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Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
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Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 276
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
SAFETY RULES
– Do not allow unauthorised personnel to operate service or maintain this machine.
– Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.
– Keep operator’s compartment, stepping points, grabrails and handles clear of foreign objects, oil, grease, mud or snow accumulation to minimise the danger of slipping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.
– Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step grab rails and handles at all times. – Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a solid support.
Also, controls may be inadvertently moved causing accidental machine or equipment movement.
– Never attempt to operate the machine or its tools from any position other than seated in the operator’s seat.
– Keep head, body, limbs, hands and feet inside operator’s compartment at all times, to reduce exposure to hazards outside the operator’s compartment.
– Be careful of slippery conditions on stepping points, hand rails, and on the ground. Wear safety boots or shoes that have a high slip resistant sole material.
– Do not leave the machine until it is completely stopped.
– Check the seat safety belt at least twice a year. If there are signs of wear or fraying or other signs of weakness that could lead to failure, replace it.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Crawler Dozer D150 D150 LGP Workshop Manual – PDF DOWNLOAD
D150 - D150 LGP CRAWLER DOZER....................................................... 1 SUMMARY............................................................................. 3 SAFETY RULES.................................................................... 5 TABLES OF TECHNICAL DATA........................................................ 15 GENERAL INSTRUCTIONS............................................................ 27 TROUBLESHOOTING................................................................. 32 UNITS OF MEASURE................................................................ 33 CLASSIFICATION OF STANDARD COMPONENTS........................................... 33 TABLE OF TIGHTENING TORQUES..................................................... 35 GENERALITIES........................................................................ 13 ENGINE.............................................................................. 36 1.1 GENERAL SPECIFICATIONS OF SERIES B ENGINE................................... 37 1.1.1. ENGINE MAIN SPECIFICATIONS........................................... 37 1.1.2 Engine identification................................................. 38 1.2 DESIGN FEATURES............................................................. 39 1.3 SERVICEABILITY.............................................................. 44 1.4 SECURING THE ENGINE TO THE FRAME............................................ 45 TRANSMISSION........................................................................ 46 2.1 GENERAL DESCRIPTION......................................................... 48 2.1.1 TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM....................... 48 Transmission housing/Propeller shaft/Torque converter....................... 50 2.2 TROUBLESHOOTING............................................................. 51 2.3 TESTS....................................................................... 55 2.3.1 Torque converter stall test........................................... 55 2.3.2 Delivery pressure test procedure...................................... 55 2.3.3 TRANSMISSION GEARSHIFTING ELECTRIC CONTROL VALVE...................... 56 2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER......................... 58 2.4.1 REMOVAL............................................................... 58 2.4.2 REINSTALLATION........................................................ 59 2.4.3 DISASSEMBLY........................................................... 60 2.4.4 REASSEMBLY............................................................ 69 2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION............................... 70 2.5.1 REMOVAL............................................................... 70 2.5.2 RE-INSTALLATION....................................................... 71 2.5.3 DISASSEMBLY........................................................... 72 2.5.4 OVERHAUL OF THE FORWARD SPEED CLUTCH.................................. 86 2.5.5 OVERHAUL OF THE 3rd SPEED............................................. 88 2.5.6 OVERHAUL OF THE REV SPEED CLUTCH...................................... 93 2.5.7 MODULATING VALVES (Disassembly / Assembly).......................... 97 2.5.8 PRESSURE RELIEF VALVE (Disassembly / Assembly)...................... 