Fiat Kobelco Crawler dozer D150 (Tier 2) Operator Manual PDF

Operation and Maintenance Instruction Manual Print No 604.19.160.00 English - Printed in Italy

Operation and Maintenance Instruction Manual

D150 (Tier 2)

Crawler dozer

Operation and Maintenance Instruction Manual Print No. 604.19.160.00 (III - 2003)

WARNING STUDY THIS MANUAL BEFORE STARTING, OPERATING, MAINTAINING, FUELLING OR SERVICING THE MACHINE.

This alert symbol signals important messages involving your safety. It means: WARNING! BE ALERT! IT INVOLVES YOUR SAFETY.

Read and heed carefully all safety instructions identified by the key words WARNING and DANGER.

The safety plates applied to this machine are colour coded yellow with black edges and wording for the points to which ATTENTION must be paid and red coloured with white edges and wording for DANGER points.

WARNING! STUDY CAREFULLY THIS MANUAL BEFORE STARTING, OPERATING, MAINTAINING, FUELLING OR SERVICING THE MACHINE.

IMPORTANT NOTICES This machine has been designed and manufactured for digging and moving loose materials only. Any other application shall be considered contrary to the use intended by the Factory who, consequently, shall not be considered responsible for any damage to property or the machine itself, nor for personal injuries which could eventually occur. Also, it must be considered that by taking the risk for an improper use, you become responsible of the consequences.

This machine must be operated, serviced or repaired exclusively by personnel previously trained on the equipment at work and the relevant safety rules, besides being authorised to operate the machine itself.

The User is always obliged to observe the general rules for safety and the prevention of injuries, as well as the rules for on-the-road travelling.

Any arbitrary modification implemented on this machine makes void any responsibility of the Factory deriving from damages or injuries.

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.

SERIAL NUMBER

TYPE OF ENGINE

ENGINE SERIAL NUMBER

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Reproduction of text or illustration, in whole or in part, is strictly prohibited

Stampato 604.19.160.00 - English - III - 2003 Printed by Satiz - Turin (Italy) Coordinamento Editoriale Satiz - Torino

TABLE OF CONTENTS SUBJECT

PAGE

SAFETY RULES .......................................................................................................................................... I-VII Decommissioning the machine ................................................................................................................... VII Dispose of wastes in an appropriate manner ............................................................................................... VII FOREWORD ................................................................................................................................................. VIII IDENTIFICATION DATA .................................................................................................................................. 2 QUANTITATIVE FEATURES OF COMFORT .................................................................................................. 3 GENERAL SPECIFICATIONS ......................................................................................................................... 4 Main dimensions and weights ....................................................................................................................... 7 Arrangement ................................................................................................................................................. 8 Stability........................................................................................................................................................11 List and location of safety decals .................................................................................................................12 Preliminary instructions and break-in period .................................................................................................20 OPERATION RULES ......................................................................................................................................21 Moving decal ...............................................................................................................................................22 CONTROLS AND INSTRUMENTS ..................................................................................................................23 OPERATING INSTRUCTIONS .......................................................................................................................40 General information ......................................................................................................................................40 Prior to starting (daily) ..................................................................................................................................40 Engine starting .............................................................................................................................................40 Stopping the machine ..................................................................................................................................42 Stopping the engine .....................................................................................................................................43 Operator's seat adjustment ..........................................................................................................................43 Fuel reservoir ...............................................................................................................................................44 Blade adjustment .........................................................................................................................................44 Cab tilting .....................................................................................................................................................45 Lowering the cab ..........................................................................................................................................46 Oil refilling and bleeding of the cab tilting system .........................................................................................46 Disengaging the brakes ................................................................................................................................47 Moving the machine with outside means ......................................................................................................48 Towing and recovering the machine .............................................................................................................48 Instructions for lowering the equipment to the ground with engine inoperative ..............................................49 Fire fighting protection ..................................................................................................................................50 Transporting the machine .............................................................................................................................50 Long storage of the machine ........................................................................................................................52 Cold climate precautions ..............................................................................................................................52 Starting the machine at low temperatures ....................................................................................................53 MACHINE OPERATION .................................................................................................................................54 CAB ................................................................................................................................................................63 MAINTENANCE ..............................................................................................................................................67 List of on-board tools ...................................................................................................................................68 Maintenance operations ...............................................................................................................................69 Walk around inspection ................................................................................................................................69 Maintenance table ........................................................................................................................................71 Every 10 work hours ....................................................................................................................................73 Every 100 work hours ..................................................................................................................................76 Every 250 work hours ..................................................................................................................................79 Every 500 work hours ..................................................................................................................................83 Every 1000 work hours ................................................................................................................................87 Every 2000 work hours ................................................................................................................................92 When required ..............................................................................................................................................96 ELECTRIC SYSTEM ......................................................................................................................................98 Megafuse 200 A ...........................................................................................................................................98 Fuses ..........................................................................................................................................................99 Link fuses .................................................................................................................................................. 100 Protection tree electric diagram .................................................................................................................. 101 TABLE OF FLUID CAPACITIES ................................................................................................................... 103 GENERAL DIAGRAM ELECTRIC SYSYEM ........................................................................... Inside back cover

SAFETY RULES

GENERALITIES

Be sure all protective guards or panels are in place, and all safety devices provided are in place and in good operating conditions.

Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine.

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.

Read and heed all safety rules before any intervention.

Do not allow unauthorised personnel to operate service or maintain this machine.

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

Do not operate the machine if not feeling in good health conditions.

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.

Fasten your seat belt (when provided).

Obey all flag signals and signs.

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.

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

Keep operator's compartment, stepping points, grab-rails 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 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.

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.

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

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.

OPERATION

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

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

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

Roll Over Protective Structures are required on loaders, dozers, graders, excavators. NEVER OPERATE machines without ROPS.

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.

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.

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.

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.

STARTING

Study and familiarise with escape routes alternate to normal exit routes.

NEVER START NOR OPERATE AN UNSAFE MACHINE. Before operating a machine, always ensure that any unsafe condition has been satisfactorily remedied.

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.

Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system.

For your personal protection, do not climb on or off machine while machine is in motion.

I

SAFETY RULES

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.

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.

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

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.

Choose and shift into the most appropriate gear to keep the speed required, thus preventing any loss of control.

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

Do not operate machinery in a condition of extreme fatigue or illness. Be especially careful towards the end of working shift.

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.

Do not operate machine with brakes out of adjustment.

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

Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection.

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

When counterweights are provided, do not work machine if they have been removed.

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.

Overtaking manoeuvres must be performed only when absolutely necessary and unavoidable. Beware of possible uneven terrains, poor visibility conditions, the presence of other machinery or persons out of sight.

Maintain a safe distance from other machines. Provide sufficient clearance for ground and visibility conditions.

Yield right-of-way to loaded machines.

Operate the machine at a speed adequate to the working conditions in the site and slow enough to ensure complete control at all times.

Maintain clear vision of areas of travel or work. Keep cab windows clean and repaired.

Never use the machine as a work platform or scaffolding, nor other inappropriate operations (i.e. pushing railway cars, trucks or other machines).

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.

Be alert of people in the operating area of the machine.

When operating a machine, know in advance what clearances will be encountered, overhead doors, cables, pipes, bearing load limitations of ground, bridges, floors or ramps.

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.

When roading, find-out what conditions are likely to be encountered, clearances, traffic congestion, type of road surfacing, etc. Beware of fog, smoke or dust elements that obscure visibility.

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.

When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions will permit a safe traverse.

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.

Explore the working area to identify potential risks such as: slopes, overhangs, pits, demolition rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, closed ambients. In such conditions, proceed with extreme care.

DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH. 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.

Whenever possible, avoid going over obstacles such as rough terrain, rocks, logs highly irregular ground, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care at an angle, if possible.

Reduce speed, shift-down. Ease up to the break over point, pass the balance point slowly on the obstruction and ease down on the other side.

In darkness, check area of operation carefully before moving in with machine. Use all lights provided. Do not move into area of restricted visibility.

II

SAFETY RULES

In steep down-hill operation, do not allow engine to overspeed. Select proper gear before starting down grade.

Return the controls to rest position. Place the gearshift lever in neutral. Disconnect the master switch and extract the key.

Avoid side hill travel, whenever possible. Drive up and down the slope. Should the machine slipping sideways, turn it immediately downhill.

See the relevant chapter in this Manual.

Park in a non- operating and no-traffic area or as instructed.

Park on firm level ground if possible. Where not possible, position machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding movements.

The grade of slope you should attempt will be limited by factors such as condition of the ground, load being handled, type of machine, speed of machine and visibility.

There is no substitute for good judgement when working on slopes.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and signals as required.

Also provide advance warning signals in the traffic lane of approaching traffic.

Avoid operating equipment too close to an overhang or high wall, either above or below the machine. Be on the look-out for caving edges, falling objects and slides. Beware of concealment by brush and undergrowth of these danger.

Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position.

Always disconnect the master switch before any intervention (i.e. cleaning, repairing, maintaining, refuelling etc.). Do the same when parking for prolonged periods of time to avoid accidental or unauthorised starting.

When pushing-over trees, the machine must be equipped with proper overhead guarding. Never allow a machine to climb up on the root structure particularly while the tree is being felled. Use extreme care when pushing over any tree with dead branches.

Never lower attachments or tools other than seated in operator's seat. Sound horn. Make sure area near the attachment is clear. Lower the attachment slowly. DO NOT USE FLOAT POSITION of hydraulic system.

When pushing trees with dead limbs, proceed with extreme care. Avoid brush piles, logs or rocks.

NEVER DRIVE OVER THEM or other surface irregularities that brake traction with the ground, especially when on slopes or near drop-offs.

Place master switch in OFF, securely block the machine and lock it every time you leave it unattended. Return keys to authorised security. Heed all shut-down operations of the Operation and Maintenance Instruction Manual are followed.

Be alert to avoid changes in traction conditions that could cause loss of control. DO NOT DRIVE on ice or frozen ground conditions when working the machine on steep slopes or near drop-offs.

Working in virgin and rough terrains is characterised by the presence of all the perils and risks listed above. In these conditions, it is emphasised the danger represented by large tree limbs (possibly falling on the machine), large roots (acting as a leverage under the machine when uprooted causing the roll-over of the unit) etc...

MAINTENANCE GENERALITIES Before operating or performing any intervention on the machine: - read carefully all the rules contained by this Manual,

STOPPING

- read and obey all safety related plates and instructions located on the machine.

When the machine is stopped for whatever reason, follow the instructions of chapters "Stopping the machine" and "Stopping the engine" of the Operation and Maintenance Instruction Manual.

Do not allow unauthorised personnel to perform any maintenance operation. Do not perform maintenance operation without prior authorisation. Follow all recommended maintenance and service procedures.

Always remember to position the transmission drive control in neutral and engage the control lock to secure the machine.

Keep operator's compartment free of all loose objects that are not properly secured.

The parking brake is automatically set.

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.

NEVER LEAVE THE MACHINE UNATTENDED with the engine running.

Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

III

SAFETY RULES

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.

Due to the presence of flammable fluids, never check or fill fuel tanks, batteries, nor use starting fluid near lighted smoking materials or open flames.

BRAKES ARE INOPERATIVE when manually released for servicing. Provisions must be made to maintain control of the machine by blocking or other means.

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.

The fuel filling nose must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated.

Do not perform any service operation on the machine with a person seated in the operator's compartment, unless he is an authorised operator co-operating in the operation to be performed.

Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load.

Keep operator's compartment, stepping points, grab-rails 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.

To move a disabled machine, use a trailer or a low-boy, if available. In case towing is needed , use all necessary signals required by local and national regulations, and follow the directions provided in this Manual.

Keep shoes free of mud or grease before climbing or driving the machine.

To load/unload a machine from transporter, choose a level surface ensuring firm support to the wheels of truck or trailer. Use strong access ramps, with adequate height and angle. Keep surface free of mud, oil or slippery materials.

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

When maintenance operations require moving hydraulically operated attachments by means of machine's hydraulic system remember that all manoeuvres must be made only when seated in the operator's seat. Before starting machine or moving attachment or tools, set brakes , sound horn and call for an all clear. Raise attachment slowly.

Anchor the machine securely to the bed of truck or trailer and block wheels or tracks with appropriate wedges.

Never align holes with fingers or hands; always use appropriate aligning tools.

Eliminate all sharp edges and burrs from re-worked parts.

Always block booms or parts of the machine which must be raised to perform interventions under them with external devices. Do not allow persons to move into the vicinities nor standing under equipment not being blocked. Unless you are totally sure about your safety, avoid staying under raised equipment, even in case it is blocked.

Use only approved grounded auxiliary power sources for heaters, chargers, pumps and similar equipment to reduce the hazards of electrical shocks.

Lift and handle heavy parts with a lifting device of proper capacity. Be sure parts are supported by proper slings and hooks. Use lifting eyes if provided. Watch-out for people in the vicinity.

Do not place the body, limbs or fingers into sharp articulation uncontrolled openings of the machine and without proper protections, unless they are blocked in a safe manner.

Never pour gasoline or diesel fuel into open, wide and low containers. Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, non-flammable, non-toxic commercial solvents.

Never perform interventions with engine running, except as called for in a Manual. Do not wear loose clothing or jewellery near moving parts.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles. Limit pressure to 2 bar, in accordance with local and national regulations.

When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Do not smoke or permit any open flames or spark near when re-fuelling or handling flammable materials.

Shop and/or field service platforms or ladders must be constructed and maintained in accordance with local and national regulations.

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine.

Disconnect batteries and tag all controls according to current regulations to warn that work is in progress. Block machine and all attachments that must be raised according to current regulations.

Make sure that all mechanic's tools are in good conditions.

NEVER USE tools with mushroomed heads or frayed.

Always wear eye protections.

IV

SAFETY RULES

Move with extreme care when working under the machine, its attachments and or on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, ear plugs.

Know your jacking equipment and its capacity. Be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under jack is appropriate and stable.

When performing operations requiring running of t he engine, h a v e a q u a l i fi e d o p e ra to r i n the operator's seat at all times with the mechanic on sight. Place the transmission in neutral and set the brakes and safety lock.

The load lifted by jacks is always dangerous: it is necessary to transfer loads to appropriate blocking as a safety measure, before proceeding with service or maintenance work, according to local or national regulations.

Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.).

