screws and remove the longer

screws.
Install the remaining screws and tighten all of the to

11 daNm (81.1 lbf.ft).
SM1461
Turn the assembly upside down and arrange the in-

stallation of the brake discs.
WARNING
The brakes have, inside, strongly compressed
springs. Always follow the procedure recom-
mended when installing or removing these
clutches.
SM1462
Insert the planet carrier into the brake drum.
Prepare the disc pack for the installation.
Note – Please refer to item 4.4.4. for the inspection

of the brake pack.
SM1463
Insert the 1st disc with outer teeth into the drum seat.
SM1436
Insert the 2nd disc with inner teeth.
SM1464
Install the discs alternating them until the disc pack

is completed.
SM1466
Install a hydraulic pump complete with connection,

ensuring at least 30 to 40 bar (435 to 580.2 psi), at
the power hole. Actuate the pump, up to a pressure
of 20 to 25 bar (290 to 362.6 psi), so that the inner
spring pressure is overcome to allow the discs to
move to the bottom.
Union
SM1467
While keeping the piston under pressure, install the

thrust disc on the drum.
Then, tighten the 12 screws complete with washer
and tighten to 11 daNm (81.1 lbf.ft).
SM1468
4.4.4 CHECK AND INSPECTION OF BRAKE

PACKS
Check that the maximum warping, on each disc (2) After checking the discs, in accordance to the in-
of the pack is less than 0.03 mm (0.00118 in); also structions above, reassemble each clutch pack (A)
check that on driven discs (1): (5 driven discs and 4 driving discs) and pressure plate
- the maximum thickness difference between the sur- (4) on the drum and check, under a press, that the
face of sintered material does not exceed 0.05 mm total thickness (A) of the pack is 36.5 to 38.5 mm
(0.00196 in); (1.437 to 1.515 in) under a load of 294 to 392 daN
- said surfaces are free from abnormal wear due, (2167.7 to 2890.2 lbf.ft). In case of discrepancy, add
generally, to dirt circulating with the oil or to dry one or more standard or undersized driving disc, from
operation of the clutches, or pitted zones. the side indicated by the arrow.
A 36.5 to 38.5 mm (1.437 to 1.515 in)
q.ty 5 driven discs

(sintered)
300 to 400 kg
(661.4 to 881.8 lbf.ft)
P= 294 to 392 daN
(2167.7 to 2890.2 lbf.ft)
q.ty 4 driving discs (steel)

SM9219
DEFINITION AND INSPECTION OF THE

BRAKE DISC PACK
Obtain thickness A under a press load P selecting

the thickness of discs (1 and 2) accordingly. P
SM9126
Quantity of discs per clutch and thickness

1 Driven (with sintered faces) ......................................... q.ty 5 discs, thickness 4.7 to 4.8 mm (0.18 to 0.02 in)
2 Driving (steel) .......................................................... q.ty 4 discs, thickness 3.35 to 3.65 mm (0.13 to 0.14 in)
Re-assembly of the sun gear.
Install the bearing into the seat on the sun gear.
SM1433
Install the retaining elastic ring of the bearing.
SM1432
Then, install the sun gear assembly on the brake drum

assembly.
SM1431
Install the spacer.
SM1430
Re-assembly of the planet carrier assembly.

1
Parts disassembled from the planetary carrier 2
assembly
1. Planet carrier
2. Pin
3. Planetary gear
4. Needles
5. Thrust washers 6
6. Pin locking plate
7. Safety plate 7
5 3
Lubricate freely all parts, gear, pin, spring and needles. 4 SM1429
Place the 29 needles inside the gear using some

grease or vaseline to hold the needles during the in-
stallation and prevent them from falling-off.
SM1474
Place the thrust washers on the sides of the gear

and repeat the operations for all three planetary gears.
SM1475
Install the first planetary gear inside the planet car-

rier and insert the pin.
Pay special attention that all needles stay inside the

planetary gear.
Repeat the operation for the other two planetary

gears, as well.
SM1428
Insert the pin stop plates in the seats and insert the
safety plates.
Hammer slightly the plate with a non ferrous mallet

to facilitate the insertion of the screws in the holes.
SM1427
Tighten the screws and bend the wings of the safety

plates.
SM1478
Using a appropriate hoist with two lifting hooks, as in

the figure, lift and install the planet carrier assembly
on the brake drum.
WARNING
Make sure that the cables are hooked and that
the hooking point is strongly enough to lift the
expected load. Keep all bystanders away from the
hooking point, cables or chains.
SM1426
Insert the two screws on the shaft and tighten them.
SM1425
Re-assembly and re-installation of the ring gear

assembly 4 1
Exploded view
1. Planetary ring gear
2. Circlip
3. Circlip
4. Ring gear support.
3 2
SM1424
Install the ring gear in the support.
SM1423
Insert the circlip in the seat on the ring gear.
SM1422
Insert the ring gear support assembly in the trans-

mission housing.
SM1421
Install the retaining circlip in the seat, using appropri-

ate pliers.
SM1485
Re-installation of brake/steering differential group

into the transmission housing.
WARNING
Never use gasoline, solvents or any other flamma-
ble fluid to clean components. Use approved com-
mercial non flammable and non toxic solvents only.
WARNING
Use appropriate tools to align holes. NEVER USE
FINGERS OR HANDS. SM1486
Lift the brake/differential group using a hoist and spe-

cial tool P/N 380001348.
Lubricate adequately al mating parts of the assembly

and the housing.
WARNING
Clean accurately the faces of the group mating
the transmission housing.
SM1487
Insert the two centring guides, special tool 380001484

on the housing, to facilitate the engaging of the steer-
ing brakes assembly.
SM1494
Approach the brakes/steering group into the trans-

mission housing, taking care that the components are
not damaged.
Make sure that the gears are matching appropriately.
SM1495
Install a few screws and tighten them slowly, to en-

sure an appropriate setting of the brake group.
SM1496
Install the remaining screws C2 and tighten them al-

ternatively and diagonally, to ensure a uniform tight-
ening (Screws C2 tightening torque 11 daNm). C2
To complete the re-assembly operation, please refer

to item 4.4.3 (preliminary operations) reversing the
procedure described.
SM1497
4.4.5 BEVEL GEAR SET

(Removal/disassembly of pinion and
bevel gear)
Preliminary operations:
WARNING
Make sure that the cables are hooked and that
the hooking point is strongly enough to lift the
expected load. Keep all bystanders away from the
hooking point, cables or chains.
WARNING
Avoid twisting chains or metal cables. Always
wear safety gloves to handle cables or chains.
Removal
Tilt the cab, as described in the OPERATION AND

MAINTENANCE manual.
Remove the fuel and hydraulic tank, as described in
SECT. 6 - EQUIPMENT HYDRAULIC SYSTEM, of
this Manual.
Remove the transmission group, as described in
SECT. 2 - TRANSMISSION.
Drain the oil from rear transmission housing, by re-
moving the plug located at the bottom, as described
in item 4.4.3.
REMOVE THE STEERING DIFFERENTIAL BRAKE

GROUPS AS INDICATED IN ITEM 4.4.3 OF THIS
SECTION.
Then, proceed as follows: 15 14
Remove cover (15), pull-out O-Ring (14).
SM9221
Pull-out half adjusting shims (16) hold with cables or

straps and remove the bevel pèinion support assem-
bly, using puller screws. 16
SM9222
Pull-out the bevel pinion from the housing.
SM9223
Loosen the housing securing screws (20 - 21).
SM9250
Install a puller to remove the bearing housing from

Rigth housing
the bevel gear shaft until it gets out from the taper
spline, complete with seat.
Repeat the operation on the other side of the housing.
SM9249
Remove the shaft complete with bevel gear, lifting it

as indicated in the figure.
SM9247
Disassembly of pinion
Secure the pinion in the appropriate bracket P/N

380000983 and place it on a vice.
Remove the cover using a screwdriver and pull-out
the O-Ring.
Pull-out the pinion retaining ring-gear, using the ap-
propriate special tool 380000919, torque wrench and
torque multiplier.
Use a bearing puller to remove the pinion from the
bearings.
SM9227
12 8
6
16
10
7
9
SM1491
Disassembly of bevel gear crown
WARNING
Lift and handle all heavy items with a hoist of
appropriate capacity.
slings and hooks.
SM9229
Use a puller to extract the bearings from the bevel

gear shaft.
Place the bevel gear assembly on a bench equipped
with a vice and remove the securing screws.
Remove the bevel gear crown from the shaft.
SM9230
Components of the pinion/bevel gear group
Pinion: 6 7 5 10
5. Bevel gear pinion
6-7. Bearing
8. Spacer
10. Bearing housing
12. Ring nut
16. Adjusting shims
8
12
16 SM9231
Bevel gear crown:

5. Bevel gear crown shaft
18. Bevel gear crown shaft 18
22. Bearings
5
22
SM9232
Re-assembly of bevel gear crown
Install the crown gear on the shaft.
SM9230
Tighten the crown gear on the shaft with the 16 self-

locking screw.
For the tightening torques, see the table of SECTION 0
TABLE OF TIGHTENING TORQUES.
SM9229
Warm-up the taper bearings up to 110 °C (248 °F)

and install them individually on the shaft.
SM9233
Installation of the bevel pinion
Warm-up the half bearing up to 110 °C (248 °F).
SM9233
Install the half bearing on the pinion.
SM9235
Install a sample ring 4 mm thick, on the pinion.
SM9236
Install the bearing spacer.
SM9237
Prepare the bearing housing, inserting first the outer

race of the bearing.
To facilitate the insertion of the race, use a hydraulic
press.
SM9238
Turn the housing upside down and insert the other

outer race of the bearing with a hydraulic press.
SM9239
Install the housing into the pinion.
SM9240
Warm-up the half bearing at a temperature of 110 °C

(248 °F).
SM9233
Lubricate and install the half bearing.
WARNING
It is dangerous to hit hardened steel made parts
with tools different from a mild steel or non fer-
rous metal mallet. When performing the removal
and installation of these components, always
wear safety glasses with side shields, gloves etc.
to minimise the possibility of injuries.
SM9242
Place the retaining ring nut on the bevel pinion.
SM9243
Secure the pinion assembly to the appropriate bracket

and place it in a vice.
Tighten the ring nut with the appropriate wrench
380000919 and torque multiplier to 130 to 150 daNm
(958.5 to 1106 lbf.ft).
SM9227
Punch the ring nut with a chisel on the two sides of

the pinion.
SM9244
Lubricate and install the O-Ring in the relevant seat

of the housing.
SM9245
Turn the pinion assembly upside down.

lubricate and insert the O-Ring in the seat of the hous-
ing.
SM9246
Re-installation of the bevel gear crown
Re-install the bevel gear crown, following what listed

here below.
Install a lifting hook to the crown and insert it into the
bevel gear compartment.
WARNING
Lift and handle all heavy items with a hoist of
appropriate capacity.
slings and hooks. SM9247
Lubricate adequately the bearings with engine oil.
Pre-install the right and left supports, installing the

bearing outer races inside, using a hydraulic press.
SM9248
First, install the left support assembly, without adjust- Rigth housing
ing shims, using 4 screws only and tighten to a torque
of 13 daNm (95.8 lbf.ft).
SM9249
Then, install the right support, without adjusting shims,

(0.73 lbf.ft) with two retaining screws, tightening them
with increments of 0.1 daNm (5.16 lbf.ft) up to a final
value of 0.7 daNm. At the same time, turn manually
the bevel gear crown a few turns, to set the taper
rollers in the relevant races.
SM9250
Re-installation of the pinion
Lubricate adequately all the mating surfaces of the

pinion.
Prearrange the assembly for the installation on the
housing, slinging it with cables and a hoist.
To facilitate the centring of the pinion, use two guid-
ing screws, positioning the notch upward, as in the
figure.
SM1489
Install the pinion in the housing and set the position

and the backlash as described at item 4.4.6 of this
section.
SM1490
4.4.6 PROCEDURE FOR THE SETTING OF THE BEVEL PINION BEARINGS PRE-LOAD
Set the pre-load of the bearing, complying with the D. After reading the value, loosen the ring nut and
phases as follows: pull-out bearing (1), remove spacer (39 and the
sample ring.
A. Install bevel pinion (8) on pinion housing (5) Deduct the value measured from the thickness
complete with bearings (1 and 2). of the sample ring (4 mm), then shim using
shims (4), in the location indicated, for the re-
B. Insert spacer (3) and the sample ring 4 mm thick, sulting value. Insert spacer (3), half bearing (1)
the inner race of bearing (1) using a press, then then tighten the ring nut to a torque of 130 to
tighten ring nut (6). 150 daNm.
C. Holding pinion housing (5) still, measure the E. Check that the rolling torque is included between
axial play of the pinion with a dial gauge located 0.2 to 0.4 daNm. Then bead the ring nut on the
on the head or the tail of it. pinion. Otherwise, repeat the operation adding
or removing shims to obtain the rolling torque
indicated.
DETAILS OF PINION
6 3
1. Pinion half bearing
2. Pinion half bearing 1
3. Spacer 7
4. Bearing adjusting shims 5
5. Housing
6. Ring nut
2
7. Adjusting shims available:
1 mm 4
0.5 mm
0.2 mm
8. Bevel pinion
SM1491
Tooth mating face
From 22 to mm long
Tooth mating face
From 5 through 7.5

DETAIL A mm from tooth tip
SM1492
4.4.7 PROCEDURE FOR THE SETTING OF THE BEVEL GEAR CROWN
Set the pre-load of the bearing, complying with the

phases as follows:
A. Shim with shims (9) to obtain a rolling torque on C. After the specified contact specified in phase B
the bevel gear crown shaft (without pinion) is obtained, split shims (9) between the two bear-
equivalent to 0.4 to 0.8 daNm (2.9 to 5.9 lbf.ft). ing housings (11) and (10) until a backlash be-
tween the pinion/crown teeth equivalent to 0.25
B. After pre-loading the bevel gear crown bearings to 0.33 mm. Re-check that the teeth contact and
according to item A, position pinion housing (5) (0.0098 to 0.013 in) the bearing pre-load of the
(see item 4.4.5, procedure for the bevel pinion bevel gear crown shaft are within the specifica-
bearings pre-load) using shims (7) until a con- tions of items A and B.
tact of the pinion/crown teeth according to what
indicated in detail "A" of item 4.4.6 is obtained. D. Check that the total rolling torque measured on
See item 4.4.6 procedure for the setting of the the pinion is equal to 0.35 to 0.70 daNm (2.6 to
preload of the bevel gear pinion bearings. 5.2 lbf.ft).
10
11
SM1493
4.4.8 RE-INSTALLATION OF HOUSING

COVER
Install two lifting eyes on the cover and arrange it for
the installation on the housing.
Apply a film of Loctite 548 to the mating faces of the

housing and cover.
WARNING
Lift and handle all heavy components with a lift-
ing device of appropriate capacity. Make sure that SM1416
the parts are supported by appropriate slings and
hooks. use the lifting eyes provided for this pur-
pose. Make sure that all bystanders keep clear
from the load to be lifted.
Insert the dowels to facilitate the installation of the

cover.
SM1500
At first, install 4 or 5 screws to secure the cover to

the housing.
SM1501
To allow the mating of the gears of the shaft and the

planetary gears, it is necessary to disengage the
brakes.
Using a hydraulic pump, power the partitioning block
of the brake control circuit box with a pressure of at
least 10 bar (145 psi).
Once the brakes are disengaged, turn the pinion a
few turns in both directions to provide a good setting
between the gears.
Tighten all the remaining screws on the cover.
Disconnect the pump from the partitioning block.
SM1473
4.5.1 BEVEL GEAR REDUCTION UNIT (General data / dimensions)
General data
Type of gears .................................................................................................................................. helical teeth
Reduction ratio (17/36) .......................................................................................................................... 1:3.076
Backlash between the face of the teeth ............................................................. 0.25 to 0.33 (0.098 to 0.013 in)
......................................................................................................................... average 0.3 mm (0.012 in)
Dimensions - See pinion - crown gear sections
A Ø Inner diameter of bevel gear shaft bearing cage ......................... 139.948 to 139.988 (5.509 to 5.511 in)
Ø Outer diameter of bearing ........................................................... 139.980 to 140.000 (5.511 to 5.512 in)
* B Ø Inner diameter of bearing ................................................................. 79.850 to 80.000 (3.144 to 3149 in)

Ø Outer diameter of bevel gear shaft ................................................. 80.020 to 80.033 (3.150 to 3.151 in)
C Ø Outer diameter of bevel gear shaft hub ....................................... 239.948 to 240.000 (9.446 to 9.448 in)
Ø Inner diameter of bevel gear ....................................................... 240.000 to 240.052 (9.448 to 9.450 in)
E Ø Inner diameter of pinion housing ................................................. 179.932 to 179.972 (7.084 to 7.085 in)
Ø Outer diameter of pinion bearing .................................................. 179.975 to 180.00 (7.086 to 7.087 in)
D Ø Inner diameter of pinion support ................................................. 149.932 to 149.972 (5.902 to 5.904 in)
Ø Outer diameter of bearing ............................................................. 149.980 to 150.00 (5.905 to 5.906 in)
* Note – The dimensions are identical on both sides.
Pinion sectional view

F14539
C
B
A
Crown gear sectional view

SM1503
4.5.2 BRAKES
General data and dimensions
TYPE ............................................................................................................................. multiple disc, oil bath

Number of discs per brake
- Driven (with sintered facing) .................................................................................................................... 5
- Driving (steel) .......................................................................................................................................... 4
Specification of springs
Number of springs for each brake .............................................................................................................. 20
- Free length of spring ......................................................................................................... 83 mm (3.268 in)
- Diameter of wire ........................................................................................ 5.5 ± 0.05 mm (0.216 ± 0.002 in)
- Outer diameter fully pressed ...................................................................... 30 ± 0.30 mm (1.181 ± 0.012 in)
Load with compression at:

66 mm (2.598 in) ................................................ 135 ± 7 daN (995.3 ± 51.6 lbf.ft)
61 mm (2.402 in) .............................................. 174 ± 9 daN (1282.9 ± 66.4 lbf.ft)
Matings and tolerances

Thickness of clutch disc pack .................................................................. 36.5 ÷ 38.5 mm (1.437 to 1.516 in)
.......................................................................................(under a load of 300 to 400 kg, 661.4 to 881.8 lb.)
Average travel of pressure plate ......................................................................................... 4.5 mm (0.177 in)
Average wear ..................................................................................................................... 3.5 mm (0.138 in)
Total travel ............................................................................................................................. 8 mm (0.315 in)
Thickness of steel plates ......................................................................... 3.35 to 3.65 mm (0.132 to 0.144 in)
Thickness of sintered driven discs .......................................................... 4.70 to 4.80 mm (0.185 to 0.189 in)
Clutch inner hub bearings

Inner diameter ................................................................................ Ø 104.985 to 105.000 (4.133 to 4.134 in)
Outer diameter ............................................................................... Ø 159.985 to 160.000 (6.298 to 6.299 in)

Ref. 3 hydraulic diagram
DATA AND DIMENSIONS

A. Diameter of piston seat ............................................... From 20.000 to 20.021 mm (From 0.787 to 0.788 in)
Outer diameter of piston ............................................. From 19.980 to 19.993 mm (From 0.786 to 0.787 in)
Clearance ................................................................... From 0.007 to 0.041 mm (From 0.0003 to 0.0016 in)
B. Guide pin seat ............................................................ From 40.000 to 40.025 mm (From 1.574 to 1.576 in)
Outer diameter of guide pin ........................................ From 39.936 to 39.975 mm (From 1.572 to 1.574 in)
C. Inner diameter of rod seat .......................................... From 10.000 to 10.015 mm (From 0.394 to 0.395 in)
Outer diameter of rod into guide ..................................... From 9.986 to 9.995 mm (From 0.393 to 0.394 in)
Clearance .................................................................... From 0.005 to 0.029 mm (From 0.0002 to 0.0011 in)
D. Diameter of plunger seat ............................................ From 16.000 to 16.018 mm (From 0.629 to 0.631 in)
Outer diameter of plunger ........................................... From 15.983 to 15.994 mm (From 0.629 to 0.630 in)
E. Diameter of washer seat ............................................. From 26.000 to 26.021 mm (From 1.023 to 1.024 in)
Outer diameter of washer ........................................... From 25.947 to 25.980 mm (From 1.021 to 1.023 in)
F. Diameter of seat in cover for pin smaller end ............. From 13.016 to 13.059 mm (From 0.512 to 0.514 in)
Outer diameter of control pin smaller end ................... From 12.973 to 13.000 mm (From 0.511 to 0.512 in)
G. Diameter of seal on cover ........................................... From 24.000 to 24.033 mm (From 0.945 to 0.946 in)
Outer diameter of pin in correspondence with seal ..... From 13.982 to 14.000 mm (From 0.550 to 0.551 in)
H. Diameter of dowel seat ................................................... From 8.013 to 8.049 mm (From 0.315 to 0.317 in)
Outer diameter of dowel ................................................. From 7.964 to 8.000 mm (From 0.313 to 0.314 in)
I. Diameter of spring seat in control pin ............................. From 5.000 to 5.030 mm (From 0.197 to 0.198 in)
Diameter spring pin seat in cam ..................................... From 5.000 to 5.030 mm (From 0.197 to 0.198 in)
Outer diameter of spring pin .................................................................................................... 5.000 (0.197)
Clearance ..................................................................................... From 0 to 0.030 mm (From 0 to 0.001 in)
J. Diameter of control pin seat in cam ............................ From 13.016 to 13.059 mm (From 0.512 to 0.514 in)
Outer diameter of control pin in cam ............................ From 12.973 to 13.000 mm (From 0.511 to 0.512 in)
J. Diameter of control pin seat in cam .......................................................................... From 13.016 to 13.059

Outer diameter of control pin in cam ......................................................................... From 12.973 to 13.000
Clearance ..................................................................................................................... From 0.016 to 0.086
K. Diameter of control pin seat in control lever ................. From 11.995 to 12.006 mm (From 0.472 to 0.473 in)
Outer diameter of pin in lever ...................................... From 12.982 to 12.000 mm (From 0.511 to 0.472 in)
Interference ................................... From 0.005 int. to 0.024 clear. mm (From 0.0002 int. to 0.0009 clear in)
1. Piston return spring

Number of turns ....................................................................................................................................... 9.5
Free length ..................................................................................................................... 76.5 mm (3.012 in)
Force required to press to 45 mm (1.771 in) .............................................................. From 54.7 to 60.3 daN
2. Piston actuating spring

Number of turns ....................................................................................................................................... 5.5
Free length ........................................................................................................................ 44 mm (1.732 in)
Force required to press to 32.1 mm (1.264 in) ........................................................... From 28.4 to 31.4 daN
3. Plunger return spring

Number of turns ..................................................................................................................................... 16.5
Free length ........................................................................................................................ 49 mm (1.929 in)
Force required to press to 40 mm (1.575 in) .................................................................. From 8.1 to 8.9 daN
1 A 2 B C
D 3 E I
SM9257 SM9258
4.5.4 REAR TRANSMISSION (Transmission side sectional view)

Hydraulic motor
Steering differential assembly Top view
Brakes assembly
SM1403A
Bevel gear crown

Left brake lubrication Right brake lubrication
Brakes control
Final drive SM1404
View of final drive and

transmission housing Left brake lubrication Right brake lubrication
Sprocket
BRAKES CONTROL
SM1402A SM1404A
NOTE:
D180 BRAKES AND STEERING DIFFERENTIAL 4 - 67
4.6 SPECIAL TOOLS
380000919 Wrench for bevel pinion ring nut
380000983 Support, steering differential

bevel pinion on vice
380001315 Brake loosening screw
380001318 Check caliper, bevel pinion

bearings play
380001322 Press fitting of bearing inner

race on pinion
4 - 68 BRAKES AND STEERING DIFFERENTIAL D180
380001324 Installation of bevel ring gear

support bearing
380001484 Brakes module dowels
SECTION 4 BIS
BRAKES AND STEERING CLUTCHES
D180 STEERING CLUTCH

TABLE OF CONTENTS
4.1 GENERAL DESCRIPTION OF THE CIRCUIT ...................................................................... 4-3

4.1.1 Brakes and steering clutches system hydraulic diagram ....................................................... 4-4
4.1.2 Main components of the hydraulic system ............................................................................. 4-5
Brakes and steering clutches feeding pump ....................................................................... 4-5
Feeding valve block ............................................................................................................ 4-6
Proportional solenoid valves block ..................................................................................... 4-7
Brake and clucthes control valve ........................................................................................ 4-8
Brake pedal valve ............................................................................................................. 4-10
Oil filters ........................................................................................................................... 4-12
Rear transmission (Transmission side section) ................................................................ 4-14
4.2 TROUBLESHOOTING ........................................................................................................ 4-16

4.2.1 Diagnosis on the display ...................................................................................................... 4-17
4.3 TESTS ................................................................................................................................ 4-20

4.3.1 Pressure test of the brakes and steering clutches circuit ..................................................... 4-20
4.3.2 Brake pedal adjustment ...................................................................................................... 4-22
4.3.3 Brake system pressure test ................................................................................................. 4-23
4.3.4 Feeding valve test and setting ............................................................................................. 4-24
4.3.5 Calibration of brakes/steering clutch levers ......................................................................... 4-25
4.4 REPAIR PROCEDURES ..................................................................................................... 4-27

4.4.1 Brake pedal valve (removal / disassembly) ......................................................................... 4-27
4.4.2 Steering clutches and brake control feeding pump (removal / disassembly / reassembly) .. 4-28
4.4.3 Brakes and steering clutches (removal / disassembly of packs) ......................................... 4-29
4.4.4 Bevel gear unit (removal / disassembly) .............................................................................. 4-34
4.4.5 Bevel gear (re-assembly / installation) ................................................................................. 4-38
4.4.6 Procedure for the setting of the pinion bearings pre-load .................................................... 4-44
4.4.7 Procedure for the setting of the bevel gear unit ................................................................... 4-45
4.5 SPECIFICATIONS AND DATA ............................................................................................ 4-46

4.5.1 Bevel gear reduction unit ..................................................................................................... 4-46
4.5.2 Steering clutches and brakes .............................................................................................. 4-48
4.5.3 Brake pedal valve ................................................................................................................ 4-50
4.6 SPECIAL TOOLS ................................................................................................................ 4-53

4.1 GENERAL DESCRIPTION OF THE CIRCUIT

The brakes and steering clutches circuit is mainly composed of:
A) A dual circuit feeding pump (ref. 1, hydraulic diagram)
B) An oil filter on the suction line (metal) and one on the delivery line (paper) (ref. 7 - 5)
C) A circuit feeding valve block (ref. 6)
D) The steering clutch levers (ref. 14)
E) A brake pedal valve (ref. 3)
F) An electronic microcontroller (ref. 16)
G) A proportional solenoid valves block (ref. 2)
H) A control valve (ref. 4)
I) The rear transmission housing (ref. 8)
L) A housing oil radiator [air - oil] (ref. 18)
Feeding pump (1) sucks the oil from rear transmission housing (8) through a mesh filter (7) sending it to port (P)
of feeding valve block (6).
Feeding valve (17) ensures a pressure of 25 ± 2 bar (362.6 ± 29 psi) to the system and diverts it through
directional solenoid valve (10). Accumulator (11) ensures the pressure in the system in case of an engine failure.
When actuating levers (14) located on the transmission and steering armrest (in the cab), an electric signal is
sent (variable depending upon the stroke applied to the levers) to microcontroller (16).
The microcontroller sends an electric signal to proportional solenoid valves (15) which regulate the proportional
oil flow through ports A1 and A2 bringing oil to control valve (4).
A brake valve (directly actuated by the pedal in the cab) activates directly the brakes, cutting-off pressure from
the system. When the two steering levers are actuated simultaneously, the same braking effect on both track
chains is obtained.
The rear transmission assembly (8) is composed of the bevel gear unit (receiving the motion directly from the
transmission) and the oil-bath brake and steering clutch packs. The transmission housing operates as an oil
reservoir used both for the piloting of the packs and the lubrication of all the components in the housing.
The engagement of steering clutch pack occurs when the system is fed and pressurised oil on the piston
presses the steering clutch pack.
The brakes are engaged when pressure to the system is cut-off and the force of the springs locks the braking
device on the brake disc pack.
An oil radiator cools-off the lube oil flowing from the feeding valve block (port C) before entering the control valve
(port LBR) to avoid an excessive overheating of the oil, when the machine is operating under heavy conditions.
4.1.1 BRAKES AND STEERING CLUTCHES SYSTEM HYDRAULIC DIAGRAM
1. Brakes and steering clutches feeding pump 14
2. Proportional solenoid valves block
3. Brake pedal valve block
4. Brakes and steering clutches control valve 16

MICROCONTROLLER
5. Brakes and clutches delivery filter
6. Feeding valve block
7. Brakes and clutches suction filter
8. Transmission housing
P
9. Check valve 1 6
5
10. Directional solenoid valve
DR T 2
11. Accumulator 15
12. Decompression valve SET 25 BAR 9 10

3
P 1 2
13. Exchange valves
2 2
1 2 A2 A1
3
14. Brakes and steering levers
1 P2 T P1
15. Proportional solenoid valves 17 12 XPI

4
16. Microcontroller XP2
50 l/min
17. Pressure relief valve C PP 11 XFRZ-DX
XFRZ-SX
18. Housing oil radiator (air/oil) LBR

2650 rpm B XP
1 19.2
CC/REV 18 XLBR
A. From torque converter 22 l/min
2 2650 rpm 1 2 XFRN-DX
8.4 XFRN-SX
B. To transmission housing CC/REV
A 13
LBR-SX : Left brake/clutch lubrication L FRN-SX FRZ-SX P FRZ-DX FRN-DX

L
FRN-SX : Left brake control

8
T
FRZ-SX : Left clutch control A P
B
LBR-DX : Right brake/clutch lubrication
FRN-DX : Right brake control 3
FRZ-DX : Right clutch control
7 SM9173
4.1.2 MAIN COMPONENTS OF THE HYDRAULIC SYSTEM
Brakes and steering clutches feeding pump

Pump type ....................................................... gear

Make ................................ SAUER SUNDSTRAND
Model .........................................PNN 19+8S SC 41
Dual gear pump mounted on the torque converter

cover; one section feeds the brakes and steering
clutches circuit, the other scavenges the oil from the
torque converter and returns into the transmission.
Flow at max. speed (2650 rpm) with engine max. rated
power speed of 2000 rpm.
Delivery of section (1) feeding brakes / clutches:
50 L/min (13.21 US gal).
Delivery of section (2), scavenging the torque con-
verter oil: 22 L/min (5.81 US gal)

SUCTION
DELIVERY
2.650 rpm
2650 RPM
Sez.1
Sec. 1 19.2 cc/rev
19.2 CC/REV
50 L/min
50 l/min
(13.2 US gpm)
2.650 rpm
2650 RPM
Sez.2
Sec. 2 8.4 cc/rev
8.4L/min
22 CC/REV
22 l/min
(5.8 US gpm)
SUCTION
DELIVERY
Section 1: Section 2:
Brakes / steering clutches Torque converter oil
circuit feeding scavenger pump
2 1
C
SM9174
P
SM9283
P. Brakes steering pump

C. Torque converter
Feeding valve block

The feeding valve block is mounted on the left side,

under the cab. To reach it is just enough to open the
left panel under the cab.
1. Brakes / steering clutches feeding pump

6. Feeding valve block 6
10. Directional solenoid valve
11. Accumulators (pressure 20 bar (290 psi)) DR
17. Pressure relief valve (setting 25 bar (362.6 psi))
Set 25 bar 10
Location on the block: 1 (362.5 psi) 3 9
P 1 2
P. From feeding pump 2
2
C. To housing oil radiator 3
DR. To proportional solenoid valves, to control valve,
to transmission housing.
PP. Pressure pick-up point. 17 1

2. To proportional solenoid valves, to brake pedal
valve
C 11
PP
SM9175
11
6
17
SM9176
Proportional solenoid valves block

It is mounted on the machine frame, on the left side.

