Page 1

D180 (Tier 3) CRAWLER DOZER

Workshop Manual Print No. 84151290 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 construction of any type of equipment, there are many conditions 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 hydraulically, mechanically, and/or cable controlled equipment (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

D180-3R001


SECTION 0

GENERALITIES TABLE OF CONTENTS

SUBJECT

PAGE

SAFETY RULES .......................................................................................................................................... I-VIII IDENTIFICATION DATA Engine data plate........................................................................................................................................ 0-3 Vehicle Identification Plate .......................................................................................................................... 0-4 Marking and serial number .......................................................................................................................... 0-4 TABLE OF FLUID CAPACITIES ..................................................................................................................... 0-5 DIMENSIONS D180 BD ................................................................................................................................ 0-6 DIMENSIONS D180 PAT ............................................................................................................................... 0-7 Technical data D180 PS - D180 SC ............................................................................................................ 0-8 D180 POWER STEERING LGP .................................................................................................................. 0-24 D180 POWER STEERING LT/XLT - STEERING CLUTCHES LT/XLT ............................................................ 0-25 WEIGHT AND EQUIPMENT D180 PAT ........................................................................................................ 0-26 WEIGHT MACHINE D180 PAT .................................................................................................................... 0-26 LIST OF WEIGHTS FOR MAIN SERVICE COMPONENTS .......................................................................... 0-27 CENTRE OF GRAVITY TABLE .....................................................................................................................0-29 GENERAL INSTRUCTIONS .......................................................................................................................... 0-30 TROUBLESHOOTING ..................................................................................................................................0-35 UNITS OF MEASURE ..................................................................................................................................0-36 TABLE OF TIGHTENING TORQUES ............................................................................................................ 0-38


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 or maintain this machine.

Before operating a machine, always ensure that any unsafe condition has been satisfactorily remedied.

- 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.

- Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system. - Be sure all protective guards or panels are in place, and all safety devices provided are in place and in good operating conditions. - Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. WALK COMPLETELY AROUND the machine before mounting. Sound horn.

- 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.

- Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of 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.

- Fasten your seat belt (when provided).

- 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.

- Obey all flag signals and signs.

- Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

- REMEMBER THAT STARTING FLUID IS FLAMMABLE. Follow strictly the recommendations printed on containers and in the Operation and Maintenance Manual.

- Due to the presence on the machine of flammable fluids, never check or fill fuel reservoirs or batteries near open flames, smoking materials or sparks.

- Keep head, body, limbs, hands and feet inside operator's compartment at all times, to reduce exposure to hazards outside the operator's compartment.

- DO NOT PUNCTURE OR BURN CONTAINERS. - Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. Follow strictly the instructions provided by the Manufacturer.

- 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.

- Never use these products near open flames, smoking materials or sparks.

- 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.

OPERATION

STARTING

- Do not run the engine of this machine in closed areas without proper ventilation to remove deadly exhaust gases.

- NEVER START NOR OPERATE AN UNSAFE MACHINE.

- Roll Over Protective Structures are required on loaders, 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 objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.

- 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.

- 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 .

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 of failure of the kinked area. Always wear heavy gloves when handling chains or cables.

- DO NOT CARRY RIDERS ON MACHINE - Study and familiarise with escape routes alternate to normal exit routes.

- Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load. Keep exposed personnel clear of anchor points and cables or chains.

- 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.

- DO NOT PULL UNLESS OPERATOR's COMPARTMENT 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 operating the equipment. Sound horn. Obey all indications provided by flags and signals.

- Be alert to soft ground conditions close to newly constructed walls. The fill material and weight of the machine may cause the wall collapse under the machine.

- NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralised.

- In darkness, check area of operation carefully before 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 authority immediately. Do not continue to operate machine, until condition has been corrected.

- 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.

- On machines supplied with suction radiator fans, be sure to periodically check engine exhaust parts for leaks, as exhaust fumes are dangerous to the operator.

- Operate the machine at speeds slow enough to ensure complete control at all times.

- In case of closed type cabs, always keep an opening with the outside, to ensure a constant air circulation.

- Travel slowly over rough terrain, on slopes or near dropoffs, in congested areas or on ice or slippery surfaces.

- Operators must know thoroughly the performances of the machine they are operating. When working on slopes or near sudden level drops of the terrain, avoid areas where ground is loose or soft since rolling-over or loss of control of machine could result.

- 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.

- Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection. - When counterweights are provided, do not work machine if they have been removed.

- Maintain clear vision of areas of travel or work.