KEEP HANDS AND CLOTHING AWAY FROM MOVING PARTS.

Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections

For field service, move machine to level ground, if possible, and block it. If work on an incline is absolutely necessary, first block machine and its attachments securely, than move it to level ground as soon as possible.

Compressed air systems can have water deposits created by moisture condensation due to changes of atmospheric conditions. If required, discharge deposits, as instructed.

Do not trust worn and /or kinked chains and cables: do not use them for lifting or pulling operations. To handle them, always use heavy gloves.

STARTING

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.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Do not place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans.

No bystanders are allowed near the hooking points, chains or cables.

STARTING FLUID IS HIGHLY FLAMMABLE. Follow strictly the recommendations printed on containers and in the Operation and Maintenance Manual. Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. DO NOT PUNCTURE OR BURN CONTAINERS.

DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH. Keep the area where maintenance operations are performed CLEAN and DRY. Eliminate immediately all water and oil spillages.

ENGINE

Do not pile oily or greasy rags; they represent a fire hazard.

Store in closed metal container.

Loosen the radiator cap very slowly, to release pressure from the system, before removing it. All coolant level topups must be performed with engine OFF.

Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine. Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn.

Avoid that flammable materials touch exhaust parts. Should this be possible, provide the necessary protections.

Do not run engine when refuelling and use care if the engine is hot due to the increased possibility of a fire if fuel is spilled.

Rust inhibitors are volatile and flammable Use only in well ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool well ventilated place, secure against unauthorised personnel.

Never attempt to check or adjust fan belts when engine is running.

Do not adjust engine fuel pump when machine is moving.

Do not carry loose objects in pockets that might fall unnoticed into open compartments.

Do not lubricate the machine with engine running.

Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly or fall.

Do not run the engine with air intakes, door or protections open.

Wear welders protective equipment such as dark safety glasses, helmets, protective clothing, gloves and safety shoes, when welding or burning. Wear dark safety glasses near welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION.

ELECTRICAL SYSTEM Always disconnect batteries prior to any intervention on machine or electrical system (cleaning, repair, maintenance).

V

SAFETY RULES

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 terminals.

Follow thoroughly the instructions of this Manual.

In case pressures must be measured, use instruments of adequate capacity. Always follow the recommended procedures.

Before any intervention, make sure that the main switch is OFF.

EQUIPMENT Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position.

BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion.

Prior to any intervention, install all safety devices according to current rules and regulations.

In case equipment on the machine must be operated by hydraulic systems, remember to proceed only after seating in the operator's compartment. Make sure that there are no persons in the operating area of the machine. Alert people before operating using the horn and by voice. Move the equipment very carefully.

Before any intervention, make sure that there are no fuel or electrolyte leakages; eliminate them before proceeding with further work. When recharging batteries in closed ambients, make sure that there is appropriate ventilation to prevent possible accidental explosions due to the accumulation of gases generated during the recharge.

Do not use machine to transport loose objects, unless proper devices for this purpose are provided.

Clutches and brakes of this machine and eventual auxiliary equipment and attachments (such as operating cylinder or winches control valves) must always be properly adjusted in accordance with the instructions provided by the Manuals of the Manufacturer.

HYDRAULIC SYSTEM Fluid escaping under pressure from a very small hole can be almost invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE HANDS. If injured by escaping fluid, see a doctor at once.

Serious infection or reaction can develop if proper medical treatment is not administered immediately.

Never perform adjustments with engine running, except when called for by the above instructions.

When changing work shift, check that wheel or rim securing screws and brackets are not loosen; if necessary, retighten to the prescribed torque.

Stop the engine and release all pressures in the system before removing panels, housings, plugs or covers.

VI

SAFETY RULES

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 controlled 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.

DECOMMISSIONING THE MACHINE

WARNING

• The decommissioning of the machine must be performed exclusively by personnel trained, qualified and authorised to perform such operation.

To decommission the machine it is necessary to have available particular tooling (hoist, hydraulic press, containers for liquids etc.) and special tools described by the Repair Manuals, available from authorised dealers.

This in order to prevent dangerous situations during the disassembly operations both for personnel and the environment.

• Start the disassembly of hydraulic components only after the same, the hydraulic oil and lubricants have fully cooled-off and after all residual pressures have been released, as described by the Repair Instruction Manual.

In the machine are present: • Fluids under pressure (hydraulic system, cooling system etc.)

• Gases (air conditioning system and accumulator, if installed) • Mechanical devices mounted under pressure (track tensioner etc.)

• Acid (battery) • Heavy machine components (frames, blades, buckets etc.)

• Prior to proceeding with disassembly operations, comply with the GENERAL SAFETY RULES and drain each components of the machine filled with fluids, both in the reservoirs and the relevant systems.

WARNING Prevent polluting the environment. Eliminate hydraulic fluids, lubricants and refrigerants and filtering elements impregnated by these fluids in compliance with current national or local regulations classifying these materials as polluting, noxious and dangerous waste.

DISPOSE OF WASTES IN AN APPROPRIATE MANNER • The improper disposal of waste is a threat for the environment. Potentially dangerous waste used on machines include lubricants, fuel, refrigerants, filters and batteries.

- Use sealed containers when draining fluids; do not use containers for food or drinks which could be erroneously used for drinking.

- Do not spread waste on the ground, in drainages or water tables.

- Seek information about the appropriate manners of re-cycling or disposing of waste from local authorities or waste management centres, or from your Dealer.

VII

FOREWORD This manual is designed to serve as a guidance for correct and safe operation of the machine and its systematic servicing.

The continued observance of the instructions provided herein will ensure best possible performance, operation economy and long life of the machine and will avoid the most common causes of accidents which may occur during work or maintenance operations.

As regards safety in particular, read carefully the general rules given on pages I through VII. The repair procedures for this machine are described in separate service publications obtainable from the Manufacturer's Organisation.

Each machine is supplied with a copy of this manual. The descriptions and illustrations appearing in this manual are not binding. The Manufacturer reserves the right, while retaining the basic features of the model herein described and illustrated, to make at any time, and without necessarily bringing this manual up-to-date, any alteration to units, parts, accessories or their supply, deemed expedient for improvement or for any manufacturing or commercial reason. For any clarification, refer to your Dealer who will provide any information you may need.

The information contained in this Manual is valid at the time it is printed. The Manufacturer improves constantly its products; thus some information could result not up-to-date. In the event discrepancies are noticed, please consult the Sales and Service Organisations.

VIII

D150

1

D150 (Tier 2) Crawler dozer

D150-2M001

The machine is shown with optional equipment.

WARNING The safety of the operator and bystanders depends upon its judgement capacity and prudence in operating the machine. Thus it is necessary to be knowledgeable of the position and function of all controls. Each machine has limitations: prior to operate it is necessary to familiarise with its capabilities and speed, braking, steering, stability and working features.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

2

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)

Cu

mm

ins

Cummins Engine Company Inc. Box 3005 Columbia, Indiana 47202-3005

Warning injuty result and warranty is voided it fuel rate or rpm or altitudes exceed published maximum values for this model and application.

C.I.D./L

Engine Serial No.

CPL

Family

Cust. Spec.

Engine Model

Low idle RPM Valve lash cold

Engin

Engni

mm3/st

Fuel rate at rated HP Timing-TDC

Firing Order

Date of Mfg Made in Great Britain by Cummins Engine Co. Ltd.

st

Rasted HP/KW

RPM

D150-2M002 D150-2M005

IMPORTANT ENGINE INFORMATION This engine conforms to 2003 U.S. EPA And California Tier 2 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.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo 323, S. Mauro Torinese (TO) - ITALIA

D150-2M003 D150-2M006

C. Marking and serial number On the right side of the transmission housing it is possible to read, etched on the upper side, the MARKING of the machine composed of: - manufacturer code (the first three digits ZEF); - machine code (0D151S); - serial number (last 8 digits).

Depending upon the configuration of the machine, the marking is one of the following: MODEL

MARKING

D150 LT PAT-T2 PS

✩ ZEF0D151SXXXXXXXX ✩

D150 LT BD-T2 PS

✩ ZEF0D151SXXXXXXXX ✩

D150 XLT PAT-T2 PS ✩ ZEFD151STXXXXXXXX ✩ D150 LGP PAT-T2 PS ✩ ZEFD151SPXXXXXXXX ✩

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M004

D150

3

Machine manufactured by:

Model

CNH Movimento Terra S.p.A. Zona Industriale Surbo 73100 LECCE (LE) Telephone: (0832) 6881

Technical type

D150 STD PAT

535.100.060

D150 STD BD

535.100.061

D150 XLT PAT

535.100.062

D150 LGP PAT

535.100.063

This machine complies with the EEC Directives relative to safety of machines (Directives 89/392, 91/368, 93/44 and 93/68)

QUANTITATIVE FEATURES OF COMFORT NOISE LEVELS 2000/14/EC Guaranteed sound power level LWA = 109 dB (A) Guaranteed sound power level, determined in compliance with European Directive 2000/14/EC.

- make sure that the machine is maintained under efficient conditions; - steer, brake, accelerate, shift gear, move the equipment in a smooth manner; - when travelling, adjust the speed of the machine so as to minimise the level of vibrations; - keep the work site under good conditions (remove stones and obstacles, fill ditches and holes etc.).

LEVELS OF VIBRATIONS SERVICE Level of vibrations on hands and arms: investigations conducted on identical machines, under travel and digging conditions in cycles of different lengths, result that the level of vibrations is EQUAL or LOWER than ?,?? m/s2.

The value must be intended rms weighted with “large band” method and weighting in compliance with ISO 2631-1.

Vertical vibrations on the operator’s seat: investigations conducted on identical machines, under travel and digging conditions in cycles of different lengths, result that the level of vibrations is EQUAL or LOWER than: ?,?? m/s2 LTS "ON" ?,?? m/s2 LTS "OFF" The value must be intended rms weighted with “large band” method and weighting in compliance with ISO 2631-1.

The exposure to vibrations by the operator can be reduced when the following recommendations are taken into account: - always use equipment compatible with the type of work to be performed; - the machine must be equipped with a seat corresponding to criteria of comfort prescribed by EN ISO 7096:2000. the same must be adjusted in accordance with his needs;

When maintenance operations not easily performed with the tooling available to the User, it is suggested that the Selling Dealer or Service Centres manned by competent personnel, adequate tooling and genuine spare parts are involved. The entire Organisation is available to Customers to provide clarifications and suggestions or to intervene with his own personnel, when abnormal operations of the machine are experienced.

SPARE PARTS To ensure a perfect operation of the machine it is found that parts must be replaced by genuine spare parts.

To order parts please specify: - type of engine and serial number of the machine provided by plate B; - in the event of loss of identification plate B, the marking and the serial number etched on the transmission housing can be read (Marking C); - the part number of the parts being ordered.

Spare Parts Catalogue Print no. 604.01.301.00

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

4

GENERAL SPECIFICATIONS ENGINE Type ..................................... CUMMINS 6BTAA5.9 Diesel, 4-stroke, direct injection, turbocharged powered by exhaust fumes.

Number of cylinders .............................................. 6 Diameter of cylinders ................ 102 mm (4.0157 in) Stroke of pistons ....................... 120 mm (4.7244 in) Total displacement ............ 5883 cu cm (359.3 cu in)

Power at flywheel KW

HP

Specifications

Nominal at 2200 rpm

Nominal at 2200 rpm

DIN 6270 SAE J1349 ISO9249 EEC 80/1269

106 104 105 106

142 140 141 142

Safety lock lever preventing, in "lock" position, the operation of the pilot gearshift, automatically engaging the service brakes.

Torque converter/transmission oil cooling by water type heat-exchanger recirculated from the engine radiator.

Transmission oil filtered by two total flow filters; one metal mesh and magnetic rod on suction line, the other cartridge type with by-pass valve on delivery line.

Reduction units Central bevel gear type reduction in the centre of rear transmission housing.

Double reduction modular type final drives.

Reduction ratio: 1 : 10.8 POWER STEERING DIFFERENTIAL

Compression ratio ....................................... 17.5 ÷ 1 Firing order .............................................. 1-5-3-6-2-4 Weight ........................................... 432 kg (952 lbs) Low idle ............................................. 750 ÷ 950 rpm High idle ........................................ 2320 ÷ 2460 rpm Maximum torque speed ............................. 1300 rpm Maximum power speed ............................. 2000 rpm Maximum torque ...................... 650 Nm at 1300 rpm Valve clearance Intake ........................................ 0.25 mm (.0098 in) Exhaust ................................... 0.50 mm (.01965 in) Lubrication system Oil pressure at low idle ................................. 69 kPa Oil pressure at nominal speed .................... 207 kPa Capacity of oil sump ................. 14.2 l (3 ¾ U.S. G.) Cooling system Capacity of coolant (engine only) .... 9.8 l (2.6 U.S. G.) Cap minimum pressure .............................. 100 kPA The engine maintains the rated power up to 2500 m (8,200 ft) altitude.

The engine complies with regulation TIER 2 EC 97/ 68 and regulations USA CARB & EPA.

The steering differential provides the steering without ever stopping the track chain, by transmitting the power with continuity to both track chains during the steering phase, also during tight steering manoeuvres.

With the two track chains constantly working, it is possible to push larger loads, also at maximum speed.

The steering occurs by increasing the speed of one track chain and slowing down the other one the same amount; the speed difference makes the machine steering. The steering system operates as a differential and it is composed of: a pump, a hydraulic motor and the relevant controls operated by just the movement of the fingers.

BRAKES Oil-bath disc brakes A single pedal in the cab actuates a single central brake blocking the motion of the bevel gear and operates both as service brake and as emergency brake. A manual system allows the disengagement of the brake in the event there is no hydraulic pressure to tow the machine in case of failure.

Parking brake: automatically engaged, by the transmission safety lever ON or with engine inoperative.

TRANSMISSION Hydraulic torque converter with max. stall torque ratio 2.33 : 1.

"Powershift" transmission providing three forward and three reverse speeds, with FINGERTIP CONTROL type electric control. Neutral button allowing the direct disengagement of the speed shifting the gear into neutral.

AUTO KICK DOWN function button and AUTO SHIFT function button.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

5

EQUIPMENT HYDRAULIC SYSTEM The equipment hydraulic system is a combined circuit with the steering system and form an entirely Loadsensing circuit, to manage with maximum efficiency, the hydraulic power required by the two circuits using the same hydraulic oil, being divided by the different operating pressures. The system operates with a logic priority to the steering when power is required at the same time, by the equipment as well.