To reach it, it is necessary to lift the cab. Clutches lever and steeering brakes
L R
15
Microcontroller
A1 A2 P
T 2
15
P
A2 A1
SM9177
Hydraulic diagram
T
A1 A2
SM9178
2. Proportional solenoid valves block

15. Proportional solenoid valve
P. Feeding
T. To reservoir
A1. To brakes / clutches control valve
A2. To brakes / clutches control valve
L. Left clutch lever
R. Right clutch lever
Brakes and clutches control valve

The control valve is mounted on the transmission

housing and it is reached by lifting the cab.
Outlet (piloting)
of proportional valves
T
LBR
Outlet of proportional P2 P1 Brakes / clutches

valves piloting lubrication
F14535
L.h. clutch R.h. clutch

control control
XP2 XP1
L.h. brake R.h. brake

control XFRNSX XFRNDX control
XP
P2 P1
XLBR
XFRZSX
LBR XFRZDX
left side view P1 - P2 piloting of proportional right side view

XFRZ - right solenoid valves XP - brake pressure
XLBR - Lube pressure LBR - Brakes - clutches lubrication pick-up point
pick-up point F14348
4
12 12
XP1
XP2
13
XFR-DX
13
XFR-SX
P
F14534
Front view Rear view
4. Steering /brakes control valve XP1. Piloting pressure port P2

12. Decompression valve XP2. Piloting pressure port P1
13. Exchange valve XFR-DX. Right brake pressure pick-up point
P. Oil inlet from brake valve XFRN-SX. Left brake pressure pick-up point
T. Discharge to housing
3 T P1
P2
1
12 XP1
1 1
2
2 XP2
4 3 3
2
4
4
XFRZ-SX XFRZ-DX
SM9184
LBR
Decompression valve XP
(Ref. 12, hydraulic diagram) XLBR 2 4 4 2

1 1
3 3
XFRN-SX XFRN-DX
13
L FRN-SX FRZ-SX
P FRZ-DX FRN-DX
L
SM9183
Control valve hydraulic diagram

4 4
3 3
2 2
1 1 SM9185
Section and view of control valve decompres-

sion valve ref. 12
Brake pedal valve

The brake pedal valve is mounted in the lower part of

the cab and it is actuated by a linkage, directly by the
brake pedal.
P. To brakes (delivery)
DR. To brakes (draining)
T. To housing (discharge)
A. To feeding valve
B. From feeding valve (pos. 2) and to proportional
solenoid valve (pos. P) DR
DR SM9181
(M12X1,5)
T
(M22X1,5)
A
(M16X1,5) P
(M22X1,5)
B
(M14X1,5)
SM9186
Valve hydraulic diagram
T SM9187
25 1 2 3 4 5 6 7 8 9 10 28
P 11
12
13
14
34
20 19 B 18 17 33 16 15 23
A SM9188
21
37 30 30 32 31
25
36
35
T
22
SM9189
Section of brake pedal valve
1. Cover 17. Piston spring

2. Spring 18. Piston
3. Washer 19. Spacer
4. Piston 20. Gasket
5. Body ass.ly 21. Pin
6. Rod 22. Dowel
7. Inner cup 25. Shaft seal
8. Washer 28. O-Ring 2.62x34.59
9. Spring 30. Spring washer
10. Outer cup 31. Screw M8x55
11. Guide 32. Screw M8x35
12. Pushing pin 33. O-Ring 2.62x20.29
13. Cover 34. O-Ring 2.62x18.72
14. Cam 35. Gasket
15. Washer 36. Plug M10x1.25
16. Gasket 37. Screw M8x75
Oil filters
(Ref. 5 - 7 hydraulic diagram)
Delivery line filter
The filter on the delivery line of the brakes / steering clutches

circuit is reached by opening the panel of the engine com- 5
partment on the left side of the machine.
Total flow, with paper filtering element, replaceable

every 500 hours work (30 µ nominal and by-pass 3
valve set at 2.5 bar (36.2 psi)). 1
Tightening torque 4 daNm (29.5 lbf.ft).
4
Fa
F14338 SM9171
F14338
1. Filter support
2. Filter cartridge
3. Filtering element
4. Cover
5. O-Ring
2
F. Transmission / torque converter oil filter
1 4
6 7
Suction filter
3
The filter on the suction line of the brakes / steering Fa
clutches circuit is reached when lifting the cab.
Total flow, with steel mesh filtering element (non re- 5
placeable, to be cleaned every 1000 hours work) and
magnetic plug (100 µ nominal, without by-pass). 8
9
Fa. Steel mesh filtering element
1. Cover securing nut
2. O-Ring
7
3. Cover
4. Stud
5. Magnetic rod
6. Filtering element retaining spring
7. Circlip
8. Gasket
9. Support SM9172
NOTE:
REAR TRANSMISSION (transmission side section)

1. Transmission housing ass.ly 50. Plug ass.ly
2. Housing cover 51. Housing inspection cover
3. Washer 12 x 24 52. Screw TE M8x20
4. Screw M12 x 25 53. Washer 8x17
5. Bevel gear set 54. Screw TE M2x40
6. Bevel pinion bearing 55. Steering clutch control valve
7. Bevel pinion bearing 56. Screw TE M8x140
8. Spacer 57. Flat washer
9. Bearing adjust. shim 0.5 58. O-Ring 1.78x20.35
9. Bearing adjust. shim 0.10 59. O-Ring 1.78x23.52
9. Bearing adjust. shim 1.025 60. R.h. clutch/brake ass.ly
9. Bearing adjust. shim 1.050 61. L-h. clutch/brake ass.ly
9. Bearing adjust. shim 1.075 62. Sprocket hub
9. Bearing adjust. shim 1.10 63. Screw TE M27x2x55
9. Bearing adjust. shim 1.125 64. Washer 27
9. Bearing adjust. shim 1.150 65. Sprocket segment
9. Bearing adjust. shim 1.175 66. Segment screw
9. Bearing adjust. shim 1.2 67. Sprocket segment nut
9. Bearing adjust. shim 1.225 68. Straight connector 20
* 9. Bearing adjust. shim 1.250 70. 90° connector 20
9. Bearing adjust. shim 1.275 71. 90° connector
9. Bearing adjust. shim 1.3 72. Pipe
9. Bearing adjust. shim 1.325 73. Lower guard
9. Bearing adjust. shim 1.350 74. Washer
9. Bearing adjust. shim 1.375 75. Screw TE M16x1.5x90
9. Bearing adjust. shim 1.4 91. L.h. supporting disc
9. Bearing adjust. shim 1.425 92. Clutch inner drum hub ass.ly
9. Bearing adjust. shim 1.450 93. Oil sealing ring
9. Bearing adjust. shim 1.475 94. Pusher disc
10. Bearing housing 95. Screw TE M12x30
11. O-Ring 3.53 x 209.1 96. Washer 12x24
12. Bevel pinion ringnut 97. Driving disc
13. O-Ring 3.53 x 221.8 98. Driven disc
14. O-Ring 3.53 x 82.14 99. Clutch piston
15. Pinion cover 100. O-Ring
16. Shim 1 101. Bearing
16. Shim 0.5 102. Spacer
16. Shim 0.2 103. Clutch spring
17. Screw TE M16x1.5x50 104. Piston guide disc
18. Ring gear shaft ass.ly 105. O-Ring
19. Self screw M16x1.5x45 106. O-Ring
20. Left bearing housing 107. Washer 8x17
21. Right bearing housing 108. Screw TE M8x25
22. Bevel gear bearing shaft 109. Clutch outer drum
23. Shim 0.7 110. Drum shaft
23. Shim 0.5 111. Screw TE M10x20
23. Shim 0.3 112. Bearing stop disc
23. Shim 0.15 113. Bearing housing
24. Self screw M12x30 114. Ball bearing
25. Straight connector 10 115. Bearing ring
26. 90° connector 10 116. Bearing ring
27. T connector 10 117. Bearing 160 ring
28. Right brake lube steel pipe 118. Brake spring
29. Left brake lube steel pipe 119. Brake piston
30. Right brake control steel pipe 120. O-Ring 5.33x405.3
31. Left brake control steel pipe 121. O-Ring 5.33x355
32. Block 122. O-Ring 5.33x430.7
33. Lower block 123. O-Ring 5.33x456.1
34. Screw TE M8x1.25x30 124. Brake outer drum
35. Right clutch lube steel pipe 125. Screw TE M12x40
36. Left clutch lube steel pipe 126. Circlip 105
37. Right clutch control steel pipe 127. Pusher disc
38. Left clutch control steel pipe 128. Screw TE M12x35
39. Oil dipstick 129. Plug M14x1.5
40. Plug 130. Plug M18x1.5
41. Gasket 131. Driving disc ass.ly
42. Breather 901. Clutch disc pack
43. Plug M27x2 902. Brake disc pack
45. Plug M42x2
46. Ring
47. PTO steel pipe
48. O-Ring
49. O-Ring 3.53x56.74 * Shims available during the bearing adjustment phase
REAR TRANSMISSION (transmission side section)
52, 53 51 39, 40, 41, 42 57 55

2 3, 4 58
5
59
32, 27
124, 129 33,
26
3, 54 53
25 127, 128 96 2
13 34 72 28
90, 125 29 2 30 32, 34, 53
103
SEE NOTE 4
119, 120, 121
26
118
31 25
38
109 36 20 24 35
8
117 37
25
95, 110 126
22
(REF BEARING) 0 - 0.45
18
9 (WEAR + CLEARANCE)
114
116
21, 24
115 111,
112
93 SEE NOTE 2
95, 96, 113 23
4.5 - CLEARANCE
101
3.5 - WEAR
102
SEE NOTE 3
91, 130
122
123
98 97 107, 104, 99, 131 96 97 92
108 105, 100 95, 96, 113 47, 48, 49, 50
106 43 45 SM9190
4.2 TROUBLESHOOTING
STEERING CLUTCHES
Important – It is assumed that the oil level in the rear 3. When one of the two steering clutch and
transmission housing has been checked (a few min- brakes lever is released, the machine
utes after the engine has been cut-off) as well as the keeps steering.
condition of the suction and delivery filters.
3.1 Measure the piloting pressure, with controls
1. When both steering clutch and brakes in neutral. It must be less than 2 bar (29 psi).
levers are fully actuated, the machine
does not stop.
Install four pressure gauges on the brakes 4. When the brake central pedal is released,
and steering clutch control valve. Actuate the machine hesitates to start.
gradually the clutch/brakes control, first on
one side and then on the other, measuring 4.1 Measure the flow of the transmission pump.
the pressure values at the brakes outlet and This test can be performed by installing a
then for the steering clutches. The reading flow meter between the torque converter and
values in the points indicated by the table the heat exchanger. Please refer to the ta-
must be those indicated in the table of para- ble in the transmission section for the flow
graph 4.3 "TESTS". value.
1.1 In the event the pressures on both sides of 4.2 Remove and inspect the brake valve (actu-
the circuit are low, perform the following ated by the brake central pedal). A stiffening
checks: of the mobile plungers or a fracture of the
main spring could have occurred.
1.1.1 Suction filter not clogged.
4.3 Check that the transmission safety lever is
1.1.2 The delivery of the steering pump must be fully open. In fact, the flow for the disengage-
50 Lt/min (13.21 US/gal/min) with engine at ment of the parking brake could be limited.
2000 rpm.
1.1.3 Safety valve (17 in the hydraulic diagram) of 5. A large amount of friction material is
the steering control valve is not seized open trapped by the oil suction filter.
by some particle. Its setting defines the con-
stant pressure in the system (25 bar 5.1 Check the clutch and brake control actuat-
(362.6 psi)). ing pressure.
2. When one of the two steering clutch and

brakes lever is fully actuated, the machine
does not steer.
Install two pressure gauges on the brakes
and steering clutches control valve. Actuate
gradually the clutch/brakes control, first on
one side and then on the other, measuring
the pressure values at the brakes outlet and
then for the steering clutches.
4.2.1 DIAGNOSIS ON THE DISPLAY
The display has 5 text field digits signalling the fol- 5 text field digits
lowing messages:
A. Work hourmeter signal

The engine hours are signalled by coming ON for
about 1 second when the general test of the in-
strument panel is performed. To repeat the read-
ing of the engine hours, it is necessary to cut-off
and to energise again the system with the starter
switch key. The hours stay ON until the engine is
started. SM9191
or
Failure code E = Failure
B. Speed engaged + failure code signal
Speed engaged Code failure
- The first digit indicates the speed engaged
1st speed
- The second digit indicates E in the event of a
failure.
- the 3rd - 4th and 5th digits indicate the code of the
type of failure and they are distinguished by two
types.
Failure codes of a single component of the brakes/
clutches and transmission control system
(see table 4-1).
Failure codes for more than one component
(see table 4-2).
Failure example SM9192
When the display shows one of the failure codes here below, identify the corresponding failed component,
as per table 4-1.
TABLE 4-1
Failure
Failed component
code
Solenoid of the left proportional solenoid valve 001
Solenoid of the right proportional solenoid valve 002
Forward speed "F" solenoid 004
Reverse speed "R" solenoid 008

3nd speed solenoid 032
Solenoid of the left steering lever 064

TABLE 4-2
Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of
left prop. right prop. Forw. Rev. 1st 3rd left right
Failed component
solen. solen. speed speed speed speed steer. steer.
valve valve "F" "R" lever lever
Solenoid of the left proportional sol. valve 001 003 005 009 017 033 065 129
Solenoid of the right proportional sol. valve 002 006 010 018 034 066 130
Forward speed "F" solenoid 004 012 020 036 068 132
Reverse speed "R" solenoid 008 024 040 072 136

Solenoid of the left steering lever 064 192
Failure code of reverse speed "R" solenoid = 008

Failure code addition on display failure code of 1st speed solenoid = 016
In the event the failed components are two, refer to The crossing in TABLE 4-2 of the two components
TABLE 4-2 where the code is determined by the determines the failure code given by the addition of
addition of the two single failure codes listed in the two single codes 024.
TABLE 4-1. As an example, code 024 indicates
that the failed parts are two: the top digit of the col- Reverse speed "R" failure code = 008 +
umn identifies the solenoid of the "1 st speed", 1st speed failure code = 016
whereas the left digit identifies the solenoid of the
"reverse speed R". Failure code for both on the display = 024
Positioning of diagnostic hoses
5
P1
4
3 9 5
FRD 8 4
3 10
2 1
2
8
9
XP1 7 A B
D 6
7
XFRZDX 1 C
E
F
XFRZSX FRS
XP2
XP
LBR
XP1
XFRNDX
XFRZDX XP2
XP XFRNSX
XFRZSX
XLBR
F14342
F14342
4.3 TESTS
Proceeding with the test of the circuits, make sure 4.3.1 PRESSURE TEST OF THE BRAKES
that the single pressure gauges are adequate for the AND STEERING CLUTCH CIRCUIT
pressures to be measured.
Remove the plugs on the diagnostic panel.
Connect a pressure gauge, with engine inoperative
(capacity 30 bar (435 psi)) to pressure pick-up points
WARNING (3-4-5-7-8-9) indicated in the illustration.
areas without proper ventilation to remove deadly Start the engine and operate the machine forward
exhaust gases. and reverse, actuating, at the same time, the steer-
ing clutches, to warm-up the oil.
Run the engine at maximum speed (2100 ÷ 2200 rpm)

and measure the relevant pressures which must co-
WARNING incide with the values listed in the nominal pressures
table here below.
Be sure exposed personnel in the area of opera-
tion are clear of the machine before moving it or
its attachments. WALK COMPLETELY AROUND Table of nominal pressures
the machine before mounting. Sound the horn.
(bar) (psi)
1. Right brake control 18 ÷ 22 261 ÷ 319
2. Left brake control 18 ÷ 22 261 ÷ 319
3. Brakes lubrication 3 43.5
4. Left steering
clutch control 22.5 ÷ 27.5 326.3 ÷ 398.8
5. Right steering
clutch control 22.5 ÷ 27.5 326.3 ÷ 398.8
6. Brake pedal valve 18 ÷ 22 261 ÷ 319
7. Right piloting 22.5 ÷ 27.5 326.3 ÷ 398.8
8. Left piloting 22.5 ÷ 27.5 326.3 ÷ 398.8
9. Feeding 22.5 ÷ 27.5 326.3 ÷ 398.8
SM1413
Diagnostic panel (pressure pick-up points)

Arrange the appropriate tooling for the measurement

of the steering / brakes levers stroke (A), as shown
in the illustration.
The brakes are powered at about 25 bar (362.6 psi),
whereas the clutches operate at about 20 bar (290 psi).
A
When pulling the lever about 5% till to 50% of its 100 % 0
stroke, the pressure gauges indicate pressures as
shown in the diagram.
Continuing pulling the lever, there is a gradual dec-
rement of the pressures in the pressure gauges in
the point, and corresponding to about 50% of the
stroke, a pressure reading of about 9 bar (130.5 psi)
occurs.
Up to 95% of the stroke. Beyond 95%, the pressure
is zeroed and the levers actuate the brakes only.
Repeat the test with the other lever, checking the most
significant points of the diagram.
Slight pressure discrepancies between the values
measured and those listed in the diagram could be
caused by: low oil level, clogged filters, oil with inap- SM9197
propriate specifications.
In the event the pressures measured are not within A. Levers stroke
the nominal tolerance prescribed, it is necessary to
identify and repair the components involved.
25
20
PRESSURE - bar
15
12
10
7,5
5,5
5
5,5 3,5
0
0 10 20 30 40 50 60 70 80 90 100
F14533
STEERING - BRAKES LEVERS STROKE
4.3.2 BRAKE PEDAL ADJUSTMENT
Position brake pedal (1) at dimension L = 175 mm

(6.88 in) from the cab floor, actuating stop 2.
Connect link (3) to fork (4).

4
Adjust the length of link (3) until it connects with lever
(5) positioned at stroke end. 2
1
Tighten locknut (6). 6
Loosen stop (2) until the pedal play is almost totally

eliminated and lock it with the relevant nut.
Actuate brake pedal (1) full stroke avoiding forcing it

beyond the lever stroke end (5). CAB FLOOR
Bring screw (7) against brake pedal (1). 7
Release the brake pedal, loosen screw (7) two turns

and lock the nut.
3
Adjustment of the modulating rod
With brake pedal (1) in rest position, adjust screw (8)

5
so that a 3 ÷ 4 mm (0.11 to 0.15 in) gap exists be-
tween the screw itself and rod (9).
Then, tighten the locknut of screw (8).
SM9198
2
3
SM1414
4.3.3 BRAKE SYSTEM PRESSURE TEST

(with brake pedal)
Connect a 30 bar (435.1 psi) scale capacity pressure Brake pedal

gauge to pressure pick-up point (1 - 2 - 6) on the
diagnostic panel.
Start the engine and perform forward/reverse ma- Scaled ruler
noeuvres, actuating, at the same time, the brake
pedal, to warm-up the oil.
Bring the engine to operating speed.
Place a scaled ruler to measure stroke (B) of the

brake pedal.
Refer to the diagram in the figure, and press the brake

pedal to 20 % of its stroke. The pressure measured
by the pressure gauge must be practically constant,
at the levels indicated by the diagram.
Continuing the pressing of the pedal from 22 %

through 32 % of its stroke, the pressure gauge must
SM9200
show a pressure drop. When pressing the brake pedal
further, a pattern of the type indicated by the diagram
must be found, until the pressure drops instantly to
zero, once the pedal stroke exceeds 75 %.
Slight pressure discrepancies between the values 1 2 3 4 5

measured and those listed in the diagram could be
6 7 8 9 10
caused by: low oil level, clogged filters, oil with inap-
1 - RH BRAKE 6 - BRAKE VALVE
propriate specifications. 2 - LH BRAKE
3 - BRAKE/CLUTCH LUBE
7 - RH PILOT
8 - LH PILOT
4 - LH CLUTCH 9 - OIL SUPPLY
5 - RH CLUTCH
Note – The pressures measured can be considered

acceptable when they are included within the dotted SM9282
area on the diagram. In the event they are below the

constant line, it is necessary to overhaul or to replace 1. R.h. brake pressure pick-up point
the control valve. 2. L.h. brake pressure pick-up point
PRESSURE DROP
TOLERANCE FIELDS
20
18
15
PRESSURES - bar
10,5
10
8,5
5 5,0
3,0
0 22 27 75 85
32
0 10 20 30 40 50 60 70 80 90 100
Brake pedal stroke % SM9203
4.3.4 FEEDING VALVE TEST AND SETTING
Open the left side panel as indicated, and connect a

pressure gauge (30 bar scale capacity (435.1 psi)) to WARNING
the quick release pressure pick-up PP on the feed- Disconnect and connect all connections with the
ing valve block. engine inoperative. The flowing of pressurised
oil from loose connections could cause personal
Start the engine at max. power speed (2100 ÷ 2200 rpm) injuries and property damages.
and measure the pressure setting of the pressure relief Wear protection glasses with side panels or gog-
valve on the pressure gauge, which should be gles.
22.5 ± 27.5 bar (326.3 ± 398.8 psi), at a flow of 50 L/min.
In the event the pressure differs from the prescribed

value, proceed as follows:
- Loosen locknut (2) and loosen or tighten screw (1) so

that the pressure is changed, setting it at 22.5 ± 27.5 bar
(326.3 ± 398.8 psi).
- Retighten locknut (2).
Pressure
relief valve
2
SM9205
Left side
PP under
Pressure quick cab door
release pick-up
point
F14340
4.3.5 CALIBRATION OF BRAKES/STEERING CLUTCH LEVERS
The calibration procedure is carried out on the machine prior to any replacement or repair intervention involving
the steering levers or the transmission/steering electronic unit.
In order to carry out the calibration, it is necessary to use the setting cable indicated.
For the connection to the instrumentation, follow the diagram illustrated in the figure, as indicated here below.
- Remove plate (1) from the cab front post and extract cap (2) installed on the pre-arranged electrical connector
(3). Connect connector (4) of the setting box cable.
- Position the two switches on the setting box, as follows:

- Switch A in position “CAL”
- Switch B in position “BASE
2
CABLE
SM9409A
B CAL LEVE
BASE ON
A
CAB
DSD
SETTING BOX
SM9409C
Position the starter switch in “ON” (second click of the key) and “_ _ _ _ “ appears on the display.
ON START
ACC.
OFF
Starter key
SM9409F DISPLAY SM9409E
- Press neutral button “N” on the armrest (with this function, the control unit recognises the zero of the
levers).
- “CAL1” appears on the display.
- Actuate, at the same time, both levers indicated to dull stroke. Staying in this position, the wording
“E000” could appear on the display for a few seconds, then “_ _ _ _ “ appears.
- With levers actuated to full stroke, press neutral button “N”.
- The display shows “0”.
- Release the levers into rest position.
- Reposition the starter key into “OFF”, remove cable (4) from connector (3).
- Reinstall cap (2) on the connector and reinstall the plate on the cab post.
The calibration of the brakes/steering levers of the machine is completed.
SM9409G

Removal
Disconnect and label the hoses of the control valve,
remove the two screws (2) and washers securing the
control valve to support (3).
Remove brake valve (1). SM9208
Disassembly Valve (5) cover section

Disconnect all connections and washers, remove
screws (4) and the relevant washers. Remove cover 6. Seal - 7. Plug M10 x 1.25 - 8. Gasket 10 x 16 x 1-
(5) from the valve body. 9. Dowel - 10. Shaft.
Remove plug (7) and copper gasket (8) from cover

(5) to reach pin (23) retaining cam (14). Pull-out the
lever using a punch and the relevant shaft. Remove
the key and the seal from the shaft.
From the other side of the valve, remove screws (25)

from cover (1). Hold the cover while loosening the
last two screws, since shaft (4) is spring loaded. Then,
remove the cover and the O-Ring; spring (2) and cup
(3).
From the opposite side, remove guide (11) pushrod

(12) and O-Ring (24), then remove pushrod assembly
(6). Press spring (9) and extract the pushrod retaining
washer (8), remove the spacer, spring (9) and cup (10).
SM9207
Extract washer (15) O-Ring (22), extract spring (17)
and the large and small plungers (18 and 19).
Brake pedal valve linkage
1. Brake control valve - 2. Valve securing screws
M10 x 1.5 - 3. Valve support - 4. Upper cover screws
M 8 x 1.25 - 5. Cover. 1. Cover
2. Spring
Remove dowel (9) securing shaft (10) using an ap-
3. Cup
propriate screw (diam. 3.81 mm (0.15 in) - pitch
4. Shaft
0.5 mm (0.02 in).
5. Body ass.ly
6. Pushrod
25 1 2 3 4 5 6 7 8 9 10 28 7. Inner cup
P
8. Washer
11
9. Spring
10. Outer cup
12 11. Guide
12. Pushrods
13 13. Cover
14. Cam
14 15. Washer
16. Gasket
17. Piston spring
18. Piston
19. Spacer
20. Gasket
21. O-Ring 2.62 x 18.72
34 22. O-Ring 2.62 x 20.29
23. Pin
20 19 18 17 33 16 15 23 24. O-Ring 2.62 x 34.59
B A SM9188 25. Cover securing screw M8 x 75
4.4.2 STEERING CLUTCH AND BRAKE Inspection of components

CONTROL FEEDING PUMP
(Removal / Disassembly / Reassembly)
WARNING
Removal Never use gasoline, solvents or other flammable
fluids to clean the components. Use approved
To remove the pump from the torque converter cover commercial non flammable and non toxic sol-
it is necessary: vents only.
- to tilt the cab and disconnect the pump (1) pipes;

Clean accurately all components and blow them with
- to remove the screws securing the front cover to dry compressed air.
converter housing (C) and remove the pump. Check the pump gear support bushes; in the event they
are scored, pitted or excessively worn, replace them.
Check that pump body (5) in correspondence with the
zone near the gears is not worn. Replace the parts if
Disassembly damaged. Replace all seals and gaskets.
To disassemble the components of the pump, it is Reassembly

necessary to remove screws (1), remove the front
and rear covers and extract supports (7) complete Reassemble the pump reversing the sequence for
with gears (8 and 9). the disassembly. Lubricate generously all inner
parts and make sure that gears (8 and 9) turn freely,
without hesitation.
Secure the pump to the torque converter cover,
smearing the mating surfaces with an adequate
sealing compound.
Connect the pipes.
3 5 8 6 7
9
10
C2
11
C1 2 1 C
SM9209
C1 and C2 P
Steering clutch / brake feeding pump
SM9210
1. Pump holding screw - 2. Rear cover - 3. O-Ring -
5. Pump body - 6. Dowel - 7. Supports - 8. and Torque converter cover
9. Pump gears - 10. Key - 11. Front cover - 12. Cen-
tring ring -13. Circlip -14. Spring washer - 15. Drive C1. Pump securing screw, tightening torque 5 ÷ 10 Nm
ring locking nut -16. Bushes - 17. Seal - 18. Circlip. (3.69 to 7.38 lbf.ft)
C1. Screw tightening torque 5 ÷ 10 Nm C2. Nut, tightening torque 44 ÷ 54 Nm
(3.69 to 7.38 lbf.ft) (32.45 to 39.83 lbf.ft)
C2. Nut tightening torque 44 ÷ 54 Nm P. Brake and steering clutch pump
(32.45 to 39.83 lbf.ft) C. Torque converter.
4.4.3 BRAKES AND STEERING CLUTCHES

T
R
Disassembly of packs
WARNING
lifting point, the cables or chains.
Drain the fuel from draining pipe T indicated, actuat-

ing valve R. Drain completely the fuel before remov-
ing it. SM9284
Capacity of full fuel reservoir: 400 L (105 US gal).

Disconnect the fuel feeding pipe to the injection pump
and remove the four securing screws (1) at the base
of the reservoir.
Hold the reservoir with a crane equipped with a lifting
hook, using the eyes indicated. Remove the two side
securing screws (2) with the hydraulic oil reservoir,
which is not necessary to be removed. 2
WARNING
Avoid twisting chains or steel cables. Always
wear heavy gloves when handling cables or
chains.
1
1
1
1
SM9287
Remove the fuel reservoir.

It is not necessary to remove the hydraulic oil reser-
voir to reach the inspection covers of the housing. A
- Drain the oil from the transmission housing, remov-

ing plug A from the rear bottom of the machine and
let it flow out completely (oil capacity of the hous-
ing: about 50 L - 13.20 US gal).
- Split the track chain as described in SECTION 5 -

UNDERCARRIAGE.
- Remove the final drive as described in SECTION 3 -

FINAL DRIVES. SM9286
Removal
Remove the housing inspection cover (51 fig.

SM9215) on the side where it is necessary to work,
disconnecting the brake control and lubrication joints
(25 and 26) and the clutch control and lubrication joints
(38 and 36).
Removal of the packs
Loosen screws (C2) securing the brake/clutch assem-

bly to the transmission housing.
SM9214
51
26
25
C2 C4
C5 C3
C6
118
38
36
111, 112
92 101
94
Brake pack Clutch pack

SM9215
Transmission housing cross section
Install a tool as shown in the illustration and extract

the brake/clutch assembly from the transmission
housing.
Place the brake/clutch pack assembly on an appro-

priate support for the disassembly of the components.
Loosen screws (C3) securing the pressure back plate

from the pack, pull-out the screws and extract disc
(94).
Remove the friction disc pack and remove the driv-
ing disc drum (92).
Loosen the two screws (111) and remove bearing
holding ring (112).
Pull-out the rear piston (99) complete with bearings
(101). SM9216
Loosen the 12 screws (C5) securing support disc (91)

and extract it; remove brake springs (118) (q.ty 20).
Pull-out piston (119) and extract the brake disc pack,
paying attention to the disassembly sequence.
Check and inspection of steering clutch

packs
Check that the warping, on each disc (2) of the clutch After checking the discs, in accordance to the in-
pack is less than 0.03 mm (0.00118 in), also check structions above, reassemble each clutch pack (A)
that on driven discs (1): (7 driven discs and 8 driving discs) and pressure
- the maximum thickness difference between the sur- plate (4) on the drum and check, under a press,
face of sintered material does not exceed 0.05 mm that the total thickness (A) of the pack is
(0.00196 in); 60 ÷ 62 mm (2.362 ÷ 2.440 in) under a load of
300 ÷ 400 kg (661.4 ÷ 881.8 lbf.ft). In case of dis-
- said surfaces are free from abnormal wear due, gen-
crepancy, add one or more standard or undersized
erally, to dirt circulating with the oil or to dry operation
driving disc, from the side indicated by the arrow.
of the clutches, or pitted zones.
A 60 ÷ 62 mm
(2.362 ÷ 2.440 in)
q.ty 7 driven discs

(sintered)
300 ÷ 400 kg
(661.4 ÷ 881.8 lbf.ft)
P= 294 ÷ 392 daN
(2167.7 ÷ 2890.2 lbf.ft)
SM9217
P
CLUTCH DISC PACK

the thickness of discs (1 and 2) accordingly. A
SM9216
1 - Driven (with sintered faces) ................................ q.ty 7 discs, thickness 4.7 ÷ 4.8 mm (0.1850 to 0.1889 in)
2 - Driving (steel) ................................................. q.ty 8 discs, thickness 3.35 ÷ 3.65 mm (0.1318 to 0.1437 in)
Check and inspection of brake packs
Check that the maximum warping, on each disc (2) After checking the discs, in accordance to the instruc-
of the pack is less than 0.03 mm (0.00118 in); also tions above, reassemble each clutch pack (A) (5
check that on driven discs (1): driven discs and 4 driving discs) and pressure plate
- the maximum thickness difference between the sur- (4) on the drum and check, under a press, that the
face of sintered material does not exceed 0.05 mm total thickness (A) of the pack is 36.5 ÷ 38.5 mm
(0.00196 in); (1.437 ÷ 1.515 in) under a load of 294 ÷ 392 daN
(2167.7 ÷ 2890.2 lbf.ft).
- said surfaces are free from abnormal wear due,
In case of discrepancy, add one or more standard or
generally, to dirt circulating with the oil or to dry
undersized driving disc, from the side indicated by
operation of the clutches, or pitted zones.
the arrow.
A 36.5 ÷ 38.5 mm (1.437 ÷ 1.515 in)
q.ty 5 driven discs

(sintered)
300 ÷ 400 kg
(661.4 ÷ 881.8 lbf.ft)
P= 294 ÷ 392 daN
(2167.7 ÷ 2890.2 lbf.ft)

SM9219

P
BRAKE DISC PACK

the thickness of discs (1 and 2) accordingly.
A
SM9216
1. Driven (with sintered faces) ................................ q.ty 5 discs, thickness 4.7 ÷ 4.8 mm (0.1850 to 0.1889 in)
2. Driving (steel) ................................................. q.ty 4 discs, thickness 3.35 ÷ 3.65 mm (0.1318 to 0.1437 in)
Re-installation
Reverse the removal sequence.