II


SECTION 1

ENGINE TABLE OF CONTENTS

CHAPTER

SUBJECT

PAGE

1.1

GENERAL SPECIFICATIONS .................................................................................................. 1-3 Identification of the engine ..................................................................................................... 1-4

1.2

SERIES "C" ENGINE DATA ..................................................................................................... 1-5

1.3

DIAGRAMS OF SERIES "C" ENGINE ..................................................................................... 1-7

1.4

MOUNTING OF ENGINE ON FRAME ..................................................................................... 1-11 Engine/converter removal and installation ............................................................................ 1-12 Removal of the radiator group .............................................................................................. 1-24 Removal of silencer group ................................................................................................... 1-26 Removal of converter group .................................................................................................. 1-27 Reinstalling the converter group ........................................................................................... 1-28 Reinstalling the silencer group ............................................................................................ 1-30 Reinstalling the radiator group ............................................................................................. 1-31 Reinstalling the engine group assembly .............................................................................. 1-33

1.5

DIAGNOSTICS WITH BLINK CODE ....................................................................................... 1-45


D180

1-3

ENGINE

1.1 GENERAL SPECIFICATIONS 1. The engine is a diesel for heavy duty applications characterised by several design concepts tending towards simplicity and a high compactness.

1850-3R002

Series C Length mm

Width

in

mm

1050 41.3

2. The engine incorporates, in a single solution, all the most important characteristics and advantages of modern diesel technology.

3. The engine has been entirely designed with metric dimensions. the only discrepancy with these specifications involves the use of connections for pipes and plugs with SAE standards. The specifications of accessories change depending upon the Supplier. Technical publications list metric values with the equivalent SAE values.

685

in

Height mm

26.9 945

in

Weight kg

37.2 550 1212.5

Technology • • • • • • • •

In-line cylinders Water cooled 4 stroke Turbocharged Afterc-ooled Direct injection Metric dimensions Air flow cooling

Engine components •

Metric specifications

Pipes connections and plugs •

lb

SAE standards

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1-4

D180

ENGINE

IDENTIFICATION OF THE ENGINE

1850-M0044

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 contacting a Iveco Authorised Repair Centre. The information data on the plate are compulsory when procuring Spare Parts. Note – Do not change the engine data plate unless authorised by IVECO. The total displacement of the engine is 6.7 litres (1.7 gal), the bore is 104 mm (4 in) and the stroke 132 mm (5.1 in). The firing order is the same as for the other in-line, 6 cylinder Iveco engines, 1-5-3-6-2-4.

Specifications of engine series Total displacement Bore Stroke

6,7 litri 104 mm 132 mm

Firing order

1-5-3-6-2-4

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

ENGINE

1-5

1.2 ENGINE DATA Generalities D180 LT/XLT D180 LGP Bore: ............................................................................... 104 mm [4.0 in] ......................... 104 mm [4.49 in] Stroke: ............................................................................ 132 mm [5.1 in] ......................... 132 mm [5.32 in] Total displacement: ......................................................... 6.7 L [408.8 in3] ........................... 6.7 L [408.8 in3] Net flywheel power (ISO 9249) .................................... 196 HP / 146 kW ........................ 210 HP / 157 kW Low idle ......................................................................... 780÷920 rpm ............................... 780÷920 rpm High idle ..................................................................... 2030÷2170 rpm ........................... 2030÷2170 rpm Implem. stall ............................................................... 2020÷2160 rpm ........................... 2020÷2160 rpm Torque converter / transmission stall ........................... 1710÷1850 rpm ........................... 1785÷1925 rpm Total stall .................................................................... 1640÷1840 rpm ........................... 1725÷1925 rpm Maximum torque ..................................................................... 860Nm .................... 952Nm A 1400 min-1 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

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1-7

ENGINE

D180

1.3 DIAGRAMS OF ENGINE The illustrations here below provide information on the engine components, the location of filters, the draining points and the access locations for engine instrumentation and controls.

The illustrations and the configuration of the components shown in these diagrams are of a general nature. The locations of some components change depending upon the application and the installation.

For the removal, testing, overhaul and installation of the engine, please refer to the Workshop Manual IVECO.

Fan pulley

Cold start device

Air inlet manifold

Engine oil dipstick

High pressure fuel pipes

Rear lifting bracket

Electronic controller

Dumper

Crankshaft pulley

Fuel filter Pressure sensor engine oil

High pressure fuel pump Engine flywheel cover

Oil draining plug

1850-3R004

View from left side

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1-8

D180

ENGINE

Water temperature Turbocharger lube pipe Tappet cover

Turbocharger Coolant outlet

Exhaust manifold

RPM sensor engine Lube oil filter

Coolant inlet

Turbocharger oil draining Starter motor

1850-3R005

View from left right

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1-9

ENGINE

D180

Centring bearing

Flyweel Flex disc mountng holes Flyweel housing 1850-3R078

Rear view

Fan pulley

Turbocharger air intake

Belt tensioner

Water pump

Oil sump

1850-3R079

Front view

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 10

D180

ENGINE

Turbocharger air outlet Turbocharger air inlet

Turbocharger exhaust outlet

Engine oil filter neck Common rail

1850-3R080

View from above

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 11

ENGINE

D180

1.4 MOUNTING OF ENGINE ON FRAME

C2 C1

C2

C3

D180-3R003

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)

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 12

D180

ENGINE

ENGINE/CONVERTER REMOVAL AND INSTALLATION REMOVAL OF ENGINE GROUP ASSEMBLY Turn the STARTER SWITCH into OFF and place the "DO NOT START" notice as indicated in the figure.