The equipment system is mainly composed of: - A variable displacement piston pump and a hydraulic oil control valve shared by the steering system.

- An oil tank located at the rear end of the machine, with two visual level gauges (MIN-MAX).

- Oil filtration by two full-flow filters. one a metal mesh on the suction line of the pump; a filter equipped with safety "by-pass" in case of clogging, on the oil return to the tank.

The monobloc control valve has 4 spools, whereas the PAT blade version has 5 spools.

Single lever control pilot valve for the first 3 spools of the control vale for the following functions: - Blade raising/lowering and floating - Blade tilting - Blade pitch (only for version with PAT blade) - Two double stroke hydraulic cylinders control the blade raising, with stroke-end valves and quick-drop valves (for the Bulldozer version) installed on the upper bottom.

Upon request, a 3rd function supplementary lever to control the ripper. Safety lever on the equipment and transmission controls in neutral position, located at the right side of the operator, with the purpose of preventing an accidental actuation. The version equipped with PAT blade offers a further possibility of tilting rightward or leftward the blade using two buttons located at the tip of the blade control pilot valve.

D150 PAT-D150 BD - Number of bottom rollers .................................... 7 - Number of support rollers ................................... 2 - Number of shoes for each track chain: ............. 43 - Width for standard shoes: ........................ 500 mm optional: ........................ 550 mm - Bearing surface on ground - with 500 mm shoes ....................... 25500 sq cm - with 500 mm shoes ........................ 28050 sq cm D150 XLT PAT - Number of bottom rollers .................................... 8 - Number of support rollers ................................... 2 - Number of shoes for each track chain: ............. 48 - Width for standard shoes: ........................ 500 mm optional: ..............550 mm - Bearing surface on ground - with 500 mm shoes ........................ 29850 sq cm - with 550 mm shoes ........................ 32835 sq cm D150 LGP PAT - Number of bottom rollers .................................... 8 - Number of support rollers ................................... 2 - Number of shoes for each track chain .............. 48 - Width for shoes: ....................................... 800 mm - Bearing surface on ground with 800 mm shoes ..................................... 47760 FRAME Load bearing with welded steel boxed structure on which the various groups are mounted.

Frontally connected to the oscillating cross-member and track frames, in the rear to the transmission housing.

ELECTRICAL SYSTEM Voltage 24 Volt.

UNDERCARRIAGE

Alternator: DELCO REMY 70 Amp.

It is composed of two boxed and welded structure track frames. The track frames are frontally connected by a pivoting swing bar and they are hinged on the PIVOT-SHAFT at the rear.

Lubricated track chains.

Seven bottom rollers (eight for the LGP and long undercarriage version) and two support rollers for each track frame, permanently lubricated.

Sprockets with replaceable toothed segments.

Permanently lubricated idlers, with track chain tension hydraulic adjuster.

Starter motor: DELCO REMY 6.8 kW Starter motor with automatic pinion engagement by solenoid.

Batteries: Two 12 Volt batteries connected in series, 100 or 160 Amph. Maintenance-free type.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

6

CAB Modular type, elastically suspended by elastic blocks, integrated in the safety structure.

The cab offers maximum visibility of the blade and rear equipment for maximum productivity.

Also, the cab provides maximum comfort to the operator, in all weather conditions.

WEIGHT AND SPEEDS Weight of the machine without ripper with 500 mm shoes, versions STD and XLT with 800 mm shoes for version LGP, cab, fluids and operator: D150 STD PAT .......................... 14,915 kg (32.9 lb) D150 STD BD (HSU) .................. 15,011 kg (33.1 lb) D150 XLT PAT ........................... 15,677 kg (34.6 lb) D150 LGP PAT .......................... 16,810 kg (37.1 lb) MAX. SPEEDS (forward - reverse) in km/hr (mph): Speeds I II III Forward 4.3 (2.7) 7.0 (4.3) 11.0 (6.8) Reverse 5.4 (3.3) 8.7 (5.4) 13.0 (8.1)

RIPPER (optional) Model ........................................................... RP12F D parallelogram type with welded box steel elements frame. Three position tool bar with three semi-curved shanks with replaceable tips.

Controlled by two double stroke hydraulic cylinders.

Weight: ............................................. 1,360 kg (3 lb)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

7

COLD STARTING (Optional)

AUXILIARY APPLICATIONS

Upon request, a cold starting device is available, allowing the starting of the machine at particularly low temperatures.

Some of the attachments described and illustrated in this manual are provided in determined markets to satisfy specific requirements.

Other devices and special applications can be provided upon request, in accordance with the Sales Organisation. Some optional accessories are listed here below: Air conditioner, Low temperature starting, Blade: HS or folding Hs for LGP version, HSU or, PAT, ripper, 1 kg Fire extinguisher Diagnostics, Forest ROPS (sweeps), Outer sound suppression, 550 mm shoes.

MAIN DIMENSIONS AND WEIGHTS TYPE OF BLADE

Blade width mm (in)

Blade width mm (in)

Blade capacity SAE J1265 cu m (cu yd)

Tilt mm (in)

Pitch

Digging depth mm (in)

Blade max. lift mm (in)

Width Weight with blade with blade mm (in) kg (lbs)

(HS)

3180 (125.19)

1100 (43.34)

3.10 (4.0)

550 (21.6)

±10°

406 (16.0)

1105 (43.5)

4750 (187.0)

14,811 (*) (32,650)

Semi-U (HSU)

3180 (125.19)

1320 (52)

4.12 (5.36)

550 (21,6)

±6°

480 (18.9)

1105 (43.5)

5025 (197.7)

15,011 (*) (33,095)

STD PAT

3200 (126)

1100 (43.34)

3.15 (4.05)

450 (17.7)

±5°

490 (19.30)

950 (37.4)

4950 (194.9)

14,915 (*) (32,280)

XLT PAT

3200 (126)

1100 (43.34)

3.15 (4.05)

450 (17.7)

±5°

490 (19.30)

950 (37.4)

5315 (209.28)

15,677 (*) (34,560)

LGP PAT

4000 (157.5)

1000 (39.4)

3.15 (4.05)

550 (21.6)

±5°

590 (21.66)

900 (35.43)

5315 (209.28)

16,810 (**) (37,060)

* Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 500 mm. ** Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 800 mm.

MACHINE BASE mm (in)

SHOES

WEIGHT

mm (in)

kg (lbs)

GROUND BEARING AREA sq cm (sq in)

PRESSURE ON GROUND kPa

STD BD (HSU)

2550 (87.7)

500 (19.5)

550 (21.6)

15,011 (33,095)

15,126 (33,277)

25,500

28,050

57.7

52.9

STD PAT

2550 (87.7)

500 (19.5)

550 (21.6)

14,915 (32,280)

15,030 (33,065)

25,500

28,050

57,4

52,6

XLT PAT

2985 (116.4)

500 (19.5)

550 (21.6)

15,677 (34,560)

15,805 (34,770)

29,850

32,835

51,5

47,2

LGP PAT

2985 (116.4)

800 (31.50)

16,810 (37,060)

47,760

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

34.5

D150

8

HS BULLDOZER ARRANGEMENT

3080

3060

500

370 1900

2550

2400

3650 4750

D150-2M007

HSU BULLDOZER ARRANGEMENT

3080

3060

500

370 2550 3650

1900 2400

5025 D150-2M007

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

9

490

450

950

1100

3060

3080

STD PAT ARRANGEMENT

5°

2550

3200

3650

5° 4950

~ 400

25°

2950

1900 2400

35

25°

5470 D150-2M008

490

950

1180 450

3060

3080

XLT PAT ARRANGEMENT

5°

2985 4010

5° 5315

2140 800 2940 3200 D150-2M133

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

10

590

550

900

3060

3080

LGP PAT ARRANGEMENT

5°

2985 4010

5° 5315

2140 800 2940 D150-2M009

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

11

POSSIBLE ARRANGEMENTS OF THE D150

Blade

HS HSU Blade PAT Undercarriage 7 rollers Undercarriage 8 rollers Shoes 500 mm 550 mm Shoes 800 mm

STD BD

STD PAT

XLT PAT

LGP PAT

x

–

–

–

x

x x

x

x

–

–

–

–

x

x

x

x x

–

–

–

x

–

–

STABILITY Basic machine (STD undercarriage) + HS blade + Ripper Configuration Hg Lg Blade and ripper on the ground 845 1160 Blade on the ground and ripper at max height 870 1175 Blade at max height and ripper on the ground 868 1145 Bladeatmaxheightandripperatmaxheight 1005 1150

Basic machine (STD undercarriage) + HS blade Configuration Hg Blade on the ground 805 Blade at max height 845

Lg 1260 1360

Basic machine (STD undercarriage) + PAT blade + Ripper Configuration Hg Lg Blade and ripper on the ground 800 1175 Blade on the ground and ripper at max height 825 1205 Blade at max height and ripper on the ground 820 1160 Bladeatmaxheightandripperatmaxheight 875 1195

Basic machine (STD undercarriage) + PAT blade Configuration Hg Blade on the ground 750 Blade at max height 926

Lg 1470 1360

Basic machine (STD undercarriage) (without blade and ripper) Lg = Distance from the sprocket centre Hg = Height from the ground

Configuration Without blade and ripper

Hg 1130

Lg

Hg

Lg D150-2M010

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

12

LIST AND LOCATION OF SAFETY DECALS All the safety plates applied on the machine to provide maximum operational safety against unavoidable risks, are listed here below: They have been divided into four groups:

Group A - danger decals Group B - warning decals Group C - general-purpose decals Group D - manoeuvre decals The exact location on the machine is found in the figure here below.

LIST OF DECALS

A

B

C

D

1A

FIELD OF OPERATION SAFETY DECAL

2A

TRACK TENSIONER SPRING DECAL

3A

TRACK TENSIONER SAFETY DECAL

4A

CAB TILTING SAFETY DECAL

1B

FLUIDS UNDER PRESSURE DECAL

2B

OPERATION SAFETY DECAL

3B

SAFETY WARNING DECAL

4B

CAB TILTING SAFETY DECAL

5B

SWITCH DECAL

6B

BATTERY SAFETY DECAL

7B

ENGINE BELTS DECAL

8B

BRAKES SAFETY DECAL

9B

MANOEUVRE SAFETY DECAL

10B

HOT ZONE WARNING DECAL

1C

MAINTENANCE DECAL

2C

FUEL DECAL

3C

CLUTCH OIL CARTRIDGE REPLACEMENT DEC.

4C

TRANSM. OIL CARTRIDGE REPLACEMENT DEC.

1D

EQUIPMENT OPERATION DECAL

2D

MACHINE LIFTING DECAL

3D

CONTROLS WARNING DECAL

4D

THROTTLE CONTROL DECAL

5D

EQUIP./TRANSM. CONTROL WARNING DEC.

6D

RIPPER CONTROL DECAL

7D

MASTER SWITCH DECAL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

13

LOCATION OF SAFETY DECALS 3B

6B

1A

2A

3A 9B 4A

10B

4B

2D

1C

10B

1B

8B

D150-2M011

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

14

3D

5B

1D

6D 2B

"A" D150-2M012

1850-2M0016

2C 4D

1850-2M0013

7B 1850-2M0017

7D

DET. "A"

1850-2M0014

1850-2M0018

5D 3C

4C

1850-2M0015

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0019

D150

15

LIST OF SAFETY DECALS Group A - Danger decals 1A

DANGER IT IS FORBIDDEN TO STAND WITHIN THE FIELD OF ACTION OF THE MACHINE D350M0040

2A

DANGER THE IDLER WHEEL RETURN SPRING IS MOUNTED WITH A HIGH COMPRESSION LOAD. TO ASSEMBLE OR DISASSEMBLE THIS COMPONENT FOLLOW THE PROCEDURES RECOMMENDED BY THE "REPAIR INSTRUCTION MANUAL".

76035797 S 76

D350M0041

3A

DANGER FLUID UNDER PRESSURE DO NOT REDUCE THE TENSION OF THE TACK CHAIN LOOSENING THE PRESSURE RELIEF VALVE. DO NOT REMOVE THE GREASE FITTING INSTALLED ON THE ADJUSTMENT VALVE. FOLLOW THE PROCEDURE RECOMMENDED BY THE "REPAIR INSTRUCTION MANUAL".

76035792 S 76 D350M0042

4A

WARNING PRIOR TO BEGINNING THE CAB TILTING MANOEUVRE MAKE SURE THAT BOTH ENGINE SIDE PANELS ARE CLOSED AND DO NOT OPEN THE LEFT ONE ONCE THE CAB IS TILTED TO PREVENT BRAKING THE CAB WINDOW. D150-2M013

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

16

LIST OF SAFETY DECALS Group B - Warning decals 1B

2B

DANGER

D150-2M014

3B

WARNING EVENTUAL MODIFICATIONS OR DAMAGES COULD CAUSE PREJUDICE TO THE PERFORMANCE OF THIS PROTECTION STRUCTURE.

STUDY CAREFULLY THIS "OPERATION AND MAINTENANCE " MANUAL, LOCATED IN THE APPROPRIATE COMPARTMENT, BEFORE STARTING, OPERATING, MAINTAINING, FUELLING OR SERVICING THE MACHINE. IN CASE THE MANUAL IS MISSING, CONTACT THE FIAT KOBELCO ORGANISATION. IT IS A SPECIFIC RESPONSIBILITY TO ENSURE A CORRECT OPERATION AND MAINTENANCE OF THE MACHINE. A WRONG OPERATION COULD CAUSE DAMAGES AND PERSONAL INJURIES, INCLUDING DEATH. D150-2M017

D150-2M015

4B

WARNING TO TILT THE CAB, PROCEED AS FOLLOWS: - PLACE THE MACHINE ON A FLAT SURFACE, WITH CLOSED DOORS. - OPEN BOTH SIDE PANELS OF THE CAB. - REMOVE THE SCREWS SECURING THE RIGHT SUSPENSION SUPPORTS OF THE FRAME. - DISCONNECT THE QUICK RELEASE COUPLINGS OF THE CONTROL LINKAGE AND THE EQUIPMENT CONTROL VALVE FUNCTIONS LOCK. - DISCONNECT THE QUICK RELEASE COUPLINGS OF THE THROTTLE LINKAGE - ACTUATE THE CAB TILTING PUMP LEVER WITH DIVERTER VALVE IN POSITION KEEPING THE LAST PART OF THE CAB TILTING STROKE UNDER CONTROL ACTUATING THE DIVERTER VALVE TO LOWER THE CAB, PROCEED WITH CARE TO AVOID DAMAGING COMPONENTS UNDERNEATH AND OPERATE AS FOLLOWS: - ACTUATE THE PUMP LEVER WITH DIVERTER VALVE IN POSITION - KEEP THE LAST 300 mm (1 ft) OF THE CAB LOWERING STROKE UNDER CONTROL ACTUATING THE DIVERTER VALVE REFER TO THE OPERATION AND MAINTENANCE MANUAL D150-2M016

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

17

9B

5B

WARNING

WARNING ALWAYS TURN THE MASTER SWITCH TO BLOCK POSITION BEFORE STARTING, OPERATING, MAINTAINING, FUELLING OR SERVICING THE MACHINE AND AFTER PARKING IT.