NOTE Non specific tightening torques are required for
the re-installation, thus refer to the tightening torque
table at the beginning of the Manual (SECTION 0
TABLE OF TIGHTENING TORQUES).
4.4.4 BEVEL GEAR UNIT
Preliminary operations:
WARNING
lifting point, the cables or chains. SM9220
WARNING
Avoid twisting chains or steel cables. Always wear
heavy gloves when handling cables or chains.
Removal
Tilt the cab, remove the fuel and hydraulic oil reser-
voir.
Remove the transmission group as described in
SECTION 2 TRANSMISSION. Drain the oil from
the rear transmission housing, removing the plug
located at the bottom, as described in item 4.4.3.
Remove the cover from the housing as shown in fig-
ure SM 9220.
Remove the brake and steering clutch group, as de-
scribed in item 4.4.3.
Then, proceed as follows: 15 14
Remove cover (15), extract O-Ring (14)
SM9221
Pull-out the adjusting half shims (16); holding it with

cables or belts, extract the bevel pinion support as-
sembly, using puller screws.
SM9222
Remove the bevel pinion from the housing.
SM9223
Loosen screws (20 - 21) securing the housing.
SM9250
Install a puller to remove the bearing housing from

the bevel crown shaft, until it gets out the taper spline
together with its seat.
Repeat the operation on the opposite side of the hous-
ing.
SM9249
Remove the shaft complete with crown gear, lifting it

as shown in the figure.
SM9247
Disassembly of the pinion
Secure the pinion into the appropriate bracket and

place it in a vice.
Remove the cover using a screwdriver and remove
the O-Ring.
Remove the pinion securing ring nut, using a socket,
a torque wrench and a torque multiplier.
Install a bearing puller and remove the pinion from
the bearings.
SM9227
5. Bevel gear set
6. Bearing
7. Bearing 14 12
8. Spacer
17 -15 6
9. Bearing setting shim
10. Bearing housing 8
11. O-Ring 10
13 9
12. Bevel pinion ring nut
13. O-ring 16
11 7
14. O-Ring
15. Pinion cover
16. Half shims
17. Securing screw M16 x 1.5
18. Bevel gear shaft 5 19
19. Bevel gear securing screw M16 x 1.5 A SM9228
Disassembly of bevel gear

WARNING
Use an appropriate puller to remove the bearings from

the shaft.
Place the crown gear on the appropriate support in a
vice to remove the self-locking screws.
SM9229
Remove the gear from the shaft.
SM9230
Components of the pinion/gear group
Pinion:
5. Bevel gear set pinion

6-7. Bearing
8. Spacer
10. Bearing housing
12. Ring nut
16. Setting shims
SM9231
Gear:
18
5. Bevel gear set crown
18. Bevel gear shaft 5
22. Bearings
22
SM9232
4.4.5 BEVEL GEAR
Re-assembly / installation of bevel gear
Gear re-assembly
Install the gear on the shaft.
SM9230
Tighten the gear on the shaft with the 16 self-locking

screws. Please refer to the table of SECTION 0
TABLE OF TIGHTENING TORQUES for the tight-
ening torques.
SM9229
Warm-up the bearings at 110 °C (230 °F) and slide

them individually on the shaft.
SM9233
Re-assembly of the bevel pinion
Warm-up the half-bearing at 110 °C (230 °F)
SM9233
Slide the half bearing over the pinion.
SM9235
Install a sample ring 4 mm (0.1575 in) thick on the

pinion.
SM9236
Install the bearing spacer.
SM9237
Prepare the bearing housing, installing, first, the bear-

ing outer race.
To facilitate the installation of the race, use an hy-
draulic press.
SM9238
Turn the housing upside down and insert the other

bearing outer race, using an hydraulic press.
SM9239
Install the housing in the pinion, as shown in the illus-

tration.
SM9240
Warm-up the half bearing at a temperature of 110 °C

(230 °F).
SM9233
Lubricate and install the half bearing.
WARNING
SM9242
Install the bevel pinion retaining ring nut.
SM9243
Secure the pinion assembly on the appropriate

bracket and place it in a vice.
Tighten the ring nut using the appropriate wrench
380000919 and torque multiplier at a torque of
130 ÷ 150 daNm (959 to 1106 lbf.ft).
SM9227
Bead the ring nut with a chisel on both sides of the

pinion.
SM9244
Lubricate and install the O-Ring into its seat in the

housing.
SM9245
Turn the pinion assembly upside down.

Lubricate and install the O-Ring into the seat on the
housing.
SM9246
Re-installation of the bevel gear
Install a lifting eye to the gear and place the compo-

nent into the bevel gear set space.
WARNING
SM9247
Lubricate the bearing with engine oil.
Prepare the right and left housing, installing the bear-

ing outer races inside, using an hydraulic press.
SM9248
Install first the left housing, without setting shims,

Left housing Right housing
using only 4 screws tightened to a torque of 13 daNm
(95.9 lbf.ft).
SM9249
Install the right housing, without setting shims, with

two securing screws, tightening them to increments
of 0.1 daNm (0.74 lbf.ft) up to a final value of
0.7 daNm (5.16 lbf.ft). At the same time, rotate the
gear a few turns manually to set-in the taper rollers
on the relevant races.
Note – For the pre-loading operations of the pinion

bearings and the setting of the bevel gear set, refer
to items 4.4.6 and 4.4.7.
SM9250
4.4.6 PROCEDURE FOR THE SETTING OF THE PINION BEARINGS PRE-LOAD
Perform the setting of the pre-load of the bearings,

complying with the phases, as follows:
A. Install the pinion complete with half bearing (7) D. After measuring, loosen the ring nut, pull-out
on pinion holding housing (10) complete with bearing (6), spacer (8) and the sample ring.
half bearings (6 and 7). Deduct the value measured from the thickness
(4 mm) of the sample ring, then shim using rings
B. Insert spacer (8) and the 4 mm thick sample (9), in the point indicated, for the resulting value.
ring, the inner race of bearing (6) using a press, Install spacer (8), half bearing (6) then tighten
then tighten ring gear (12). the ring nut to a torque of 130 ÷ 150 daNm
(959 to 1106 lbf.ft).
C. Keeping pinion holding housing (10) still, meas-
ure the axial movement of the pinion using a E. Check that the rolling torque is between
dial instrument located on its nose or tail. 0.2 ÷ 0.4 daNm (1.47 to 2.95 lbf.ft). Then bead
the nut on the pinion. If wrong, repeat the op-
eration, adding or removing shims, until the pre-
scribed rolling torque is obtained.
DETAIL OF PINION
14 12
6
17 -15
8
10
13 9 See note 1
See note 2 16
11 7
5 19
A SM9228
Tooth mating face
From 22 (0.87 in) through

30 mm (1.18 in) long
Tooth mating face
From 5 (0.20 in) through

7.5 mm (0.29 in) from tooth end
Detail A SM9252
4.4.7 PROCEDURE FOR THE SETTING OF THE BEVEL GEAR UNIT
Perform the setting of the bearing pre-load, comply-

ing with the following phases:
A. Shim with rings (23) to obtain a rolling torque C. After obtaining the pattern prescribed in phase
on the gear shaft (without pinion) equivalent to B, divide shims (23) between the two bearing
0.4 ÷ 0.8 daNm (2.95 to 5.9 lbf.ft). housings (20) and (21) until a backlash equiva-
lent to 0.25 ÷ 0.30 mm (0.010 to 0.012 in) be-
B. After pre-loading the gear shaft bearings as per tween the pinion / gear teeth is obtained. Re-
item A, position pinion housing (10), using shims check that theteeth mating pattern and the pre-
(16) (see page 4-44) until the mating pattern be- load of the bevel gear shaft are within the speci-
tween the pinion / gear teeth is according to the fications of notes A and B.
indication of detail "A" (see the procedure for
the setting of the bevel pinion bearing pre-load). D. Check that the total rolling torque measured on
the pinion i equal to 0.35 ÷ 0.70 daNm (2.58 to
5.16 lbf.ft).
21
23
20
SM9253
4.5.1 BEVEL GEAR REDUCTION UNIT (General data / dimensions)
General data Ref.
Type of gears helical teeth 5
Reduction ratio (13/40) 1:3.076 5
Backlash between the face of the teeth 0.25 ÷ 0.33 mm (0.0098 to 0.0130 in) 5
average 0.3 mm (0.0118 in)
Dimensions mm inches Ref.
A Inner diameter of bevel gear shaft bearing cage 139.948 ÷ 139.988 5.5098 to 5.5113 21
Outer diameter of bearing 139.980 ÷ 140.000 5.5110 to 5.5118 22
* B Inner diameter of bearing 79.850 ÷ 80.000 3.1437 to 3.1496 22

Outer diameter of bevel gear shaft 80.020 ÷ 80.033 3.1504 to 3.1509 18
C Outer diameter of bevel gear shaft hub 239.948 ÷ 240.000 9.4468 to 9.4488 18
Inner diameter of bevel gear 240.000 ÷ 240.052 9.4488 to 9.4508 5
E Inner diameter of pinion housing 179.932 ÷ 179.972 7.0839 to 7.0855 10

Outer diameter of pinion bearing 179.975 ÷ 180.00 7.0856 to 7.0866 7
D Inner diameter of pinion support 149.932 ÷ 149.972 5.9028 to 5.9044 10

Outer diameter of bearing 149.980 ÷ 150.00 5.9047 to 5.9055 6
* Note – The dimensions are identical on both sides.
14 12
6
15 -17
8
10
13 9
16
11 7
5 19
A SM9254
22
18
21 - 24
24
SM9255
4.5.2 STEERING CLUTCHES
General data and dimensions Ref.

TYPE ................................................................................................................... multiple disc, oil bath
Number of discs per clutch
- Driven (with sintered facing) ................................................................................................. Q.ty 7 98
- Driving (steel) ....................................................................................................................... Q.ty 8 97
Number of springs for each clutch ...................................................................................................... 6 103
- Free length of spring ........................................................................................... 38 mm (1.496 in) 103
- Diameter of wire ...................................................................... 2 ± 0,025 mm (0.079 ± 0.00098 in) 103
- Outer diameter fully pressed ......................................................... 14 ± 0.1 mm (0.551 ± 0.004 in) 103
Load with compression at: - 33.5 mm (-1.318 in) ............... 4.7 ± 0.2 daNm (34.665 ± 1.4751 lbf.ft) 103
- 29.5 mm (-1.161 in) ................... 8.9 ± 0.4 daNm (65.643 ± 2.9502 lbf.ft) 103

Thickness of clutch disc pack .............................................................. 60 ÷ 62 mm (2.362 to 2.441 in)
.............................................................................. (under a load of 300 ÷ 400 kg (661.5 to 882 lb))
Average travel of pressure plate ............................................................................... 4.5 mm (0.177 in)
Total travel ................................................................................................................... 9 mm (0.354 in)
Thickness of steel plates .............................................................. 3.35 ÷ 3.65 mm (0.132 to 0.144 in) 97
Thickness of sintered driven discs ................................................ 4.70 ÷ 4.80 mm (0.185 to 0.189 in) 98
- Inner diameter ................................................................. Ø 64.985 ÷ 65.000 (2.5585 to 2.5590 in) 101
- Outer diameter ............................................................. Ø119.985 ÷ 120.000 (4.7238 to 4.7244 in) 101
BRAKES
General data and dimensions Ref.
TYPE ................................................................................................................... multiple disc, oil bath
Number of discs per brake
- Driven (with sintered facing) .......................................................................................................... 5 98
- Driving (steel) ................................................................................................................................ 4 97
Number of springs for each brake .................................................................................................... 20 118
- Free length of spring ............................................................................................ 83 mm (3.268 in) 118
- Diameter of wire .......................................................................... 5.5 ± 0.05 mm (0.216 ± 0.002 in) 118
- Outer diameter fully pressed ........................................................ 30 ± 0.30 mm (1.181 ± 0.012 in) 118
Load with compression at:

66 mm (2.6 in) ............................................ 135 ± 7 daN (303.48 ± 15.74 lb) 118
61 mm (2.4 in) ............................................ 174 ± 9 daN (391.15 ± 20.23 lb) 118

Thickness of clutch disc pack ........................................................ 36.5 ÷ 38.5 mm (1.437 to 1.516 in)
........................................................................... (under a load of 300 ÷ 400 kg (661.5 to 882 lb))
Average travel of pressure plate ............................................................................... 4.5 mm (0.177 in)
Average wear ........................................................................................................... 3.5 mm (0.138 in)
Total travel ................................................................................................................... 8 mm (0.315 in)
Thickness of steel plates ............................................................. 3.35 ÷ 3.65 mm (0.132 to 0.144 in) 97
Thickness of sintered driven discs ................................................ 4.70 ÷ 4.80 mm (0.185 to 0.189 in) 98

Inner diameter ................................................................ Ø 104.985 ÷ 105.000 (4.1333 to 4.1338 in) 114
Outer diameter ............................................................... Ø 159.985 ÷ 160.000 (6.2986 to 6.2992 in) 114
51 39, 40, 41, 42 57

53, 52
2 3, 4 58
5
1
32,
124, 129 33,
26 53
3, 54
25 127, 128, 96 2
13 34
29 2
90, 125
103 SEE NOTE 4
119, 120, 121
118
31
38
109 36 20, 24
8
117
95, 110 126
(REF BEARING) 0 - 0.45
9 (WEAR + CLEARANCE)
114
116
111,
115 112
95, 96, 113 93

4.5 - CLEARANCE
101
3.5 - WEAR
102
SEE
NOTE 3
91, 130
122
123
98 97 107, 104, 99, 131 96 97 92
108 105, 100
95, 96, 113
106
SM9408
DATA AND DIMENSIONS (Ref. 3 hydraulic diagram)

mm in
A. Diameter of piston seat 20.000 ÷ 20.021 0.7874 to 0.7882

Outer diameter of piston 19.980 ÷ 19.993 0.7866 to 0.7871
Clearance 0.007 ÷ 0.041 0.0003 to 0.0016
B. Guide pin seat 40.000 ÷ 40.025 1.5748 to 1.5758

Outer diameter of guide pin 39.936 ÷ 39.975 1.5723 to 1.5738
Clearance 0.025 ÷ 0.089 0.0010 to 0.0035
C. Inner diameter of rod seat 10.000 ÷ 10.015 0.3937 to 0.0343

Outer diameter of rod into guide 9.986 ÷ 9.995 0.3931 to 0.3935
Clearance 0.005 ÷ 0.029 0.0002 to 0.0011
D. Diameter of plunger seat 16.000 ÷ 16.018 0.6299 to 0.6306

Outer diameter of plunger 15,983 ÷ 15.994 0.6292 to 0.6297
Clearance 0.006 ÷ 0.035 0.0002 to 0.0014
E. Diameter of washer seat 26.000 ÷ 26.021 1.0236 to 1.0244

Outer diameter of washer 25.947 ÷ 25.980 1.0215 to 1.0228
Clearance 0.020 ÷ 0.074 0.0008 to 0.0029
F. Diameter of seat in cover for pin smaller end 13.016 ÷ 13.059 0.5124 to 0.5141
Outer diameter of control pin smaller end 12.973 ÷ 13.000 0.5107 to 0.5118
Clearance 0.016 ÷ 0.086 0.0006 to 0.0034
G. Diameter of seal on cover 24.000 ÷ 24.033 0.9449 to 0.9462

Outer diameter of pin in correspondence with seal 13.982 ÷ 14.000 0.5505 to 0.5512
H. Diameter of dowel seat 8.013 ÷ 8.049 0.3155 to 0.3169

Outer diameter of dowel 7.964 ÷ 8.000 0.3135 to 0.3150
Clearance 0.013 ÷ 0.085 0.0005 to 0.0033
I. Diameter of spring seat in control pin 5.000 ÷ 5.030 0.1968 to 0.1980

Diameter spring pin seat in cam 3.000 ÷ 3.030 0.1181 to 0.1193
Outer diameter of spring pin 5,000 0.1968
Clearance 0 ÷ 0.030 0 to 0.0012
J. Diameter of control pin seat in cam 13.016 ÷ 13.059 0.5124 to 0.5141

Outer diameter of control pin in cam 12.973 ÷ 13.000 0.5107 to 0.5118
Clearance 0.016 ÷ 0.086 0.0006 to 0.0034
K. Diameter of control pin seat in control lever 11.995 ÷ 12.006 0.4722 to 0.4727
Outer diameter of pin in lever 12.982 ÷ 12.000 0.5111 to 0.4724
Interference 0.005 int. ÷ 0.024 clear. 0.0002 to 0.0009
1. Piston return spring

Number of turns 9.5
Free length 76.5 mm (3.012 in)
Force required to press to 45 mm 54.7 ÷ 60.3 daN (122.97 to 135.56 lb)
2. Piston actuating spring

Number of turns 5.5
Force required to press to 32.1 mm 28.4 ÷ 31.4 daN (63.84 to 70.59 lb)
3. Plunger return spring

Number of turns 16.5
Force required to press to 40 mm 8.1 ÷ 8.9 daN (18.21 to 20 lb)
1 A 2 B C
D 3 E I
SM9257 SM9258
4.6 SPECIAL TOOLS
380000919 Wrench for bevel pinion ring nut
380000983 Support, steering differential

bevel pinion on vice
380001315 Brake loosening screw
380001318 Check caliper, bevel pinion

bearings play
380001322 Press fitting of bearing inner

race on pinion
380001324 Installation of bevel ring gear

support bearing
380001484 Brakes module dowels
SECTION 5
UNDERCARRIAGE
TABLE OF CONTENTS
5.1 GENERAL DESCRIPTION ........................................................................................................ 5-3

5.1.1 Generalities ............................................................................................................................... 5-3
5.1.2 Main components ...................................................................................................................... 5-4
5.2 TROUBLESHOOTING .............................................................................................................. 5-7
5.3 INSPECTIONS .......................................................................................................................... 5-8

5.3.1 Inspection and adjustment of track chains ................................................................................. 5-8
5.3.2 Setting of the track tensioner pressure relief valve .................................................................... 5-9
5.4 REPAIR PROCEDURES ......................................................................................................... 5-10

5.4.1 Track chain (removal / installation) .......................................................................................... 5-10
5.4.2 Replacing a damaged link and re-installation ........................................................................... 5-12
5.4.3 Idler (removal / Re-installation / overhaul) ................................................................................ 5-14
5.4.4 Track chain support rollers (removal / installation / overhaul) .................................................. 5-17
5.4.5 Track chain bottom rollers (removal / installation / overhaul) ................................................... 5-19
5.4.6 Track chain tensioner spring (removal / installation) ................................................................ 5-22
5.5 SPECIFICATIONS AND DATA ................................................................................................. 5-23

5.5.1 Idler ......................................................................................................................................... 5-23
5.5.2 Sprockets ................................................................................................................................. 5-24
5.5.3 Track chains ............................................................................................................................ 5-24
5.5.4 Bottom rollers .......................................................................................................................... 5-25
5.5.5 Support rollers ......................................................................................................................... 5-26
5.5.6 Track tensioner device ............................................................................................................. 5-27
5.5.7 Front cross-member pivots ...................................................................................................... 5-28
5.5.8 Wear limits ............................................................................................................................... 5-32
5.6 SPECIAL TOOLS .................................................................................................................... 5-33

D180 UNDERCARRIAGE 5-3
5.1.1 GENERALITIES
When evaluating the undercarriage conditions, it is appropriate to consider that an accurate inspection, a proper
preventive maintenance and a correct operation of the machine, are the elements contributing most to extend
the life of components. It is good practice to clean, lubricate, adjust and repair the undercarriage at regular
intervals, not limited to quick and incomplete inspections.
To evaluate exactly the conditions of components, proceed with a systematic and thorough inspection. If
the machine was subject to excessive stress, the track frames could be deformed. Excessive or strange
wear patterns on the idlers, the roller edges and the sprocket segments could be caused by deformed
track frames.
Also, it is important to consider the conditions under which a crawler machine is often compelled to oper-
ated.
TERRAIN
Obviously, it is not always possible to choose the terrain and the operating conditions, but it is necessary to
consider the geological configuration and the gradients which could influence the wear type and speed the
undercarriage shall be subject to.
Working uphill - It results in moving weights and loads towards the rear end of the machine. The wear on the
rear bottom rollers and the forward motion side of the sprocket segments and bushes increases.
Working downhill - It results in moving weights and loads towards the side of the machine facing downhill.
There is a higher wear of the components, such as flanges a link sides, working in this position.
Working sideways - The weight of the machines is bearing on the side located on the downhill side, with a
wear of the flanges and other components guiding the track chain.
Working on a cat's back - It causes a concentration of the loads on the inner side of the components. It
increases the wear of the inner side of rollers and idlers and the inner tip of the grousers.
Working into a ditch - It causes the concentration of loads on the outer flanges of rollers and the outer race of
idlers.
The environment and the type of materials moved are the elements determining the life of undercarriage, since
some materials are more abrasive than others. Also, the abrasive action is generally higher when they are.
Under this point of view, the most common materials can be classified as follows:
Gravel and rocks - intense breakage and wear

sand (in water) - fast wear
wet sand - packing and high wear
sand (dry) - high wear
top soil (wet) - moderate wear
clay (wet) - light - moderate wear
clay (dry or slightly wet) - slight wear
talcum
gypsum
coal - very slight wear
phosphates
5-4 UNDERCARRIAGE D180
Also, it is important, when the undercarriage is overhauled, to check the operation of the track tensioner device.
An inefficient tack tensioner can cause a premature wear of pins and bushes, the torsion of idler shafts, and, as
a limit, troubles on the sprocket shafts and the final drives.
The more components are worn the faster wear occurs. When components are new, hardened surfaces are
thick and resistant; with the wear progression of components between them and contact with the ground, their
harder outer surfaces are replaced by softer layers of material, thus the wear becomes faster.
What said above can be summarised in a few preventive rules and operations:
- do not operate the machine at high speed, unless this is strictly necessary. This is particularly true when
operating in reverse;
- reduce the load when it is felt that the track chain starts slipping;
- avoid parking the machine in mud, water or conditions facilitating corrosions;
- inspect daily the components, check the tightening of bolts and nuts, eventual leakages from seals or signs of
abnormal wear;
- clean mud and debris accumulated during the work shift from the undercarriage.
5.1.2 MAIN COMPONENTS

The main components making the undercarriage are:
1. Track frames
2. Track frame bottom rollers
3. Track chain support rollers
4. Track tensioner device and pressure relief valve
5. Idler wheels
6. Track chains
7. Sprocket and toothed segments
7 6 2 3 4 1 3 5
SM9350
Fig. 5-1 Undercarriage components
1. Track frames
Each track frame is composed of a frame made with material with high mechanical specifications fabri-
cated with boxed section bars. Inside, fully enclosed track tensioner devices are mounted, protected from
the entry of loose materials.
The two frames are hinged, at the back, on the PIVOT SHAFTS, whereas, in the front, the connection is
provided by a suspended cross-member, hinged centrally and to the frame of the machine on the sides.
Thus, each track frame is allowed to pivot independently from the other one.
The alignment of the track frames is provided, frontally, by guides, the position of which is adjusted by
shims.
The following components are mounted on the track frames:

- bottom rollers
- track chain support rollers
- idler and track tensioner device.
2. Track frame bottom rollers
The rollers (q.ty 7) are three double flange and four single flange, made of special steel, heat treated to better
withstand wear and abrasion. These rollers, mounted in the lower side of each track frame, support the mass of
the machine. The shafts turn on lubricated bushes.
The sealing is provided by metal (long-life) seals.
3. Track chain support rollers
The support rollers support the upper part of the track chain. Each roller is secured, by supports, to the track
frames. The shafts turn on lubricated bushes and the sealing is provided by metal (long-life) seals.
4. Track chain tensioner device
The track tensioner device provides a dual function: keep the track chain tension; absorb the stress
transferred by the idler.
The track chain tension is provided by an hydraulic device, made of a cylinder and a piston connected to
the idler yoke by a rod.
To stretch a track chain, grease is pumped inside the cylinder. This causes a forward movement of the
piston and the idle, connected to it.
Please note that the spring is normally compressed, but it does not actuate its action against the track chain.
Idler spring assembly/disassembly tool.
5. Idler
The idler, of a spring type, located in the front side of each track frame, is connected to the track chain
tensioner hydraulic device by a yoke and a rod against the adjusting cylinder piston. The tensioner effort
and the absorption of shocks received by the track chain while working, are transferred through this
system. For this reason, the idler is not rigidly connected to the track frame body, but it is allowed to slide
on guides, which must be properly aligned by adjusting shims. The shafts turn on lubricated bushes. The
sealing is provided by metal (long-life) seals.
6. Track chain
The track chain is essentially, made of:

- pins
- bushes
- links
- shoes
Pins and bushes are the components of the track chain most subject to wear. The symptoms characterising the
wear of pins and bushes are wear of the sides of the links, fast wear of the sprocket teeth and excessive sagging
of the track chains.
Shoes are single ribbed. The ribbing, besides providing traction, contribute to reinforcing the shoe. Worn shoes,
besides facilitating the slipping of the track chains, are more easily deformed.
The track chain is permanently lubricated and the wear between pin and bush is greatly reduced. In fact, each
pin (1) see fig. 2-2, has an axial hole (2) and two radial holes (3) perpendicular to the first one, providing a
constant and continuos lubrication. The movement between pin and bush, ensures the distribution of lubricant
over all the contact surfaces.
Seals (4) provide the sealing, avoiding the entry of foreign materials and keeping the lubricant. Rubber plug (2)
allows the filling with oil and provides sealing.
Fig. 5-2 Permanent lubrication (SALT) track

chains 4 6 1
7
1. Pin with lube oil reserve drilling
2. Rubber plug
3. Radial lube drillings
4. Seal
5. Thrust ring
6. Bush
7. Link
8. Pin
2 8 5 3
SM9351
Note – On lubricated track chain, it is recommended to turn pins and bushes, as well.
7. Toothed segment idler
The idler transfers, directly, to the track chain the rotation received from the final drive. The sprocket is
mounted on the final drive output shaft. There are nine toothed segment bolted to the hub, thus they are
individually replaceable. The profile of the teeth is of a self-cleaning type. The toothed segments can be
replaced without removing the chains.
5.2 TROUBLESHOOTING
The major causes for premature or abnormal wear High track chain tension
of the undercarriage components are listed here be-
low. Troubles
1. Low speed and insufficient traction power. The

Slack track chain tension machine fails to develop the prescribed pushing
capacity.
Troubles
2. The machine turns rightward or leftward, caused
1. Very fast wear on links, pins and bushes of the by the track chain which is tighter.
track chain.
3. Fast wear of pins, bushes and links.
2. Fast wear of the sprocket teeth and the rib of the
shoe. 4. Wear of the final drive bearings.
3. Possible damage or breakage of the sprocket,

idler,idler supports, bottom rollers and guards.
Insufficient tightening of the screws secur-
4. The track chain could fail to engage correctly the ing the shoes to the track chain
sprocket teeth, both when moving forward or re-
verse. The track chain could jump the idler, Troubles
when the machine is steering.
Elongation of the screw holes on the link.
5. Noisy track chain.
Remedies
6. The track chains fills with foreign materials. (*)
The loosening can be caused by a thinning of the
shoe due to wear, or by an incorrect torque tighten-
(*) Note – When the machine operates under condi- ing of the screws to the prescribed values. Make sure
tions facilitating the entry of foreign materials into the that the mating faces between shoe and track chain
undercarriage components, it is recommended that are perfectly clean and free from paint.
the tension of the system is checked frequently.
In fact, the tension can increase the rubbish included
between the track chain components and the idler
tensioner device. Working on steep slopes
The presence of foreign materials inside, could cause
delay or prevent the movement of the idler. This pre- Troubles
clusion could result in a dangerous load on the track
chain (pins, bushes, links), on the idler shaft and the Wear at the tips of pins, on the side of the master
final drives. link, on the inner and outer rims of the bottom rollers,
the sprockets and idlers.
Remedies
Operating on steep slopes, causes strong stress to

the undercarriage components, with subsequent fast
wear. Whenever possible, change frequently the di-
rection and/or the trajectory of the machine.
5.3 INSPECTIONS
5.3.1 INSPECTION AND ADJUSTMENT OF TRACK CHAINS

In sealed and lubricated track chains, strong phenomena of internal wear do not occur, if the track chain
adjustment is done timely, when required.
When the track chain is too tight, it is subject to useless and dangerous stress. The wear speed increases
and drawbar traction power is lost. When it is too slack, the links are hitting the undercarriage, increasing
the wear of all parts involved.
Keep in mind that a normal adjustment is proper for dry, stony or rocky terrains, whereas it is necessary to
slack further the track chains in muddy, very wet and clayey conditions, or when sand, gravel, snow or ice
are present.
Tightening the track chain

L = 30 to 40
In the event the track chain has become slack, it
is necessary to increase the tension. Prior to any
operation, measure the sagging of the track chains
in section (L, Fig. 5-3) between the support roller and
the idler. If sagging (L) exceeds 30 to 40 mm (1.18 to
1.57 in) (regular sagging) pump grease into fitting (I,
Fig. 5-4) of valve (VR) of the adjustment cylinder, until
the correct tension is obtained.
Loosening the track chain
When disassembly operations must be performed or SM9353

the track chain is excessively tensioned, the tension
must be loosened. Prior to slackening the track chain, Fig. 5-3 Track chain sag
check that the sag on section (L) is lower than
30 to 40 mm (1.18 to 1.57 in). If loosening is required,
proceed as follows: WARNING
- Remove access cover (C) on the track tensioner Fluid under pressure. Do not loosen track ten-
frame, removing retaining screws (V). sion by loosening pressure relief valve (VS). Do
not remove the grease fitting (I) mounted on ad-
With a 24 mm wrench, loosen slightly adjustment valve justing valve (VR).
(VR) and back-up the machine a few metres, if required.
Re-tighten the valve and check sag (L).
C V
VS VR I
SM9352
Fig. 5-4 Adjusting the track chain
VR. Adjustment valve - VS. Pressure relief valve - I. Grease fitting - C. Cover - V. Securing screws.
5.3.2 SETTING OF THE TRACK TENSIONER PRESSURE RELIEF VALVE
Disassemble all parts of the valve and clean them - to obtain the setting value required, change shims
from all traces of grease. (S1 accordingly, or actuate threaded element (1);
Reassemble the valve and proceed as follows:
- reassemble the valve and fill it with AMBRA GR9
- secure tool (A) 380001310 (Fig. 5-5) in a vice, grease;
screw valve (VS) on the tool placing in between
the relevant O-Ring. - reinstall the valve on the cylinder and tighten it to
the prescribed torque (see chapt. 5).
- fill well (P) of the tool with gasoline or alcohol;
Setting of the pressure relief valve:
V1 = 6.41 to 6.86 daNm (47.3 to 50.6 lbf.ft)

WARNING
V2 = 6.86 to 7.35 daNm (50.6 to 54.2 lbf.ft)
Extinguish all smoking materials and free flames.
- Thickness of valve setting shims 0.1 - 0.2 - 0.5
mm (0.0039 - 0.0079 - 0.20 in).
- actuate torque wrench (B) considering that the Setting 900 to 950 bar (13053 to 13778 psi).
valve must stay closed, thus the level of the liquid
inside well (P) must not change until value (V1) =
6.41 to 6.86 daNm (47.3 to 50.6 lbf.ft).
The valve should open and the well drain-out when
a torque value (V2) is applied, equivalent to a set-
ting of 900 to 950 bar (13053 to 13778 psi).
A
B
VS
SM9358
T 6 1
C1
S1 3
T
2 1
3 5
4
4 S1
C1
5 2
6
SM9356 SM9357
Fig. 5-5 Sectional view, parts and check of the pressure setting of pressure relief valve (VS) of the
hydraulic adjusting cylinder
A. Test tool 380001310 - B. Torque wrench - C1. Valve cover - P. Gasoline or alcohol well - S1. Adjusting shims -
T. Pressure setting marking - 1. Rubber cap - 2. Steel washers - 3. Disc springs (Bauer type) - 4. and 5. Plunger
and ball valve - 6. Cap (1) securing screw.
5 - 10 UNDERCARRIAGE D180
5.4.1 TRACK CHAIN

(Removal / Installation)
Removal
Place blocks of an appropriate thickness under the

transmission housing and the cross-member so that
the track chains do not touch the ground.
SM9360
Fig. 5-6
Remove the cover on the track frame and loosen the
tension of the track chain, as described in item 5.3.1
INSPECTION AND ADJUSTMENT OF TRACK
CHAINS.
WARNING
Fluid under pressure. Do not loosen track ten-
sion by loosening pressure relief valve VS (Fig. 5-4).
Do not remove the grease fitting mounted on the
adjusting valve.
Remove the screws securing the shoe indicated (Fig.