WARNING

T NO ATE DO PER O

Do not allow unauthorized persons to repair or maintain this machine. Read carefully the Operation and Maintenance Manual prior to starting, operating, maintaining or refueling and repairing the machine.

D180-3R009

Oil draining Remove plug (1) from the bottom of the machine, with the transmission oil warm, and let it drain into a container with a 40 liter (10 USG) capacity, at least.

DANGER Pressurized fluid: before removing the plug or the cover turn it slowly to release the pressure. See the Instruction Manual.

1

D180-2M195

To facilitate the draining, open the right panel under the cab and loosen plug (2) from the transmission oil filler neck.

2

1850-3R922

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 13

ENGINE

D180

With engine cold, drain the coolant from the radiator by opening the valve indicated in the figure, located at the bottom of the radiator itself. To facilitate the draining, remove the coolant filler cap on the radiator.

1850-2R435

Remove the windshield washer liquid pipes (1) from the engine hood upper panels.

WARNING Handle all components with great care. Never place hands or fingers between parts. Wear approved protective clothing such as glasses, gloves and safety shoes.

1

1850-2R431

Remove the plastic protection caps (2) (q.ty 4) of the screws securing the engine hood.

2

1850-2R432

Remove the engine hood securing screws (3) (q.ty 4) complete with washers and vibration damper rubber rings.

3

1850-2R433

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 14

D180

ENGINE

Open the side doors and using a hoist and cables, sling the engine hood complete with upper panels and rest it on an appropriate stand.

WARNING Lift and handle all heavy materials with lifting devices of appropriate capacity. Make sure that the parts are secured by appropriate hooks and slings. Use the lifting eyes provided for this purpose. Do not stand under suspended loads. Beware of persons in the vicinity of the loads to be lifted.

1850-2R434

Remove the panels by removing securing screws (1) (q.ty 8) complete with washers.

1

D180-3R010

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

1 - 15

MOTORE

Disconnect ground braid (1) and cold start device cable (2). 2

1

1850-3R033

Disconnect in and out lines (4) from fuel prefilter (3).

4 3 1850-3R034

Disconnect sensor lead (5) from water in fuel prefilter (3).

3

5

1850-3R035

Remove the six safety screws (6) from the right side of the cab.

6 1850-3R018

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 16

D180

MOTORE

Open the lower panel on the left side of the cable and make sure that the cab doors are closed. Insert a steel bar (1) in the cab tilting device compartment (2) and pry it to lift the cab. Make sure that lever (3) of the cab tilting device is directed toward the rear side of the machine, as indicated in the figure.

1

2

3 1850-3R027

IMPORTANT

4

From this phase onward, identify all electrical connections and hydraulic pipes to facilitate the CONNECTIONS DURING THE INSTALLATION PHASE.

Disconnect the horn power wire (4).

1850-3R036

Disconnect the air cleaner clogging sensor wire (5).

5 1850-3R037

Remove steel-rubber bands (6) (q.ty 3) to remove completely the electric connections from frame (7).

6 7

1850-3R038

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

1 - 17

MOTORE

Disconnect all wires connected to the 50 Amp (1) and 80 Amp (2) fuse links.

1

2

1850-3R074

Remove the turbine-air filter hose (3) by removing metal collars (4) (q.ty 2). Close the turbine inlets with adhesive tape to prevent foreign bodies entering the turbine itself.

4 3 1850-3R019

Disconnect converter breather hose (5) by loosening metal collar (6). 6

5

1850-2R447

Install lifting eyes on frame (7) and using a hoist complete with chains secure the frame to prevent accidental falls.

7

WARNING Lift and handle all heavy materials with lifting devices of appropriate capacity. Make sure that the parts are secured by appropriate hooks and slings. Use the lifting eyes provided for this purpose. Do not stand under suspended loads. Beware of persons in the vicinity of the loads to be lifted.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

1850-2R448


1 - 18

D180

MOTORE

Remove securing screws (1) (q.ty 4) and relevant washers (2) from the base of the frame. Then, lift the frame complete with air cleaner and place it on an appropriate stand.

2 1 1850-2R449

Remove the radiator fan guard side grills (3) (q.ty 2) by removing securing screws (4) (q.ty 4) complete with washers.

3 4

1850-2R450

Remove radiator fan (5) by removing securing screws (6) (q.ty 4) and the relevant washers.