THIS MACHINE IS EQUIPPED WITH A POWER STEERING OPERATING ONLY WHEN THE ENGINE IS IN OPERATION. THIS MACHINE IS EQUIPPED WITH AN EMERGENCY SYSTEM ACTUATING THE BRAKES WHEN THE ENGINE IS CUT-OFF.

D350M0140

6B

WARNING

THE EQUIPMENT OR VARIOUS ATTACHMENTS CAN BE LOWERED BY MOVING THE CONTROL LEVER WITH ENGINE OPERATING OR INOPERATIVE.

EXPLOSIVE GASES Cigarettes, open flames or sparks could trigger the explosion of batteries.Consult the Operation and Maintenance Manual for the procedures relative to recharging and emergency starting.

Keep the area around the terminals clean.

WHEN A ROPS STRUCTURE IS MOUNTED, THE USE OF SAFETY BELTS IS RECOMMENDED. DO NOT CARRY RIDERS UNLESS THE MACHINE IS PROPERLY EQUIPPED TO TRANSPORT PASSENGERS

POISON - CORROSIVE Batteries contain sulphuric acid.

Avoid contacts with the skin, eyes and clothing.

In case of contact, wash with water and seek medical help.

FOR NOISE LEVELS EXCEEDING 90 dB FOR CONTINUOUS WORK SHIFTS EXCEEDING 8 HOURS, WEAR APPROVED EAR PROTECTIONS.

D150-2M018

7B

MONITOR CONSTANTLY THE WORK AREA TO IDENTIFY DANGEROUS SPOTS. A FEW EXAMPLES OF DANGEROUS WORKING CONDITIONS ARE: DITCHES, FORESTS, ROCK OVERHANGS, DEMOLITION, FIRES, LAND FILLING, UNEVEN GROUND, INTENSE TRAFFIC, CROWDED PARKING, CROWDED MAINTENANCE AREAS AND FENCED ZONES. PAY GREATER ATTENTION IN THE ZONES MENTIONED ABOVE. KEEP FLAMMABLE MATERIALS AWAY FROM THE ZONES NEAR ENGINE EXHAUST MANIFOLDS AND DUCTS. CUT-OFF THE ENGINE FOR CLEANING OPERATIONS.

D150-2M019

8B 10B

WARNING

D350M0141

THE BRAKES ARE INOPERATIVE WHEN MANUALLY DISENGAGED FOR MAINTENANCE. THE MACHINE MUST BE SECURED BY APPROPRIATE BLOCKING DEVICES. THE BRAKES ARE EQUIPPED WITH VERY STRONG SPRINGS. TO DISASSEMBLE OR REASSEMBLE THE BRAKES, ALWAYS FOLLOW THE DIRECTIONS RECOMMENDED BY THE REPAIR INSTRUCTION MANUAL. 76066220 S 76 D350M0046

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M020

D150

18

LIST OF SAFETY DECALS Group C - General purpose decals 1C

2C

FUEL

D150-2M022

3C

WARNING REPLACE THE CLUTCH OIL FILTER CARTRIDGE EVERY 500 HOURS. D150-2M023

4C

WARNING REPLACE THE TRANSMISSION OIL FILTER CARTRIDGE EVERY 500 HOURS. D150-2M021

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M024

D150

19

LIST OF SAFETY DECALS Group D - Manoeuvre decals 1D

2D

D350M0142

D350M0143

3D

WARNING 4D BEFORE STARTING OR OPERATING THE MACHINE, READ THE "OPERATION AND MAINTENANCE" MANUAL. D350M0144

5D

WARNING BEFORE LEAVING THE OPERATOR'S SEAT, PLACE THE LEVER IN LOCK POSITION D350M0145

D350M0146

7D

6D

D150-2M025

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350M0147

D150

20

PRELIMINARY INSTRUCTIONS AND BREAK-IN PERIOD PRELIMINARY INSTRUCTIONS

BREAK-IN PERIOD

When delivering the machine, the Sales Organisation personnel provides the main instructions regarding its operation and maintenance to the Customer.

This instructions are summarised in the list here below: - Decantation of fuel.

- Check of capacities: coolant, fuel and lubricants.

- Draining of deposits from the fuel reservoir.

- Air bleeding of fuel system.

- Starting and cutting-off the engine.

- Rules for a safe conduct at work.

- First period of operation.

- Operation of the machine and of the equipment.

- Lubrication and lubricants.

- Maintenance of the air cleaner.

- Maintenance of filters: fuel, engine oil and hydraulic oil.

- Maintenance of the engine cooling system (the system is provided with a water/antifreeze mixture of a glycol type).

- Maintenance of the hydraulic systems: torque converter/transmission, steering, equipment.

- Checking the on-board tooling.

A break-in period of at least 60 hours, is required, following the directions listed here below: - after each cold steering, operate the engine a few minutes at idle speed; - do not operate the engine at maximum power for prolonged time; - check frequently, if there are oil or coolant leakages.

Start the engine. Monitor all instruments and indicator lights; actuate the controls of the machine to check their operation. Cut-off the engine and check if there are eventual leakages from sleeves, pipes and connections.

WARNING Never perform interventions with engine running, except as called for in this Manual.

Before operating or performing any intervention on the machine, read carefully all the rules listed in this Manual.

During the first period of operation of the machine, besides the normal maintenance operations listed in the relevant chapter, it is recommended that supplementary operations are performed, which, at a later stage, are carried-out ad longer intervals, as listed here below: Within the first 250 hours work: - change the fuel filter; - change the torque converter/transmission oil and relevant filter; - change the filter on the hydraulic system oil return to the reservoir.

Within the first 500 hours: - check the fuel injection system and the engine valve clearance.

The above directions must be followed after overhauls, as well.

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

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

21

OPERATION RULES WARNING Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine.

This alert symbol signals important messages involving your safety. It means: WARNING! BE ALERT! IT INVOLVES YOUR SAFETY. Read and heed carefully all safety instructions identified by the key words WARNING and DANGER. Do not operate machinery in a condition of extreme fatigue or illness; do not jump on or off the machine; use the appropriate handrails and steps which must always be kept clean. Also keep the operator's compartment clean; all tools and/or personal belongings not required on the machine must be removed or be secured.

This machine and its equipment must be operated exclusively by qualified personnel, seating in the operator's seat.

Your safety and the safety of bystanders depends upon your prudence and common sense in operating this machine.

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

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 all persons away form equipment being raised to avoid possible injuries.

Never attempt to operate the machine or its tools from any position other than seated in the operator's seat. Under all circumstances, keep head, body, limbs, arms and feet inside the operator's compartment to minimise the possibility of exposure to external dangers.

Make sure that the portion of the engine exhaust system under the hood is sealed.

In darkness, check area of operation carefully before moving in with machine. Use all lights provided. Check, during daylight as well, that all lights are operating. Replace burnt bulbs at once.

NEVER LEAVE THE MACHINE UNATTENDED with the engine running. The equipment can be lowered moving the control lever with engine running or inoperative.

Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

Move eventual supplementary equipment to closed and safe position.

Return all controls to rest position.

Place engine controls on cut-off position.

Lock all controls and disconnect the starter switch.

Do not park the machine on a slope, without blocking it accurately, to prevent any movement.

Always engage the parking brake, before leaving the machine.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M026

B

D350M0152

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

N

S

P

F N R

D350M0154

A

D150-2M028

B

D150-2M033

A

disinserire la chiave di avviamento, aprire lo sportello esterno sinistro e ruotare l’interruttore generale in posizione “OFF”.

9 - Al termine delle operazione: spegnere il motore,

Main switch

OFF

ON

safety device are in position “A”.

1850-2M0154

Starter switch

START

D

7

D350M0156

7

position “D”.

3

D150-2M032

D150-2M029

6

4-7 2-5

turn it into position “START”.

Warm-up the engine for at least 5 minutes.

6 - Raise the equipment moving the blade control lever into

1-9

7-8

H

OFF

ACC

ON

3 - Insert the key into the starter switch, push it in and

2-5

D350M0149

B

2 - Make shure that the transmission and implement control

D350M0148

B

A

- Move the L control in “F” position for (forward speed), or in “R” position for (reverse speed) press the switch “N” to obtain neutral position.

- Press the switch P (to increase speed), or press switch S (to decrease speed).

- Accelerate using the lever “A” on dashboard.

- To brake, press the pedal “B”.

7 - To move the machine:

L

rightward pull the “B” lever,

8 - For steer leftward, pull the “A” lever, for steer

A

switch into position “ON”.

1 - Open the external left panel and turn the main

Moving direction

OFF

ON

MOVING DECAL

A

D150-2M031

D150-2M030

B

control safety devices, moving the levers from position “A” into position “B”.

5 - Unlock the transmission and implement

B

A

the lever “A” (throttle control).

4 - Adjust the engine speed operating on

D150-2M027

A

22 D150

D150

23

CONTROLS AND INSTRUMENTS 1.

Safety lever (equipment control and gearshifting lever locking) 2. Transmission safety lever (transmission controls locking) 3. Blade control lever 4. Ripper control lever 5. Engine starter switch 6. Ashtray 7. Cigarette lighter 8. Horn 9. Engine deceleration control pedal 10. Cab heating and ventilation controls (on cab ceiling) 11. Transmission control buttons and direction control lever (Forward/Reverse)

11

12. AUTO SHIFTING "AS" function button (Optional) 13. AUTO KICK DOWN "AL" function button (Optional) 14. Steering and brakes control levers 15. Neutral button 16. Air ventilation ducts 17. Instrument panel 18. Switch and indicator panel 19. Engine throttle lever 20. Armrest adjustment levers 21. Electrical system master switch 22. Brake pedal

18 17

22

19

9

15 2

1

16 10 20

16

20

3

14 12

4

13 21

6 7

5

16

8 16

7 5

8

D150-2M034

For the version equipped with ROPS structure, components 5, 7, 8 are located on the dashboard, as indicated.

Note –The terms left and right used in this text, are intended as referred to the operator seating in its seat facing forward.

D350M0073

on ROPS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

24

1.

SAFETY LEVER (Equipment control and gearshifting lever lock)

2.

The device, lifted as illustrated in the figure in position A (vertically) blocks the EQUIPMENT CONTROL LEVERS AND THE GEARSHIFTING BUTTONS in neutral position.

This is to avoid unwanted movements of levers (3-4) and buttons (11) which could cause dangerous manoeuvres. In this position, the parking brake is automatically applied.

Position B: it activates the equipment control levers, the gearshiftng buttons and disengages the parking brake.

TRANSMISSION SAFETY LEVER

This device can be in two positions.

Position A (vertical): in this position it is possible to start the machine.

During the parking with engine running, the transmission control buttons are deactivated, to prevent dangerous manoeuvres which can be caused by unwanted movements. In this position, the parking brake is engaged.

Position B (lowered position): the lever allows the gearshifting and releases the parking brake.

A A B

B

D350M0074

Position A = neutral Position B = operation position

The indicator lights come ON (green light) when the machine is started and the equipment control safety (1) and transmission control safety (2) levers are in position A raised (NEUTRAL).

The indicator lights go OFF when the levers are lowered to operate the machine (posit. B).

D150-2M035

Position A = neutral Position B = operation position

With one or both levers upward: The engine starting is allowed.

The machine is prevented from moving forward or backward.

One or both indicator lights are ON. In all positions of the starter switch: The machine is braked.

D350M0160

Safety lever indicator lights

Both levers downward: The machine can be moved.

Starting is inhibited.

The indicator lights are OFF. With starter switch in ACC (and OFF).

The machine is braked.

With starter switch in ON: The machine is not braked.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

3.

25

BLADE CONTROL LEVER (Bulldozer version)

BLADE CONTROL LEVER (PAT version with 6-function blade)

The lever controls the raising, lowering and tilting of the blade.

To raise or to lower the blade, move the lever backward to position D or forward to position H, respectively.

To stop the blade in the desired position, in both cases, release the lever which is automatically returned to neutral N. To float the blade, meaning bearing on the ground exclusively under its own weight, push the lever to stroke-end forward, into position F, where it engages an appropriate detent.

The float condition is terminated when the lever is returned into neutral position N. Moving the lever leftward into position A or rightward into position B, the cross tilting of the blade is obtained. The lever must be held until the blade reaches the desired tilting.

In the version arranged with "PAT" equipment, the equipment control lever has the same functions of the HS blade, and, on top of that, the following two control functions can be performed: 1 Blade leftward tilting: pressing button 1 2 Blade tilting rightward pressing button 2 1

1

Leftward tilting

2

F

H

B

A

2 D

Rightward tilting

D350M0159

Blade control lever F

H N B

A D

D150-2M037

D150-2M036

The button must be held until the blade reaches the desired tilting.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

26

4.

RIPPER CONTROL LEVER (upon request)

Pre-heating indicator Safety lever indicator

- With lever forward in P = ripper lowering - With lever backward in R = ripper raising - Lever in N = neutral

5

D150-2M040

on ROPS 1850-2M0060

WARNING Prior to starting the engine, make sure that the gearshifting lever is in neutral position and that the parking brake is engaged.

Ripper control lever P N R

The starter switch starts and cuts-off the engine.

To actuate it, turn the key: Position H: Operation to be perfomed only on machines equipped with cold starting device.