5-7) from the master link. SM9359
Fig. 5-7
Remove the shoe and split the master link.
Using a proper hoist and sling, remove the chain

from the machine.
WARNING
provided for this purpose.
WARNING
When removing the track chains, sling the two SM9361
end links and spread the track chain slowly, us- Fig. 5-8
ing a hoist. Make sure that the zone where the
track chain is going to be placed is completely
free and no by-standers are in the vicinities.
Start the machine and moving forward slowly, disen-

gage the track chain from the sprocket, the support
rollers and the idler.
D180 UNDERCARRIAGE 5 - 11
Re-installation
WARNING
Handle all parts with extreme care. Never place
hands and fingers between one piece and an-
other. Wear approved personal protection equip-
ment such as glasses, gloves and safety shoes.
1. Position the track chain so that the junction point

is corresponding to the sprocket (fig. 5-9).
SM9362
2. Start the machine and move it slowly forward, guid-
Fig. 5-9
ing, at the same time, the track chain over the
sprocket, using a strong bar placed through the
holes of a link.
3. Place a wooden block under the rib of the shoe

nearest the junction point. Connect half links (1),
install the master shoe and tighten the screws to
the prescribed torque indicated in fig. 5-11. 1
Note – Before installing, degrease screws (C) and

the treaded seats on master link (1).
Apply LOCTITE Super Rapid 242 on the screw thread
and tighten to the prescribed torque. Lubricate with
engine oil the other screws and tighten to the same
torque.
SM9363
Tighten the master link screws with the relevant Fig. 5-10
shoes to a torque C = 30 daNm (221.3 lbf.ft), plus
a further 180° (half turn).
For the screws securing the screws , tighten to a
3 C 1 2 C1
torque C 1 = 30 daNm (221.3 lbf.ft) plus a further
120° (1/3 turn).
4. Reset the correct track chain tension, making ref-

erence to item 5.3.1 INSPECTION AND ADJUST-
MENT OF TRACK CHAINS.
SM9364
Fig. 5-11 Track chain master link
1. Master SPLIT link

2. Master shoe
3. Link pin
C. Master link hinging securing screws
(30 daNm + 1/2 turn)
C1. Shoe and split link securing screws
(30 daNm + 1/3 turn)
5.4.2 REPLACING A DAMAGED LINK AND

RE-INSTALLATION
To replace a damaged link, not adjacent a master
link, it is possible to perform the operation, without
removing the track chain assembly, proceeding as
follows:
1. Remove shoe (1, fig. 5-12) secured to the link to

be replaced (2) and the two adjacent shoes: Spread
the track chain.
2. Pull-out the hinging pins (3 and 4) of the damaged

link, using portable press (A, fig. 5-13).
3. Cut with a torch a section of bush (5) 20 to 30 mm

SM9365
long.
Fig. 5-12
M L
A
SM9366
Fig. 5-13
SM9367
Fig. 5-14
4. Remove the damaged link (2).

WARNING
Wear welder personal protection equipment, such 5. Remove link (6) and pull-out the section from it
as mask or dark glasses, helmet, apron, shoes remaining in bush (5).
and heavy gloves, every time arc cutting or weld-
ing is performed. Always wear dark protective 6. For the re-installation, use a portable hydraulic
glasses near welding in progress. NEVER LOOK press complete with the tooling illustrated in figure
DIRECTLY AT THE ARC WITHOUT APPROPRIATE 15.
EYE PROTECTION.
7. Install a master bush (9) on a new link (11) and
secure it to the track chain.
8. Reinstall the second link (6) on the master bush.
9. Install the two master bush rings (10) on links (7

and 8) and complete the operation reinstalling pins
(3 and 4).
A B C
a G 9 11 F
SM9368
6 9 G b
SM9369
Fig. 5-15 Installation phases of bushes on the links of the track chain
a. Installation phase of the bush on the first link - b. Installation phase of the second link.
Re-assembly of a lubricated track chain
Prior to reassembling the components of the track

chain, follow the notices and procedures listed in item
5.4.1.
1. Press the pins using the portable hydraulic

press.
2. Press the rubber plug into the pin hole using tool
(A, fig. 5-16). Take care in positioning the plug in-
side 8 to 10 mm (0.3150 to 0.3937 in) from the rim
SM9370
of the pin.
Fig. 5-16
3. Check the tightness of the seals and the oil filling

into the pins, using tool (B) fig. 5-17.
SM9371
Fig. 5-17
5.4.3 IDLER
(Removal/Re-installation/Overhaul)
Removal
1. Split the track chain (see item 5.4.1 TRACK

CHAIN - Removal).
2. Remove the idler guards. 1
3. Remove screws (1, fig. 5-18) securing the idler 6

supports. SM9372
Fig. 5-18
4. Separate the idler from yoke (2) fig. 5-19.
WARNING
Handle all components with extreme care. Never
place hands and fingers between one piece and
another.
2
5. Remove the idler from the machine using tool

380001311 (A) fig. 5-20.
4 5
SM9373
Fig. 5-19
Re-installation
1. Position the idler on the track frame, using tool (A).
2. Split the same number of adjusting shims (3, fig.

A
5-21) between the inner and outer end plates, pre-
viously removed.
Position the end paltes (4) and tighten the fixing
screw (5).
WARNING
SM9374
Handle all parts with extreme care. Never place Fig. 5-20
Note- If the original quantity of shims is unknown, 3

split them so that clearance (G1) between the end
plate and the guide plate is 1 mm (0.0394 in), on
each side of the idler.
Also, check that the axis of the idler is aligned
with the axis of the bottom rollers.
3. Tighten screws (1, fig. 5-18) connecting the yoke

SM9375
to the idler supports.
Fig. 5-21
4. Reinstall the idler guards.
5. Connect the track chain (see 5.4.1 TRACK CHAIN A

- Installation) and re-adjust to a correct tension.
6. Refill the idler with oil.
Overhaul SM9376
Fig. 5-22
Remove the idler from the machine (see removal).
G
1. Support adequately the idler. Remove plug (6,
fig. 5-18) and drain the lube oil. H
A
Then retighten the plug to avoid the entry of dirt
B
inside the lube duct.
2. Remove screw (7, fig. 5-25) locking the idler

shaft. Mark end supports (8).
3. Pull-out the ends using tool (A, fig. 5-22). In case F

E
this operation is difficult, use portable press (A, D
C SM9377
fig. 5-23), complete with the tooling illustrated in
the figure, to pull-out the supports. Fig. 5-23
4. Remove the front seals (9 fig. 5-24) and keep the

matching to avoid mixing them, when reassem-
bling. Remove O-Rings (10).
Remove screws (11 fig. 5-26) securing the bush
housings. Remove bush housings (2 fig. 5-27) as- 9
semblies forcing the idler shaft end (3) with a hy-
draulic press.
5. In case of replacement, press-out the bushes from

the relevant housings, using an adequate punch.
6. Reassemble the components in the same man-

SM9378
ner as described in paragraph 5.4.5 TRACK
CHAIN BOTTOM ROLLERS - Overhaul. Fig. 5-24
7. Check the axial play of the idler, using dial gauge

(A) as illustrated in fig. 5-28. The reading value 7
to be obtained is listed in paragraph 5.5.1
IDLER.
Reinstall the front seals, making sure that the 8
metal ring faces are free from dents, scratches
or traces of wear.
9
DEGREASE AND CLEAN THE FRONT SEAL

SEATS. ELIMINATE ALL TRACES OF DUST OR SM9379
IMPRINTS FROM THE SURFACES THEN COVER Fig. 5-25

THEM WITH A THIN FILM OF OIL, MAKING SURE
THAT THE OTHER SURFACES REMAIN DRY.
11
WARNING
Never use gasoline, solvents or other flammable
fluids to clean components. Use approved non-
toxic and non-flammable commercial solvents.
10
Reinstall idler supports (8 fig. 5-25) and block the idler
shaft with screw (7) making sure, before tightening SM9380
to torque, that item (9) is properly seated. Fig. 5-26
Reinstall the idler on the machine (see Installation).
2 3
WARNING
SM9381
Fig. 5-27
WARNING
provided for this purpose. Beware of by-standers
in the vicinity of the load to be lifted.
A
5.4.4 TRACK CHAIN SUPPORT ROLLERS
(Removal/Installation/Overhaul) SM9382
Fig. 5-28
Removal
1. Loosen and split the track chain (see paragraph

5.4.1 TRACK CHAIN - Removal).
2. Remove screws (1, fig. 5-29) securing the roller

support to the track frame. 1
WARNING
SM9383
provided for this purpose. Beware of by-standers Fig. 5-29
in the vicinity of the load to be lifted.
WARNING
hands and fingers between one piece and an- 1
3. Remove the roller complete with support, as shown 2

in fig. 5-30.
If the roller must be disassembled, it is necessary
to separate it from support (2), loosening com- SM9384
pletely screws (1) securing it to the track frame. Fig. 5-30
Re-installation
4. To re-install the rollers, reverse the operation de-

scribed above. Tighten the screws securing the
roller support to the track frame to a torque of 48
daNm.
Reassemble the track chain and reset the tension
(see paragraph 5.4.1 TRACK CHAIN - Instal-
lation).
Overhaul
5 18
Remove the roller from the machine.
Block the roller in a vice using tool 380001309 (A,
fig. 5-31), and drain the lube oil.
Loosen completely screws (18) and remove roller
10
support (2).
Loosen screws (10) and remove cover (5) complete
with seal (6). 2
Remove the screws securing thrust ring (4,
fig. 5-32) and remove the ring; pull-out the shaft from
the roller body. A
Remove bearing (13) using an appropriate puller.
Remove the front seal metal rings.
Pull-out the second bearing from the relevant seat,
using an appropriate puller.
In case of replacement of the bearings, press them
into their seats in the roller body.
SM9385
Fig. 5-31
WARNING
Install the shaft into the roller body and the thrust ring.
Never use gasoline, solvents or other flammable If a high wear of the thrust face of the ring toward the
fluids to clean components. Use approved non- roller is found, reverse the position of the ring. Tighten
toxic and non-flammable commercial solvents. the screws to the prescribed torque (see SPECIFI-
CATIONS AND DATA - support rollers).
Install cover (5) complete with O-Ring. Tighten se-

Install the front seals. DEGREASE AND CLEAN curing screws (10) to the prescribed torque.
THE FRONT SEAL SEATS. ELIMINATE ALL Re-install the roller on the support, tighten locking
TRACES OF DUST OR IMPRINTS FROM THE screws (18).
SURFACES THEN COVER THEM WITH A THIN
FILM OF OIL, MAKING SURE THAT THE OTHER Refill the roller with SAE 40 oil (0.370 kg - 13 oz). Re-
SURFACES REMAIN DRY. install the roller on the machine (see Installation).
Fig. 5-32 Support roller components
10
1. Roller 11
2. Support 6
3. Shaft 7 4
8 1
4. Plate
5 13
5. Cover
9
6. O-Ring 13
7. Plug
8. O-Ring
9. Screw 14
10. Screw
11. Washer 3 18
12. Support roller 19
13. Bearing
15
14. Seal
16
15. Collar 17
16. O-Ring
17. Circlip
18. Screw 18x1.5x110
12
19. Washer 18x34
2
SM9412
5.4.5 TRACK CHAIN BOTTOM ROLLERS

(Removal / Installation / Overhaul)
Removal
If the intervention is limited to one or few rollers, to 1

remove them, it is sufficient to follow the procedure
described here below.
1. Remove screws (1 and 2, fig. 5-33) and remove

the bottom roller inner and outer guards. Salvage
the spacers mounted coaxial with screws (2). 2
SM9386
2. Split the chain (see 5.4.1 TRACK CHAIN -Re- Fig. 5-33
moval).
3. Lift the machine using an hydraulic jack (3,

fig. 5-34) of adequate capacity. Immediately sup-
port the machine using a strong wooden block (4)
capable of supporting its weight (fig. 5-35).
3
4. Loosen screws (5) securing the rollers to the track
frame.
5. Insert tool P/N 380001313 (A), remove the screws

and remove the roller, as illustrated in fig. 5-35.
SM9387
WARNING Fig. 5-34

Every time groups of the machine must be re-
moved or installed, requiring to be supported by
jacks, make sure that the contacts under the jack
and between jack and machine are appropriate
for the load to be supported. Immediately trans-
fer the load to appropriate supports or stands.
Do not work under or near a machine or its com-
ponents which are supported only by jacks or
other lifting devices, according to current national
or local regulations. 4
A
5
SM9388
Re-installation Fig. 5-35
1. Place the roller on tool (A, fig. 5-35) and arrange it

on the track frame. Install screws (5) and tighten
to the prescribed torque (see 5.5.4 BOTTOM
ROLLERS).
2. Re-install the roller guards, placing the spacer pre-

viously removed, and lower the machine to the
ground.
3. Reassemble the track chain and set the correct

tension (see 5.4.1 TRACK CHAIN - Installation).
Overhaul
Remove the roller from the machine and proceed as 2

described here below.
1. Block the roller in a vice using tool P/N 380001309 1

(A, fig. 5-36),remove plug (1) and drain the lube
oil.
A
2. Remove roller support retaining plate (2).
SM9389
Fig. 5-36
3. Use a screw puller (B, fig. 5-37) to pull-out sup-

ports (3) from the roller shaft.
B
SM9390
Fig. 5-37
In the event this operations becomes difficult, use A
portable press (B, fig. 5-38), equipped with the tool- B D
ing illustrated, to pull-out the supports. Remove the
C
O-Rings on the roller shaft.
3 H
E
I F
L G
M
SM9391
Fig. 5-38
4. Remove screws (1, fig. 5-43) securing the bush

housings and pull-out housing assemblies
(2, fig. 5-39) pushing roller shaft (1) using a uni- 1 2
versal puller or a stand press. Match the front seals
to avoid mismatching during reassemble.
5. In case of replacement, pull-out bushes (1) from

the relevant housings (2) using an appropriate
punch.
SM9392
Fig. 5-39
6. Install new bushes into the relevant housings, op-

erating as follows:
- remove dowels (3, fig. 5-41) from the housing
or, in case of necessity, cut them flat with the
face;
- press the new bushes into the housing so that,
after pressing, lube holes (F) are coaxial with a
maximum run-out of 2.5 mm (0.984 in).
- drill two new holes for dowels (3) as far as pos-
sible from the lube holes. Press the dowels mak-
ing sure that they don't protrude over the bush
surface.
SM9393
Fig. 5-40
7. Install O-Ring (*) (1, fig. 5-40) on bush housing

(2).Press the first housing, using guide pins (S,
fig. 5-42) to facilitate the alignment of the holes of
the housing securing screws.
8. Install the roller shaft, press the second bush hous-

ing assembly and make sure that the shaft turns
freely.
Install and tighten to the prescribed torque screws
(1, fig. 5-43) (see 5.5.4 BOTTOM ROLLERS).
9. Check the axial play of the roller shaft using dial

SM9394
gauge (A) as illustrated in fig. 5-43.
Compare the value measured with the data of Fig. 5-41
5.5.4 BOTTOM ROLLERS.
10.Re-install the front seals.
DEGREASE AND CLEAN THE FRONT SEAL

SEATS. ELIMINATE ALL TRACES OF DUST OR
IMPRINTS FROM THE SURFACES THEN COVER
THEM WITH A THIN FILM OF OIL, MAKING SURE
THAT THE OTHER SURFACES REMAIN DRY.
Install supports (3, fig. 5-37) on the shaft, pushing

them fully to win the resistance provided by the front
seals and hold the pack inserting securing plate (2, SM9395
fig. 5-36) into its seat. Fig. 5-42
(*) It is recommended that the O-Rings are always

replaced.
SM9396
Fig. 5-43
11. Check the tightness of the front seals.

Connect tool (A, fig. 5-44) to the threaded hole of
the lubrication duct. Inject compressed air into
the roller at a pressure of 2 to 3 bar (29 to 43.51
psi). If the seals are efficient and correctly in-
stalled, no pressure drops must occur for about
15 seconds.
12. Refill the roller and install it on the machine (see A

Installation). SM9397
Fig. 5-44
5.4.6 TRACK CHAIN TENSIONER SPRING
(Removal/Installation)
CAUTION
Be careful during handling. Transporting, or dis-
assembling the track chain tensioner spring. The
spring is under a high installed pre-load. Possi-
ble nicks or weld craters in spring rod assembly
can cause an immediate failure and risk of per-
sonal injury. Put an adeguate protecting cover-
ing around spring assembly when handling,
transporting or disassembling.
Stay on the side of spring during the operation
above.
1850-2R401
Extract the spring from track frame usings special
Fig. 5-45 Assembly/disassembly tensioner
tool P/N 380001316 (see fig. 5-45).
spring tool P/N 380001316
- Put the special tool P/N 380001476 (fig. 5-46)
around spring assembly;
- Remove the pressure reliefe valve (VS, fig. 5-47);
- Screw the three nut of the special tool to compress
the spring and tighten nut (7) until half-ring (8) and
cup (9) comes out;
- Unscrew nut (7);
- Release the spring, operating the three nut of the
special tool slowly;
1850-2R402
Note – For spring reassembly, reverse the opera- Fig. 5-46 Tool for assembly/disassembly of the
tions described above. spring (4) from cylinder (1) P/N 380001476
2 5 3 4 1 6 7
vS vR
8
9
1850-2R403
Fig. 5-47 Track chain tensioner
VR. Track chain tensioner adjustment valve with grease fitting - VS. Pressure relief valve - 1. Track tensioner
cylinder - 2. Mud scraper - 3. Hydraulic adjust. cylinder seal - 4. Track tensioner spring - 5. Track tensioner
cylinder flange - 6. Rear central disc - 7. Track tensioner cylinder nut - 8. Half-ring - 9. Cup.
5.5.1 IDLER Tightening torque

Type ............. permanently lubricated, equipped Bush housing self-locking securing screws (C1)
with metal (long-life) front seals. ................................ M10x1.5 (6.5 daNm) (47.94 lbf.ft)
Thickness of clearance adjusting shims (S1) between

end plates and idler guide pads: 0.5 mm (0.0197 in).
Thickness of clearance adjusting shims (S2) between

end idler support pads and track frame pads: 0.5 mm
(0.0197 in).
Note – Degrease and clean the front seal seats. Elimi-

nate all traces of dust or imprints from the surfaces
then cover them with a thin film of oil, making sure
that the other surfaces remain dry.
SM9398
Fig. 5-48 Idler
C1. Bush housing self-locking securing screws - C2. Guide pad securing screws - C3. End plates self-locking
securing screws - C4. Idler shaft locking screw - C5. Idler support pad securing nuts - G1 = 1 mm. Clearance
between end plates and guide pads G2 = 0.5 ÷ 1 mm. Clearance between support pads and track frame -
S1. Clearance (G1) adjusting plates - S2 Clearance (G2) adjusting shims - 1. Idler - 2. Bush housing - 3. Idler shaft -
4. Idler support - 5. Front seal - 6. Shaft bushes - 7. Lube plug - 8. End plate - 9. and 10. O-Ring -
11. Guide pad - 12. Idler support pads.
5.5.2 SPROCKETS
Type ...............................................bolted segments
1
Number of teeth per crown ................................ 27
Sprocket pitch diameter ................. 878 mm (34.6 in)
Width of segment ...........87± 0.8 mm (3.42 ± 0.03 in)
Wear limit .........................................(see page 5-30) 2
Tightening torque
Self-locking nuts for sprocket segment securing
screws ......................M22x1.5 (66 daNm 486.79 lbf.ft)
3
5.5.3 TRACK CHAINS
LT
Link type ........................................ with master pins
Number of shoes per track chain 39 plus master shoe
Total shoes per track chain ...................................40
Number of split master links per track chain ...........2 SM9399
Width of shoes:
- standard ..................................... 560 mm (22.05 in) Fig. 5-49 Section view of sprocket
- optional ........................................ 600 mm (23.6 in)
1. Toothed sector - 2. Sector securing screw - 3. Hub.
XLT/LGP
Link type ..................................... with master pins
Number of shoes per track chain 44 plus master shoe
Total shoes per track chain ...................................45
Number of split master links per track chain ...........2
Width of shoes:
Tightening torques
- XLT .............................. 560-610 mm (22.05-24 in)
- LGP .................................. 762-915 mm (30-36 in) Master link C securing screws (30 daNm) (221.27 lbf.ft)
plus a further 1/2 turn tightening.
Note – Prior to installation, degrease screws (C) and
the treaded seats on master links (1). Shoe securing screws C1 (30 daNm) (221.27 lbf.ft)
Apply LOCTITE 243 on the screw tread and tighten plus a further 1/3 turn tightening.
to the prescribed torque. Lubricate the other screws
(C1) with engine oil and tighten to the prescribed
torque.
3 C 1 2 C1
SM9364
Fig. 5-50 Master links
1. Split master link - 2. Master shoe - 3. Link pivot pin - C. Master link hinging securing screws - C1. Shoe and
split link securing screws.
5.5.4 BOTTOM ROLLERS

Type ........ permanently lubricated, equipped with Tightening torque
metal (long-life) front seals. Self-locking screws (C1) securing the bush housings
M10x1.25 .......................... (7.8 daNm) (57.53 lbf.ft)
Quantity of bottom rollers per track chain: version LT
- double flange ..................................................... 3 Screws securing the rollers to the track frame
- single flange ...................................................... 4 M16x1.5 .......................... (24.5 daNm) (180.7 lbf.ft)
Quantity of bottom rollers per track chain: version XLT/ Lube plug (6) 3/8" x 18 NPSF ....... (13 - 17 daNm)
LGP (95.88-125.38 lbf.ft)
- double flange ..................................................... 3
- single flange ...................................................... 5 Note – Before assembling, degrease and clean the
front seal seats. Eliminate all traces of dust or im-
Single flange prints from the surfaces then cover them with a
- weight of roller assembly .......... kg 51.25 (113 lb) thin film of oil, making sure that th e other sur-
- diameter of race ............... 210 mm (8.2677 lbf.ft) faces remain dry.
- diameter of outer flange ....... 246 mm (9.6850 in)
- quantity of oil (SAE 30/40) ........ kg 0.360 (0.79 lb)
Double flange
- weight of roller assembly ...... kg 56.45 (124.45 lb)
- diameter of race ................... 210 mm (8.2677 in)
- diameter of outer flange ....... 246 mm (9.6850 in)
- quantity of oil (SAE 30/40) ........ kg 0.360 (0.79 lb)
SAE 30 oil
or 40
2 4 19 5 3
7
6
8
C1
1
SM9401
Fig. 5-51 Bottom roller
1. Double flange roller body - 2. Single flange roller body - 3. Bush housing - 4. Front seal - 5. Shaft bush -
6. Lube plug - 7. Lube shaft - 8. Support roller - 9. and 10. O-Ring - C1. Bush housing self-locking securing
screws.
5.5.5 SUPPORT ROLLERS Tightening torque

Type ........ permanently lubricated, equipped with Self-locking screws (C1) securing the bush
metal (long-life) front seals. housings M10x1.25 .......... (4.5 daNm) (33.19 lbf.ft)
Quantity of rollers per track chain ........................ 2 Self-locking screws (C2) securing thrust
- weight of roller assembly .......... kg 32.57 (71.8 lb) washer M12x1.25 ........ (6.5 daNm) (*) (47.94 lbf.ft)
- diameter of race ................ 187.5 mm (7.3819 in)
- diameter of outer flange ...... 216 mm (8.5039 in) Plug (C3) ............................ 19 daNm (140.14 lbf.ft)
- quantity of oil (SAE 30/40) .......... kg 0.370 (13 oz)
- diameter of shaft .................... 57 mm (2.2441 in) (*) Apply LOCTITE No. 243
- specs of material of support roller body according
to standard ........................................ PDQB 4000
- material of body .................................. 35 MB4 - 2
Note – Before assembling, degrease and clean the

front seal seats. Eliminate all traces of dust or im-
prints from the surfaces then cover them with a
thin film of oil, making sure that the other surfaces
remain dry.
7 C1 8 5 6 4 3 1 9 11 10 12 13
14
16
C3
C2 Fill with SAE 30

or SAE 40 oil
SM9404
Fig. 5-49 Support roller
1. Support roller body - 2. Shaft - 3. Thrust washer - 4. Shaft lock screw - 5. Cover - 6. Cover seal - 7. Cover
securing screw - 8. Flat washer - 9. Bearing assembly - 10 Sealing ring - 11. Elastic ring - 12. Collar with dowels -
13. Shaft seal - 14. Circlip - 15. Plug - 16. Plug seal.
5.5.6 TRACK TENSIONER DEVICE

Type ................................................... single spring
Track tension adjustment ......................... hydraulic
Pressure relief valve (VS) setting ...... 900 to 950 bar
.................................................. (13053-13778 psi)
V1............................................. 6.41 to 6.86 daNm
.................................................. (47.28-50.60 lbf.ft)
V2 ............................................. 6.86 to 7.35 daNm
.................................................. (50.60-54.21 lbf.ft)
Thickness of valve setting adjusting shims (S 1 )
................................................... 0.1 - 0.2 - 0.5 mm SM9405
Fig. 5-53 Pressure relief valve VS

Specifications of track tensioner spring:
- Free length ............................... 865 mm (34.05 in)
- Length of pre-loaded spring L 1........................
(9080 daNm) ........................... 700 mm (27.56 in)
SM9406
Fig. 5-54 Track tension adjustment valve VR
2 5 3 4 1 6 7
Vs VR
70 22 9
L1 = 700
935.5
SM9407
Fig. 5-55 Track chain tensioner
1. Track tensioner cylinder - 2. Mud scraper - 3. Hydraulic adjust. cylinder seal - 4. Track tensioner spring -
5. Track tensioner cylinder flange - 6. Rear central disc - 7. Track tensioner cylinder nut - 8. Half-ring - 9. Cup -
VS. Pressure relief valve - VR. Track chain tensioner adjustment valve with grease fitting.
5.5.7 FRONT CROSS-MEMBER PIVOTS
3 1 (*)
2
8 (*)
9
5 3
4
A A1
Side pivot
1
Central pivot
7
6
B1 B
F14536
F14536
Fig. 5-56 Front cross-member pivots
1. Front cross-member
2. Ball joint
3. Circlip
4. Seal
5. Side pivot pin
6. Phenolic bushing
7. Central pivot pin
8. Greaser
9. Dowel with gauged hole
(*) Before installing seal (4) smear a line of LOCTITE 603 on its seat.
FRONT CROSS-MEMBER PIVOTS

(mm) (in)
Min. Max Min. Max

A. Side pivot
- Pin diameter 59.920 to 59.950 2.359 to 2.360
- Ball joint inner diameter 60.000 to 60.300 2.362 to 2.374
- Clearance 0.050 to 0.380 0.002 to 0.015
A1. Side pivot

- Joint seat diameter 89.965 to 90.000 3.52 to 3.543
- Joint outer diameter 89.960 to 89,985 3.542 to 3.543
0.025 clear. to 0.040 interf. 0.001 clear. to 0.0016 interf.
B. Central pivot
- Pin diameter 69.954 to 70,000 2.754 to 2.756
- Ball joint inner diameter(*) 70.259 to 70.359 2.766 to 2.770
- Clearance 0.259 to 0.405 0.010 to 0.016
B1. Central pivot

- Bush seat diameter 85.000 to 85.054 3.346 to 3.348
- Phenolic bush outer diameter (*) 85.224 to 85.324 3.355 to 3.359
- Interference 0.170 to 0.324 0.007 to 0.013
(*) Dimension referred to prior press fitting into seat.
PIVOT SHAFT
(mm) (in)
Min. Max Min. Max

C. Pivot shaft
- Shaft diameter 119.946 to 120.000 4.722 to 4.724
- Phenolic bush inner diameter 120.460 to 120.560 4.742 to 4.746
- Clearance 0.460 to 0.614 0.018 to 0.024
C1. Pivot shaft

- Bush outer diameter 135.310 to 135.410 5.327 to 5.331
- Bush seat diameter on track frame 135.000 to 135.050 5.315 to 5.317
2 1
3
5
4
C1
*
F14531
F14531
Fig. 5-57 Pivot Shaft hinging
1. PIVOT SHAFT
2. Phenolic bush
3. Track frame body
4. Seal
5. Cover
* Dimension referred to prior press fitting into seat.
CROSS-MEMBER SUPPORT
(mm) (in)
Min. Max Min. Max

D. Cross-member pivot support
- Bush inner diameter 60.200 to 60.270 2.370 to 2.373
- Pin diameter 59.920 to 59.950 2.359 to 2.360
- Clearance 0.250 to 0.350 0.009 to 0.014
D1. Cross-member pivot support

- Bush outer diameter 71.970 to 72.000 2.833 to 2.835
- Support inner diameter 71.895 to 71.941 2.830 to 2.832
D1 D
SM9410
Fig. 5-58 Cross-member support
1. Bush
2. Cross-member support
3. Track frame body
5.5.8 WEAR LIMITS
Measuring procedure Nominal dimension Wear limit

mm (in) mm (*) (in)
Pitch
4XP 812 (32)
4XP
Link
TRACK
(height) LINK 128 (5) 117 (4.6)
HEIGHT
Bottom
roller 187.5 (7.4) 173.5 (6.8)
(diameter)
ROLER DIA.
Support 210 (8.3) 190 (7.5)

roller
(diameter)
ROLER DIA.
S H O E S U R FA C E
Bushes 73 73 (2.9) 67 (67)

(diameter)
SHOE BUSCHING
D I S TA N C E
Idler
(diameter) 95 (3.7) 105 (4.1)
Idler
(diameter 20 (0.8) 27.5 (1.1)
CENTER FLANGE HEIGHT
GROUSER HEIGHT
Grousers
(height) 71.5 ± 1 (2.8 ± 0.04) ~ 20.5 (~ 0.8)
Sprocket
(rim) 8 (0.3)
(*) The wear limit indicated corresponds, generally to the thickness of the hardened layer at 100 % wear.
5.6 SPECIAL TOOLS
380001316 Tool, removal/installation of

track chain tension spring
380001308 Guide pin
380001309 Support, track rollers on vice
380001310 Tool, track chain pressure

relief valve setting
380001311 Tool, wheel lifting
380001312 Puller, roller body support
380001313 Tool, roller disassembly
380001314 Pushing adapter
380001350 Tooling for track chain

pins removal
380001476 Track chain tension spring

safety tool
SECTION 6
DOZING EQUIPMENT HYDRAULIC SYSTEM
D180 POWER STEERING

TABLE OF CONTENTS
6.1 GENERAL DESCRIPTION ................................................................................................. 6-3

6.1.1 Operation of the hydraulic system ...................................................................................... 6-3
6.1.2 Dozer hydraulic system diagram ........................................................................................ 6-5
6.2 TESTS ............................................................................................................................... 6-7

6.2.1 Use of the flow meter ......................................................................................................... 6-7
6.2.2 Flow test in single circuits ................................................................................................... 6-7
6.3 REPAIR PROCEDURES .................................................................................................... 6-8

6.3.1 Hydraulic oil reservoir ......................................................................................................... 6-8
6.3.2 Equipment hydraulic pump ............................................................................................... 6-10
6.3.3 Hydraulic control valve ..................................................................................................... 6-11
6.3.4 Installation of blade .......................................................................................................... 6-12