98 2.6 SPECIFICATIONS AND DATA.....................................................101 2.6.1 GENERAL DATA..........................................................101 2.6.2 TIGHTENING TORQUES (TORQUE CONVERTER)................................102 2.6.3 TRANSMISSION DATA TRANSMISSION HOUSING................................103 TRANSMISSION CLUTCHES...................................................104 TRANSMISSION CLUTCH DISCS...............................................106 1st - 2nd - 3rd SPEED TRANSMISSION CLUTCH MODULATING VALVES.............106 LUBE OIL PRESSURE RELIEF VALVE..........................................107 FORWARD REVERSE MODULATING VALVES.......................................108 TRANSMISSION PRESSURE RELIEF VALVE AND TORQUE CONVERTER SAFETY VALVE....109 TORQUE CONVERTER / TRANSMISSION FEEDING PUMP............................110 OIL FILTERS.............................................................111 FINAL DRIVES........................................................................112 3.1 GENERAL DESCRIPTION.......................................................113 3.1.1 FINAL DRIVE...........................................................114 3.2 REPAIR PROCEDURES...........................................................116 3.2.1 FINAL DRIVE (REMOVAL/DISASSEMBLY).....................................116 3.2.2 PULLING THE HOUSING COVER.............................................120 3.2.3 DRIVEN GEAR (BEARING REMOVAL).........................................121 3.2.4 DRIVING GEAR SHAFT (BEARING REMOVAL...................................121 3.2.5 DESCRIPTION OF INSTALLATION OF FRONT SEALS (LONG LIFE)................122 3.2.6 FINAL DRIVE (ASSEMBLY)................................................123 3.3 SPECIFICATIONS AND DATA.....................................................132 3.3.1 FINAL DRIVE SHAFT AND BEARING FITTINGS................................132 BRAKES AND STEERING CLUTCHES........................................................134 4.1 GENERAL DESCRIPTION OF THE CIRCUIT..........................................136 4.1.1 BRAKES AND STEERING CLUTCHES SYSTEM HYDRAULIC DIAGRAM.................137 4.1.2 MAIN COMPONENTS OF THE HYDRAULIC SYSTEM...............................138 BRAKES AND STEERING CLUTCHES FEEDING PUMP...................................138 00 ˝1.........................................................139 PROPORTIONAL SOLENOIDE VALVES BLOCK.........................................140 BRAKES AND CLUTCHES CONTROL VALVE...........................................141 BRAKE PEDAL VALVE...........................................................143 OIL FILTERS.................................................................145 REAR TRANSMISSION (gearbox side section)....................................146 4.2 TROUBLESHOOTING.............................................................148 4.2.1 DIAGNOSIS ON THE DISPLAY..............................................149 4.3 TESTS.......................................................................151 4.3.1 PRESSURE TEST OF THE BRAKES AND STEERING CLUTCHES CIRCUIT.............151 4.3.2 BRAKE PEDAL ADJUSTMENT................................................153 4.3.3 BRAKE SYSTEM PRESSURE TEST ...........................................154 4.3.4 FEEDING VALVE TEST AND SETTING........................................155 4.3.5 BRAKE LEVERS/STEERING LEVERS CALIBRATION..............................156 4.4 REPAIR PROCEDURES ..........................................................159 4.4.1 brake pedal valve (removal / disassembly)...........................159 4.4.2 STEERING CLUTCH AND BRAKE CONTROL FEEDING PUMP .......................160 4.4.3 BRAKES AND STEERING CLUTCHES ........................................161 4.4.4 BEVEL GEAR UNIT (REMOVAL/DISASSEMBLY).................................166 4.4.4.1 BEVEL RING GEAR REMOVAL.........................................167 4.4.4.2 BEVEL PINION REMOVAL............................................171 4.4.4.3 BEVEL GEAR CROWN DISASSEMBLY....................................172 4.4.4.4 CROWN GEAR ASSEMBLY.............................................173 4.4.4.5 BEVEL GEAR DISASSEMBLY..........................................173 4.4.4.6 INSTALLATION OF BEVEL PINION....................................176 4.4.4.7 REINSTALLING THE BEVEL GEAR CROWN...............................181 4.4.4.8 REINSTALLATION OF THE BEVEL PINION ............................183 4.4.4.9 SETTING THE PINION-GEAR CROWN BACKLASH..........................184 4.4.5 STEERING/BRAKES CONTROL PILOT VALVE...................................185 4.4.5.1 REMOVAL.........................................................185 4.5 SPECIFICATIONS AND DATA.....................................................186 4.5.1 BEVEL GEAR DIMENSIONS.................................................186 4.5.2 BEVEL GEAR REDUCTION..................................................188 4.5.3 STEERING CLUTCHES.....................................................191 4.5.4 BRAKE PEDAL VALVE.....................................................192 UNDERCARRIAGE.......................................................................194 5.1 GENERAL DESCRIPTION.........................................................195 5.1.1 GENERALITIES..........................................................195 5.1.2 MAIN COMPONENTS.......................................................196 5.2 TROUBLESHOOTING.........................................................199 