Arrange the machine as described at point (STARTING THE MACHINE AT COLD TEMPERATURES)

D150-2M038

5.

Engine pre-heating position Place the starter key onto "H" position when the temperature is particularly low (less than - 15 °C) (5 °F).

Keep the key in this position for a time sufficient to allow the pre-heating. The time changes depending upon the ambient temperature. see Table A. In this position, for the entire duration of the pre-heater, the pre-heater indicator light is ON.

ENGINE STARTING SWITCH

WARNING

Starting switch D150-2M039

Do not pre-heat the engine more than 30 seconds, to avoid possible damages to the glow plug.

on Cab

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

27

In the event the engine fails to start, wait for 30 seconds before a new attempt; this is to protect the batteries and the starter motor from overheating.

ON

Note – For low temperatures use an engine oil with appropriate viscosity and fuel with low temperature additives. Down to - 20 °C (- 4 °F) the use of Arctic fuel is recommended as well larger HD type batteries (180 Amph - 770 Amp).

START

ACC.

Safety lever indicator lights

OFF H

Pre-heater indicator light

Starter key on CAB

TABLE A Temperature

Pre-heating time

Below -15°C

20 sec.

Below -24°C

30 sec.

At the end of this phase, the engine pre-heating indicator light (see figure) goes OFF and the machine can be started, turning further the key into "START".

This operation is not required when the engine is hot or the ambient temperature exceeds 8 °C (46 °F), thus the key can be turned from "OFF" to "START".

Positions: OFF

- Position allowing the insertion and removal of the starter key. Engine inoperative.

ACC

- All functions related to electrical system services are activated. The indicator lights onthe instrument panel (see Instrument panel) come ON.

ON

WARNING

1850-2M0064

Under forced starting conditions (i.e. low ambient temperatures) don not insists beyond three attempts of 30 sec.s max. each, intervalled by at least a 2 minutes pause, to avoid thermal overheating damaging electrical components. After the third attempt, let the starter solenoid to cool-off to a temperature of 25 °C (77 °F).

6.

ASHTRAY

7.

24V DC POWER OUTLET/CIGARETTE LIGHTER The power outlet is equipped with cigarette lighter (on the option with cab) and can be used to feed 24V DC power supply to a trouble lamp or a fuel transfer pump.

8.

HORN

- All other functions of the electrical system are activated and the safety lever indicator lights come ON

D350M0160

Safety lever indicator lights

START - The functions relative to position "ACC" are cut-off. Starting of the engine. The switch returns automatically to position "ON" when the key is released.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

28

9.

ENGINE DECELERATION CONTROL PEDAL

When pressing the pedal, the engine speed is momentarily decreased to low idle.

11. GEARSHIFTING GROUPE The machine is equipped with three forward and three reverse speeds. The controls are electrically actuated by the following buttons, located in the left side of the cab, on the ergonomic armrest.

With the two safety levers lowered, when lever L is turned and pushed forward into position F the machine moves forward, selecting 1st gear.

L

N F

N R

P S

D350M0077 D150-2M041

F. Selection of forward speed - L. Direction selection lever (forward/reverse) - R. Reverse speed selection

Buttons P. Upshifting - S. Downshifting - N. Neutral.

10. CAB HEATING AND VENTILATION CONTROLS (For the setting of the controls, refer to the cab)

AUTO

ECOM

1

2

STOP

3

C F

On the contrary, when turning and pulling lever L into position R, the transmission shifts into 1st REVERSE and the machine moves backward. When engaging the reverse direction, a back-up alarm sounds. The gear shifting and the direction reversing can be performed with the machine standing or in motion. When pressing button P it is possible to upshift to the most appropriate speed from 1st through 3rd.

To downshift, for example from 3rd to 1st, it is necessary to push button S twice.

When pressing button N, the transmission is shifted into neutral, not withstanding the gear or direction selected.

D150-2M042

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

29

Selecting forward speed ("F")

Gear upshifting (P)

When pressing button ("F") the machine is set in 1st forward.

When pressing, afterward, button P, the speeds are upshifted.

When pressing S the downshifting to the lower speed occurs.

The display on the dashboard shows the speed engaged.

The transmission gears are upshifted each time button P is pressed, to select the most appropriate working speed, up to 3rd gear.

Gear downshifting (S) To downshift, press button S.

AUTO KICK DOWN AND AUTO SHIFT FUNCTIONS When pressing buttons AS - AL the two operating modes are selected. The selection of one excludes the function of the other.

15 20

10 50 40

70 90 120 C

25

5 RPM x 100

Display on the dashboard

D350M0078

Selection of reverse ("R") When turning lever L into position ("R") the machine shifts automatically into 1st REVERSE, so that the machine can move backward only, with the possibility of choosing always among 1st, 2nd, 3rd, with buttons P or S. In the event, for example, the machine operates in 2nd forward and the direction is reversed, moving the gearshifting selector lever into position "R", there is an automatic shifting from second forward into 2nd reverse.

INVERSION LOGIC The gears are selected in accordance with the following inversion logic: if in 1st F and R is pressed it shifts into 1st R " 2nd F " R " 2nd R rd " 3 F " R " 3rd R " " "

1st R 2nd R 3rd R

" " "

F F F

" " "

1st F 2nd F 3rd F

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

30

12. AUTO SHIFT "AS"

13. AUTO KICK DOWN "AL"

Button AS is selected when the operating cycle requires frequent FORWARD - REVERSE shifting. The system selects 1st forward for the work phase and 2nd reverse for back-up travel.

When button AL is pressed, a semi automatic gearshifting is selected.

The system is capable of down shifting automatically to the nearest speed, when the machine changes from a travel to a digging phase, gradually arranging the most appropriate speed, depending upon the resistance encountered during the pushing phase.

Operation of AUTO KICK DOWN option : AL

Activation of option The "Auto kick-down" option is activated by pressing button AL. When the option is engaged, symbol "AL" appears on the monitor display.

D150-2M043

AUTO SHIFT "AS" button.

AUTO KICK DOWN "AL" button

When pressing button AS one intervenes on the direction inversion logic.

When pressing the AUTO SHIFT button once, the option is activated and the display shows symbol AS (without error signals EXXX).

The option is cut-off by pressing the button a second time.

The gears are shifted in accordance with the following inversion logic.

INVERSION LOGIC (with "AS" function activated) If you are in1st F by pushing R shifts into 2nd R " 2nd F " R " 2nd R rd " 3 F " R " 3rd R " " "

1st R 2nd R 3rd R

" " "

F F F

" " "

1st F 1st F 1st F

Deactivation of the option The "Auto kick-down" option is disengaged by pressing (a second time) button AL. When the option is deactivated, symbol "AL" on the monitor display goes OFF.

Logic of the Auto kick-down The logic of the "Auto kick-down" is managed by the electronic controller unit. The Auto kick-down provides the automatic downshifting of the gear engaged (from 3rd to 2nd or 2nd to 1st) when the engine speed decreases below the pre-arranged threshold. With the option activated, by pressing the brake pedal or the decelerator pedal, the automatic downshifting is only temporarily cut-off.

The option does not operate in reverse.

Note – When the machine operates at an engine speed below the pre-arranged threshold and the option is engaged, the machine operates in 1st only and the system does not allow shifting into 2nd or 3rd (this limitation applies to "Forward" direction only).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

31

14. STEERING CONTROL LEVERS

Leftward steering

The Power Steering device provides a steering without ever blocking the track chain; thus the steering is obtained by actuating the levers indicated.

To steer leftward, pull the left lever. The operation of the left lever is similar to the right one.

Consequently, the track chains reverse their speeds; the right track chain speed increases, whereas the left one slows down in the same amount.

When both levers are pulled, no steering occurs.

D350M0080

Rightward steering When pulling gradually the right lever, the rightward steering occurs, the right track chain slows-down, whereas the left track chains accelerates in the same amount. The speed difference makes the machine steer.

The higher the lever stroke is, the higher the steering of the machine is.

D350M0082

Leftward steering

D350M0081

Rightward steering

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

32

15. NEUTRAL BUTTON Under any travel condition, when neutral button N is pressed, the transmission id directly shifted into neutral.

16. VENTILATION AIR DUCT (on cab only)

N

D150-2M044

D150-2M045

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

33

17. INSTRUMENT PANEL

Indicator lights and instruments

1

2

3

4

5

6

7

8

9

10

11

12

13

15 20

10 50

70 90

40

120 C

25

5 RPM x 100

Coolant temperature

Tachometer

Display

Fuel level

D350M0161

Indicator lights and instruments (R = Red) (G = Green)

1.

2.

3.

4.

5.

6.

7.

Engine air cleaner clogging (R) Engine coolant high temperature (R) Hydraulic oil filter clogging (R) Transmission oil high temperature (R) Transmission oil low pressure (R) Engine oil low pressure (R) General alarm signal (R)

8.

9.

10.

11.

12.

13.

Front work lights (G) Battery charger (R) Rear work light (G) Brake failure (R) Head lights + dashboard light (G) Fuel reserve (R)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

34

1. Engine air cleaner clogging The constant glowing of the indicator signals the clogging of the air cleaner cartridges, requiring cleaning or replacement.

2. Engine coolant high temperature It comes ON when the temperature of the coolant in the radiator is too high.

3. Hydraulic oil return filter clogging The activation of the indicator signals the clogging of the oil filters, which require to be replaced.

4. Transmission oil high temperature The activation of the indicator signals an excessively high temperature of the oil; trouble which could be caused by: - clogged oil suction filter; - prolonged operation of the machine under irregular conditions; - abnormal operation of the hydraulic system.

The overheating of the oil must be avoided since it alters the specifications of the oil and causes prejudice to the operation of the components.

Operating with oil at temperatures relatively high is permitted for short periods, provided that the engine coolant, circulating in the heat exchanger and cooling the oil, does not reach excessive temperatures.

Notice – In any case, keep in mind that, to obtain maximum performance by the torque converter, the speed engaged must be appropriate for the work to be done.

5. Transmission oil low pressure The activation of the indicator signals an insufficient pressure, which could be caused by: - clogged oil filters; - use of oil with a viscosity not appropriate for the ambient temperature; - abnormal operation of the system.

If required, perform appropriate inspections taking the necessary corrective actions; if the trouble persists, contact the Service Organisation.

6. Engine oil low pressure The indicator light is activated when the pressure of the engine lube oil drops below a defined value. Also, it comes ON when the engine oil filter is clogged.

7. General alarm signal It warns the operator with a dual signal (sound and flashing light) about eventual functional troubles signalled by the indicators.

When the general signal operates, it is necessary: - to stop the machine and cut-off the engine; - to disengage the electrical system master switch; - to take the measures required to eliminate the cause of the trouble. If the trouble persists, contact the Service Organisation.

8. Front work lights The indicator light comes ON when the switch is engaged.

9. Battery charger The indicator light comes ON when the charging of the batteries is insufficient.

10. Rear work lights The indicator light comes ON when the switch is engaged.

11. Brake system failure

12. Head lights, low beam lights and dashboard lights The indicator light comes ON when the switch is engaged.

13. Fuel reserve The activation of the indicator light signals that it is necessary to refuel.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

35

INSTRUMENTS

The engine work hours are counted only when the engine speed exceeds 500 rpm.

The instrument is arranged to receive data from an external unit indicating the number of the speed engaged.

These data are shown on the 5-digit numerical display.

Tachometer

Display

15 20

10 50 40

70 90 120 C

25

5 RPM x 100

15

Coolant temperature

Fuel level

40

120 C

Tachometer (rpm's x 100) It indicates the engine rpm's.

Fuel level It indicates the level of the fuel in the reservoir. When the pointer is near the red zone, indicator light (13) comes ON, signalling an "empty reservoir". Refuel as soon as possible.

Operation of the instrument cluster When the starter key is in position ACC/ON the instrument performs a short test for one second, activating all the LED's, the segments of the display and the buzzer; thereafter, the display shows the engine hours.

The indicator lights and the instruments monitor the state of the machine. When the engine is started, pointer display (R) shows the engine rpm's with 100 rpm steps To return to the engine hours, it is necessary to cut-off and to re-energise using the starter key; the hours are shown as long as the engine is inoperative.

All troubles are monitored by the LED indicator lights with ISO standard symbols and part of them are associated to a sound warning lasting 3 seconds; in the event the trouble persists, the alarm warns the operator with one minute cycles lasting 1 second.

25

5

D350M0162

Coolant temperature This instrument indicates the temperature of the coolant.

When the temperature is too high (red zone) indicator light (3, indicator lights figure) comes ON, signalling that the engine is overheating. Wait to cool-off the engine at idle speed.

20

10 70 90 50

RPM x 100

R D350M0162

Display The display shows three functions: A) - Digital hourmeter, indicating the total work hours and it is automatically activated when the engine is in operation.

B) - Speed engaged C) - Diagnosis of the correct operation of the transmission

Diagnosis on display The display has 5-digit text to indicate the following messages.

1st

2nd

3rd

4th

5th Digit

e

D150-2M046

A - Work hourmeter reading or B - Speed engaged signal + trouble code

Work hourmeter reading The engine hours are indicated when the instrument is activated and the general test is performed. To return to read the engine hours, it is necessary to cut-off and reactivate the power with the starter key.

The hours are shown as long as the engine is inoperative.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

36

Speed engaged signal + trouble code The first digit indicates the speed engaged (ex. 1st speed). The second indicates (in case of trouble) the letter E.

↑ st

1

nd

↑

D150-2M047

2 (digit)

The 3rd 4th and 5th digits indicate the trouble code (ex. trouble code no. 132).

When the failed component is one only, the display shows a code listed in TABLE 1.

For each trouble code, find the corresponding component.

↑

D150-2M048

3rd

↑

↑

4th

5th (digit)

TABLE 1 Failed component

Trouble code

Left proportional solenoid valve coil

001

Right proportional solenoid valve coil

002

Forward "F" speed solenoid

004

Reverse "R" speed solenoid

008

1st speed solenoid

016

3rd speed solenoid

032

Left steering lever solenoid

064

Right steering lever solenoid

128

TABLE 2 Failed component

Left prop. solenoid valve coil Right prop. solenoid valve coil Forward "F" speed solenoid Reverse "R" speed solenoid 1st speed solenoid 3rd speed solenoid Left steering lever solenoid

LH prop. RH prop. For. "F" Rev. "R" sol. sol. speed speed valve valve solen. solen. coil coil

001

1 st speed solen.