6.4.2 Hydraulic power pump ...................................................................................................... 6-14
6.4.3 Blade lifting cylinder ball joint ............................................................................................ 6-15
6.4.4 Blade lifting control cylinder .............................................................................................. 6-16
6.4.5 Blade Tilt control cylinder (Bulldozer version) ................................................................... 6-17
6.4.6 Blade Tilt control cylinder (Angledozer version) ................................................................ 6-18
6.4.7 Ripper cylinder ................................................................................................................. 6-19
6.4.8 Blade push arms and rods ............................................................................................... 6-20
6.4.9 Frame and rods ................................................................................................................ 6-21
6.4.10 Ripper linkage for LT/XLT model ...................................................................................... 6-22
6.4.11 Ripper linkage for LGP model .......................................................................................... 6-24
D180 DOZING EQUIPMENT HYDRAULIC SYSTEM 6-3
6.1.1 OPERATION OF THE HYDRAULIC SYSTEM
The dozer D180 Power Steering can be equipped with a Bulldozer or a 1-cylinder Angledozer. The D180 LGP is
available in the Bulldozer version only. The hydraulic system is similar in both cases.
In the Angledozer version, a fully mechanical Tilt configuration is also available in which the relevant spool is not
used.
The equipment hydraulic circuit is equipped with a variable displacement piston power pump (P) mounted on the
torque converter, sucking oil from tank (S) through metal filter (Fa). The steering circuit and the equipment circuit
are separate, but they have in common the same power (piston) pump and the same control valve. Thus, the two
circuits use the same hydraulic oil, but operate at different pressures.
The operating pressures of the single circuits are:
- equipment circuit 190 ± 5 bar (2755.7 ± 72.5 psi)
- steering circuit 350 ± 5 bar (5076.3 ± 72.5 psi).
The pump powers the steering circuits through a section of the control valve dedicated to the steering.
Pilot valve (Mr) controlling the ripper can move into three positions corresponding to: raising, neutral and lowering.
Pilot valve (Ma) controlling the blade can move into four position corresponding to: raising, neutral, lowering and
floating and also blade tilting (Tilt) rightward or leftward.
Two safety levers, located on the right and left sides of the driver’s seat, cut-off electrically (in raised position) with
a proximity sensor, the powering of the control pilot valves, preventing accidental movements of the pilot valve.
When the machine is standing still and the lever is lowered, allowing the machine to perform all working opera-
tions.
The actuation of indicator light (4) on the monitor panel in the cab signals that oil return filter (9) is clogged and
must be promptly replaced.
Oil sucked by pump (P) powers control valve (D), powering block (Va) reaching pilot valves (Mr and Mr) through
steering piloting block (Vp) providing the hydraulic piloting of the control valve spools (Powering pressure of the
pilot valves 30 bar) (435.1 psi).
The movement of any spool occurs through the check valves in the actuator circuit selected. The pressure that is
established in the delivery circuit is proportional to the effort required and it is limited by pressure relief valve (4) set
at 190 bar (2755.7 psi). Also, the following valve are installed on the control valve.
The circuit is equipped with a L.S. (Load Sensing) system. A connection between power pump and control valve,
allows the sending of a signal from the control valve 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 L/min) (65.5
gpm).
Also, the circuit regulates the distribution of the flow according to a logic of priority for the steering, prevailing over
the equipment circuit, when the operation of both of them is required.
QUICK DROP VALVES
Quick-drop valves (V) hydraulic system diagram; located on the blade lift cylinder bottom, operate during the blade
lowering phase, accelerating the movement.
When the operator pushes the blade control pilot valve into lowering position, oil flowing out the lower chamber
of the cylinder, under the effect of the weight of the blade and the flow of oil to the cylinder upper chamber,
pushes the ball which actuates the plunger, which, by moving, opens the oil delivery port from the valve to the
cylinder upper chamber, thus speeding up the descent of the blade.
When the operator pushes the blade control lever slightly forward, the condition when the blade drops by gravity,
instead of under the effect of pressurised oil, occurs. The ball has been blocked in its seat and the oil is pre-
vented from flowing from one side of the cylinder to the other.
Stroke-end valves are mounted in the blade control cylinders. They are made by ducts inside the piston, in which
seats and a plunger are located. The plunger cuts-off the passage when the oil pressure blocks it against the
relevant seat. It stays closed until the piston ends its stroke. The plunger is moved away from its seat by the
contact of the plunger rod against the end of the cylinder. Oil flows from one end of the cylinder to the other,
limiting the movement of the piston. These valves are necessary, as a result of the blade Tilt action. Thus it is
possible that the piston of a blade control cylinder is at stroke-end, whereas the other one still has to travel part
of it.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6-4 DOZING EQUIPMENT HYDRAULIC SYSTEM D180
BLADE HYDRAULIC TILT
The Tilt control is obtained by a sideways movement of the lever. The rightward movement of the lever causes the
rightward tilting of the blade (clockwise rotation); in the same manner, the leftward movement of the lever causes
the leftward tilting of the blade (anticlockwise rotation).
The Tilt control circuit is equipped with a flow reduction (7) limiting the flow of oil to the cylinder, facilitating the
control of the blade. When the pump flow is reduced, oil operates lifting the valve plunger.
BLADE CONTROL LEVER POSITIONS
The lever controls the lifting, lowering and tilting of the

blade.
To lift or lower the blade, move the lever respectively
backward into position D or forward into position H.
The holding of the blade into a desired position occurs,
in both instances, by releasing the lever, which returns
automatically into neutral N.
To make the blade floating, bearing on the ground just
under the effect of its weight, push the lever full stroke
forward, into position F, where it is held by an
appropriate detent.
The floating condition ends when returning the lever into
neutral position N.
Moving the lever leftward into position A, or rightward
into position B, the tilting of the blade is obtained. The
lever must be held until the blade reaches the desired
position.
SM9474
Blade control lever positions decal
RIPPER CONTROL LEVER POSITIONS

(upon request)
- With lever forward in P = ripper lowering.

- With lever backward in R = ripper lifting.
- Lever in N = neutral.
SM9475
Ripper control lever positions decal
6.1.2 EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

BLADE
RIPPER TILT
MANIPULATOR M
(RIPPER)
2 abb.
HYDRAULIC
MOTOR
Mr
T
A S B
P
1 soll.
Q=180L/min
Q=240L/min
Q=165L/min
Q=170L/min
Q=65L/min
Q=65L/min
(47.5 gpm)
(63.4 gpm)
(18.5 gpm)
(18.5 gpm)
(59.4 gpm)
(43.6 gpm)
(44.9 gpm)
(59.4 gpm)
225 l/min
225 l/min
4
Ma
P 2 b1 B1 A1 b2 A2 b3 B3 A3 b4 X1 B4 A4 Y1 K
D
B2
5 float 210±5 bar 210±5 bar 210±5 bar 210±5 bar 210±5 bar 210±5 bar
(3045.8±72.5 psi) (3045.8±72.5 psi) (3045.8±72.5 psi) (3045.8±72.5 psi) (3045.8±72.5 psi) (3045.8±72.5 psi)
1 abb.
T
8 7 6
25 bar
(362.5 psi)
STEERING PILOT VALVE

TL.
76069705 T T
3 soll. L A P STEERING 3 2
23 22 SECTION 10 1 (160/350) (2320.6/5076.3)
Vp 19
± 5 bar ± 72.5 psi
X
MANIPULATOR
(FRONT. IMPL.) A
Q = 0.7 lt/min
40 bar
(580.7 psi) B
5 bar
(72.5 psi)
20
D
21 5
S 380 ± 10 bar
T
A (5511.4±145 psi)
18 A
T
P
R P
TR PS PM a1 Mp a4 P
a2 a3 MLS T
24 24 24
14 19 LS
5 bar (72.5 psi)
P1
SUPPLY BLOCK
15 16 Va C
35bar
(507.6 psi) EQUIPMENT
17 PUMP
M A G X
45bar
(652.6 psi)
P2 T PR 20 to 21 bar
LOAD
SENSING
VALVE "S"
(290 to 304.6 psi) 11
PRESS.
CUT-OFF 350 bar (5076.3 psi)
"D"
CONSTANT 12
9 2.20 bar (31.9 psi)
POWER
"LR" 90KW
1950 RPM
(120.7 Hp)
13
2.5 bar (36.2 psi)
β 10 75
Vol 110 lt (29 gal.) 4 28 to 32 bar

STAND-BY
PRESS (406.1
to 464.1 gal.)
130 (Qmax=130 cc/rev;
0.2 bar (2.9 psi) CC/REV
Qmin=15 cc/rev)
F 250 µ
OIL
HI-TECH 46
S
P
S
Fig. 6-3 Dozer equipment hydraulic diagram SM1600
C. Heat exchanger - D. Equipment/steering control valve - M. Steering hydraulic motor (see Section 4 - STEERING) - P. Variable displacement piston power pump 90 kW/1950 rpm - Ma. Blade control pilot valve - Mr. Ripper control pilot valve - Va. Supply block - Vp. Steering
pilot valve - 1. Blade spool - 2. Tilt spool - 3. Ripper spool - 4. Hydraulic oil filter clogging indicator light - 5. Load sensing limitation valve (160 ± 5 bar/350 ± 5 bar, 2320.6 ± 72.5 psi/5076.3 ± 72.5 psi) - 6. Blade control spool safety valves (210 ± 5 bar, 3045.8 ± 72.5 psi) - 7.
Tilt control spool safety valves (210 ± 5 bar, 3045.8 ± 72.5 psi) - 8. Ripper control spool safety valves (210 ± 5 bar, 3045.8 ± 72.5 psi) - 9. By-pass valve - 10. Unloading valve (34 bar, 493 psi) - 11. Load Sensing regulating valve - 12. Cut-off signal valve - 13. Constant power
control valve - 14. Accumulator 0.7 lt, 0.2 gal. - 15. Flow reduction valve - 16. Supply block pressure relief valve 45 bar (652.7 psi) - 17. Supply block solenoid valve - 18. Priority valve - 19. Solenoid valve - 20. LS line decompression valve (stabilising the LS signal)
(0.7 lt/min, 0.2 gpm) - 21. Main safety valve - 22. Piloting valve - 23. Selector valve - 24. Pressure compensator.
EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
Connection ports
Control valve - Cylinders Delivery

A1. Ripper cylinder lowering Q = 165 L/min (43 ½ US gal/min)
B2. Ripper cylinder raising Q = 170 L/min (44 ¾ US gal/min)
A3. Tilt cylinder lowering Q = 65 L/min (17 ½ US gal/min)
B3. Tilt cylinder raising Q = 65 L/min (17 ½ US gal/min)
A4. Blade control cylinders lowering Q = 240 L/min (63 ½ US gal/min)
B4. Blade control cylinders raising Q = 180 L/min (47 ½ US gal/min)
Blade control pilot valve - Control valve (piloting)

Blade lowering 1 Ü a4
Floating 5 Ü x
Blade tilt 2 Ü a3
Blade raising 3 Ü b4
Blade tilt 4 Ü b3
Ripper control pilot valve - Control valve (piloting)

Raising 1 Ü b2
Lowering 2 Ü a2
6.2 TESTS
6.2.1 USE OF THE FLOW METER REFERENCE PERFORMANCE TABLE

ENGINE RPM PRESCRIBED VALUES
The use of flow meter 380060080 facilitates the trou-
bleshooting of the hydraulic system. To avoid possi- LT/XLT LGP
ble counter pressures, the return piping of the flow Low idle 780 to 920 780 to 920 rev/min
meter must have a diameter slightly higher the inlet
pipe. The return pipe is connected to the reservoir High idle 2080 to 2220 2080 to 2220 rev/min
fillerneck: remove the mesh filter and insert the pipe Transmission stall 1710 to 1850 1760 to 1900 rev/min
into the reservoir at a depth ensuring that it is well
Equipment stall 2070 to 2210 2070 to 2210 rev/min
submerged. The pipe connected to the reservoir, has
the tendency to “jump out” during the tests and then, Full stall 1640 to 1840 1700 to 1900 rev/min
must be well secured in its position. When applying
pressure using the load valve of the instrument, this
PRESSURE PRESCRIBED VALUES
tendency could increase however with limits of con-
trollability. Prior to starting the tests, make sure that Equipment (Max.) 155 to 165 bar
the pipes used are of a high pressure type, capable (LS pick-up) (2248 to 2393.1 psi)
of bearing at least 210 bar. (3045.8 psi)
Supply pressure 31.5 to 35 bar
(Pick-up M) (456.8 to 507.6 psi)
Stand-by pressure in neutral 33 to 37 bar
(Pump pressure pick-up P) (478.6 to 536.6 psi)
Stand-by pressure in float 33 to 37 bar
6.2.2 FLOW TEST IN SINGLE CIRCUITS (Pump pressure pick-up P) (478.6 to 536.6 psi)
Steering 340 to 360 bar
Plug the delivery pipes to the blade and tilt actuating
(LS pick-up) (4931.3 to 5221.4 psi)
cylinders, so that they can be loaded. Since the cylin-
dersare equipped with stroke-end valves on the pis- Brake pressure 18 to 22 bar
tons, the load needed cannot be obtained when ac- (Pick-up) (261 to 319.1 psi)
tuating the cylinders to stroke-end. On the other hand,
Transmission 16.5 to 17.5 bar
the ripper circuit can be tested working at stroke-end
(Pick-up) (239.3 to 253.8 psi)
in both directions.
DANGER
Fluid under pressure - Always drop the hydraulic
equipment to the ground. Cut-off the engine, per-
forma few no-load movements of the control le-
vers, then loosen and re-close the reservoir cap,
prior to disconnecting the connections of the
system du circuit.
WARNING
DO NOT USE YOUR HANDS to identify pressure
leakages. Jets of fluid under pressure have
enough force to penetrate the skin. Start the en-
gine and wait that the hydraulic oil reaches the
operational temperature, then accelerate the en-
gine to maximum speed.
6.3.1 HYDRAULIC OIL RESERVOIR

(Removal / Installation)
Moving
Removal direction
Turn the main switch into "OFF" to cut-off the electri-
calsystem and apply a signal "DO NOT OPERATE"on
the switch as illustrated. ON
OFF
WARNING
DO PER
To minimise the risk of fires or explosions, prior
NO AT
T E
to performing any welding operation on the fuel
reservoir, it is recommended that the reservoir is
fully drained, all pipes are disconnected, protect-
ing their ends, and the inside of the reservoir is
Fig. 7 - Electrical system main switch
steam cleaned. Also all traces of fuel must be re-
moved before starting welding.
Flood the reservoir with carbon dioxide (CO2)
before and during the welding operation.
While welding, all caps and covers must be re-
moved and all then other openings kept open to
provide ventilation.
Then, proceed as follows:

– tilt the cab; B
– drain the hydraulic oil from the tank using a con- A
tainer with a 130 lt (34 US Gal) loosening the ap-
propriate plug (T) located under the tank on the
right side, as indicated in the figure.
Note – When loosening the plug, after a few turns,
the condensation in the tank is drained. When loos-
ening completely the plug, the oil is totally drained.
– disconnect the oil suction pipes (1) and oil return
pipes on the tank;
– disconnect the connection of oil return filter clog- T
ging indicator (5, fig. 9).
SM1602
Fig. 8 - Hydraulic oil reservoir
– remove the two upper screws (C) securing the oil

reservoir to the fuel reservoir; DANGER
– remove the three lower screws (C1) securing the Make sure that the cables are secured and that
reservoir to the frame; the securing point is strong enough to hold the
– remove the reservoir using a handle welded to the load applied.
rear side with an adequate lifting device. Keep all by-standers away from the lifting point,
the cables or chains.
C C2
2
4 3
Fr
T 1
3
6
C2
Fa
C1 SM1603
Fig. 9 - Hydraulic oil reservoir and filters.

1. Hydraulic oil reservoir; 2. Return filter cover; 3. O-Ring; 4. Oil filler cap; 5. Return oil filter clogging sensor;
C. Reservoir upper securing screw (M14x2x45); C1. Reservoir lower securing screw (M14x2x45); C2. Cover
securing screw; Fa. Suction filter; Fr. Return filter; T. Breather plug.
FILTERS
The purification of the equipment hydraulic oil is en-

sured by two separate full flow filters, located inside DANGER
the hydraulic oil reservoir and precisely: Never use gasoline, solvents or other flammable
– filter (Fa, fig. 9) located on the pump suction with a fluids to clean components. Use commercial non-
metal mesh filtering element; toxic, non-flammable approved solvents only.
– filter (Fr) located on the pump return, equipped with
a paper filtering element, with by-pass valve
cuttingof the filter in case of clogging. Sender (5)
signals the clogging of the filter by an indicator on
the monitor. Re-installation of filters and reservoir
Both filters are accessible by removing the relevant The re-installation of hydraulic oil filters and reser-
covers, loosening retaining screws (C2). voir is done, reversing the removal sequence.
Filter (Fa) is cleaned using an appropriate solvent
each time the hydraulic oil is changed (every 2000 Note – To fill the tank with oil, it is necessary to re-
hours) and must be replaced only when required. move breathing plug T, to bleed the air trapped in-
Return filter (Fr) must be replaced periodically every side.
500 hours work, to avoid that the oil with a clogged
filter is no longer filtered.
6 - 10 DOZING EQUIPMENT HYDRAULIC SYSTEM D180
6.3.2 EQUIPMENT HYDRAULIC PUMP

WARNING
Removal Avoid kinking chains or steel cables. Always wear
safety gloves when handling chains and cables.
Operate as described, here below: Make sure that the cables are secured and that
- Drain the oil from equipment reservoir (S) as de- the securing point is strong enough to hold the
scribed at point 6.4.1. load applied.
- Start the engine and let it run for a few seconds, to Keep all by-standers away from the lifting point,
drain pump (P) suction pipe (1). the cables or chains.
- Tilt the cab/operator's compartment.
- Disconnect suction pipe (1) from pump P, looseing
retaining screws C1.
- Disconnect pipes (2) loosening screws C2 on half-
flanges (5).
- Disconnect draining pipes (6 - 7) from the pump
side.
Only after disconnecting all pipes, proceed with the

removal of the torque converter pump.
Hold the pump appropriately with cables and loosen
screws (8) securing the pump. Then, remove the
pump from torque converter cover (3). 5
4
7
5
C2
2
P 8 C1
SM1604
Fig. 10 - Equipment hydraulic pump and pipes
P. Equipment hydraulic pump - S. Tank - 1. Suction pump from tank - 2. Delivery pump to control valve - 3. Torque
converter cover - 4. Control valve - 5. Half-flanges - 6. Draining pipe - 7. LS signal pipe - 8. Pump securing screws -
C1 Screw TE M12x1.75x60 - C2 Screw M14x45.
D180 DOZING EQUIPMENT HYDRAULIC SYSTEM 6 - 11
6.3.3 HYDRAULIC CONTROL VALVE

(Removal/Disassembly/Overhaul)
The control valve is located under the cab and to re-

move it from the machine, it is necessary to tilt the
cab, as described in the OPERATION AND MAIN-
TENANCE MANUAL of the machine.
Removal of the control valve
WARNING
Fluido sotto pressione. Portare sempre l’attrezzatura
idraulica a terra. Fermare il motore, compiere alcuni
movimenti a vuoto delle leve di comando quindi svi-
tare e richiudere il tappo del serbatoio impianto id-
raulico per scaricare la pressione residua, prima di
staccare le connessioni dell’impianto idraulico.
Tag and disconnect all the hydraulic pipes, remove

three screws (C1) securing the control valve to the
relevant support on the machine; sling appropriately
the control valve with a cable and lift it and remove it
with a hoist.
Disassembly and overhaul
Drain completely the oil from the control valve and

place it on a work bench, proceeding wit a complete
disassembly.
Loosen the control valve securing screws and pro-
ceed with the disassembly of the single spools.
C1
SM1605
Fig. 11 - Hydraulic control valve
6.3.4 INSTALLATION OF BLADE
A. Push beam front pivot G1. 67 to 82 da Nm (494.7 to 604.80 lbf.ft)

B. and C. Cross rods pivot H. Tilt cylinder front pivot or side rod
D. Blade control cylinder rods pivot L. Blade cutting edge securing nuts (49 to 53 da
E. Blade central link pivot Nm) (361.40 to 390.91 lbf.ft)
F. Tilt cylinder rear pivot or side rod
G. Push beam rear pivot
D
E
L
G1 A
F B
SM1606
G
Fig. 12
PREPARATION
Print to installing any blade component, eliminate all Move the machine forward in between the push
protective wrappings, paint or scales from the mount- beams, aligning the beams with the ball joints.
ing or mating faces. Remove all plugs from the mount- Remove the pin covers and grease the ball joint.
ing holes and re-thread each hole with a tap. Install the shims and the cover, then lubricate the
screws prior to tightening them.
Install the blade lifting cylinder pins and locking.
INSTALLATION Install the hoses and eventual tilt cylinder guards.
Grease accurately all linkages.
Install a joint (G) on each track frame, tightening the
relevant securing screws.
Clean accurately the joint ball and the ball seats on
the beams and the pin covers. Smear generously the
ball joints and the joint ball seats with grease.
Position the blade and block it in a secure manner.
Position the individual blade push beams and install
the lower pins. Install the blade cross rods, install the
lever pins and the locking plates.

Single, 4-spool control valve, made by Rexroth
Max. operating pressure 160/350 bar (2320.6/5076.3 psi)
Oil temperature - 20 °C through 80 °C ( - 4 °F through
176 °F)
Recommended hydraulic oil HI-TECH 46 (ISO VG46)
Ports connections
SPOOL
A1 B1
A1 - B1 Hydraulic motor
STEERING
s
powering ports
2 2
A2 B2
Cylinders powering ports
RIPPER
s
8 A3 B3 8
}
A2 - B2
TILT
s
A3 - B3 a = Lowering
X1 7 A4 B1 7
A4 - B4 b = Raising
BLADE
s
MP
6 6
Spools piloting MSL
Y1 LS
a 1 - b1 = Steering 5
}
a 2 - b2 = LS
a 3 - b3 = a= lowering piloting
a 4 - b4 = b= raising piloting
SPOOL
b1 a1
STEERING
b2 a2
RIPPER
b3 a3
TILT
Steering hydraulic motor control b4 a4
safety valves, setting 380 ± 5 bar M
BLADE
TT
(5511.4 ± 72.52 psi)
P T
SM1607
Fig. 13 - Hydraulic control valve and connections (Ref. D hydraulic system diagram)
2. Steering hydraulic motor control safety valve setting 380 ± 5 bar (5511.4 ± 72.52 psi)
5. Equipment circuit main safety valve (setting 190 bar) and steering circuit (350 bar) (5511.4 psi)
6. Ripper spool safety valves (setting 230 ± 5 bar) (2320.6 ± 72.52 psi)
7. Tilt spool safety valves (setting 230 ± 5 bar) (2320.6 ± 72.52 psi)
8. Blade spool safety valve (setting 230 ± 5 bar) (2320.6 ± 72.52 psi)
T. To hydraulic oil tank
P. From powering pump
6.4.2 HYDRAULIC POWER PUMP
M H leftward rotation
S A
SM1608
R
Fig. 14 - Hydraulic pump
S. - Suction from tank
M. - Pressure pick-up
X. - To control valve Power to control valve
A. - Power to control valve To piloting
- To powering block block
M A G X
20÷21
LOAD
SENSING
VALVE "S"
bar
11
11
PRESS.
CUT-OFF 350 bar
"D"
CONSTANT
12
12
POWER
"LR" 90KW
1950 RPM
13
13
28÷32 bar
STAND-BY
PRESS
TORQUE 130
CC/REV
Qmax Qmin
CONVERTER
P
S
Hydraulic diagram
SM1609
Brand ................................................................................................................................................ REXROTH

Variable displacement piston type ............................................................................................................ A11V0
Total nominal delivery at 2000 rpm ................................................................................280 L/min (74 US gpm)
6.4.3 BLADE LIFTING CYLINDER BALL JOINT
C
E B A
D
F SM9455
Fig. 15 - Section of blade cylinder ball joint
A. Diameter of inner bush seat .......................................................... 84.875 to 84.929 mm (3.341 to 3.344 in)
Outer diameter of inner bush ......................................................... 84.965 to 85.000 mm (3.345 to 3.346 in)
Installation interference...................................................................... 0.036 to 0.125 mm (0.001 to 0.005 in)
B. Diameter of outer bush seat ...................................................... 144.837 to 144.900 mm (5.702 to 5.705 in)
Outer diameter of inner bush ....................................................... 145.07 to 145.100 mm (5.711 to 5.713 in)
Installation interference...................................................................... 0.170 to 0.263 mm (0.007 to 0.010 in)
C. Inner diameter of inner bush .......................................................... 76.200 to 76.270 mm (3.000 to 3.003 in)
Outer of pin in correspondence with inner bush ............................. 75.970 to 76.000 mm (2.990 to 2.992 in)
Clearance .......................................................................................... 0.200 to 0.300 mm (0.008 to 0.012 in)
D. Diameter of outer bush .............................................................. 130.300 to 130.350 mm (5.130 to 5.132 in)

Outer diameter of pin in correspondence with outer bus ............. 129.960 to 130.000 mm (5.116 to 5.118 in)
E. Inner diameter of cylinder pin (in its seat) ...................................... 50.050 to 50.112 mm (1.970 to 1.973 in)
Outer diameter of cylinder joint ...................................................... 49.975 to 50.000 mm (1.967 to 1.968 in)
F. Joint plate securing screws tightening torque ............................................................. 18 daNm (132.7 lbf.ft)
6.4.4 BLADE LIFTING CONTROL CYLINDER
C
6 4 13 15
C2 18
16
A B
1 2 3 8 C3 14
17
C1 - 5
10 7
18
12
11
SM9456
1. Cylinder sleeve
Fig. 16 - Section of blade cylinder
2. Piston
3. Piston seal kit
A. Nominal diameter of rod ................... 60 mm (2.362 in)
B. Nominal diameter of piston .............. 95 mm (3.740 in) 4. Rod seal kit
C. Stroke of cylinder rod ................. 1250 mm (49.212 in) 5. Front sleeve
C1. Tightening torque of front 6. Rod assembly
sleeve ............... (114 to 126 daNm, 840.8 to 929 lbf.ft) 7. Rod bearing
C2. Tightening torque of piston 8. S-E. valves stop washer
securing nut .... (93 to 103 daNm, 685.9 to 759.7 lbf.ft) 9. Piston securing nut
C3. Tightening torque
10. Circlip
of dowel .................... (3.4 to 3.8 daNm, 25 to 28 lbf.ft)
11. Plug
12. O-Ring 2.62 x 17.12
13. O-Ring 3.53 x 94.84
14. Dowel
15. O-Ring 5 x 85
16. Grease fitting TS M x 1
17. Plate
18. Make-up valve (quick-drop)
6.4.5 BLADE TILT CONTROL CYLINDER

(Bulldozer version)
3 C 1- 4 6 9 -8 1 2 5-7 13 12-C2 14-15-C3

11 10
A
B
C
SM9457
Fig. 17 - Section of blade tilt cylinder 1. Sleeve assembly

2. Rod assembly
A. Nominal diameter of rod ................... 70 mm (2.756 in) 3. Ball joint flange
B. Nominal diameter of piston ............ 140 mm (5.512 in) 4. Front sleeve
C. Stroke of cylinder rod ..................... 126 mm (4.961 in)
5. O-Ring
C1. Tightening torque of front
6. Seal assembly kit
sleeve screws ........................ 13.6 daNm (100.3 lbf.ft)
C2. Tightening torque of piston 7. Retaining ring
securing nut .......................... 250 daNm (1843.9 lbf.ft) 8. Guide ring
C3. Tightening torque of dowel (14) .... 5.7 daNm (42 lbf.ft) 9. O-Ring
10. Retaining ring
11. Screw TCE M12 x 1.75 x 45
12. Piston
13. Seal
14. Dowel
15. Steel ball

(Angledozer version)
C1 1 1 - 4 6 9-10 8 2 1 1 2 - 7 5-3-C4
C2 C3
A B
SM9458
Fig. 18 - Section of blade tilt cylinder 1. Sleeve assembly

2. Rod assembly
A. Nominal diameter of rod ....................... 70 mm (2.8 in) 3. Steel ball
B. Nominal diameter of piston ................. 110 mm (4.3 in)
4. Front sleeve
C. Stroke of cylinder rod ......................... 124 mm (4.9 in)
5. Screw
C1. Tightening torque .................. 210 daNm (1548.9 lbf.ft)
C2. Tightening torque of sleeve 6. Seal ass.ly kit
securing screw ................................. 8 daNm (59 lbf.ft) 7. Seal
C3. Tightening torque of piston 8. Guide ring
M45x2 ................................. 210 daNm (1548.9 lbf.ft) 9. O-Ring
C4. Tightening torque of piston 10. Retaining ring
blocking screw M8x1.25 ........... 1.6 daNm (11.8 lbf.ft) 11. Screw TCE M10 x 40
12. Piston
6.4.7 RIPPER CYLINDER
A B
1 2 3 4 5-C1 6 7 8 9 10 11-C2 12-C3
D1 C
D
SM9459
Fig. 19 - Section of ripper cylinder
A. Nominal diameter of rod ................................................................................................... 56 mm (2.205 in)
B. Nominal diameter of piston ............................................................................................. 100 mm (3.937 in)
C. Stroke of cylinder rod .................................................................................................... 480 mm (18.898 in)
D1. Outer diameter of rod bush ........................................................... 78.070 to 78.100 mm (3.074 to 3.075 in)
Diameter of bush seat .................................................................. 78.000 to 78.046 mm (3.071 to 3.073 in)
Installation interference .................................................................... 0.034 to 0.100 mm (0.001 to 0.004 in)
D. Inner diameter of rod bush ........................................................... 63.195 to 63.265 mm (2.488 to 2.491 in)
Diameter of bush seat .................................................................. 62.954 to 63.000 mm (2.478 to 2.480 in)
Installation interference .................................................................... 0.195 to 0.311 mm (0.007 to 0.012 in)
1. Sleeve ass.ly
C1. Tightening torque of sleeve ............. 133 to 147 daNm
2. Rod ass.ly
(981 to 1084.2 lbf.ft)
3. Plate
C2. Tightening torque of rod
4. O-Ring
securing nut ..................................... 110 to 121 daNm
5. Front sleeve
(811.3 to 892.4 lbf.ft)
6. Anti-extrusion ring
C3. Tightening torque of dowel ............... 3.4 to 3.8 daNm
7. O-Ring
(251.1 to 28 lbf.ft)
8. Sleeve ass.ly
9. Piston
10. Seal kit
11. Nut
12. Dowel
6.4.8 BLADE PUSH ARMS AND RODS
G1 A
C B
D
G SM1606
Fig. 20 - Bulldozer equipment linkage
A. Outer diameter of push arm front joint opin .................................. 59.954 to 60.000 mm (2.360 to 2.362 in)
Inner diameter of ball joint ............................................................ 60.190 to 60.264 mm (2.369 to 2.372 in)
Clearance ......................................................................................... 0.190 to 0.310 mm (0.007 to 0.012 in)
B. Outer diameter of rear rod and tilt cylinder pin .............................. 69.954 to 70.000 mm (2.754 to 2.756 in)
Inner diameter of pin bush ............................................................ 70.210 to 70.280 mm (2.764 to 2.767 in)
C. Diameter of push on rod and tilt cylinder ...................................... 81.875 to 81.929 mm (3.223 to 3.225 in)
Outer diameter of bush ................................................................. 81.965 to 82.000 mm (3.227 to 3.228 in)
D. Outer diameter of diagonal main rod and blade main pin ............. 59.954 to 60.000 mm (2.360 to 2.362 in)
Inner diameter of bushes .............................................................. 60.200 to 60.270 mm (2.370 to 2.373 in)
E. Inner diameter of diagonal main rod and blade main pin .............. 71.911 to 71.957 mm (2.831 to 2.833 in)
Outer diameter of bushes ............................................................. 71.970 to 72.000 mm (2.833 to 2.835 in)
Installation interference .................................................................. 0.013 to 0.089 mm (0.0005 to 0.003 in)
F. Outer diameter of front diagonal pin ............................................. 59.954 to 60.000 mm (2.360 to 2.362 in)
Inner diameter of ball joint ............................................................ 60.190 to 60.264 mm (2.370 to 2.372 in)
G. Outer diameter of push arm joint pin ........................................ 119.780 to 120.000 mm (4.716 to 4.724 in)
Inner diameter of push arm rear pin bush (in its seat) .............. 120.180 to 120.400 mm (4.731 to 4.740 in)
6.4.9 FRAME AND RODS
A C-D-E-F G H
SM9460
Fig. 21 - Angledozer equipment linkage
A. Outer diameter of C-frame joint opin ........................................ 119.780 to 120.000 mm (4.716 to 4.724 in)
Inner diameter of C-frame rear pin bush ................................... 120.180 to 120.400 mm (4.731 to 4.740 in)
B. Inner diameter of blade on seat .................................................... 50.130 to 50.290 mm (1.974 to 1.980 in)
Outer diameter of pin .................................................................... 49.840 to 50.000 mm (1.962 to 1.968 in)
C. Diameter of small seat in the rod pin flange .................................. 60.300 to 60.490 mm (2.374 to 2.381 in)
D. Diameter of small seat in the rod pin flange .................................. 68.300 to 68.490 mm (2.689 to 2.696 in)
E. Outer diameter of ball pin ............................................................. 89.780 to 90.000 mm (3.535 to 3.543 in)
Inner diameter of rod pin seat ....................................................... 90.220 to 90.440 mm (3.552 to 3.561 in)
F. Outer diameter of pin seat flange ............................................. 101.964 to 102.000 mm (4.014 to 4.016 in)
Inner diameter of rod pin seat ................................................... 102.000 to 102.140 mm (4.016 to 4.021 in)
G. Diameter of upper rod pin seat flange in lower rod ....................... 40.120 to 40.280 mm (1.579 to 1.586 in)
Outer diameter of upper rod pin .................................................... 39.840 to 40.000 mm (1.568 to 1.575 in)
H. Inner diameter of ball seat for pin ................................................. 40.120 to 40.280 mm (1.579 to 1.586 in)
6.4.10 RIPPER LINKAGE FOR LT/XLT MODEL
Model ......................................................................................................................... PD 180

