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Fiat Hitachi Crawler Dozer D180 Workshop Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Crawler Dozer D180 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Crawler Dozer D180 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 261
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Crawler Dozer D180 Workshop Manual – PDF DOWNLOAD
SAFETY RULES
– Check monitoring instruments at start-up and frequently during operations. in case the brake pressure gauge shows a pressure lower than the minimum operating pressure, stop immediately the machine .
– DO NOT CARRY RIDERS ON MACHINE
– Study and familiarise with escape routes alternate to normal exit routes. – Seat belts are required by current regulations to be provided with Roll Over Protection Structures or cabs. Keep safety belts fastened around you during operation.
– For your personal protection, do not climb on or off machine while machine is in motion.
– Make sure that exposed persons in the area of operation are clear of the machine, before starting the engine and operating the equipment. Sound horn. Obey all indications provided by flags and signals.
– NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralised. Choose and shift into the most appropriate gear to keep the speed required, thus preventing any loss of control. – Do not operate machinery in a condition of extreme fatigue or illness. Be especially careful towards the end of working shift. – Do not operate machine with brakes out of adjustment.
– Operate the machine at speeds slow enough to ensure complete control at all times.
– Travel slowly over rough terrain, on slopes or near dropoffs, in congested areas or on ice or slippery surfaces.
– When backing, always look to where the machine is to be moved. Be alert to the position of exposed personnel. DO NOT OPERATE if exposed personnel enter the immediate work area. STOP THE MACHINE.
– Maintain a safe distance from other machines. Provide sufficient clearance for ground and visibility conditions. Yield right-of-way to loaded machines.
– Maintain clear vision of areas of travel or work. Keep cab windows clean and repaired. – When machines are operating in tandem, the pusher (rear) must be equipped with the appropriate deflectors to protect the unit in front from the air stream coming from the radiator.
– When pulling or towing through a cable or chain, do not start suddenly at full throttle; take-up slack carefully. Inspect carefully for flaws or troubles before using.
– Avoid kinking chains or cables. Do not pull through a kinked chain or cable to the high stresses and possibility
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) 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) establishing 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. 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Crawler Dozer D180 Workshop Manual – PDF DOWNLOAD
D180 CRAWLER DOZER........................................................ 1 Workshop manual........................................................... 1 SUMMARY................................................................... 3 SECTION 0 GENERALITIES.................................................... 4 SAFETY RULES.......................................................... 5 TECHNICAL DATA TABLES................................................. 13 GENERAL INSTRUCTIONS.................................................. 26 TROUBLESHOOTING....................................................... 31 UNITS OF MEASURE...................................................... 32 CLASSIFICATION OF STANDARD COMPONENTS................................. 32 TABLE OF TIGHTENING TORQUES........................................... 34 SECTION 1 ENGINE.......................................................... 35 GENERAL SPECIFICATIONS................................................ 36 SERIES "C" ENGINE DATA................................................ 38 DIAGRAMS OF SERIES "C" ENGINE......................................... 41 MOUNTING OF ENGINE ON FRAME........................................... 44 SECTION 2 TRANSMISSION.................................................... 45 GENERAL DESCRIPTION................................................... 46 TRANSMISSION TORQUE CONVERTER HYDRAULIC DIAGRAM................... 0 Transmission housing.............................................. 0 TROUBLESHOOTING....................................................... 49 TESTS................................................................. 53 Torque converter stall test....................................... 0 TRANSMISSION GEARSHIFTING ELECTRIC CONTROL VALVE.................. 0 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER..................... 68 REMOVAL........................................................... 0 RE-INSTALLATION................................................... 0 DISASSEMBLY....................................................... 0 REASSEMBLY........................................................ 0 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION......................... 68 REMOVAL........................................................... 0 RE-INSTALLATION................................................... 0 DISASSEMBLY....................................................... 0 OVERHAUL OF THE FORWARD SPEED CLUTCH.............................. 0 OVERHAUL OF THE 3 rd SPEED........................................ 0 OVERHAUL OF THE REV SPEED CLUTCH.................................. 0 MODULATING VALVES (Disassembly / Assembly)........................ 0 PRESSURE RELIEF VALVE (Disassembly / Assembly).................... 0 SPECIFICATIONS AND DATA............................................... 99 GENERAL DATA...................................................... 0 TIGHTENING TORQUES (TORQUE CONVERTER)............................. 0 TRANSMISSION HOUSING.............................................. 0 TRANSMISSION DATA................................................. 0 TRANSMISSION CLUTCH DISC.......................................... 0 LUBE OIL PRESSURE RELIEF VALVE.................................... 0 FORWARD REVERSE MODULATING VALVES................................. 0 TRANSMISSION PRESSURE RELIEF VALVE AND TORQUE CONVERTER SAFETY.... 0 TORQUE CONVERTER / TRANSMISSION FEEDING PUMP...................... 0 OIL FILTERS....................................................... 