3 rd speed solen.

LH steer. lever solen.

RH steer. lever solen.

003

005

009

017

033

065

129

002

006

010

018

034

066

130

004

012

020

036

068

132

008

024

040

072

136

016

048

080

144

032

096

160

064

192

Right steering lever solenoid

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

128

D150

37

In the event two components fail, a trouble code (given by the summation of the two codes listed in TABLE 1) listed in TABLE 2 appears on the display.

Example of identification of trouble code listed in Table 2

In the event the display shows, as an example, code 024 (listed in Table 2) to identify the troubled components it is necessary to read in the table the corresponding troubles at the left top. One is identified in the top column "1st speed sol." the other is identified in the left line "reverse speed solenoid valve coil".

TABLE 2 Failed component Left prop. solenoid valve coil Right prop. solenoid valve coil Forward "F" speed solenoid Reverse "R" speed solenoid 1st speed solenoid 3rd speed solenoid Left steering lever solenoid Right steering lever solenoid

LH prop.sol. RH prop.sol. For. "F" Rev. "R" 1st speed Valve coil valve coil speed solen. speed solen. solen.

001

003 002

005 006 004

009 010 012 008

017 018 020 024 016

3rd speed solen.

033 034 036 040 048 032

LH steer.

RH steer. lever solen. lever solen.

065 066 068 072 080 096 064

129 130 132 136 144 160 192 128

Reverse "R" speed solenoid trouble code 008+ Trouble code on display = 024 1st speed solenoid trouble code 016

Whereas, on the left, it identifies the reverse speed "R". The crossing in TABLE 2 of the two components determines the trouble code 024, given by the addition of the twos.

Reverse "R" speed solenoid trouble code 1st speed solenoid trouble code

= 008 + = 016

Trouble code for both

= 024

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

38

18. SWITCH AND INDICATOR PANEL

a

b c

d

e

f

g

h

g.

REAR WORK LIGHT ACTIVATION SWITCH

h.

SAFETY LEVER INDICATOR The indicator lights come ON when the machine is started and the equipment control safety lever (1) and gearshifting safety lever (2) are in raised position (A) (NEUTRAL).

The indicator lights go OFF, when the levers are lowered to operate the machine (Posit. B).

i D150-2M049

on CAB D350M0160

A

A B

2

1 B

g i h e f D350M0126

on ROPS a. Front/rear 1 speed switch (with cab only) - b. Front/rear washer button (with cab only) - c. Side doors washer button - d. Side doors wiper 2 speed switch - e. Light switch f. Front work light activation switch - g. Rear work light activation switch - h. Safety lever indicator - i. Pre-heating indicator light.

D350M0086

Position A = NEUTRAL Position B = operation position

i.

PRE-HEATING INDICATOR LIGHT

19. ENGINE THROTTLE LEVER Forward = maximum acceleration.

Backward = minimum acceleration.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

39

20. ARMREST ADJUSTMENT LEVERS

22. BRAKE PEDAL

To adapt the position of the transmission control/ steering levers armrest to the requirements of the operator, perform the following manoeuvres.

To adjust the height and the angle, loosen lever A, adjust as required and lock it. To adjust horizontally on the sliding guide, loosen lever B, adjust (forward/ backward) and lock it once the forearm reaches the optimised working position.

(Stroke: about 100 mm - 4 in).

When the pedal is pressed, both track chains are braked.

Armrest

A

B

D150-2M050

21. ELECTRICAL SYSTEM MASTER SWITCH The electrical system master switch is found when opening the left panel, indicated in the figure. The key of the electrical system master switch must be in position ON when the system must be operational.

Turn the switch key into position OFF ( same as moving direction of machine) when the machine is parked at the end of the work shift, then extract the key.

In doing so, the eventual abuse by unauthorised personnel is made more difficult.

Moving direction

ON

OFF

D150-2M051

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M052

D150

40

OPERATING INSTRUCTIONS GENERAL INFORMATION Before placing the machine in motion, be certain it has been properly prepared for use and has been properly serviced since the last operating period. Refer to the chapter "PRELIMINARY INSTRUCTIONS AND BREAK-IN PERIOD" for detailed information.

If repairs have been made during the last period of inactivity of the machine, ensure that all bolts and nuts of the components involved are properly tightened and that all necessary adjustments are made.

- Check the hydraulic oil level.

- Check the torque converter/transmission oil level.

- Check the operation of the throttle pedal, the colour of exhaust fumes and the exhaust noise.

- Check the ROPS cab, safety belt for eventual damages and the loosening of securing fixtures.

- Prior to starting operating the machine, warm-up the various components, without considering the season.

- Do not operate the engine at high speed without load, especially when cold.

PRIOR TO STARTING (DAILY) By reacting promptly as soon as troubles develop it is possible to reduce maintenance costs and machine downtime. Thus, it is recommended that, every day, prior to starting working or at the end of the day, a walkaround inspection is done, performing the following operations: - remove dirt, mud, oil and snow from the machine.

- Check if there are oil leakages.

WARNING-DANGER In case it is difficult to identify the cause of leakage due to the presence of dirt, clean the component to be inspected.

Start the engine to identify coolant or oil leakages.

Oil leakages under pressure are dangerous since hydraulic oil could penetrate under the skin.

Do not try to locate leakages from the hydraulic system using bare hands. Use a piece of cardboard.

- Check for eventual damaged hoses and pipes in the hydraulic system.

- Check the engine oil level and the presence of contaminants in the oil.

- Check fuel level in the tank.

- Drain eventual water from the sedimentation filter.

- Check the coolant level and the presence of dirt on the radiator fins.

- Check the engine air cleaner clogging indicator.

- Check the operation of instruments and indicator lights on the dashboard, lights, horn.

ENGINE STARTING Open the left side panel.

WARNING Warn all people who may be servicing or working around the machine before starting.

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

Observe all start-up procedures and WARNINGS listed in this Manual.

Turn ON the ELECTRICAL MASTER SWITCH located inside the left side panel of the cab indicated in the figure.

Moving direction

ON

OFF

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M051

D150

41

Climb on the machine using only points where handrails and steps are provided.

Prior to climbing on the machine, clean and inspect steps and handrails.

Climb and descend the machine facing it.

Kepp three contact points with handrails and steps.

Note – The three contact points can be two feet and one hand or two hands and one foot.

Do not climb or leave the machine while in motion.

Do not junp off the machine.

Do not attempt climbing or leaving a machine while transporting equipment or other materials.

When entering or leaving the operator's compartment, do not use any control as a grabbing point.

D350M0087

Make sure that the GEARSHIFTING and BLADE CONTROL safety levers are in neutral position (raised).

Insert the key into the starter switch, pressing it slightly and turn it clockwise into position "ON", fig. starter key.

Moving direction ON

START

ACC. OFF

D150-2M053

H

Starter switch key Secure the safety belt before placing the machine in motion.

Adjusted it while seated.

Adjust and block the seat in the most convenient and comfortable position.

1850-2M0082

Monitor the instrument panel and the indicator lights that there are no troubles on the machine. Return the switch into OFF. Eliminate eventual troubles identifying the cause. Return the switch into "ON" then move the throttle lever half way.

Press the engine starter switch key and turn it into position "START".

Once the engine is started, release the key.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

42

Do not keep the starter key in position START more than 10 seconds at each attempt; otherwise, the starter motor is damaged.

Warm-up the engine for at least 5 minutes, without considering ambient conditions.

Reduce the engine speed.

Move the gearshifting control to neutral, pressing button N and engage the relevant safety lever into neutral position A. N

Notice – If the engine has been inoperative for a long time or with low ambient temperature, increment eventually, the circulation of fuel with a few strokes of the primer pump.

Notice – Do not operate the starter motor for more than 10 seconds. If necessary, wait for a few seconds to facilitate the cooling-off of the starter motor. Avoid pointless starting attempts, since there is the risk of exhausting the batteries. Search for cause of failed starting.

D150-2M044

Note – The most frequent causes of starting failure may be: presence of air in the fuel system, low battery charge, defective operation of the starter motor or faults in the electrical system.

A B

STOPPING THE MACHINE WARNING Never park on a slope without blocking accurately the machine to prevent any movement.

Every time the operation of the machine is interrupted, for whatever reason, check that all controls are in neutral position and that the equipment control lever locking device is in lock position.

D150-2M035

Position A = neutral Position B = operation position

Lower the equipment to the ground and engage the equipment safety lever into neutral position A.

WARNING Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

Move eventual supplementary equipment to closed and safe position.

Return all controls to rest position.

Place engine controls on cut-off position Lock all controls and disconnect the starter switch.

A

B

D350M0074

Position A = neutral Position B = operation position

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

43

STOPPING THE ENGINE

OPERATOR'S SEAT ADJUSTMENT

WARNING - NOTICE At the end of each operation period of the machine, do not cut-off the engine suddenly, but it is recommended that a cooling-off period variable from 3 to 5 minutes is observed, prior to stopping the engine. A sudden cutting-off of the engine with the turbine at high temperature will result in a transfer of heat to the bearing housing. Repeated hot cutting-off could damage the shaft bearings.

With engine at low idle, move the engine starter key into position OFF and remove the key.

The seat is provided with devices allowing the inclination and height of the cushion, the height and rake of the back rest and the controls reach distance.

WARNING Before starting the machine, adjust and lock the seat for maximum comfort and control of the machine.

Inspect periodically the seat belt. No traces of fraying, wear or other weaknesses that could lead to failure must be found.

Moving direction ON

START

ACC.

a

OFF H

Starter switch key

e

1850-2M0084

Prior to leaving the machine, in case this is going to be unmanned, move the ELECTRICAL SYSTEM MASTER SWITCH into OFF and remove the key.

b c

d D350M0089

Moving direction

a - Adjusting lever for the setting of the weight of the operator seated, with respect to the shock absorber. b - Controls reaching distance adjustment lever. c - Front and rear cushion, vertical adjustment. d - Back rest angle adjustment lever. e - Setting the weight of the operator.

ON

OFF

D150-2M051

If outdoor temperature is low, it could be difficult starting the engine. It is appropriate to pre-heat the engine; please refer the relevant instructions at item 5 (Starter switch).

Setting the weight of the operator Get into the seat and place the plastic indicator e at the front edge of the seat side frame, actuating lever a.

At this point, the shock absorber of the seat is set according to the weight of the operator.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

44

The seat illustrated here below is provided with the arrangement with air conditioner.

e D150-2M054

d

Fuel filter cap

a

BLADE ADJUSTMENT Angle version (with PAT blade)

b c 1850-2M0165

To increase or decrease the blade pitch on the ground, adjust forward/backward rod (A) with the support pry bar to facilitate operations (max. blade pitch angle 10°).

a - Seat reach distance adjustment with respect to controls. b - Height and operator weight setting adjusting lever. c - Swing adjustment lever. d - Backrest angle adjustment lever. e - Back support adjustment control.

A

FUEL RESERVOIR DANGER Extinguish all smoking materials and open flames before checking and filling fuel reservoirs.

Never refuel with engine in operation.

Never use matches, cigarette lighters or torches as a source of light near flammables.

Min. 10˚ Max.

D150-2M055

Bulldozer version (with HS blade) In the bulldozer version, with a blade tilt control cylinder on the right side, tighten or loosen sleeve E using bar T to move further.

E

Always use fuel that has settled. When transferring fuel from the settling vessel to the machine reservoir, use a pump equipped with a filter, using the 24 Volt power socket.

It is recommended that the refuelling occurs at the end of each day's work; this will prevent condensations during overnight parking. Do not run-out of fuel; this will cause the entry of air into the fuel system with consequent need for a bleeding operation.

T D350M0091

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

45

CAB TILTING The cab is tiltable on the left side of the machine to allow an easy accessibility for the maintenance of the main groups of the machine.

To tilt the cab using an hydraulic cylinder and an hand pump, proceed as follows: - place the machine on a flat surface and open right and left side panels (2) under the cab;

S S

V 1

2

V D150-2M058

3

- return to the right side and loosen the six screws V securing the cab to the frame.

The screws secure the two cab supports S to the base of the machine frame (three screws for each support);

D150-2M056

- open upper left panel (1) of the engine compartment and lower side panel (3); - disconnect quick coupling joint G of the accelerator pedal link;

WARNING-DANGER Prior to tilting the cab, make sure that left panel (1) of the engine compartment is closed, to prevent that it interferes, in open position, with front central window (4) of the cab.

Also, make sure that right and left panel (2) under the cab are open to prevent they interfere with the frame during the tilting phase.

G 1

4 2

D150-2M057

G. Accelerator control quick coupling joint

➞

D150-2M059

➡

➯

- turn diverter valve B into "cab tilting" position

";

Diverter valve B in cab tilting position D150-2M060

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

46

- actuate hand pump P using lever A inserted into hole C to tilt the cab, very slowly.

LOWERING THE CAB

➞

To lower the cab, proceed as follows: - turn diverter valve B into lowering position

➡

➯

A

;

Diverter valve B in cab lowering position D150-2M062

- actuate hand pump P with lever A and constantly check that there is no interference with the parts below, such as wires or pipes.

C

P

Note – During the final portion of the travel, the lowering of the cab occurs under the effect of gravity which must be controlled by moving gradually diverter valve B into "tilting position".

Re-connect quick release joint G of the accelerator pedal .

Tighten the six screws V securing the cab, to a torque of 51÷ 55 daNm.

➞

B

D150-2M061

A. Pump actuating lever - B. Diverter valve - C. Lever hole - P. Hand pump.

➞ ➞

Note – Once the centre of gravity of the cab overcomes the dead point, it is no further necessary to pump oil with lever A, since the tilting continues naturally under the effect of gravity, to the position determined by the tension of safety cable F. Control the last tilting travel of the cab, by alternating diverter valve B from one position to the other .

OIL REFILLING AND BLEEDING OF THE CAB TILTING SYSTEM F

Proceed as follows: - make sure that cylinder E as the rod fully retracted; - remove pump plug T and fill with prescribed oil; - perform two or three tilting and lowering manoeuvres of the cab, to bleed the air from the system; - top-up with oil through the plug, with the rod of cylinder E fully retracted; - close plug T.