Type ........................................................................................................................... parallelogram, actuated
by two double stroke
cylinders, equipped
with semi curved teeth
with interchangeable
tips.
A. Max. work depth ........................................................................................................... 540 mm (21.260 in)
B. Max. work widt ............................................................................................................ 1900 mm (74.803 in)
C. Max. tooth lifting ........................................................................................................... 503 mm (19.803 in)
D. Nominal diameter of cylinder piston ................................................................................ 100 mm (3.937 in)
E. Cylinder rod max. stroke ............................................................................................... 480 mm (18.898 in)
F. Diameter of bush seat in cylinder rod .......................................... 78.000 to 78.046 mm (3.071 to 3.073 in)
Outer diameter of bush ................................................................ 78.070 to 78.100 mm (3.074 to 3.075 in)
Installation interference ................................................................... 0.034 to 0.100 mm (0.001 to 0.004 in)
Inner diameter of bush................................................................. 63.195 to 63.265 mm (2.488 to 2.491 in)
Outer diameter of pin ................................................................... 62.954 to 63.000 mm (2.478 to 2.480 in)
Clearance ....................................................................................... 0.195 to 0.311 mm (0.008 to 0.0012 in)
G. Diameter of bush seat in frame ................................................... 78.000 to 78.046 mm (3.071 to 3.073 in)
H. Diameter of bush seat in link ....................................................... 95.000 to 95.054 mm (3.740 to 3.742 in)
Clearance ........................................................................................ 0.210 to 0.326 mm (0.008 to 0.013 in)
I. Diameter of bush seat in frame ................................................... 95.000 to 95.054 mm (3.740 to 3.742 in)
Clearance ........................................................................................ 0.210 to 0.326 mm (0.008 to 0.013 in)
J. Tightening torque of support securing screws ..................................... 96 to 106 daNm (708 to 781.8 lbf.ft)
K. Tightening torque of pin locking plate securing screws .............................................. 7.1 daNm (52.4 lbf.ft)
C E
I G
Fig. 22 - Ripper SM9462
6.4.11 RIPPER LINKAGE FOR LGP MODEL
Model ......................................................................................................................... RP 14F

Type ........................................................................................................................... parallelogram, actuated
by two double stroke
cylinders, equipped
with semi curved teeth
with interchangeable
tips.
F. Under beam headroom with lowered ripper .................................................................... 138 mm (5.433 in)
G. Rampe angle ......................................................................................................................................... 26°
SECTION 6 BIS
DOZING EQUIPMENT HYDRAULIC SYSTEM
D180 STEERING CLUTCHES

TABLE OF CONTENTS
6.1 GENERAL DESCRIPTION ................................................................................................. 6-3

6.1.1 Operation of the hydraulic system ...................................................................................... 6-3
6.1.2 Diagram of dozing equipment hydraulic system ................................................................. 6-5
6.2 TROUBLESHOOTING ....................................................................................................... 6-7
6.3 TESTS ............................................................................................................................. 6-11

6.3.1 Use of the flow meter ....................................................................................................... 6-11
6.3.2 Flow test in single circuits ................................................................................................. 6-11
6.4 REPAIR PROCEDURES .................................................................................................. 6-12

6.4.1 Hydraulic oil reservoir ....................................................................................................... 6-12
6.4.2 Equipment hydraulic pump ............................................................................................... 6-14
6.4.4 Blade installation .............................................................................................................. 6-16

6.5.2 Supply hydraulic pump ..................................................................................................... 6-18
6.5.3 Blade lifting cylinder ball joint ............................................................................................ 6-18
6.5.4 Blade lifting control cylinder .............................................................................................. 6-20
6.5.5 Blade Tilt control (Bulldozer version) ................................................................................ 6-21
6.5.6 Blade Tilt control (Angledozer version) ............................................................................. 6-22
6.5.7 Ripper cylinder ................................................................................................................. 6-23
6.5.8 Blade push arms and rods ............................................................................................... 6-24
6.5.9 Frame and rods ................................................................................................................ 6-25
6.5.10 Ripper linkage for LT/XLT model ...................................................................................... 6-26
6.6 SPECIAL TOOLS ............................................................................................................. 6-29

6.1.1 OPERATION OF THE HYDRAULIC SYSTEM
The D180 dozer can be equipped with Bulldozer or a 1 cylinder Angledozer. The hydraulic system is similar in
both instances.
In the angledozer version, a configuration with fully mechanical Tilt is also available, in which the relevant spool
on the control valve is not used.
The hydraulic system is equipped with a variable displacement, piston type supply pump (P) mounted on the
torque converter, sucking oil from oil reservoir (S), through metal mesh filter (Fa).
The ripper control pilot valve (9) can take four positions, corresponding to: lift, neutral, lowering and floating, and
also for the blade tilting, rightward or leftward.
Two safety levers, located to the right and left of the operator's seat, electrically cut-off (in raised position)
through a proximity switch, the powering of the control pilot valves, preventing accidental movements of the pilot
valve. When the machine is standing and the lever is in lowered position, the machine is capable of performing
all work operations.
The activation of indicator light (19) located on the Monitor instrument panel in the cab, warns that return filter
cartridge (Fr) is clogged and that it must be promptly replaced.
Oil sucked by pump (P) supplies control valve (D) and the supply block, flows from pilot valves (8 and 9) allowing
the hydraulic piloting of the spools of the control valve (Powering pressure of the pilot valves 30 bar, 435.11 psi).
The movement of any spool occurs through check valves in the actuating circuit being selected. The pressure
established in the delivery circuit is proportional to the effort required and it is limited by pressure relief valve (4)
set at 190 bar, 2755.72 psi. Also, the following valves are mounted on the control valve:
- two multiple safety valves (5), located on the blade lift and lowering circuits.
- two accidental over pressure safety valves (6) located on the tilt circuit, and two valves (7) also for the ripper
lifting and lowering circuit.
The circuit is equipped with an L.S. (Load Sensing) system. A connection between the feeding pump and the
control valve allows the latter to send a signal to the pump, regulating the oil flow, depending upon the effective
requirements of the actuators, making the pump delivery change up to maximum flow at maximum speed
(170 Lt/min - 44.91 USGal/min).
QUICK DROP VALVES
Quick-drop valves (V) hydraulic system diagram; located on the blade lift cylinder bottom, operate during the
blade lowering phase, accelerating the movement.
When the operator pushes the blade control pilot valve into lowering position, oil flowing out the lower chamber
of the cylinder, under the effect of the weight of the blade and the flow of oil to the cylinder upper chamber,
pushes the ball which actuates the plunger, which, by moving, opens the oil delivery port from the valve to the
cylinder upper chamber, thus speeding up the descent of the blade.
When the operator pushes the blade control lever slightly forward, the condition when the blade drops by gravity,
instead of under the effect of pressurised oil, occurs. The ball has been blocked in its seat and the oil is pre-
vented from flowing from one side of the cylinder to the other.
Stroke-end valves are mounted in the blade control cylinders. They are made by ducts inside the piston, in which
seats and a plunger are located. The plunger cuts-off the passage when the oil pressure blocks it against the
relevant seat. It stays closed until the piston ends its stroke. The plunger is moved away from its seat by the
contact of the plunger rod against the end of the cylinder. Oil flows from one end of the cylinder to the other,
limiting the movement of the piston. These valves are necessary, as a result of the blade Tilt action. Thus it is
possible that the piston of a blade control cylinder is at stroke-end, whereas the other one still has to travel part
of it.
BLADE HYDRAULIC TILT
The Tilt control is obtained by a sideways movement of the lever. The rightward movement of the lever causes
the rightward tilting of the blade (clockwise rotation); in the same manner, the leftward movement of the lever
causes the leftward tilting of the blade (anticlockwise rotation).
The Tilt control circuit is equipped with a flow reduction (7) limiting the flow of oil to the cylinder, facilitating the
control of the blade. When the pump flow is reduced, oil operates lifting the valve plunger.
BLADE CONTROL LEVER POSITIONS
The lever controls the lifting, lowering and tilting of the

blade.
To lift or lower the blade, move the lever respectively
backward into position D or forward into position H.
The holding of the blade into a desired position
occurs, in both instances, by releasing the lever,
which returns automatically into neutral N.
To make the blade floating, bearing on the ground just
under the effect of its weight, push the lever full stroke
forward, into position F, where it is held by an
appropriate detent.
The floating condition ends when returning the lever
into neutral position N.
Mowing the lever leftward into position A, or rightward
into position B, the tilting of the blade is obtained. The
lever must be held until the blade reaches the desired
position. SM9474
Blade control lever positions decal
RIPPER CONTROL LEVER POSITIONS

(upon request)
- With lever forward in P = ripper lowering.

- With lever backward in R = ripper lifting.
- Lever in N = neutral.
SM9475
Ripper control lever positions decal
6.1.2 DIAGRAM OF DOZING EQUIPMENT HYDRAULIC SYSTEM

(Principle diagram)
Bucket
Tilt
From control valve
Ripper
From control valve to pump
Fig. 5 Principle diagram of dozing equipment hydraulic system (bulldozer version)
1. Blade control spool. 2. Tilt control spool. 3. Ripper control spool. 4. Pressure relief valve (190 bar/2698 psi). 5. Blade control spool safety valves (230 bar/3266 psi). 6. Tilt control spool safety valves (230 bar/3266 psi). 7. Ripper control spool safety
valves (230 bar). 8. Blade lifting/lowering control pilot valve plus blade tilt. 9. Ripper lifting/lowering control pilot valve. 10. Unloading valve. 11. Compensators. 12. Hydraulic oil filter by-pass valve. 13. Draining valve. 14. Feeding block solenoid valve.
15. Feeding block pressure relief valve (40 bar/568 psi). 16. Accumulator 0.7 lt. (0.18 US gal) 17. Flow reduction valve (30 bar/426 psi).18. Discharge control pressurising valve. 19. Hydraulic oil filter clogging indicator light. 20. Cut-off signal valve. 21.
LS (Load sensing) regulating valve. 22. Main ppressure relief valve.
DOZER EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
P. Piston, variable displacement supply pump (170 L/min at 2000 rpm)

D. Piloted control valve
S. Hydraulic oil reservoir
Va. Pilot valves supply block
Cl. Blade lifting/lowering cylinder
Ct. Tilt lifting/lowering cylinder
Cr. Ripper lifting/lowering cylinder
Fa. Oil reservoir suction filter
Fr. Oil return filter to reservoir
Ls. Load-sensing signal
V. Quick-drop valves
Connecting ports
Control valve - Cylinders Flow

A1. Ripper cylinder lowering Q= 170 L/min (44.91 US gal/min)
B1. Ripper cylinder lifting Q= 170 L/min (44.91 US gal/min)
A2. Tilt cylinder lowering Q= 70 L/min (18.49 US gal/min)
B2. Tilt cylinder lifting Q= 70 L/min (18.49 US gal/min)
A3. Blade control cylinders lowering Q= 170 L/min (44.91 US gal/min)
B3. Blade control cylinders lifting Q= 170 L/min (44.91 US gal/min)
Blade control pilot valve

Blade lowering 1 Ü a3
Floating 5 Ü x
Blade tilt 2 Ü a2
Blade lifting 3 Ü b3
Blade tilt 4 Ü b2
Ripper control pilot valve

Lifting 1 Ü b1
Lowering 2 Ü a1
6.2 TROUBLESHOOTING
POSSIBLE TOOLS
TROUBLE CAUSE REQ.ED TEST SOLUTION
All cylinders Worn pump Perform test flow If the test proves a
operate slowly pressure drop of
15% from no load
through test load, re-
place the pump
Main safety valve Perform test flow If the flow is very low
stuck open and the pressure
does not reach the
prescribed values,
reset the main pres-
sure relief valve
Control linkage out of Perform test flow Check and adjust the
adjustment linkage for a precise
spool stroke
A series of Control valve broken Move the spool Negative test, re-
cylinders moves manually place the valve
slowly
Control valve stuck Perform test flow Replace the valve if
in its seat spool stucks
Safety valve stuck Perform test flow Negative test, replace

open the valve
Cylinder piston seal Negative test of cylin-

leaking der, replace seal
The hydraulic oil Insufficient oil level Operation and Perform test flow Refill equipment res-
overheats Maintenance ervoir with oil of the
Manual prescribed type
Suction filter clogged Suction is clogged,

clean suction filter
Pump suction Perform test flow Repair seal or tighten

leaking connections
Main safety valve out Re-set at prescribed

of setting value
POSSIBLE TOOLS
TROUBLE TEST SOLUTION
CAUSE REQ.ED
Noisy pump Insufficient oil level Operation and Refill the equipment
after 15 minutes Maintenance reservoir with oil of
in operation Instruction Manual the prescribed type
Suction filter clogged Perform flow test If the suction remains

clogged, clean suction
filter
Leakages on pump Check if there are Repair seal or tighten

suction traces of oil on the connections
ground or trans-
mission
Oil too thick Operation and Refill the equipment

Maintenance reservoir with oil of
Instruction Manual the prescribed type
The equipment Main pump defective Replace pump

does not oper-
ate
The equipment Control valve Perform flow test Overhaul or replace

does not oper- defective control valve
ate in one
direction Circuit safety valve Perform flow test Clean or replace
blocked open valve
(blade only) Quick drop valve Clean or replace

plunger blocked valve
open
(blade and tilt) Stroke-end valves Perform flow test Repair stroke-end
blocked open valves
The equipment Circuit safety valve Perform flow test If the valve does not
does not stay in blocked open in pass the test, repair
position se- usage involved or replace it
lected
Excessive leakage at Perform flow test If replacing circuit
control valve spools safety valve does not
suffice, replace con-
trol valve
Leakage from Perform flow test If cylinder does not

cylinder piston seals pass test, replace
seal
Presence of air in Bleed air from cylinder

the cylinders
Insufficient oil level Operation and Perform bleeding Refill the equipment
Maintenance test reservoir with oil of
Instruction Manual the prescribed type
POSSIBLE TOOLS
The equipment Pump suction leaking Check if there are Repair the seal or
does not stay in traces of oil on the tighten the connec-
the position ground or the tions
chosen (contin- transmission
ued)
The blade does Cylinder piston seal Perform flow test If cylinder fails the
not maintain the leaking test replace seal
pitch and tilt
positions Excessive spools Perform flow test If replacement of cir-
leakage cuit safety valve is
not sufficient, re-
place control valve
Stroke-end valves Perform flow test Replace stroke-end

stuck open valves
Equipment Suction filter clogged Perform flow test If suction is clogged,

operation slow clean suction filte e
or weak
Main safety valve set Perform flow test Re-set at correct
too low pressure
Main pump defective Perform flow test Replace pump

Main valve body Perform flow test If it fails test, replace
broken valve
(blade only) Quick drop valve Perform flow test Clean or replace
plunger stuck open valve
Faulty operation Oil level insufficient Operation and Refill equipment res-
of equipment Maintenance ervoir with oil of the
Instruction Manual prescribed type
Suction filter clogged Perform flow test If suction is clog-ged

clean suction filter
Pump suction leaking Check if there are Replace seal or

traces of oil ou tighten connections
ground or trans-
mission
POSSIBLE TOOLS
Tilt and pitch op- The delivery control Operation and Perform flow test Clean or overhaul
erations too valve does not open Maintenance the valve
slow in both enough Manual
directions
The blade or Insufficient oil level Re-fill the equipment

ripper do not with oil of the
raise, but the prescribed type
descent power
is good Cylinder piston seal Pushing speed too If the cylinder fails
leaking fast the test, replace the
seal
(blade only) Quick-drop valve Clean or replace the

plunger stuck open valve
Stroke-end valves Clean or overhaul

insufficient the valve
6.3 TESTS
6.3.1 USE OF THE FLOW METER REFERENCE PERFORMANCE TABLE
The use of flow meter 380060080 facilitates the trou-

bleshooting of the hydraulic system. To avoid possi- ENGINE RPM PRESCRIBED VALUES
ble counter pressures, the return piping of the flow D180 LT/XLT
meter must have a diameter slightly higher the inlet
pipe. The return pipe is connected to the reservoir Low idle 830 ÷ 970 g/min
filler neck: remove the mesh filter and insert the pipe
into the reservoir at a depth ensuring that it is well High idle 2080 ÷ 2220 g/min
submerged.
Transmission stall 1730 ÷ 1870 g/min
The pipe connected to the reservoir, has the tendency
to "jump out" during the tests and then, must be well Equipment stall 2070 ÷ 2210 g/min
secured in its position. When applying pressure us-
ing the load valve of the instrument, this tendency Full stall 1675 ÷ 1875 g/min
could increase however with limits of controllability.
Prior to starting the tests, make sure that the pipes
used are of a high pressure type, capable of bearing PRESSIONI PRESCRIBED VALUES
at least 210 bar (3045.79 psi).
Equipment (Max.) 180 ÷ 200 Bar
(2610.66 ÷ 2900.75 psi)
Supply pressure 30 ÷ 32 Bar

6.3.2 FLOW TEST IN SINGLE CIRCUITS (Pick-up M) (435.11 ÷ 464.12 psi)
Plug the delivery pipes to the blade and tilt actuating Stand-by pressure 28 ÷ 32 Bar
cylinders, so that they can be loaded. Since the cylin- neutral (Pick-up P) (406.10 ÷ 464.12 psi)
ders are equipped with stroke-end valves on the pis-
tons, the load needed cannot be obtained when ac- Stand-by pressure 28 ÷ 32 Bar
tuating the cylinders to stroke-end. On the other hand, float (Pick-up P) (406.10 ÷ 464.12 psi)
the ripper circuit can be tested working at stroke-end
in both directions. Steering 340 ÷ 360 Bar
(4931.28 ÷ 5221.36 psi)
Brake control 18 ÷ 22 Bar

(261.07 ÷ 319.08 psi)
DANGER
Fluid under pressure - Always drop the hydraulic Transmission 16.5 ÷ 17.5 Bar
equipment to the ground. Cut-off the engine, per- (239.31 ÷ 253.82 psi)
form a few no-load movements of the control le-
vers, then loosen and re-close the reservoir cap,
prior to disconnecting the connections of the sys-
tem du circuit.
WARNING
DO NOT USE YOUR HANDS to identify pressure
leakages. Jets of fluid under pressure have
enough force to penetrate the skin. Start the en-
gine and wait that the hydraulic oil reaches the
operational temperature, then accelerate the en-
gine to maximum speed.
6.4.1 HYDRAULIC OIL RESERVOIR

(Removal / installation)
Removal Moving
Turn the main switch into "OFF" to cut-off the electri- direction
cal system and apply a signal "DO NOT OPERATE"
on the switch as illustrated.
ON
WARNING OFF
DO PER
To minimise the risk of fires or explosions, prior
NO ATE
to performing any welding operation on the fuel
T
reservoir, it is recommended that the reservoir is
fully drained, all pipes are disconnected, protect- SM1601
ing their ends, and the inside of the reservoir is
steam cleaned. Also all traces of fuel must be re- Fig. 7. Electrical system main switch
moved before starting welding.
Flood the reservoir with carbon dioxide (CO2)
before and during the welding operation.
While welding, all caps and covers must be re-
moved and all then other openings kept open to
provide ventilation.
Then, proceed as follows: B

– lift the machine; A
– drain the hydraulic oil from the reservoir using a
container of at least 70 Lt (18.49 US gal) capacity,
loosening the appropriate plug (T) located under
the reservoir and magnetic rod (Z).
– disconnect the oil delivery and return pipes to the
equipment control valve; Z
– disconnect the oil filter clogging indicator sensor
connector (5 fig. 9) of the equipment hydraulic cir-
cuit.
T
– remove the two upper screws (C) securing the oil
reservoir to the fuel reservoir; SM9470
– remove the three lower screws (C1) securing the
reservoir to the frame;
Fig. 8. Hydraulic oil reservoir
– remove the reservoir using a handle welded to the
rear side with an adequate lifting device.
DANGER
Make sure that the cables are secured and that
the securing point is strong enough to hold the
load applied.
Keep all by-standers away from the lifting point,
the cables or chains.
C
C2
C 2
4 3
Fr
1
5
3
2
C2
Fa
C1 SM9471
Fig. 9. Hydraulic oil reservoir and filters.

1. Hydraulic oil reservoir; 2. Filter covers; 3. O-Ring; 4. Oil filler cap; 5. Return oil filter clogging sensor;
C. Reservoir upper securing screw (M14x2x45); C1. Reservoir lower securing screw (M14x2x45); C2. Cover securing
screw; Fa. Suction filter; Fr. Return filter.
FILTERS
The purification of the equipment hydraulic oil is ensured Return filter (Fr) must be replaced periodically every 500
by two separate full flow filters, located inside the hydrau- hours work, to avoid that the oil with a clogged filter is no
lic oil reservoir and precisely: longer filtered.
– filter (Fa, fig 9) located on the suction line from the pump,
equipped with magnetic rod (3) and a metal filtering el-
ement; DANGER
– filter (Fr), located on the pump return, equipped with a
paper filtering element, equipped with a filter cut-off by- Never use gasoline, solvents or other flammable flu-
pass valve, in case of clogging and sender (5) for the ids to clean components. Use commercial non-toxic,
indicator light located on the dashboard. non-flammable approved solvents only.
Both filters are accessible by removing covers (2) located
on the reservoir, removing the relevant securing screws (C2).
Filter (Fa) is cleaned using an appropriate solvent each Re-installation of filters and reservoir
time the hydraulic oil is changed (every 2000 hours) and The re-installation of hydraulic oil filters and reservoir is
must be replaced only when required. done, reversing the removal sequence.
6.4.2 EQUIPMENT HYDRAULIC PUMP

WARNING
Removal
Avoid kinking chains or steel cables. Always wear
Operate as described, here below: safety gloves when handling chains and cables.
– Drain the oil from equipment reservoir (S) as de- Make sure that the cables are secured and that
scribed at point 6.4.1. the securing point is strong enough to hold the
– start the engine and let it run for a few seconds, to load applied.
drain pump (P) suction pipe (1). Keep all by-standers away from the lifting point,
– tilt the cab/operator's compartment. the cables or chains.
– disconnect suction pipe (1) from pump P, loosen-
ing retaining screws C1.
– Disconnect pipes (2) loosening screws C2 on half-
flanges (5).
– Disconnect draining pipes (6 - 7) from the pump
side.
S
After disconnecting all the connection pipes to the
pump, proceed with the removal of the pump from
the torque converter.
Hold, appropriately, the pump with cables and loosen
nuts (8) retaining the pump. Extract the pump from
studs (9) of torque converter (3).
4
3
1
7
2
C1
C2
5
8
SM9451
Fig. 10. Equipment hydraulic pump and pipes

P. Equipment hydraulic pump; S. Reservoir; 1. Suction pipe from reservoir; 2 Delivery pipe to control valve;
3. Torque converter; 4. Control valve; 5. Half-flanges; 6. Draining pipe; 7. LS signal pipe; 8. Pump securing nut
(M16x1.5); 9. Studs; C1. Screw TE M12x1.75x60; C2. Screw M14x45.

(removal/disassembly/overhaul)
The control valve is located inside the right side panel Disassembly and overhaul
of the cab.
Drain completely the oil from the control valve and
place it on a work bench, proceeding wit a complete
Removal disassembly.
Loosen the control valve securing screws and pro-
DANGER ceed with the disassembly of the single spools.
Fluid under pressure. Always lower the hydrau-
lic equipment to the ground. Cut-off the engine,
move the control levers with no load a few times,
then open and close the hydraulic system reser-
voir cap to relieve residual pressures, prior to
disconnecting the connections of the hydraulic
system.
To remove the control valve from the machine, it is

necessary:
– to tilt the cab;

– to label and disconnect all hydraulic pipes, to re-
move the three screws (C1) securing the control
valve to the relevant support on the machine, sling
the control valve appropriately with a cable and lift
it and remove it with a hoist.
C1
SM9479
Fig. 14. Hydraulic control valve
6.4.4 INSTALLATION OF BLADE
A. Push beam front pivot G1 = 67 to 82 daNm (494.17 to 604.80 lbf.ft)

B. and C. Cross rods pivot H. Tilt cylinder front pivot or side rod
D. Blade control cylinder rods pivot L. Blade cutting edge securing nuts (49 to 53 daNm)
E. Blade central link pivot (361.40 to 390.91 lbf.ft)
F. Tilt cylinder rear pivot or side rod
G. Push beam rear pivot
C
E
L
A
B
G1 F
SM9477
Fig. 16
G
PREPARATION
Print to installing any blade component, eliminate all Move the machine forward in between the push
protective wrappings, paint or scales from the mount- beams, aligning the beams with the ball joints.
ing or mating faces. Remove all plugs from the mount- Remove the pin covers and grease the ball joint.
ing holes and re-thread each hole with a tap. Install the shims and the cover, then lubricate the
screws prior to tightening them.
Install the blade lifting cylinder pins and locking.
INSTALLATION Install the hoses and eventual tilt cylinder guards.
Grease accurately all linkages.
Install a joint (G) on each track frame, tightening the
relevant securing screws.
Clean accurately the joint ball and the ball seats on
the beams and the pin covers. Smear generously the
ball joints and the joint ball seats with grease.
Position the blade and block it in a secure manner.
Position the individual blade push beams and install
the lower pins.
Install the blade cross rods, install the lever pins and
the locking plates.

Single 3-spool control valve made by Kayaba Blade lift
piloting
Max. operating pressure: 190 bar (2755.75 psi)
Oil temperature from -20 through 80° C (-4 through
176° F) a3
Recommended hydraulic oil HI-TECH 46 (ISO VG46)
b3 Blade lowering
piloting
Tilt lifting a2
piloting
b2
Tilt lowering
piloting
a1
b1
P
Ripper lowering
Ripper lifting piloting
piloting
SM9480B
Control valve
supply
Lowering
bucket cyl.
A B Lifting bucket cyl.
5 B3 5
Lowering tilt cyl. 3

A3
Lifting tilt cyl.
6
6 B2
2
A2
7
1
A1
4 T B1
Lifting ripper
Lowering ripper
SM9480
Fig. 17. Hydraulic valve control valve (Ref. hydraulic valve diagram)
4. Main pressure relief valve (set at 190 bar/2755.72 psi)

5. Blade spool safety valve (set at 230 ± 5 bar / 3335.87 ± 72.52 psi)
6. Tilt spool safety valve (set at 230 ± 5 bar / 3335.87 ± 72.52 psi)
7. Ripper spool safety valve (set at 230 ± 5 bar / 3335.87 ± 72.52 psi)
A1- B1

A2- B2  Supply ports to cylinders
A3- B3  A = Lowering
B = Lifting
T. To hydraulic oil reservoir
P. From supply pump
6.5.2 SUPPLY HYDRAULIC PUMP
SM9481
Fig. 18. Section of hydraulic pump
Made b ............................................................................................................................................. REXROTH

Variable displacement, piston type ............................................................................................... A10V085DFR
Nominal pressure 250 bar (3625.94 psi) ....................................................................................... anticlockwise
Total nominal flow at 2000 rpm ............................................................................ 170 L/min (44.91 US gal/min)
6.5.3 BLADE LIFTING CYLINDER BALL JOINT
E B A C
D
F SM9455
Fig. 19. Section of blade cylinder ball joint
A. Diameter of inner bush seat ........................................................84.875÷84.929 mm (3.3415 to 3.3436 in)

Outer diameter of inner bush .......................................................84.965÷85.000 mm (3.3451 to 3.3464 in)
Installation interference .................................................................. 0.036÷0.125 mm (0.0014 to 0.0049 in)
B. Diameter of outer bush seat ....................................................... 144.837÷144.900 mm (5.7022 to 5.7047)

Outer diameter of inner bush .......................................................... 145.07÷45.100 mm (5.7114 to 1.7756)
Installation interference .................................................................. 0.170÷0.263 mm (0.0067 to 0.0103 in)
C. Inner diameter of inner bush ........................................................76.200÷76.270 mm (2.9999 to 3.0027 in)

Outer of pin in correspondence with inner bush ...........................75.970÷76.000 mm (2.9909 to 2.9921 in)
Clearance ........................................................................................ 0.200÷0.300 mm (0.0079 to 0.0118 in)
D. Diameter of outer bush ............................................................ 130.300÷130.350 mm (5.1299 to 5.1319 in)

Outer diameter of pin in correspondence with outer bus.......... 129.960÷130.000 mm (5.1165 to 5.1181 in)
Clearance ........................................................................................ 0.300÷0.390 mm (0.0118 to 0.0153 in)
E. Inner diameter of cylinder pin (in its seat) .................................... 50.050÷50.112 mm (1.9705 to 1.9729 in)
Outer diameter of cylinder joint ....................................................49.975÷50.000 mm (1.9675 to 1.9685 in)
Clearance ....................................................................................... 0.050÷0.137 mm (0.0020 to 0.0054 in)
F. Joint plate securing screws tightening torque ......................................................... 18 daNm (132.76 lbf.ft)
6.5.4 BLADE LIFTING CONTROL CYLINDER
C
6 4 13 15
C2 18
16
A B
1 2 3 8 C3 14
17
C1 - 5
10 7
18
12
11
SM9456
1. Cylinder sleeve
Fig. 20. Section of blade cylinder
2. Piston
A. Nominal diameter of rod ........................... 60 mm (2.362 in) 3. Piston seal kit
B. Nominal diameter of piston ...................... 95 mm (3.740 in) 4. Rod seal kit
C. Stroke of cylinder rod .......................... 1250 mm (49.212 in) 5. Front sleeve
C1. Tightening torque of front sleeve ............... 114 ÷ 126 daNm 6. Rod assembly
........................................................ (840.82 to 929.33 lbf.ft) 7. Rod bearing
C2. Tightening torque of piston securing nut ..... 93 ÷ 103 daNm
8. S-E. valves stop washer
........................................................ (685.93 to 759.69 lbf.ft)
9. Piston securing nut
C3. Tightening torque of dowel .......................... 3.4 ÷ 3.8 daNm
10. Circlip
............................................................ (25.08 to 28.03 lbf.ft)
11. Plug
12. O-Ring 2.62 x 17.12
13. O-Ring 3.53 x 94.84
14. Dowel
15. O-Ring 5 x 85
16. Grease fitting TS M x 1
17. Plate
18. Make-up valve (quick-drop)

(Bulldozer version)
3 C1-11 4 6 9 -8 1 2 5-7 13 12-C2 14-15-C3

10
A
B
C
SM9457
1. Sleeve ass.ly
Fig. 21. Section of blade tilt cylinder
2. Rod ass.ly
3. Ball joint flange
A. Nominal diameter of rod ............................. 70 mm (2.75 in)
4. Front sleeve
B. Nominal diameter of piston ...................... 140 mm (5.51 in)
C. Stroke of cylinder rod ............................... 126 mm (4.96 in) 5. O-Ring
C1. Tightening torque of front sleeve screws ............ 13.6 daNm 6. Seal ass.ly kit
....................................................................... (100.31 lbf.ft) 7. Retaining ring
C2. Tightening torque of piston securing nut ............. 250 daNm 8. Guide ring
...................................................................... (1843.90 lbf.ft) 9. O-Ring
C3. Tightening torque of dowel (14) ........................... 5.7 daNm 10. Retaining ring
......................................................................... (42.04 lbf.ft) 11. Screw TCE M12 x 1.75 x 45
12. Piston
13. Seal
14. Dowel
15. Steel ball