5 6 1850-2R459

Disconnect converter oil temperature sensor wire (7).

7

1850-2R452

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

1 - 19

MOTORE

Disconnect radiator- hydraulic oil hose (2) on the right side, from steel pipe (1) located on the spacer between engine and converter.

2

1

1850-2R510

Disconnect radiator - hydraulic oil (delivery) (3) and hose (4) coming from the hydraulic motor from the left side of steel pipe (1).

1 3

4

1850-2R511

Disconnect hose (5) from the left side of steel pipe (1) after securing bands (6). Proceed in the same manner for the right side of steel pipe (1) disconnecting the relevant hose.

5

6 1

1850-2R512

Disconnect steel pipe (1) complete with relief valve (7) by removing screws (8) complete with washers.

7

1

8 1850-2R513

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 20

D180

MOTORE

Disconnect converter oil pressure sensor wire (1) and the hydraulic hoses indicated in the figure.

1

1850-2R453

Disconnect all electric connections (2) from starter motor (3). 3

2

1850-3R020

Disconnect ground wires (4) connected to the frame by removing securing screw (5). 5

4 1850-3R021

Disconnect engine coolant temperature sensor wire (6).

6

1850-3R022

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


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D180

1 - 21

MOTORE

Disconnect electric wire (1) from alternator (2). 2

1

1850-3R023

Disconnect engine rpm sensor lead (3).

3

1850-3R032

Free hydraulic hoses (4) from the frame by removing screws (6) (q.ty 4) of the relevant securing brackets (5) on the right and left side of the frame. 4

5

6 1850-2R458

Disconnect the inlet and outlet hoses from transmission oil filter (7) and hydraulic oil filter (8).

8 8

7 1850-2R461

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 22

D180

MOTORE

Proceed in the same manner on hydraulic oil filter (1) by disconnecting the pipes indicated I the figure.

1 1850-2R462

Disconnect engine oil pressure sensor connector (2).

2 1850-3R024

Disconnect air conditioner compressor lead (3), and refrigerant in and out lines (4).

3

4 1850-3R025

Disconnect engine cable from ECU removing connectors (5).

5

1850-3R031

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

1 - 23

MOTORE

Disconnect radiator-engine steel suction pipe (1) by loosening the relevant metal collar. 1

WARNING Handle all components with great care. Never place hands or fingers between parts. Wear approved protective clothing such as glasses, gloves and safety shoes.

1850-3R026

Place a container of adequate capacity (23 l - 6 USG) under the oil sump. Open the lower panel (2) of the engine compartment and drain the oil through lower plug (3).

3

2

1850-3R923

Remove the propeller shaft (converter side) (4) by removing securing screws (5) (q.ty 4). 5

4 D180-3R039

The engine is secured to the frame of the machine in four points. Remove engine securing screws (6) (q.ty 8) from these points. 6

D180-3R040

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


1 - 24

D180

MOTORE

Using adjustable hoist and chains, sling the engine complete with converter, with the appropriate lifting eyes indicated in the figure and place it on an appropriate stand.

WARNING Lift and handle all heavy materials with lifting devices of appropriate capacity. Make sure that the parts are secured by appropriate hooks and slings. Use the lifting eyes provided for this purpose. Do not stand under suspended loads. Beware of persons in the vicinity of the loads to be lifted.

1850-3R011

REMOVAL OF THE RADIATOR GROUP Open front end grill to gain access to the top retention point of the radiator-aftercooler unit. Remove cap screws (1) (4 off) complete with washers from support (2).

1

WARNING Do not allow unauthorized persons to repair or maintain this machine. Read carefully the Operation and Maintenance Manual prior to starting, operating, maintaining or refuelling and repairing the machine.

2 1850-3R008

Disconnect in hose (5) from drivetrain exchanger matrix (3) and hydraulic oil exchanger matrix (4).

3

4 5

1850-3R013

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual


D180

1 - 25

MOTORE

Disconnect out lines (1).

1

1850-3R014

From the top of the radiator disconnect hoses between engine and radiator (2) by loosening metal collars (3). 3

WARNING Lift and handle all heavy materials with lifting devices of appropriate capacity. Make sure that the parts are secured by appropriate hooks and slings. Use the lifting eyes provided for this purpose. Do not stand under suspended loads. Beware of persons in the vicinity of the loads to be lifted.

2

1850-3R006

Similarly, disconnect aftercooler lines (4) and engineradiator coolant in line (5).

5

4 1850-3R028

Apply two lift eyes to radiator unit and take the weight using a suitable hoist to prevent the risk of accidental falls.

1850-3R007

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

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New Holland D180 Tier 3 Crawler Dozer Service Repair Manual  

New Holland D180 Tier 3 Crawler Dozer Service Repair Manual  

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