E

1850-2M0091

E. Hydraulic cylinder - F. Safety cable

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

47

DISENGAGING THE BRAKES In the event of an engine failure and the machine must be moved, it is necessary to disengage manually the brake located at the centre of the transmission housing.

Proceed with the disengagement, as follows:

Note – During the last three or four turns (brake disengagement phase) the screws get tighter, thus, actuate the two screws alternatively, until the brake disengagement is completed.

Tooling required: - Allen wrench, 8 mm; - Wrench, 19 mm; - 2 brake disengagement screws, M12x28x40 (P/N 380001315); - 2 spacers 28x12x4.

WARNING The brakes, mechanically disengaged, are inoperative. Prior to starting the brake disengagement operation, implement all the precautions required to secure the machine.

D150-2M065

- Using the Allen wrench, loosen the two plugs (T) on the brake assembly on the rear side of the machine.

2.5 ÷ 3 mm

S

D

V

T

D150-2M066

Brakes disengaged D150-2M063

- Insert the two screws (P/N 380001315) (V) complete with spacers into the holes.

S. Piston - D. Outer disc - V. Disengagement screw (P/N 380001315).

Under these conditions the machine is ready to be towed.

V

D150-2M064

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

48

MOVING THE MACHINE WITH OUTSIDE MEANS Towing and recovering the machine Should the engine fail to start or when the machine must be towed, it is necessary to disengage manually the brakes, as described in chapter "TOWING THE MACHINE" of the Instruction Manual.

For this operation, use equipment or vehicles appropriate for this purpose.

When using cables for towing or recovery, make sure that all parts are in good conditions and are free from defects or troubles.

Avoid kinking or bending cables; do not pull unless this conditions are eliminated, since they could cause failures and backlashes.

The maximum allowable load on the rear towing hook is 250 kN (only for machine excluding an eventual ripper).

The maximum allowable load on the front hook is 120 kN. Cables and chains must be firmly secured; make sure that they are attached to a point strong enough in relation to the effort to be made, which, in any case, must not exceed the maximum allowed value for the towing hook involved.

MAX. 250 kN MAX. 120 kN

D150-2M067

Weight of machine D150 (with 500 mm shoes without ripper) with HS bulldozer blade …………………… 14,915 kg (32,815 lbs) with PAT (6-way) blade …………………… 15,677 kg (34,490 lbs) Weight of machine D150 LGP (with 500 mm shoes without ripper) with PAT (6-way) blade …………………… 16,810 kg (36,980 lbs)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

49

Lifting

INSTRUCTIONS FOR LOWERING THE EQUIPMENT TO THE GROUND WITH ENGINE INOPERATIVE

The same recommendations seen in the preceding point for the use of cables and chains apply.

Always handle tractor and equipment separately.

For the tractor, a slinging as illustrated in the figure is recommended.

For the front equipment it is recommended that the two end eyes of the blade and the tips of the blade are hooked, as illustrated in the figure.

WARNING Obey all procedures and WARNINGS relative to the instructions for STOPPING THE MACHINE and CUTTING-OFF THE ENGINE listed in this Manual.

The equipment can be lowered with appropriate movements of the control levers, with engine running or inoperative.

Move slowly FORWARD the specific control lever (blade or ripper) causing the lowering of the equipment involved; grade the lowering speed, with particular care, towards the final tract of the descent, before touching the ground.

When the blade is firmly bearing on the ground, move the lever alternatively FORE and BACK to stroke-end, a couple of times.

With this manoeuvres the equipment is bearing firmly on the ground and the residual pressures in the hydraulic system are released as well.

D350M0167

Prior to lifting, check that: - the parking brake is applied; - all cab doors, panels and mobile parts are secured; - all actuating cylinders are secured by the appropriate pins.

D350M0168

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

50

FIRE FIGHTING PROTECTION

TRANSPORTING THE MACHINE

Location and retaining system of fire extinguisher

Machines equipped with bulldozer , when being moved by means of transportation requiring the disassembly of the equipment, must have the cylinders secured by the safety bracket provided and the extension of the rods must be prevented by securing them with cables or flexible bands to the handle indicated.

WARNING Ventilate enclosed area after usage.

In the cab, near the right rear post, a fire extinguisher holder is located.

To use the fire extinguisher, in case of necessity, it is necessary: - to unlock the fire extinguisher from its support, grabbing the handle located in the upper part of the bottle; - remove the safety pin; - grab the sprayer;.

- press fully the control lever and direct the jet to the base of the flames.

The fire extinguisher provided is a 1 kg powder type code: 79088038.

D150-2M069

D150-2M068

Loading Note – Recharge after use, even partial.

NOTE: The fire extinguisher is normally supplied upon request.

Before proceeding with the loading operation, make sure the ramps and carrier platform are lined with suitable non-skid material (wood, rubber etc.) securely fixed to the above parts (avoid using wood planks, old tyres etc.). Proceed as follows: - apply the trailer and tractor parking brakes; - lower the rear stabilisers of the trailer; - align the machine tracks properly with the ramps for a correct climbing; - seek the help of a flagman standing in a position from which he can easily keep in sight the ramps, loading platform, machine and operator; - raise the equipment from the ground only as high as will not interfere with the loading operation, - climb up very slowly keeping the blade or frame close to the trailer platform; do not steer or change direction on the ramps;

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

51

- position the machine on the platform so as to ensure an optimised load distribution with soft manoeuvres, avoiding sudden starts or stops; - lower the equipment, apply the parking brake and follow the entire procedure recommended for stopping and leaving the machine.

Transportation Before moving off, it is necessary to perform the following operations: - apply and bolt, wooden chocks to platform, at the ends of the track chains; safety links or chains on the sides and along the machine to avoid movements during the transport; - check that cab door panels and other mobile port are correctly closed; - apply the signals prescribed by road traffic regulations in the event the dimensions of the machine exceed admissible values.

Unloading The operations and precautions to be followed during the unloading phase are practically similar to those applicable for the loading phase. During the descent it is necessary to keep the equipment as near the ground as practical to prevent slipping or wavering of the machin.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

52

LONG STORAGE OF THE MACHINE If the unit is going to be inoperative for a long time, comply with the following rules: - Clean the machine completely and lubricate all components equipped with grease fittings.

- Drain the water from the cooling system. If the system is filled with an antifreeze mixture, this operation is not necessary.

- To avoid rusting, it is necessary to refill completely the fuel reservoir.

- Remove the injectors and inject, through the injector holes, some engine oil (the operation should be performed using a syringe, after moving each piston to B.D.C.).

- After injecting the oil, crank the engine a few turns using the starter motor, so as to spread a protective film of oil on the sleeve walls. Then reinstall the injectors.

If possible, store the batteries in a place where there is no danger of freezing. Recharge them monthly.

WARNING To recharge the batteries, a slow charge is preferable.

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 terminals.

Place the machine in a protected place or cover it with a tarpaulin.

To ensure an adequate protection of the transmission components, at least once a month, the engine should be moved for short distances, so that a film of oil is renewed on the parts.

COLD CLIMATE PRECAUTIONS When ambient temperatures are near 0 °C (32 °F) make sure that the cooling system is filled with an antifreeze mixture, to prevent the danger of freezing., otherwise, replace the water in the system with such a mixture.

Flush the cooling system before adding the antifreeze mixture. Use appropriate specific products for this operation, following the instructions on the container.

WARNING Remove the radiator cap only after the engine has sufficiently cooled-off. With engine inoperative, turn the cap slowly so that residual pressure is released before removing it completely.

The use of FIAT PARAFLU 11 is recommended. Please find in the table below the percentages of the mixture related to ambient temperatures: AMBIENT TEMPERATURE Down to: - 18 °C (17.6 °F) - 15 °C (5 °F) - 25 °C (-13 °F) - 35 °C (-31 °F)

ANTIFREEZE

WATER

20 % 30 % 40 % 50 %

80 % 70 % 60 % 50 %

Run the engine for some time after adding the fluid, to obtain a correct mixing.

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

Also, use lube oils with a proper viscosity for temperature conditions, as indicated in the lube capacity.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

53

STARTING THE MACHINE AT LOW TEMPERATURES The engine starts regularly down to a temperature of -15 °C (5 °F) with the help of Arctic fuel, 50% anti-freeze in the cooling system, 10W-30 engine oil and fully efficient batteries.

To start at temperatures near or below - 15 °C (5 °F) it is necessary to activate the cold starting device (optional).

To activate the cold starting device, please refer to item 5 (engine starting switch - position H)

Temperature °C (°F)

Activation of engine pre-heating

Fuel

Engine oil

Antifreeze %

> 0 °C (32 °F) 0 to -14 °C (32° to 6.8 °F) -15 to -24 °C (5° to -11.2 °F) < -24 °C (-11.2 °F)

No No Yes, for 20 sec.s Yes, for 30 sec.s

STD Artic fuel Artic fuel Artic fuel

15W-40 15W-40 10W-30 10W-30 (*)

20 % 30 % 40 % 50 %

(*) For temperatures below -24 °C (-11.2 °F) a pre-heating device of the sump oil is available (optional)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

54

MACHINE OPERATION WARNING Never attempt to operate the machine or its equipment from any position other than seated in the operator's seat. In all circumstance, keep head, body, limbs, feet, hands and fingers within the operator's compartment to minimise the possibility of exposure to eventual external dangers.

Keep all equipment low or in a position ensuring maximum visibility and the control of the machine.

Never use the equipment as a platform to lift personnel nor to carry riders on the machine.

When pulling or towing through a cable or chain, do not start suddenly at full throttle; take-up slack carefully.

Use only designated anchoring points when pulling or towing. Take extreme care when hooking.

Make sure that pins and locks are properly secured before pulling.

Keep exposed personnel clear of the equipment (or supplementary attachments) when raised, to avoid possible injuries.

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

Explore the working area to identify potential risks such as: slopes, overhangs, pits, demolition rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, closed ambients. In such conditions, proceed with extreme care.

Working on slopes is dangerous.

Pay special attentions when working near overhangs.

Always designate a flagman when visibility of the working place, by the operator, is limited. The flagman must be capable of communicating directly with the operator and the latter must obey the signals.

Be aware of falling walls, falling objects and landslides. Always remember that these dangers could be concealed by brushes, undergrowth etc.

When working in ditches or near high embankments, make sure that the walls are adequately supported, so as to prevent landslides.

Before working in the vicinity of gas lines or other utility lines always contact the nearest utility office before beginning work.

You and the utility representative must jointly determine what specific precautions must be taken to insure safety.

Work in proximity of overhead or underground power lines involves serious body injuries and death hazards, thus special precautions must be taken according to national and local safety regulations.

For the purposes of this Manual you are considered to be working in the proximity of power lines when the attachment or the load raised by machine, in any position, can reach to within the minimum distances specified by local and national safety regulations.

Slow down working speeds. Reaction times could be too slow and distances could be erroneously evaluated.

PRACTICAL OPERATION TIPS It is good practice, when the operator first gets on the machine, to familiarise with its controls.

The operator must perform all the operations the equipment is capable of doing, to develop sufficient "feeling" with the controls and their reaction.

Remember that, when the control levers are in neutral position, the equipment is solid with the machine: this means that it will follow along any movement of the machine.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

55

DOZING

ROAD AND DITCH CUTTING

When working on grades, it is best to move downhill for better traction. Gradually lower the blade at the beginning of each pass and accelerate the engine fully. The dozing depth should be such as to allow a load within a short distance (5-6 m /15-18 ft); the full load should, then, just be pushed to the unloading area.

When the ground is hard, getting a full load in a short distance becomes difficult. Under these conditions, instead of pushing a half empty blade towards the unloading area, it is better to return to the starting point and doze more. The load of the second pass is added to the first one and will result in more effective dozing, especially when the unloading distance is considerable.

Working is often made more difficult when large rocks are present and are caught under the blade and pushed forward or lifting the front of the machine, making uneven cuts. This humped effect can be avoided by backing-up with the blade at a lower depth capable of dislodging the rock. If necessary, operate with the moldboard corner tilted.

When dozing in hard terrain and the blade is unable to cut the material, it is advisable to increase the moldboard's draft.

Under these conditions the angle is good for the initial cutting, but during continued dozing the moldboard will pick-up more resistance as the load will push the blade upward. Also, a high pitch reduces the rolling of the material on the blade, increasing the resistance. In hard and rough dozing, the operation might be easier if the blade is tilted; if the work to done is over a considerable area, first use the ripper to break-up the soil.

When cutting steep slopes (for roads or ditches) dozing should begin by cutting the depth of the ditch and tilting the blade to cut the sides with the desired angle.

Care must be taken in monitoring that the profile of the slope is regular, as any correction would be most difficult or, in some cases, even impossible.

FORDING DEPTH The fording depth is an important factor to be considered when the dozer works in marshland conditions.

Never enter into water deeper enough to reach the engine fan blades. As a general rule, the MAX allowed depth is about 500 mm (20 in).

Follow these rules: - check the depth of the water prior to fording water; - implement the same precautions, before entering a marshland.

Note – Avoid operating the dozer in seawater. Salty water causes the development of rust, reducing the life of the machine.

After working in marshland, wash accurately the machine and apply some protective.

BLADE PITCH

A. Loose soil.

B. Hard soil.

D150-2M070

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

56

PUSHING LOADS When pushing materials have the tendency to spill out the sides of the blade. This problem can be reduced by working repeatedly, when possible, following the same path on successive trips so that the spills forming windrows on both sides prevent a further loss of material from the blade. When pushing loads on a level terrain, keep the blade just touching the ground or at a depth deep enough to skim the surface. However, if the terrain is uneven it is appropriate to cut a little deeper to compensate the dirt which falls out the sides or in the hollows.

SPREADING When spreading materials, hold the blade slightly above the ground, so that it can slide under the cutting edge, creating an even layer.

If the layer to be spread is of a considerable height, let the blade rest at a height just above the desired layer, since the compactation occurring later will lower the layer, especially when loose materials are involved.

GRADING STEERING The D150 Power Steering solves steering difficulties, especially during the material-pushing phase, since it provides constant power to both track chains, under all conditions, making the machine steering in a natural manner.

Thus traction and ease of operation result, as well as a more uniform ground surface (not damaged by the blocking of the track chains), limiting the loss of material previously accumulated, during the steering.

After the ground has been dozed, the surface might be rough due to small windrows, ground lifted by the tracks or small piles left around turning points. These terrain irregularities must be smoothed over by operating the dozer in reverse and leaving the blade floating.