(Angledozer version)
C1 11-C2 4 6 9-10 8 2 1 1 2 - 7 5-3-C4

C3
A B
SM9458
Fig. 22. Section of blade tilt cylinde 1. Sleeve ass.ly

2. Rod ass.ly
A. Nominal diameter of rod .....................................70 mm (2.75 in) 3. Steel ball
B. Nominal diameter of piston .............................. 110 mm (4.33 in) 4. Front sleeve
C. Stroke of cylinder rod ....................................... 124 mm (4.88 in) 5. Screw
C1. Tightening torque ............................... 210 daNm (1548.88 lbf.ft) 6. Seal ass.ly kit
C2. Tightening torque of sleeve securing screw .... 8 daNm (59 lbf.ft) 7. Seal
C3. Tightening torque of piston M45x2 .... 210 daNm (1548.88 lbf.ft)
8. Guide ring
C4. Tightening torque of piston blocking screw M8x1.25 .. 1.6 daNm
9. O-Ring
................................................................................... (11.8 lbf.ft)
10. Retaining ring
11. Screw TCE M10 x 40
12. Piston
6.5.7 RIPPER CYLINDER

A B
1 2 3 4 5-C1 6 7 8 9 10 11-C2 12-C3
D1 C
D
SM9459
Fig. 23. Section of ripper cylinder
A. Nominal diameter of rod ..................................................................................................... 56 mm (2.20 in)
B. Nominal diameter of piston ............................................................................................... 100 mm (3.94 in)
C. Stroke of cylinder rod ...................................................................................................... 480 mm (18.90 in)
D1. Outer diameter of rod bush .......................................................... 78.070÷78,100 mm (3.0736 to 3.0748 in)
Diameter of bush seat ................................................................. 78.000÷78.046 mm (3.0709 to 3.0727 in)
Installation interference ................................................................... 0.034÷0.100 mm (0.0013 to 0.0039 in)
D. Inner diameter of rod bush .......................................................... 63.195÷63.265 mm (2.4880 to 2.4907 in)

Diameter of bush seat ................................................................. 62.954÷63.000 mm (2.4785 to 2.4803 in)
Installation interference ................................................................... 0.195÷0.311 mm (0.0077 to 0.0122 in)
1. Sleeve ass.ly
2. Rod ass.ly
3. Plate
C1. Tightening torque of sleeve133 ÷ 147 daNm (980.96 to 1084.22 lbf.ft) 4. O-Ring
C2. Tightening torque of rod 5. Front sleeve
securing nut .................. 110 ÷ 121 daNm (811.32 to 892.45 lbf.ft) 6. Anti-extrusion ring
C3. Tightening torque of dowel 3.4 ÷ 3.8 daNm (25.08 to 28.03 lbf.ft) 7. O-Ring
8. Sleeve ass.ly
9. Piston
10. Seal kit
11. Nut
12. Dowel
6.5.8 BLADE PUSH ARMS AND RODS F
A
B
D C SM9477
Fig. 24. Bulldozer equipment linkage
A. Outer diameter of push arm front joint pin ................................... 59.954 ÷ 60.000 mm (2.364 to 2.3622 in)
Inner diameter of ball joint ......................................................... 60.190 ÷ 60.264 mm (2.3697 to 2.3726 in)
Clearance ...................................................................................... 0.190 ÷ 0.310 mm (0.0075 to 0.0122 in)
B. Outer diameter of rear rod and tilt cylinder pin ........................... 69.954 ÷ 70.000 mm (2.7541 to 2.7559 in)
Inner diameter of pin bush ......................................................... 70.210 ÷ 70.280 mm (2.7641 to 2.7670 in)
C. Diameter of bush on rod and tilt cylinder ................................... 81.875 ÷ 81.929 mm (3.2234 to 3.2255 in)
Outer diameter of bush .............................................................. 81.965 ÷ 82.000 mm (3.2270 to 3.2283 in)
D. Outer diameter of diagonal main rod and blade main pin .......... 59.954 ÷ 60.000 mm (2.3604 to 2.3622 in)
Inner diameter of bushes ........................................................... 60.200 ÷ 60.270 mm (2.3701 to 2.3728 in)
E. Inner diameter of diagonal main rod and blade main pin ............ 71.911 ÷ 71.957 mm (2.8311 to 2.8329 in)
Outer diameter of bushes .......................................................... 71.970 ÷ 72.000 mm (2.8335 to 2.8346 in)
Installation interference ................................................................. 0.013 ÷ 0.089 mm (0.0005 to 0.0035 in)
F. Outer diameter of front diagonal pin .......................................... 59.954 ÷ 60.000 mm (2.3604 to 2.3622 in)
Inner diameter of ball joint ......................................................... 60.190 ÷ 60.264 mm (2.3697 to 2.3726 in)
G. Outer diameter of push arm joint pin ..................................... 119.780 ÷ 120.000 mm (4.7157 to 4.7244 in)
Inner diameter of push arm rear pin bush (in its seat) ........... 120.180 ÷ 120.400 mm (4.7315 to 4.7401 in)
6.5.9 FRAME AND RODS
A C-D-E-F G H
SM9460
Fig. 25. Angledozer equipment linkage
A. Outer diameter of C-frame joint pin ....................................... 119.780 ÷ 120.000 mm (4.7157 to 4.7244 in)
Inner diameter of C-frame rear pin bush ................................ 120.180 ÷ 120.400 mm (4.7315 to 4.7401 in)
B. Inner diameter of blade on seat ................................................. 50.130 ÷ 50.290 mm (1.9736 to 1.9799 in)
Outer diameter of pin ................................................................. 49.840 ÷ 50.000 mm (1.9622 to 1.9685 in)
C. Diameter of small seat in the rod pin flange ............................... 60.300 ÷ 60.490 mm (2.3740 to 2.3815 in)
D. Diameter of small seat in the rod pin flange ............................... 68.300 ÷ 68.490 mm (2.6890 to 2.6964 in)
E. Outer diameter of ball pin .......................................................... 89.780 ÷ 90.000 mm (3.5346 to 3.5433 in)
Inner diameter of rod pin seat .................................................... 90.220 ÷ 90.440 mm (3.5520 to 3.5606 in)
F. Outer diameter of pin seat flange .......................................... 101.964 ÷ 102.000 mm (4.0143 to 4.0157 in)
Inner diameter of rod pin seat ................................................ 102.000 ÷ 102.140 mm (4.0157 to 4.0212 in)
Clearance ........................................................................................ 0.000 ÷ 0.194 mm (0.000 to 0.0076 in)
G. Diameter of upper rod pin seat flange in lower rod .................... 40.120 ÷ 40.280 mm (1.5795 to 1.5858 in)
Outer diameter of upper rod pin ................................................. 39.840 ÷ 40.000 mm (1.5685 to 1.5748 in)
H. Inner diameter of ball seat for pin .............................................. 40.120 ÷ 40.280 mm (1.5795 to 1.5858 in)
6.5.10 RIPPER LINKAGE FOR LT/XLT MODEL
Model ......................................................................................................................... PD 180

Type ........................................................................................................................... parallelogram, actu-
ated by two double
stroke cylinders,
equipped with
semi curved teeth with
interchangeable tips.
F. Diameter of bush seat in cylinder ro .......................................... 78.000 ÷ 78.046 mm (3.0709 to 3.0727 in)
Inner diameter of bush............................................................... 63.195 ÷ 63.265 mm (2.4880 to 2.4907 in)
G. Diameter of bush seat in frame ................................................. 78.000 ÷ 78.046 mm (3.0709 to 3.0727 in)
H. Diameter of bush seat in link ..................................................... 95.000 ÷ 95.054 mm (3.7401 to 3.7423 in)
I. Diameter of bush seat in frame ................................................. 95.000 ÷ 95.054 mm (3.7401 to 3.7423 in)
J. Tightening torque of support securing screws ................................... 96 ÷ 106 Nm (708.06 to 781.81 lbf.ft)
K. Tightening torque of pin locking plate securing screws ............................................. 7.1 daNm (52.37 lbf.ft)
C E
Fig. 26. Ripper
I G
SM9462
NOTE:
6.6 SPECIAL TOOLS
380060080 CE – EST DIAGNOSTIC KIT
D180-2M001
ref cod q.ty description

A 380001594 1 PFT-8 Hydraulic Test Kit
B 380060080 1 Diagnostic Kit
HYDRAULIC KIT PFT – 8

FLOWS – PRESSURES – TEMPERATURES
(380001594)
cod q.ty description

380001494 1 750L/M Flow Block
380001495 2 700 Bar Pressure Sensors
380001496 2 Temperature Sensors 150 °C
380001497 5 Sensor Cables
380001498 1 Hydraulic Kit Carry Case
380060105 1 PFT-8 Module
CE – EST DIAGNOSTIC KIT

(380060080)
cod q.ty description

380001501 1 PC to Vehicle Interface
380001502 1 Cable PC to Vehicle Interface
380001503 1 Cable PC to FK Vehicle
380001504 1 Cable PC to FH Vehicle
380001505 1 "SMS key" with FK-EST application software
380060088 1 STHP PC
380001465 1 Docking Station
380001510 1 12V Vehicle Power Supply
380001511 1 PC Carry Case
380001499 1 Printer
380001500 1 USB Printer Cable
380060080 1 STHP HDD
SECTION 7
ELECTRICAL SYSTEM
TABLE OF CONTENTS
SAFETY RULES ........................................................................................................................ 7-3
7.1 ELECTRICAL DIAGRAM OF PROTECTIONS TREE ................................................................ 7-4

7.1.1 Fuses ...................................................................................................................................... 7-5
7.1.2 “Link” fuses and cold starting fuse .......................................................................................... 7-6
7.1.3 Main switch ............................................................................................................................. 7-7
7.1.4 Engine starting switch ............................................................................................................. 7-7
7.1.5 Back-up alarm ........................................................................................................................ 7-8
7.1.6 Starter motor ........................................................................................................................... 7-8
7.2 INSTRUMENT PANEL/MONITOR ............................................................................................. 7-9

7.2.1 Electrical diagram of instrument panel/monitor ..................................................................... 7-11
7.3 MONITOR SENDERS ............................................................................................................. 7-12
7.4 DISPLAY .................................................................................................................................. 7-16

7.4.1 Diagnosis on display ............................................................................................................. 7-16
7.5 BUZZER .................................................................................................................................. 7-18
7.6 RELAYS - DIODES - DIVERTER BOX GROUP ...................................................................... 7-19
7.7 MAIN CONNECTORS 19 - 21 - 23 WAYS ............................................................................... 7-22
ELECTRICAL SCHEMATIC FOLDOUT ............................................................ IN REAR POCKET

D180 ELECTRICAL SYSTEM 7-3
SAFETY RULES
WARNING
When working on the electrical system, always
wear safety glasses and remove rings, wrist
watches and any metal jewellery.
DISCONNECT
WARNING
Prior to inspection or repair interventions on elec-
trical components, DISCONNECT GROUND CA- A C
BLE "A" from the battery negative terminal "B". B
DISCONNECT CABLE "D" FROM POSITIVE TER-
D
MINAL "D".
Battery 12 V x 2
TO GROUND
WARNING
NEVER REST METAL OBJECTS on the battery to
prevent dangerous short-circuits.
WARNING
SM9500
FUMES FROM THE BATTERY ELECTROLYTE ARE FLAMMABLE.

Never generate sparks nor bring free flames near the batteries. The emission of fumes is stronger when
recharging.
WARNING
BATTERY FUMES ARE DANGEROUS if in contact with the skin or materials.
WARNING
Beware when maintaining the battery.
SM9538
CORRECT
Use a flashlight to inspect the level of the battery electrolyte.
Always perform the inspection with engine inoperative.
SM9539 Do not charge the battery or start the engine with jumper
cables if the battery is frozen-up. warm-up the battery to
WRONG 15 °C (59 °F) otherwise it could explode.
7.1 ELECTRICAL DIAGRAM OF PROTECTION TREE
7-4
FUSE 50A STARTER MOTOR

FUSE 150A
GRID HEATER
FUSE 80A
ALTERNATOR
F7A - 7.5A MICROCONTROLLER

(PIN 1,2,33,46)
TRACTOR RELAY F8A - 5A MICROCONTROLLER
KEY SWITCH
(PIN 12,13,14,24,39,40,41,43,52)
F10A - 7.5A
FLOOD LIGHTS (SIDE BEAM)
F11A - 7.5A
F3A - 5A REAR FLOOD LIGHTS (SIDE BEAM)
STARTING RELAY SOLENOID
F1B - 7.5A
ENG. STOP ELECTR. RELAY SOLENOID FLOOD LIGHTS (FRONT BEAM)
SWITCHES LAMPS
F2A - 5A
OPERATOR SAFETY PROXIMITY SW. F2B - 20A
CR CLIMATE CONTROL
ENGINE STOP ELECTROMAGNET
HOLD SOLENOID CAB RELAY
ELECTRIC CUT-OFF TIMER

F3B - 7.5A
F5A - 5A R-H DOOR WINDSHIELD MOTOR PUMP
STEERING SAFETY SOLEN. VALVE
F4B - 7.5A
I.R.C. BLOCK SUPPLY SOLEN. VALVE L-H DOOR WINDSHIELD MOTOR PUMP
ENGINE STOP ELECTR. PULL
F11B - 5A SOLENOID SIDE WINDSHIELD WASHER MOTOR PUMP
ELECTRICAL SYSTEM
STEERING S.V. CUT-OFF RELAYS

STARTER MOTOR CONTROL F5B - 7.5A
REAR WINDSHIELD WIPER MOTOR I SPEED
A
BUZZER F6B - 7.5A FRONT AND REAR WINDSHIELD MOTOR
F6A - 7.5A PUMP
HORN
MONITOR FRONT WINDSHIELD WIPER MOTOR I
6W/B SOLENOID VALVE SPEED
F9A - 7.5A
RESISTANCE CAB LIGHTS
CONTROL VALVE LINKAGE LIGHTER
F10B - 7.5A
POT. DIVIDER
OPTIONAL
RADIO - OPTIONAL
F1A - 5A
TRACTOR RELAY SOLENOID
F7B - 20A
CAB RELAY SOLENOID CR CLIMATE CONTROL
F8B - 5A
COLD STARTING RELAY SOLENOID COMPRESSOR SOLENOID-OPTIONAL
D180
DC180-BM053
COLD START. INDICATOR LAMP
7.1.1 FUSES
Fuses are located on the left side of the dashboard
for the cab version and inside the front pocket (as
A
indicated in the figure).
Remove the pressure fitted covers on fuse boxes (A)
and (B).
The fuses protect:

B A
FUSE BOX A B
(upper mounted)
1850-2M0147
1 = Tractor relay solenoid - Cab relay solenoid -
5A Fig. 7-2
2 = Operator safety proximity sw. - Engine stop
electromagnet hold solenoid - Timer
elettrostop - 5 A
3 = Starting relay solenoid - Eng. stop electr. relay
solenoid - 5 A
4 = Buzzer - Monitor - 6W/B solenoid valve - Resi- Fuse box A
stance - Control valve linkage - 5 A
5 = Steering safety solenoid valve - I.R.C. block
supply solenoid valve - 5 A
6 = Horn - 7.5 A
7 = Micro controller (PIN 1,2,33,46) - 7.5 A
8 = Micro controller (PIN 12,13,14,24,39,40,41,
43,52) - 5 A
9 = Cab lights - Lighter - Pot. divider - Radio
(optional) - 7.5 A
10 = Flood lights (side beam) - 7.5 A Fuse box B
11 = Rear flood lights (side beam) - 7.5 A
FUSE BOX B
(lower mounted)
1 = Flood lights (front beam) - Switches lamps -
7.5 A
2 = CR climate control - 20 A
3 = R-H door windshield motor pump - 7.5 A
4 = L-H door windshield motor pump - Side D350M0183
windshield washer motor pump - 7.5 A
5 = Rear windshield wiper motor 1 speed - 7.5 A
6 = Front and rear windshield motor pump - Front Fig. 7-3
windshield wiper motor 1 speed - 7.5 A
7 = CR climate control - Compressor solenoid
(optional) - 20 A
8 = Cold starting relay solenoid - Cold start.
indicator lamp - 5 A
10 = Optional - 7.5 A
11 = Steering s.v. cut-off relay - 5 A
WARNING
Always disconnect the battery grounding cable
prior to cleaning, repairing, connecting or discon-
necting any wire of the electrical system, to pre-
vent personal injuries.
Always keep all lights mounted on the machine
in working conditions. Replace all burnt-out bulbs
as soon as possible.
7-6 ELECTRICAL SYSTEM D180
7.1.2 "LINK" FUSES AND COLD STARTING

FUSE
"LINK" fuses are seen when opening the left side engine
hood, located on the inner side of the frame beam.
Fuse 1 protects the machine - 50.
Fuse 2 protects the alternator - 80.
MACHINE SERVICES "LINK" FUSE

(50 Amp)
WIRES
777 AL + batteries
772 To diverter box
ALTERNATOR "LINK" FUSE (80 Amp)

WIRES
777 AL + batteries
773 To alternator
WIRE 773 FUSE 2
WIRE 772 FUSE 1

D180-2M017
1850-2M0148
COLD STARTER FUSE

MEGA FUSE (150 Amp) Optional
WIRES
777 AL + batteries
780 To cold starter relay
SM9504
7.1.3 MAIN SWITCH
LOCATION - Inside the left panel, under the cab.
D180 POWER STEERING D180 STEERING CLUTCH
DO PER
O
NO AT
T E
Battery To ground
SM9508
7.1.4 ENGINE STARTING SWITCH
LOCATION - Right console in the cab.
R A-G G-R
H-R M-V
SM9505
POSITION
WIRES
Red position “B”
Yellow/Red position “G1”
Brown/Green position “ACC”
Grey/Red position “M”
Light blue/Yell position “ST” SM9506
7-8 ELECTRICAL SYSTEM D180
7.1.5 BACK-UP ALARM
WIRES
163 To electronic controller

000 To ground
LOCATION - Left side of machine under the fuel

reservoir.
7.1.6 STARTER MOTOR To batteries
Brand: DELCO - REMY To engine starting

power relay 90 A
Type: 42 MT-7.8 kW (10.5 Hp)
LOCATION: on engine.
SM9510
7.2 INSTRUMENT PANEL / MONITOR

The monitor is seen in the cab, in front of the operator's seat and is made of a panel on which no repair
intervention are possible, including a circuit board and L.E.D.s.
- Turn the electrical system main switch indicated

Moving into "ON", for the cab or ROPS structure version.
of motion - Turn the starter motor switch in the cab into the
first stepe.
Moving
of motion
DO PER
O
NO AT
T E
D180 POWER STEERING
DO PER
O
NO AT
T E
D180 STEERING CLUTCH
Operation
When activated, the instrument performs a short test for 1 second switching all LEDs, segments of the display
and buzzer ON; then the display (ref. S) indicates the engine hours.
The indicator lights and instruments indicate the state of the machine. Once the engine is started, pointer (R)
shows the engine r.p.m., with 100 rpm increments.
To return visualising the engine hours, it is necessary to switch off and re-power the system using the key; the
hours stay ON until the engine is cut-off.
In the event of any malfunction, this is signalled by the relevant LED indicators, identified by the appropriate "ISO
standard" symbols, and, for part of them, a sound alarm during 3 seconds is associated; in case the malfunction
persists, the alarm warns the operator with one minute cycles, lasting one second.
The engine work hours are recorded only when the engine speed exceeds 500 rpm.
The instrument receives data from an outer control unit, through serial line RX for the indication of the speed
selected and eventual error codes.
These codes are indicated on the 5-digit numerical display (S).
2 6MA SCREWS SECURING THE SUPPORT
L M N O P
A B C D E F G H
REAR VIEW CONNECTOR SIDE
FH
8 WAY CONN. 12 WAY CONN.
Q R S T
SM9511 SM9512
7 - 10 ELECTRICAL SYSTEM D180
REF. DESCRIPTION ALARM SIGNAL 12 WAY 8 WAY

CONN. CONN.
A Red LED, engine air cleaner NO IN (-) 2
B Red LED, hydraulic oil filter NO IN (-) 1
C Red LED, transmission oil pressure YES IN (-) 8
D Red LED, Engine oil pressure YES IN (-) 2
E Red LED, general alarm YES activated by ind. C, D, L, M, N, O, P
F Green LED, front work lights NO IN (+ 24V) 3
G Green LED, rear work lights NO IN (+ 24V) 7
H Green LED, head lights + instr. light. NO IN (+ 24V) 12
L Red LED, engine coolant temperature YES IN (-) 10
M Red LED, transmission oil temperature YES IN (-) 9
N Red LED, battery YES IN (-) 4
O Red LED, brakes failure YES IN (-) 4
P Red LED, fuel reserve NO IN (-) 11
Q Engine coolant temperature indicator at 10 lcd YES IN (var. -) 1
R Engine rpm analogical display at 24 lcd – IN (+ 24V) 6
S 5 digit display for No. speeds and
"engine hours" NO IN (-) (NPN -NO) 3 (RX)
T Fuel level indicator at 10 lcd YES IN (var. -) 5
BUZZER OUTPUT – OUT (-) 8
POWER INLET "positive" – IN (+ 24V) 6
GROUND INPUT (GND) – IN (-) 7
Then connectors are male, one 8-way and one 12-way.
The corresponding connectors for the harness are of a female type, 12-way and 8-way, both with female con-
tacts.
D180 ELECTRICAL SYSTEM 7 - 11
7.2.1 ELECTRICAL DIAGRAM OF INSTRUMENT PANEL/MONITOR
8-12 way rear

connectors
CONN. 8 WAY CONN. 12 WAY

SM9513
7.3 MONITOR SENDERS
1
Location on engine
2
1. Air cleaner clogging sensor.
2. Engine coolant max. temperature switch. 4
3. Engine rpm sensor.
4. Engine oil low pressure sensor.
5. Alternator.
Location on oil - fuel reservoirs
6. Fuel level sensor.

7. Hydraulic oil filter clogging sensor. 5
8. Brakes - clutches low oil pressure sensor
(set at 11.5 bar) (166.79 psi). 3
9. Transmission oil low pressure sensor SM9514
(set at 11.5 bar) (166.79 psi).

6
10.Transmission oil temperature sensor Hydraulic oil
(119 °C - 246 °F). reservoi
Fuel reservoir
SM9515
9
Torque converter
10
SM9516
1. AIR CLEANER CLOGGING SENSOR

WIRES
663 To monitor
000 To ground
Setting: (closing of contact) 62 mbar (0.899 psi)
± 8 °C - (46.4 °F).
LOCATION - Left front side of machine, over the air

cleaner.
Installation notes
The depression switch must be tightened manually, SM9517
without using tools.
2. ENGINE COOLANT MAX. TEMPERATURE

SWITCH
WIRES
552 to monitor
000 To ground
Thread: M16 x 1.5
Setting: 100° ± 3 °C (212 ± 37.4 °F)
Wrench: 22 mm (0.866 in)
Torque wrench: 2.5 daNm (18.44 lbf.ft)
LOCATION - Right front side of machine, on engine.
SM9518
3. ENGINE RPM
Monitor Electronic
Thread: 3/4 - 16 UNF controller
Torque wrench: 1.9 ÷ 2.5 daNm
(14.01 ÷ 18.44 lbf.ft)
LOCATION - On engine flywheel housing
SM9519
4. ENGINE OIL LOW PRESSURE SENSOR
WIRES
503 To monitor
000 To ground
Thread: M10 x 1 taper
Setting: 1.2 ÷ 0.8 bar
Wrench: 27 mm
Torque wrench: 3.5 daNm
The sensor is normally closed, it opens when the pres-
sure drops or reaches the setting value.
SM9520
5. ALTERNATOR
BRAND: DELCO - REMY 70 Amp
To Link fuse 80 Amp
Power voltage: 24 VOLT
Batteries
LOCATION - on engine
Grounding
wire
SM9521
6. FUEL LEVEL SENSOR
WIRES
555 To monitor
557 To monitor
000 To ground

Setting: 1.2 to 0.8 bar (17.4 to 11.6 psi)
LOCATION - Rear side of machine over the fuel

reservoir SM9522
7. HYDRAULIC OIL FILTER CLOGGING

SENSOR
WIRES
580 To monitor
000 To ground
Thread: M18 x 1,5
Setting: 2 ÷ 2.2 bar (29 ÷ 31.91 psi)
LOCATION - On hydraulic oil reservoir.
SM9523
8. BRAKES AND STEERING CLUTCHES OIL

LOW PRESSURE SENSOR
WIRES
611 To monitor
000 To ground
Setting: 12.5 ÷ 11 bar
(181.30 ÷ 159.54 psi)
SM9524
9. TRANSMISSION OIL LOW PRESSURE

SENSOR
WIRES
581 To monitor
000 To ground
Setting: 12.5 ÷ 11 bar
SM9525
10. TRANSMISSION OIL MAX

TEMPERATURE SWITCH
WIRES
559 To monitor
000 To ground
Thread: M16 x 1.5
Setting: 119° ± 3 °C (246 ÷ 37.4 °F)
SM9526
7.4 DISPLAY
The display indicates three functions:

A) - Digital hourmeter, indicating the total hours
work and is automatically actuated when the
engine operates.
B) - Speed engaged
C) - Troubleshooting the transmission operation
15
10 20
50 70 90
40 120
5 25
C
RPM
x 100
7.4.1 DIAGNOSIS ON DISPLAY

The display has 5 digit fields providing the following
messages.
SM9527
DISPLAY
1st 2nd 3rd 4th 5th digit
A - Work hour indication
B - Speed engaged indication + failure code
Work hourmeter indication

The engine hours are indicated when the instrument panel is switched ON, for about one second, when the
instrument undergoes a general test. To return visualising the engine hours, cut-off and re-power with the starter
key.
The hours stay On until the engine is cut-off.
Speed engaged signal + failure code

The first digit indicates the speed engaged (ex. 1st
speed).
The second indicates (in case of failure) letter E.
↑st ↑nd SM9528
1 2 (digit)
The 3rd and 4th digits identify the failure code (ex.
failure code No. 024).
When the components failed is one only, the codes
listed in TABLE 1 appear.
For each failure code, identify the corresponding
component listed.
↑rd ↑th ↑th
SM9528
3 4 5 (digit)
TABLE 1
Failed component Failure code
Left proportional solenoid valve coil 001
Right proportional solenoid valve coil 002
Forward "F" speed solenoid 004
Rear "R" speed solenoid 008
rd
3 speed solenoid 032
Left steering lever solenoid 064
Right steering lever solenoid 128
TABLE 2
LH RH For. Rev. 1st 3rd LH RH
prop. prop. "F" "R" speed speed steer. steer.
Failed component
sol. sol. speed speed solen. solen. lever lever
valve valve solen. solen. solen. solen.
coil coil
Left prop. solenoid valve coil 001 003 005 009 017 033 065 129
Right prop. solenoid valve coil 002 006 010 018 034 066 130
Forward "F" speed solenoid 004 012 020 036 068 132
Reverse "R" speed solenoid 008 024 040 072 136
Left steering lever solenoid 064 192
Example of identification of a trouble code
When the failed components are two, the display shows a trouble code listed in TABLE 2, (given by the addition
of two single codes listed in TABLE 1). As an example, code 024 indicates that two parts are in trouble. On the
top, the column identifies, in correspondence with the "1st speed " solenoid (first failed component).
TABLE 2
LH prop. sol. RH prop. sol. For. "F" Rever. "R" 1st speed 3rd speed LH steer LH steer
Failed component
valve coil valve coil speed solen. speed solen. solen. solen. lever solen. lever solen.
Left prop. solenoid valve coil 001 003 005 009 017 033 065 129
Right prop. solenoid valve coil 002 006 010 018 034 066 130
Forward "F" speed solenoid 004 012 020 036 068 132
Reverse "R" speed solenoid" 008 024 040 072 136
Left steering lever solenoid 064 192
Reverse "R" speed solenoid trouble code
Trouble code on display
1st speed solenoid trouble code
Whereas, on the left, it identifies the reverse speed "R" the crossing of the two components determines the trouble
code, given by the addition of the two.
Reverse "R" speed solenoid trouble code = 008 +

1st speed solenoid trouble code = 016
Trouble code for both = 024
7.5 BUZZER
LOCATION - Inside the cab, behind the instrument panel.
SM9529
7.6 RELAYS - DIODES - DIVERTER BOX GROUP

The group is seen opening the left rear panel of the
machine, near the batteries.
1 2 3 10 5
2
8 11
12
4
7
1. Diodes box - 2. Relay 24 Volt - 50 Amp - 3. Relay 24 Volt - 10/20 Amp - 4. Diverter box - 5. Power relay 90 Amp -
6. 19 way connector - 7. Batteries 12 Volt x 2 - 8. Cold starting relay - 9. Fuse - 10. Time elettrostop - 11. Timer - 12. Timer
wire assembly.
A 891 564 M F 801 907 H
C 566 163 L G 542 869 I
B 543 860 D E 592

890 N
803 O
1 - Diode boxes 2 - Relay 24 Volt - 50 Amp 3 - Relay 24 Volt - 10/20 Amp

B. Steering safety solenoid valve A. Cab services C. Steering solenoid valve (only D180)
D. Cut-off/cold starting F. Machine services M. Steering solenoid valve (only D180)
L. Operator safety indicators O. Air conditioner 50 Amp (opt.) G. Operator's safety
H. Starter safety
N. Air conditioner relay 10/20 Amp (opt.)
1. DIODE BOXES (REF. B - D - L)

- For the wires and the connections of the compo-
nents, please refer to the principle electrical dia-
gram.
SM9532
2. RELAY 24 VOLT - 50 Amp (REF. A - F - O)
SM9533
3. RELAY 24 VOLT - 10/20 Amp (REF. C - M - G - H - N)

The relay is a magnetically activated mechanical switch.
Pins 86 and 85 are used to activate the relay.
Pins 30 to 87a form a N/C (normally closed) switch.
Pins 30 to 87 form a N/O (normally open) switch.
Nominal current Electrical diagram
SM9534
4. DIVERTER BOX
OUTPUT INPUT
SM9535
5. POWER RELAY (ENGINE STARTING)
SM9536
7.7 MAIN CONNECTORS 19 - 21 - 23 WAYS
YELLOW BLUE SM9537
MACHINE - CAB INTERFACE OF 19 WAY CONNECTOR
CABE
CONTACT WIRE ROUTING WIRE MACHINE WIRE WIRE
NUMBER SECTION NUMBER COLOUR SECTION
1 1 FROM FUSE 11 SWITCH ACC 801 H-L 1
2 1 CUT-OFF DIODE 15 904 S-G 1
3 1 FROM FUSE 17 SWITCH 907 L-B 1
4 1 TO FUSE 24 FOR EV 542 A-V 1
5 1 FROM ALTERNATOR I 637 S 1
6 1 FROM DIODES CONNECTING PROXIM. OPERAT. SAFETY 164 L-N 1
7 - NOT USED - - -
8 2.5 CONDITIONER RELAY 87 809 G-N 2.5
9 - NOT USED - - -
10 2.5 KEY STARTER SWITCH POWER 724 R 2.5
11 - NOT USED - - -
12 2.5 SERVICES UNDER ACC 864 H-R 2.5
13 - NOT USED - - -
14 2.5 CONDITIONER RELAY 30 803 A 2.5
15 1 BRAKE SAFETY SOLENOID VALVE 543 Z-B 1
16 2.5 CAB SERVICES FROM RELAY 73 887 R-N 2.5
17 - NOT USED - - -
18 2.5 POWER. OF SERVICES NOT UNDER KEY 772 R 2.5
19 1 COLD STARTING RELAY 860 A/R
CABE
A 1 4WEG SOLENOID VALVE 597 C 1
B 2.5 (III SPEED) ELECTRIC FAN 706 B 2.5
C 1 CONDITIONER THERMOSTAT 824 M 1
D 2.5 (II SPEED) ELECTRIC FAN 709 M 2.5
E 2.5 GROUNDING FOR CAB 000 N 2.5
F - NOT USED - - -
G 2.5 (I SPEED) ELECTRIC FAN 745 L 2.5
H 1 ENGINE RPM SENSOR + 536 G 1
J 1 ENGINE OUT RPM SENSOR 537 N 1
K 1 DOOR WINDOW WASHERS ELECTRIC PUMP 885 G-V 1
L 1 FRONT/REAR WINDOW WASHERS ELECTRIC PUMP 886 C-B 1
M 1 FROM R.H. PROX. SW. TO DISCONN. DIODE 156 B 1
N 1 TRANSM. F/R SV - GND 009 V-N 1
P 1.5 F INPUT TRANSM. SV 549 A-G 1
R 1 R INPUT TRANSM. SV 548 A-N 1
S 1 FROM L.H. PROX. SW. TO DISCONN. DIODE 157 G-N 1
T 1 1ST/ 3RD TRANSM. SV - GND 008 C/B 1
U 1 1ST/ 3RD TRANSM SV INPUT 1ST 546 B/R 1
V 1 1ST/ 3RD TRANSM SV INPUT 3RD 547 V/B 1
W - NOT USED - - -
X 1 SCREENED CABLE GROUND SLEEVE 011 SCREEN 1
CABE
A 1 FROM BRAKE PEDAL VALVE PRESS. SWITCH TO CONTROLLER 166 C-L 1
B 1 AIR CLEANER CLOGGING 663 B-N 1
C 1 FROM ACC TO BRAKE PEDAL VALVE PRESS. SWITCH (+) 143 M-N 1
D 1 COOLANT HUGH TEMP. INDIC. 528 V-B 1
E - NOT USED - - -
F 1 COOLANT TEMP. SENSOR (TEMP. GAUGE) 552 V 1
G - NOT USED - - -
H 1 TRANSM. OIL LOW PRESS. IND. 581 C-N 1
J - NOT USED - - -
K 1 TRANSM. OIL HUGH TEMP. INDIC. 559 S-N 1
L 1.5 HORN + (1ST WIREE) 119 L-N 1
M 1.5 HORN GROUND (2ND WIREE) 000 N 1
N - NOT USED - - -
O 1 LH PRESS. TRANSDUCER (+) 503 H 1
P 1 ELECTR. CUT-OFF (HOLD COIL) 903 S-G 1
Q 1 BRAKES OIL LOW PRESS. IND. 611 H-N 1
R - NOT USED - - -
S 1 BACK-UP ALARM 163 A-B 1
T - NOT USED - - -
U 1 EQUIPM. OIL FILTER CLOGGING INDIC. 580 M-B 1
V 1 FUEL RESERVE INDICATOR 555 Z-N 1
W 1 FUEL LEVEL SENSOR 557 Z 1
X - NOT USED - - -
COLOUR CODE
A LIGHT BLUE
B WHITE
C ORANGE
G YELLOW
H GREY
L BLUE
M BROWN
N BLACK
R RED
S PINK
V GREEN
Z PURPLE
SECTION 8
AIR CONDITIONING UNIT
TABLE OF CONTENTS
8.1 AIR CONDITIONING UNIT ........................................................................................................ 8-3