0 SECTION 3 FINAL DRIVES....................................................110 GENERAL DESCRIPTION...................................................111 Final drive.......................................................112 REPAIR PROCEDURES.....................................................114 Disassembly.......................................................116 Pulling the housing cover.........................................118 Driven gear.......................................................119 Driving gear shaft................................................119 Description of installation of front seals (long life)............120 Final drive (removal / disassembly)...............................114 Final drive (assembly)............................................121 SPECIFICATIONS AND DATA...............................................129 Final drive shaft and bearing fittings............................129 BEARING INSTALLATION SPECIFICATIONS AND DATA......................130 SECTION 4 BRAKES AND STEERING CLUTCHES....................................131 GENERAL DESCRIPTION OF THE CIRCUIT.................................... 0 BRAKES AND STEERING CLUTCHES SYSTEM HYDRAULIC DIAGRAM............. 0 MAIN COMPONENTS OF THE HYDRAULIC SYSTEM........................... 0 REAR TRANSMISSION (transmission side section)..................... 0 TROUBLESHOOTING....................................................... 0 DIAGNOSIS ON THE DISPLAY.......................................... 0 TESTS................................................................. 0 PRESSURE TEST OF THE BRAKES AND STEERING CLUTCH CIRCUIT........... 0 BRAKE PEDAL ADJUSTMENT............................................ 0 BRAKE SYSTEM PRESSURE TEST (with brake pedal)..................... 0 FEEDING VALVE TEST AND SETTING.................................... 0 CALIBRATION OF BRAKES/STEERING CLUTCH LEVERS...................... 0 REPAIR PROCEDURES Brake pedal valve................................... 0 STEERING CLUTCH AND BRAKE......................................... 0 BRAKES AND STEERING CLUTCHES...................................... 0 BEVEL GEAR UNIT................................................... 0 BEVEL GEAR........................................................ 0 PROCEDURE FOR THE SETTING OF THE PINION BEARINGS PRE-LOAD......... 0 PROCEDURE FOR THE SETTING OF THE BEVEL GEAR UNIT.................. 0 SPECIFICATIONS AND DATA............................................... 0 BEVEL GEAR REDUCTION UNIT (General data / dimensions)............. 0 STEERING CLUTCHES................................................. 0 BRAKE PEDAL VALVE................................................. 0 SECTION 5 UNDERCARRIAGE...................................................179 GENERAL DESCRIPTION...................................................180 GENERALITIES......................................................180 MAIN COMPONENTS...................................................181 TROUBLESHOOTING.......................................................184 INSPECTIONS...........................................................185 INSPECTION AND ADJUSTMENT OF TRACK CHAINS.........................185 SETTING OF THE TRACK TENSIONER PRESSURE RELIEF VALVE..............186 REPAIR PROCEDURES.....................................................187 TRACK CHAIN (removal / installation)..............................187 REPLACING A DAMAGED LINK AND RE-INSTALLATION......................189 IDLER.............................................................191 TRACK CHAIN SUPPORT ROLLERS (removal/installation/overhaul).......194 TRACK CHAIN BOTTOM ROLLERS (removal / installation / overhaul)....196 SPECIFICATIONS AND DATA...............................................200 IDLER.............................................................200 SPECIFICATIONS AND DATA...............................................201 SPROCKETS.........................................................201 TRACK CHAINS......................................................201 BOTTOM ROLLERS....................................................202 SUPPORT ROLLERS...................................................203 TRACK TENSIONER DEVICE............................................204 FRONT CROSS-MEMBER PIVOTS (*).....................................205 FRONT CROSS-MEMBER PIVOTS.........................................205 WEAR LIMITS.......................................................209 SECTION 6 DOZING EQUIPMENT HYDRAULIC SYSTEM...............................211 GENERAL DESCRIPTION...................................................212 OPERATION OF THE HYDRAULIC SYSTEM.................................212 DIAGRAM OF DOZING EQUIPMENT HYDRAULIC SYSTEM......................215 DOZER EQUIPMENT HYDRAULIC SYSTEM DIAGRAM..........................214 TROUBLESHOOTING.......................................................216 TESTS.................................................................220 USE OF THE FLOW METER.............................................220 FLOW TEST IN SINGLE CIRCUITS......................................220 PUMP FLOW TEST....................................................221 REPAIR PROCEDURES.....................................................223 HYDRAULIC OIL RESERVOIR (Removal / installation)..................223 Equipment hydraulic pump..........................................225 Hydraulic control valve...........................................226 Montage du godet..................................................227 SPECIFICATIONS AND DAT................................................228 Hydraulic control valve...........................................228 Supply hydraulic pump.............................................229 Blade lifting cylinder ball joint.................................230 Blade lifting control cylinder....................................231 Blade tilt control cylinder (Bulldozer version)...................232 Blade tilt control cylinder (Angledozer version)..................233 Ripper cylinder...................................................234 Blade push arms and rods..........................................235 Frame and rods....................................................236 Ripper linkage....................................................237 SECTION 7 ELECTRICAL SYSTEM...............................................239 SAFETY RULES..........................................................240 ELECTRICAL SYSTEM.....................................................241 FUSES.................................................................243 LINK" FUSES AND COLD STARTING.........................................244 MAIN SWITCH...........................................................245 ENGINE STARTING SWITCH................................................245 BACK-UP ALARM.........................................................246 STARTER MOTOR.........................................................246 INSTRUMENT PANEL / MONITOR............................................247 MONITOR SENDERS.......................................................250 BUZZER................................................................256 RELAY - DIODES - DIVERTER BOX GROUP...................................257 MAIN CONNECTORS 19 - 21 - 23 WAYS.....................................260
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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