5.3 INSPECTIONS.................................................................200 5.3.1 INSPECTION AND ADJUSTMENT OF TRACK CHAINS.............................200 5.3.2 SETTING OF THE TRACK TENSIONER PRESSURE RELIEF VALVE..................201 5.4 REPAIR PROCEDURES..........................................................202 5.4.1 TRACK CHAIN (removal/installation)....................................202 5.4.2 REPLACING A DAMAGED LINK AND RE-INSTALLATION..........................204 5.4.3 IDLER (REMOVAL/INSTALLATION/OVERHAUL).................................206 5.4.4 TRACK CHAIN SUPPORT ROLLERS (removal/installation/overhaul).........209 5.4.5 TRACK CHAIN BOTTOM ROLLERS (removal / installation / overhaul).....211 5.5 SPECIFICATIONS AND DATA ....................................................215 5.5.1 IDLER.................................................................215 5.5.2 SPROCKETS.............................................................216 5.5.3 TRACK CHAINS..........................................................216 5.5.4 BOTTOM ROLLERS.......................................................217 5.5.5 SUPPORT ROLLERS.......................................................218 5.5.6 TRACK TENSIONER DEVICE ...............................................219 5.5.7 FRONT CROSS-MEMBER PIVOTS.............................................220 5.5.8 WEAR LIMITS...........................................................224 DOZING EQUIPMENT HYDRAULIC SYSTEM...................................................225 6.1 GENERAL DESCRIPTION.........................................................226 6.1.1 OPERATION OF THE HYDRAULIC CIRCUIT....................................226 6.1.2 D150 EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...............................228 EQUIPMENT HYDRAULIC SYSTEM DIAGRAM......................................229 6.2 TROUBLESHOOTING.............................................................231 6.3 TESTS.......................................................................235 6.3.1 USE OF THE FLOW METER.................................................235 6.3.2 FLOW TEST IN SINGLE CIRCUITS..........................................235 6.3.3 PUMP FLOW TEST........................................................236 6.4 REPAIR PROCEDURES...........................................................238 6.4.1 HYDRAULIC OIL RESERVOIR (Removal / installation)....................238 6.4.2 Equipment hydraulic pump..............................................240 6.4.3 Hydraulic control valve...............................................241 6.4.4 INSTALLATION OF BLADE.................................................242 6.5 SPECIFICATIONS AND DATA.....................................................243 6.5.1 Hydraulic control valve...............................................243 6.5.2 EQUIPMENT HYDRAULIC PUMP..............................................244 6.5.3 Blade lifting cylinder ball joint.....................................245 6.5.4 BLADE LIFTING CONTROL CYLINDER (Version Angledozer)...................246 6.5.5 BLADE LIFTING CONTROL CYLINDER (Bulldozer version)....................247 6.5.6 BLADE TILT CONTROL CYLINDER (PAT version).............................248 6.5.7 BLADE TILT CONTROL CYLINDER (Angledozer version)......................249 6.5.8 BLADE TILT CONTROL CYLINDER (Bulldozer version).......................250 6.5.9 RIPPER CYLINDER.......................................................251 6.5.10 Blade push arms and rods.............................................252 6.5.11 Frame and rods.......................................................253 6.5.12 ripper...............................................................254 ELECTRICAL SYSTEM...................................................................255 SAFETY RULES....................................................................256 GENERAL DIAGRAM OF PROTECTION TREE..............................................257 FUSES...........................................................................258 LINK" FUSES AND COLD STARTING...................................................259 MAIN SWITCH.....................................................................260 ENGINE STARTING SWITCH..........................................................260 BACK-UP ALARM...................................................................261 STARTER MOTOR...................................................................261 INSTRUMENT PANEL / MONITOR......................................................262 ELECTRICAL DIAGRAM OF INSTRUMENT PANEL/MONITOR..................................264 MONITOR SENDERS.................................................................265 DISPLAY.........................................................................269 BUZZER..........................................................................271 RELAY GROUP - DIODES - DIVERTER BOX.............................................272 MAIN CONNECTORS 19 - 21 - 23 WAYS...............................................275 ELECTRICAL DIAGRAM..............................................................276
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