8.1.1 Operating instructions ........................................................................................................... 8-3
8.1.2 Technical data ....................................................................................................................... 8-3
8.1.3 Cab climate conditioner and error codes ............................................................................... 8-6
8.1.4 Air conditioning unit - Diagnostics ......................................................................................... 8-7
8.1.5 Service precautions ............................................................................................................... 8-8
8.1.6 Tool connections .................................................................................................................. 8-11
8.1.7 Discharging ......................................................................................................................... 8-12
8.1.8 Refrigerant charging ............................................................................................................ 8-12
8.1.9 Leak inspection ................................................................................................................... 8-13
8.1.10 Special tools ....................................................................................................................... 8-16
8.1.11 Troubleshooting ................................................................................................................... 8-17
8.2 LIST OF OVERHAUL SPECIAL TOOLS ................................................................................. 8-25

D180 AIR CONDITIONING UNIT 8-3
8.1 AIR CONDITIONING UNIT
8.1.1 OPERATING INSTRUCTIONS

The principle of operation can be summarised as follows: the refrigerant, Freon R134a, in its gaseous state, is
sucked by the compressor at a pressure of 2 bar (29 psi) and taken to a final compression at a pressure of 19 to
25 bar (145 to 290 psi). The gas, heated by the compression to 89 to 100 °C (192 to 212 °F), flows, still in a
gaseous state, into the condenser where, under the effect of the cooling provided by the air flowing through it by
the action created by the fan, reaches the condensation point, passing into a liquid state at high pressure.
Subsequently, the refrigerant, at liquid state, reaches a dehydration filter, which has the function of capturing
itself. Then, the Freon reaches the expansion thermostatic valve, which has the purpose of regulating the refrig-
erant flow into the evaporator at a pressure of 2 bar (29 psi), causing its passage from liquid to gaseous state. At
the same time, the air flowing through the evaporator, under the action of the fan, having a temperature which is
higher than the refrigerator contained by the evaporator itself, causing its boiling and full evaparation, releasing
heat.
The air, being cooled, deposits on the fins of the evaporator parts of its moisture content, under the form of little
drops, which drop into the tanks and are discharged outside the cab.
Air cooled and dehumidified, is sent into the cab. The refrigerant, at the outlet of evaporator, is sucked again by
the compressor, beginning a new cycle.
8.1.2 TECHNICAL DATA
Heater group
Efficiency > 89%
Capacity micron 20
Dimensions cm2 (in2) 13680 (2120.4)
Conditioner group
Max gas charge gr (lb) 1800 (3.97)
Compressor
Brand
Model SD7H1SMD7948
Condenser
Brand
Air flow m3/h (gpm) -1570 (-6912)
No. of fans -2
Cab air flow m3/h (gpm) ≥ 400 (1761)
Open Closed
Thermostatic valve °C (°F)
≤ -2 (28.4) ≥ 2 (35.6)
8-4 AIR CONDITIONING UNIT D180
COMPONENTS DATA
COMPONENTS TECHNICAL CHARACTERISTIC
EXPANSION
VALVE 1.5 TON
6.44 kW @ 45 °C of ambient (8.6 HP @ 113 °F of ambient)

CONDENSER
7.78 kW @ 37 °C of ambient (10.4 HP @ 98.6 °F of ambient)
HEATER 9.93 kW @ 45 °C of ambient (13.3 HP @ 113 °F of ambient)

EVAPORATOR 10.8 kW @ 37 °C of ambient (14.5 HP @ 98.6 °F of ambient)
Air Flow 810 m3/h (3566 gpm) x no. 2 fans

FAN MOTOR
24V - 9.5 A
COMPRESSOR 154.9 cm3/rev, max rpm 7000

Low level High level
PRESSURE GAUGE Open Closed Open Closed
BINARY
2 bar (29 psi) 2.1 bar (30.4 psi) 25 bar (362 psi) 19 bar (275 psi)
Pressurization
Cool Down (37 °C, 98.6 °F) ≤ 24 °C (75.2 °F)

(after ½ h)
q T Ambient 37 °C Cab average
temperature
q R.H. 60% ≤ 20 °C (68 °F)
(after 1 h)
q Solar load on the roof
950 W/m2
Max cab temperature
difference
≤ 5 °C (41 °F)
≤ 27 °C (80.6 °F)
Cool Down (45 °C, 113 °F)
(after ½ h)
q T Ambient 45 °C (113 °F) Cab average
temperature
q R.H. 30% ≤ 24 °C (75.2 °F)
(after 1 h)
q Solar load on the roof
950 W/m2
Max cab temperature
≤ 5 °C (41 °F)
difference
1850-2R381
Fig. 8-1
8.1.3 CAB CLIMATE CONDITIONER AND

ERROR CODES
1 2 3 4 5 6 7
STOP
AUTO ECOM
C F
1 2 3
13 12 8 9 10 11
D150-2M076
1. Decrement of internal temperature - 2. Increment of

internal temperature - 3. Automatic function - 4. Compres-
sor cut-off - 5. Re-circulation - 6. Outer temperature -
7. Cut-off - 8. Fan 1st speed - 9. Fan 2nd speed - 10. Fan 3rd
speed - 11. °C/°F conversion - 12. Display reading of
temperature setting - 13. Cab inside temperature sensor.
ERROR CODES TABLE
ERROR ERROR DESCRIPTION
E1 OUTSIDE TEMPERATURE FEELER (TE) OPEN
E2 OUTSIDE TEMPERATURE FEELER (TE) IN SHORT CIRCUIT
E3 INSIDE TEMPERATURE FEELER (TI) OPEN
E4 INSIDE TEMPERATURE FEELER (TI) IN SHORT CIRCUIT
E5 MIXED AIR TEMPERATURE FEELER (TIM) OPEN
E6 MIXED AIR TEMPERATURE FEELER (TM) IN SHORT CIRCUIT
8.1.4 AIR CONDITIONING UNIT -

DIAGNOSTICS
Electronic temperature control (E.C.C.) 4 - COMPRESSOR ENGAGEMENT
In order to check the correct operation of the heating By pressing the ECO button the relevant LED will
and cooling system the E.C.C. has a software pro- cycle ON and OFF alternatively and the compressor
gram to identify any existing component failure by will be engaged and disengaged accordingly through
means of error codes appearing on the display; in the its electromagnetic clutch.
case that the E.C.C. display will not show an error code
in spite of operational problems you must enter a self 5 - RECIRCULATION AND DYNAMIC
diagnosis program by switching on the engine while AIR CONTROL
keeping the AUTO button pressed and releasing it
By pressing the recyrculation button the relevant LED
when the display shows the code A1.
will cycle On and OFF showing the actual change of
Please make sure to start the engine with closed cowl-
state from recirculation to external dynamic air
ing, ambient temperature between 15 °C (59 °F) and
30 °C (86 °F) and cooling engine water sufficiently hot.
6 - FAN SPEED CONTROL
Higher or lower ambient temperatures will automati-
cally set the system to maximum cold or maximum The cabin airflow is regulated by three fan speed push
hot conditions respectively. buttons for low, medium, high airflow values.
1 - WATER VALVE CHECK 7 - °C and °F SELECTION

By pressing the inside cabin temperature increase When the relevant LED is OFF the °C is selected;
and decrease button the water valve will move to- when the LED is ON the °F (Farenheit) condition is
wards max hot or max cold conditions. selected.
Pls make sure that mixed air temperature will vary The maximum value of cabin temperature setting is
accordingly. 37 °C or 99 °F.
2 - MIXED AIR TEMPERATURE SENSOR 8 - Press the AUTO button to return to normal
CONTROL function
By pressing the STOP button the Mixed air tempera-
ture (TM) will appear on the display and the relevant 9 - OUTSIDE TEMPERATURE CONTROL SENSOR
LED remains switched on for about 8 seconds. Simply press the outside temperature button during
In case of faulty sensor the display will show the fol- normal automatic system operation. The display will
lowing error codes: show the value of the outside temperature (TE) for
E5 MIXED AIR TEMPERATURE SENSOR (TM) about 8 seconds. In the case of a faulty sensor the
OPEN display will show the following error codes:
E6 MIXED AIR TEMPERATURE SENSOR (TM) E1 OUTSIDE TEMPERATURE CONTROL SEN-
IN SHORT CIRCUIT SOR (TE) OPEN
E2 OUTSIDE TEMPERATURE CONTROL SEN-
3 - INSIDE CABIN AIR TEMPERATURE CONTROL SOR (TE) IN SHORT CIRCUIT
SENSOR In both cases you can directly increase or decrease
In case of faulty sensor the display will show the fol- manually the temperature of the cabin by pressing
lowing error codes: the relevant buttons. All other functions (air distribu-
E3 INSIDE CABIN AIR TEMPERATURE (TI) SEN- tion, compressor engagement, dynamic air or
SOR OPEN recirculation) can also be operated manually by press-
E4 INSIDE CABIN AIR TEMPERATURE SEN- ing the relevant push buttons.
SOR (TI) IN SHORT CIRCUIT
conditioning Performance Piping precautions
IN ACCORDING WITH ISO 10263 - Position the O-Ring against the bulge in the pipe
when connecting hoses and pipes.
8.1.5 SERVICE PRECAUTIONS - Coat the piping connections and the O-Rings with
PAG oil.
- Fit the nuts and unions tightly against the base of
WARNING the companion pieces then hand tighten the nut as
Direct contact with refrigerant can cause frost- much as possible. Then, tighten to the specific
bite or blindness. torque.
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face. Note – Always use oil specified for R134a system to
coat the O-Rings.
CAUTION
O-Ring
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere.
Union
Handle the air conditioner components carefully. Do

not knock or drop them.
Nut
1850-2R392
Fig. 8-2
Do not mistakes refrigerants

Before charging an air conditioning system be sure
that refrigerant is correct. Confirm before charging Do not exchange the A/C refrigerants
that the type of air conditioner system is in fact an
R134a system.
R 134a
HFC134a
W110R0317
Fig. 8-3
Do not release refrigerant into the air

Do not release the refrigerants
Although R134a is not subject to CFC regulations, it into the atmosphere
can have an effect on global warming, and so should
not be released into the air.
WARNING
When removing refrigerant from the air condi- R 134 a
tioner system, always use a refrigerant recovery
unit made especially for R134a (Special tool
380001326).
Recovery unit
W110R0318
Fig. 8-4
8 - 10 AIR CONDITIONING UNIT D180
Compressor oil
Use compressor oil made specifically for use with
R134a.
R134a system compressor oil has an extremely high
moisture absorption capacity.
OIL
WARNING
Cap the oil container after use and the air condi-
tioner system parts, when servicing.
Never mix compressor oil with other types of oil.
Cap all container and components

W110R0319
Fig. 8-5
The oil must be replaced or replenished in the follow-

ing cases:
- when refrigerant or oil leaks from the system;
Temperature
- when refrigerant is suddenly discharged from the
system; Oil-refrigen
Condensation separation
- when system components are replaced. temperature range
Blending range
Note – The oil plug O-Ring must be replaced with a

Vaporization
new one. temperature
range
Refrigerant charge inspection
As shown in the left hand figure, R134a compressor
oil will not blend with refrigerant (R134a) at certain
Oil-refrigerant blending rate
temperatures. At these temperatures, the refrigerant
may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged W110R0320
as insufficient.
Fig. 8-6
D180 AIR CONDITIONING UNIT 8 - 11
8.1.6 TOOL CONNECTIONS 1. Fully close both manifold gauge valves.

2. Connect the three hoses securely to the manifold
gauge.
WARNING
3. Connect the utility hose to the vacuum pump or
Do not connect hoses to the air conditioner sys- refrigerant source.
tem when the manifold gauge valves are open.
4. Connect the couplers to the high and low pressure
hoses. Turn the knob on the fitting to depress the
CAUTION core if so equipped.
If there is any refrigerant in the air conditioner Before disconnecting hoses, close both manifold
system, connect the hoses only after the service gauge valves.
hoses and the manifold gauge have been evacu-
ated.
Manifold gauge
Low pressure High pressure
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
W110R0321
Fig. 8-7
8.1.7 DISCHARGING
CAUTION
If the pointer moves toward 0 (zero) the system
WARNING is not sealed. Inspect the system to identify the
Do not release the refrigerant into the air. leakages and repair them.
Discharge refrigerant only into the refrigerant
recovery unit.
0
The recovered refrigerant must be recycled trough a
refrigerant recovery unit to ensure that it is clean and
free of moisture.
Refer to the user's instruction manual for refrigerant

recovery unit handling and operations.
Check for leaks and

repair if gauge needle
moves towards 0
W110R0322
Fig. 8-8
Evacuation
8.1.7 REFRIGERANT CHARGING
1. Operate the vacuum pump.
There are various methods of charging refrigerant 2. Open both manifold gauge valves
into the air conditioner system. These include using 3. Evacuate the system for at least 20 minutes.
refrigerant recovery units and direct charging using a 4. Close both manifold gauge valves.
scale.
Initial charge
Note for servicing – Check every year the refriger- 1. Put the refrigerant container on the scale.
ant charge. Change refrigerant in the system every 2
years.
Initial evacuation
1. Close both manifold gauge valves.
2. Connect the high and low pressure hoses to the R 134a
system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure
valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to sta-
bilize the vacuum inside the system.
W110R0323
7. Close both valves and stop the vacuum pump.
Fig. 8-9
Checking air tightness
1. Leave the system as it is for 5 to 10 minutes. 2. Disconnect the utility hose from the vacuum pump
and connect it to the refrigerant container.
Ensure the low pressure gauge needle does not 3. Purge air from the utility hose.
move towards the atmospheric pressure side (gauge 4. Record the refrigerant weight.
pressure 0). 5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side

valve to charge refrigerant from the low pressure Pressure in high
side valve to charge refrigerant from the low pres- pressure line
sure side.
7. Charge with refrigerant until the low pressure gauge
reaches 2 bar (29 psi).
8. Close the manifold gauge's low pressure valve. Pressure
CAUTION
Pressure in low
Do not overcharge the system. pressure line
Compressor stops
W110R0325
Fig. 8-11
Initial Leak check

Using the leak detector, check the system connec-
tion for leaks.
Note – As the system pressure is not yet high, only

large leaks can be detected at this time.
8.1.9 LEAK INSPECTION

To facilitate refrigerant leak detection, operate the air
conditioner at the full cooling setting with the fan run- Electronic leak detector
ning at maximum speed for at least 5 minutes. 380001327 A22090
Stop the engine and, using a leak detector, check for
refrigerant leaks on the high pressure side. Fig. 8-10
This must be done immediately because when the
refrigerant stops circulating, the high pressure de-
creases gradually, as shown in the graph, while the
low pressure side pressure increases gradually.
Inspection procedure
Evacuation
Refrigerant
charging
Operate compressor
for at last 5 min Repair
Check for refrigerant

leaks from high
pressure side parts
Operation test
Inspection sequence
High pressure side
Compressor Condenser Cooling unit Receiver drier inlet

discharge port inlet and outlet inlet and outlet
Low pressure side
Compressor Cooling unit

suction port outlet
CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity
of the vehicle.
1850-2R382
Fig. 8-12 Inspection points
8.1.10 SPECIAL TOOLS
Model: D180
Tool Code Description Model
Refrigerant recovery, recycling and changing D180

station
380001326
Electronic leak detector D180
380001327
Belt tension test tool D180
380001325
Sanden compressor overhauling tools D180
380050012
8.1.11 TROUBLESHOOTING
Air conditioner switch ON
Lights Does not light
Air conditioner fuse inspection
Normal Fuse blown

Air outlet flow rate check
Replace
No air flow Air flow
Blower motor inspection
Does not operate Operates, but low flow rate Compressor operation
inspection
A (a) A (b)
Magnetic clutch rotates Magnetic clutch does not rotate
A (d)
CAUTION
Refrigerant pressure
inspection Refer to REFRIGERANT CHARGE
INSPECTION on page 8-7
Troubleshooting chart
(a) Fan motor does not operate
Possible cause Inspection Remedy
1. Blown fuse Inspect the air conditioner fuse. Replace.
2. Broken wiring Check the fan motor earth and connectors. Repair the wiring or
or bad connection connect correctly.
3. Fan motor malfunction Check the two lead wires from the motor with a circuit tester. Replace.
If there is no conductance, the motor is malfunctioning.
4. Broken resistor wiring Check resistor conductance using a circuit tester. If there is Replace.
no conductance, the wiring is broken.
5. Fan motor switch Operate the fan switches in sequence and check whether Replace.
failure the fan operates.
(b) Fan motor operates normally, but air flow is insufficient
1. Evaporator iniet Check the iniet. Remove the obstruction

obstruction and clean.
2. Air leak Check the cooling unit case fittings. Repair of adjust.
3. Detective thermo Check whether the evaporator is frozen. Check the switch Replace.
switch using a circuit tester.
(c) Insufficient cooling although air flow and compressor operation are normal
1. Insufficient refrigerant There will be little temperature difference between the low- Repair any leaks and
and high-pressure sides. Air bubbles or a "cloudy" flow will recharge the refrigerant
be visible in the sightglass. to the correct level.
2. Excessive refrigerant The high-pressure side pressure will be high and even if the Drain small quantity of
condenser is cooled using water, air bubbles will not appear refrigerant until air bub-
in the sightglass. bles appear periodically
through the window.
(d) The compressor does not operate at all, or operates improperly
1. Loose V-belt The belt oscillates considerably. Adjust the tension.
2. Internal compressor The V-belt slips. Repair or replace.

malfunction
3. Magnetic clutch
related
• Low battery voltage Clutch slips. Recharge the battery.
• Faulty coil Same as above. Replace the magnetic

clutch.
• Oil on the clutch The magnetic clutch face is dirty, causing it to slip. Replace, or clean the
surface clutch surface.
• Excessive clearance Adjust the clearance, or

between the clutch replace.
plate and clutch disk.
The clutch plate clings
when pushed
• Open coil Clutch does not engage and there is no reading when a cir- Replace.
cuit tester is connected between the coil terminals.
• Broken wiring or poor Clutch will not engage at all. Inspect the earth and connec- Repair.
earth tions.
• Wiring harness Test the conductance of the pressure switch, thermoswitch, Check operation, refer-
components relay, etc. ring to the wiring dia-
gram, and replace de-
fective parts.
WARNING
In the event of damages to the compressor, re-
place it together with the expansion valve and
the dehydrating filter, taking care of flushing pre-
viously the system with appropriate detergent
liquid.
Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35 °C (86 ~ 95 °F)
and engine speed of approx. 1500 rpm are:
High pressure side pressure : 19 ~ 25 bar (275.58 ~ 362.59 psi)
Low pressure side pressure: 2 ~ 2.1 bar (29 ~ 30.46 psi)
Low-pressure side The pressure in the low-pressure side becomes, normally,

pressure too high too high when the pressure on the high-pressure side is ex-
cessive. As explained here below, the check that follows is
performed only when the pressure on the low-pressure side
is too high.
1. Defective The magnetic clutch switch turns off before the outlet air tem- Adjust or replace.
thermoswitch perature is sufficiently low.
2. Defective compressor The high- and low-pressure side gauge pressures equalize Repair or replace the
gasket or valve when the magnetic clutch is turned off. compressor.
3. Poor expansion valve Frost has adhered to the compressor connector so that the Install the temperature
temperature sensor temperature is lower than that of the evaporator outlet side sensor against the low-
contact piping. pressure pipe.
4. The expansion valve Same as above, or there is little pressure fluctuation when Replace.
opens too far the temperature sensor is places against the pipe and then
removed.
5. Clogged compressor The compressor connector is cool but the low-pressure hose Remove and clean the
suction filter is not. filter.
Low-pressure side
pressure too low
1. Insufficient refrigerant Refer to "Insufficient refrigerant" on previous page. Same as at left.
2. Clogged receiver Considerable temperature difference between the inlet and Replace the receiver
drier outlet sides, or the tank is frosted. drier.
3. Clogged expansion The expansion valve's inlet side is frosted. Clean the filter or replace
valve the expansion valve.
4. Expansion valve tem- The expansion valve's outlet side is chilled, and low pres- Clean or replace the pip-
perature sensor gas sure gauge indicates a vacuum. ing.
leak (damaged capil-
lary tube, etc.)
5. Clogged or blocked When the piping is clogged or blocked, the low-pressure Clean or replace piping.
piping gauge reading will decrease, or a negative reading may be
shown.
6. Defective The evaporator is frozen. Adjust or replace.

thermoswitch
High-pressure side
pressure too high.
1. Poor condenser Dirty or clogged condenser. Cooling fan does not operate Clean, and repair the
cooling correctly. Blown fuse, broken wiring or poor contact. Fan motor fan. Repair the wiring or
malfunction. replace the fuses.
2. Excessive refrigerant Refer to "Excessive refrigerant" on previous page.
3. Air in the system Evacuate and recharge

with refrigerant.
High-pressure side
pressure too low
1. Insufficient refrigerant Refer to "Insufficient refrigerant" on previous page. Same as at left.
Gauge pressure diagnosis

Low pressure side High pressure side
• Problems in the system can be diagnosed using a 0.2 ~ 0.21 MPa 1.9 ~ 2.5 MPa
manifold gauge by reading the system's low and {2 ~ 2.1 bar, {19 ~ 25 bar,
high pressures. 29 ~ 30.46 psi} 275.57 ~ 362.59 psi}
6 7 8 1.5 2.0
5 9
1.0 15 20 2.5
4 5 10
10 10 25
11
3 0.5 5 3.0
30
Normal pressures 2
1
0 15
12
13 0
0 35
3.5
0 14
15
Low-pressure side: 0.2 ~ 0.21 MPa (2 ~ 2.1 bar /
29 ~ 30.46 psi)
High-pressure side: 1.9 ~ 2.5 MPa (19 ~ 25 bar /

275.57 ~ 362.59 psi)
1850-2R385
Conditions
Atmospheric temperature 30 ~ 35 °C Fig. 8-13
(86 ~ 95 °F)
Engine speed 1500 r/min
Blower speed HI (high-speed)
Temperature switch Full cooling
Insufficient refrigerant
Indications: • Low pressures on both the low pres- 98 MPa 0.78 ~ 0.98 MPa
sure and high-pressure sides. {1.0 bar, {8 ~ 10 bar,
14.50 psi} 116 ~ 145.04 psi}
• Discharge temperature will not de-
7
crease. 5
6 8
9
1.0
1.5
15
2.0
20 2.5
4 5 10
10 10 25
11
3 0.5 5 3.0
30
Cause: Refrigerant leakage. 2
1
0 15
12
13 0
0 35
3.5
0 14
15
Remedy: Inspect using a gas leak detector, re-

pair the leak, and replenish the refriger-
ant.
1850-2R386
Fig. 8-14
Excessive refrigerant
(poor condenser radiation)
0.25 ~ 0.29 MPa 2.8 MPa
Indication: Both the low and high pressures are too {2.5 ~ 3.0 bar, {28 bar,
high. 36.26 ~ 43.51 psi} 406.10 psi}
7
Causes: Pressure increment due to excessive re- 5
6 8
9
1.0
1.5
15
2.0
20 2.5
4 5 10
frigerant. 3
10
11
0.5 5
10 25
30 3.0
2 12
Insufficient condenser cooling. 1

0 15 13 0
0 35
3.5
0 14
15
Remedy: Clean the condenser.

Inspect and adjust the fan belt and con-
denser motor.
Check the refrigerant level.
1850-2R387
Fig. 8-15
Air in cooling system

(insufficient suction)
0.25 ~ 0.34 MPa 2.9 ~ 3.3 MPa
Indications: Both the low and high pressures are too {2.5 ~ 3.5 bar, {29 ~ 33 bar,
high. 36.26 ~ 50.76 psi} 420.61 ~ 478.62 psi}
The low-pressure side piping is not cold. 6 7 8 1.5 2.0
5 9
1.0 15 20 2.5
4 5 10
Cause: Air entered the cooling system. When 3

10
11
0.5 5
10 25
30 3.0
2 12
the suction is not applied, the reading 1

0 15 13 0
0 35
3.5
0 14
of the instruments are indicated in the 15
illustration on the left.
Remedy: Evacuate the system, replenish the re-

frigerant and check the gauge readings.
After prolonged operation with air in the
system, the receiver drier must be re-
placed. 1850-2R388
Fig. 8-16
Defective expansion valve

Indication: Both the low and high pressures are too 0.25 MPa 2.7 ~ 3 MPa
high. {2.5 bar, {27 ~ 30 bar,
36.26 psi} 391.60 ~ 435.11 psi}
Causes: Improper refrigerant charge.
7
Defective expansion valve. 5
6 8
9
1.0
1.5
15
2.0
20 2.5
4 5 10
Improper temperature sensor installa- 3

10
11
0.5 5
10 25
30 3.0
2 12
tion. 1
0 15 13 0
0 35
3.5
0 14
15
Remedy: Check temperature sensor installation,

and insulation.
If normal, replace the expansion valve.
1850-2R384
Fig. 8-17
Insufficient compressor compression

Indications: High pressure on the low-pressure side, 0.39 ~ 0.59 MPa 1 ~ 1.5 MPa
pressure too low on the high pressure {4 ~ 6 bar, {10 ~ 15 bar,
side. 58 ~ 87.03 psi} 145.04 ~ 217.56 psi}
The high and low pressures are already 6 7 8 1.5 2.0
equal when operation is stopped. 4

5
5
9
10
1.0
10
15 20 2.5
10 25
11
3 0.5 5 3.0
30
2 12
Causes: Insufficient compression due to a defec- 1

0 15 13 0
0 35
3.5
0 14
tive compressor gasket or damaged 15
suction valve.
Remedy: Disassemble and repair the compres-

sor.
1850-2R389
Fig. 8-18
Infiltration of moisture
Indication: The low-pressure side pressure alter- Vide ~ 0.2 MPa 1 ~ 2 MPa
nates between a vacuum and normal {Vide ~ 2 bar, {10 ~ 20 bar,
pressure. Vide ~ 29 psi} 145 .04~ 290.07 psi}
7
Causes: Moisture has frozen in the air conditioner 5
6 8
9
1.0
1.5
15
2.0
20 2.5
4 5 10
system, clogging the expansion valve, 3

10
11
0.5 5
10 25
30 3.0
2 12
which then blocks the air conditioner 1

0 15 13 0
0 35
3.5
0 14
system. When the ice melts, normal op- 15
eration resumes.
Remedy: Replace the receiver drier.

Evacuate the system.
Recharge with refrigerant to the proper
level.
1850-2R390
Fig. 8-19
Refrigerant does not circulate

Indications: The low pressure side pressure becomes a
vacuum and the high pressure side pres- - 101.3 MPa 0.49 ~ 0.59 MPa
{- 760 mm Hg, {5 ~ 6 bar,
sure reads 0.49 ~ 0.59 MPa
- 29.92 in Hg} 72 ~ 87.02 psi}
{5 ~ 6 bar, 72.52 ~ 87.02 psi}.
Ice or condensation are forming on the pip- 5
6 7 8
9
1.5 2.0
1.0
ing connections of the drier receiver or the 4 5
10
10
11
10
15 20
25
2.5
3 0.5 5 3.0
expansion valve. 2 12
0
30
35
0 15 13
1 0
3.5
0 14
15
Causes: The air conditioner system is blocked by ice
or dirt.
The air conditioner system is shut off by a
defective expansion valve temperature sen-
sor.
Remedy: Stop operation and check for ice or contami-

nation. 1850-2R391
If the problem is moisture, evacuate the sys-
tem.
Replace the expansion valve temperature Fig. 8-20
sensor if defective.
Replace the receiver drier.
Recharge with refrigerant to the proper
level.

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THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents, whether they occur in industry, on the

Prior to engaging in any maintenance, adjustment

SAFETY RULES ......................................................................................................................................... I-VIII

TECHNICAL DATA TABLES

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

- Check the seat safety belt at least twice a year. If there

- Whenever possible, avoid going over obstacles such as

- Keep shoes free of mud or grease before climbing or

- Never attempt to operate the machine or its tools from

- Rust inhibitors are volatile and flammable Use only in

SAFETY RULES FOR SEALS

VITON SEALS (fluoroelastomer)

TEST FOR THE DISCRIMINATION OF RUBBER (BUNA N) MATERIALS

NITRILIC/BUNA N RUBBER VITON"

TECHNICAL DATA TABLES

The engine data plate is visible by opening the engine

IMPORTANT ENGINE INFORMATION

B. Machine identification plate

The identification plate includes the main data of the

C. Marking and serial number MODELLO MARKING

ITEM QUANTITY Fluids and lubricants VISCOSITY Outdoor temperatures International

Mixture of water and antifreeze at

Fuel reservoir 400 – – – DIESEL FUEL ASTM No. 2D

from 0.5 to 1 % Half normal interval

TRACTOR DIMENSIONS LT XLT LGP

TECHNICAL DATA D180 Power Steering - D180 Steering Clutch

TECHNICAL DATAS LT/XLT LGP

Max. towbar pulling effort

Climbing capacity (FWD)

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

TECHNICAL DATA D180

Engine manufacturer - Cummins

TECHNICAL DATA D180

Fan (Blowing) / Soundproof blowing fan TRUFLO ABB

Fan diameter mm (in) 762 (30) 704 (27.7)

Dry type, two stages with safety element

Total volume L (US gal) 400 (106)

Brand: Twin Disc

TECHNICAL DATA D180

Description of auto mode

TECHNICAL DATA D180

Gleason type, modular pinion assembly. Forced lube pinion bearings

The open hydrostatic circuit includes:

TECHNICAL DATA D180

Max. differ. track chain

STEERING Steering clutches:

Number of clutch driven discs (sintered) 7 (per clutch)

Multiple discs, spring actuated, oil released, oil cooled

TECHNICAL DATA D180

Max. braking torque daN (lb) 1016 (2284)

TRACK Fabricated structure with two sealed boxes

Link pitch mm (in) 203 (8) 203 (8)

No. of track rollers - 7 8

Sliding idler guides with replaceable wear strips

Nominal load of spring assembly daN (lb) 19509 (430173)