Under these conditions, the blade operates as a harrow, topping off high spots and filling voids, without altering the level.

Grading is often made difficult, and sometimes impossible, because of boulders or other debris, which have to be removed first.

PUSHING LOADS ON TURNS WITH Power Steering

D350M0169

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

57

MOVING LARGE ROCKS AND BOULDERS It could become necessary to move boulders with the dozer, during all kinds of works. There are several procedures. In fact a fully loaded blade may be used or the boulder can be pushed directly by the blade by the forward or reverse action of the machine.

The choice of procedures used depends upon several factors: the dimensions and shape of the boulder, space available, type of work being performed. With tractor in forward and fully loaded blade the boulder can be moved by glancing it off the load; in this manner the rock will roll-off to the nearest side of the machine.

Repeating this type of manoeuvre will eventually edge the boulder from the working area.

The same result can be obtained by manoeuvring in reverse. In such a case, turn the machine so that the side of the blade contacts the boulder, then disengage the steering clutch on the machine's opposite side and lock that side's brake. The dozer will steer, pivoting on the track being braked, while the blade pushes the rock backward and sideways.

MOVING BOULDERS WITH FULL BLADE

D350M0170

MOVING BOULDERS WITH THE SIDE OF THE BLADE

249

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

58

PILING

PILE LEVELLING

To pile materials, two well accepted methods are recommended: Form a pile of material on the first pass, then, with successive passes, accumulate material in front of the established pile.

After forming an initial pile on the first pass push material on successive passes to the top of the established pile and make it fall over the opposite side.

Sometimes, instead of piling it, the material is pushed to fill a ditch. In this case, since the filling material tends to let the machine sink it is appropriate to build a small step before reaching the edge of the ditch, raising slightly the blade.

This step improves safety since, proceeding with subsequent passes, the front of the tracks shall allow, in steps, to protrude over the original edge.

If the pile is not too bulky or hard, it can be levelled by dozing the blade into it, than it can be spread or re-piled somewhere else.

If the pile is too large or too hard to be spread with a single pass, or it must be spread in different directions, the first pass may be made grading one side to ground level, repeating the cuts, as required from different angles, on the remaining pile. If the dozing leaves high walls which could fall on the machine, turn the blade from time to time toward the wall and with it raised, push the mound down.

If the dozer is unable to cut a pile because of its steep sides, a ramp can be built by pushing into one side with the blade raised and then backblading with a down pressure.

The levelling of a pile can also be made by dozing a centre slot and continually cut away the top. This method is always recommended when the pile is excessively high and it is the only possible when there no access to the side of the pile.

The centre slot with must be quite greater than the width of the blade, thus allowing a protective border to be built preventing the dozer from getting trapped, once the digging reaches a certain depth or boulders and earth or the walls collapse on the machine.

Also, a narrow cut does not allow the machine to properly manoeuvre and dispose of rocks or roots encountered while dozing.

PILING A

B

CUTTING A PILE WITH SIDE CUTS

251

253

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

59

CUTTING A PILE WITH CENTRE SLOT

CENTRE SLOT DOZING OF PILE

D150-2M071

D350M0171

GOING OVER OBSTACLES Any obstacle (logs, roots, ridges etc.) must be removed, if possible, or avoided. If this is impossible, crossing must be done very slowly and at an angle so that one track will reach the top and starts to descend on the other side, while the track is still climbing. This method of operation slows down the dropping and decreases the shock against the ground, which could cause damages to the machine and the operator.

If the obstacle is made of soft material it is good practice to sharply turn the machine while crossing, so that the track edges will help cut the material down.

When the dozer is operating in heavy work, the tracks often spin, forming small pile of earth near their rear end. Under these circumstances, when reversing direction, it is good practice to move sideways as much as required, to avoid the tracks hitting these windrows.

A ditch may be crossed without danger only if its width is not greater than 1/3 the track length and if the track movement will not collapse the banks. To prevent the latter from occurring, move the machine over wooden planks, even if not very strong.

HILL WORK Dozing on side slopes requires special care. Even when the dozer appears to have sufficient margin of safety, the sudden running over an unseen obstacle by the upper track or the lower track moving into a hollow, the machine could tip over.

Chances of this occurring are lessened when the machine is dozing as it is moving along using the load as an additional stabiliser. Also, the machine is stabilised by the low windrow.

Dozing on frozen slopes is hazardous as the grousers act as skates causing the machine to slide uncontrolled downhill. There is a danger of tipping over rocky slopes as well, especially shale with beds parallel to the surface and on soft fills where the lower track sinks deeper than the upper one.

If the machine starts to slowly roll over, sometimes it is possible to prevent the trouble by quickly turning downhill, lowering the blade at the same time.

Slopes too steep to be safely worked sideways, sometimes, may, be dozed by operating the machine along it diagonally.

On the other hand, the machine overcomes safely steep slopes downhill. Steering is apt to be tricky on steep slopes, whether up or down, because when one steering clutch is released, the track on that side slips and turns faster and the machine pulls to this side under gravity and might place itself transversally of the grade with the consequent danger of tipping over.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

60

Digging and pushing should be done downhill to obtain a better pushing effort. This is particularly advantageous when the ground is very tough, even if the soil must be pushed up the hill. When digging is limited to a given area on the slope and material must then be pushed downhill, it is a good technique to drop to or three loads at the end of the cut, then pushing most of the pile down in a single pass.

252

Notching a shelf on side slopes, travelling across the slope, steering and unloading downhill.

GRADING ON SIDE SLOPES If a slope must be notched (i.g. road cuts in hillsides) it will be necessary to first build a shelf. Set the blade in tilt position opposite to the slope so the dirt moved will slide downhill and help in building up the shelf. If the slope is too steep to work effectively with tilted blade, proceed in one of the following ways: Push the material downhill to form a shelf as in (A), so the dozer can start level cuttings, as in (B).

Dig a strip transversally to the slope, then proceed with a series of parallel cuts, always operating the higher track in the previous strip.

In each case the best possible advantage should be taken with the soil configuration. When natural aids are not available, the machine can be moved onto boards or other lifts to start the cut at the desired slope.

A

B

D150-2M072

Notching a shelf on side slopes, travelling and unloading downhill.

Start cut transversally to the slope, then turn at the same time to unload downhill. This will provide a more level shelf, which can than be enlarged or graded off as required.

D350M0172

Dozing a shelf on side slopes by successive cuts across the slope.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

61

CLEARING

RIPPER

In land clearing of brush and small trees, clearing can be accomplished in one pass, with the blade cutting slightly below the ground. This will allow the blade to shear the roots. It may be necessary to back up occasionally to clear the roots from the cutting edge.

Roots under the edge cause the blade to ride up and waste machine power.

When uprooting a tree, first place the blade fully raised against the trunk, then engage first gear forward and push with the engine fully accelerated. If the tree resists, shift the transmission to neutral then into first forward again; repeat a few times. If the tree does not fall quickly, make a few passes to cut some of the outlaying root structure. To improve the pushing, buildup an earth ramp opposite the direction the tree is to be felled, so that the blade can touch the tree in a higher position. Remember, when the tree begins to fall, to back-up rapidly, so that the uplifting roots will not catch under and tilt over the machine.

The ripper is supplied as an optional.

To raise or lower the ripper, move the control lever backward or forward, respectively. To stop the ripper in the desired position, release the control lever which will return to hold position in neutral.

The ripper is equipped with shanks/teeth removable from the relevant frame, as required. Thus it is possible to work with all the teeth or, in particularly heavy conditions, with the central one only.

OPERATING TIPS

Work depth It is good practice to work to maximum depth permitted by the available power and traction of the machine, taking into account the breakage desired.

Note that: - With strongly cohesive materials, such as clay, tuff, marl, gypsum, sandstone, calcite and other compact soils, the greater the depth the coarser the breakage; - With stratified materials, such as limestone, schist, gneiss, travertine etc., the greater the depth the finer the breakage.

Before beginning to doze, the moldboard should have proper tilt and pitch for the work to be done. While dozing, always use a speed adequate to obtain best results from the machine.

To get smooth cuts, (meaning regular surfaces) the operator should closely watch the ground pattern and when the machine noses down or up, he must react swiftly with the control lever to raise or lower the blade, as required.

Note – Keep the cutting edges in good conditions.

Engage FIRST gear for all ripping operations. Use more shanks rather than increasing travel speed.

To obtain the best results, the following considerations should be kept in mind: Breakage The soil can be broken in fine or coarse pieces, as required. It depends on work depth, number and shape of the shanks and pass spacing.

Breakage must be established on the basis of the subsequent use of the ripped material. As an example, if the material must be spread and back bladed, a finer breakage is required than when it must be dozed away.

Number and shape of teeth The number of teeth depends on the power required of the machine in relation to the desired breakage.

Generally, the greater the number of teeth, the finer is the breakage. Exceptions are stratified materials where large slabs are lifted when working with more than one tooth.

As regard tooth shape, the partially curved type can be considered a universal standard. Curved teeth facilitate the lifting and to some extent, also the turning over of the material.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

62

Spacing between passes It must be such as to complete the breakage of the previous pass, always in relation to the desired fineness. Generally, spacing must be less than work depth.

In plastic soils, e.g. gypsum (in which the implement makes just a cut) or in hard soil (in which the working depth must be reduced) criss-cross passes may be required.

Speed and direction It is good practice not to exceed 1.5 - 2 kmph (1 to 1.2 mph) to prevent harmful shocks to the implement and excessive wear. When working on soft material, it is preferable to increase the depth rather than the speed.

In the case of stratified materials, work crosswise and against the vein; on the contrary, if the material is landslipping. work in the direction of the landslide.

Material heaping Generally it is convenient to heap material crosswise to the ripping direction in order to keep the transport distance to a minimum and to smooth out any irregularity.

1850-2M0098

Notice – Do not reverse or steer while the teeth are into the ground. Torsional forces could breake the teeth.

WARNING To make sharp turns, raise the ripper teeth off the ground, to prevent damages. Only wide turns or small directional corrections are permissible when the ripper is sunk-in.

With surfaces with deep depressions, first make passes to level the ground, prior to ripping, to avoid breaking the shanks.

WARNING When not in use, always carry the ripper in full raise position during operation and lowered to the ground when parked.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

63

CAB SAFETY CAB Safety cab with roll-over protection structure (ROPS) and against falling objects (FOPS) safegarding the operator.

The cab has two doors which can be open 90° (to be used only to enter the cab) assisted by gas filled cylinders and two hinged side panels, with lock in maximum open position, providing enough ventilation and reducing the inlet of dust. It is amply glazed and provides maximum operator comfort under whatever climatic condition.

Do not climb or leave a machine while in motion.

Do not jump off the machine.

Do not climb or leave the machine while transporting equipment or other materials.

When climbing or leaving the operator's compartment, do not use any control as a grabbing point.

Note – The key provided with the machine is universal, i.e. it operates the cab door locks, the side panels and the engine starting switch.

WARNING The protection offered by ROPS may be prejudiced by any damage or structural change.

Inspect your seat belt periodically for signs of fraying, wear or other weaknesses leading to failure.

DOOR The door is open by the handle indicated in the figure, after opening its locks (incorporated in the handle itself) with the appropriate key.

D150-2M053

Enter and exit the operator's compartment using the appropriate grab handles and stepping points.

Before climbing the machine, clean and inspect steps and handrails.

Climb and leave the machine facing it.

Keep three contact points with steps and handrails.

Note – The three points can be two feet and one hand or two hands and one foot.

D350M0092

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

64

To open from inside, rotate the handle as indicated in the figure.

Lubricate the door hinges through the grease fittings indicated.

During machine operation the doors can be kept open turning them until pin A enters into the appropriate receptacle.

M

A D150-2M074

D150-2M073

GLASSES

To release door, press button P inside and pull the door using handle M. WARNING If replacement of glass is necessary, be sure to use safety glass as spare.

Do not strike the glass to remove it from cab parts.

Glass may shatter and cause personal injuries.

Note – Windows must always be kept clean to ensure good visibility.

P

It is recommended to use specific window cleaners and dust free cloth to avoid scratching the glass and impair transparency.

1850-2M0101

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

65

CAB LIGHTING

CAB INSIDE HEATING AND VENTILATION

The ceiling lights are located on the top of the cab.

Switch M in raised position activates fixed light L, in lowered position it actuates movable light P. In central position both lights are OFF.

The regulation of the cab climate is obtained by actuating the control panel located under the front part of the ceiling in front of the operator.

1

M

2

3

4 5 6

AUTO

ECOM

1

2

8

9 10

7

L P

13

12

STOP

3

C F

11 D150-2M076

1850-2M0103

1. Decrement of internal temperature - 2. Increment of internal temperature - 3. Automatic function - 4. Compressor cut-off - 5. Re-circulation - 6. Outer temperature - 7. Cutoff - 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.

12 VOLT SUPPLEMENTARY RECEPTACLE (On cab only) Supplementary power receptacle P, located in the rear left part of the cab, can be used to power an eventual refrigerator to be located in the compartment behind the seat or to power a portable phone.

Demisting and defrosting To achieve a fast demisting and defrosting of the front windshield and side and rear windows proceed as follows: - insert the fan at full speed using button 10; - actuate button 2 until maximum temperature is reached.

T Open the cab vents directing the flow of warm air toward the windows.

P D150-2M075

Phone holder (T) to be used to store a portable phone, during battery charging phase as well.

D150-2M077

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

66

WIPER Should visibility be unsatisfactory as a result of faulty wiper blade operation, clean rubber blades using a specific detergent or alcohol. Should faulty operation persist, change the blades.

For the front wiper proceed as follows: - tilt out complete arm C from glass; - loosen screws D and remove the blade.

Note – Always keep windows clean to ensure good visibility.

It is recommended to use specific window cleaners and dust free cloth to avoid scratching the glass and impair transparency.

Check and eventually top-up the level of the detergent liquid in the appropriate reservoir, accessible by opening the right rear panel.

C

D350M0096

To replace the side and rear window blades, proceed as for the front wiper.

D D150-2M078

Note – Use DP1 detergent diluted with water, in relation to ambient temperatures. A 50/50 mixture of detergent and water is not freezing down to -10 °C (14 °F). Below this temperature, use pure detergent only.

S

D350M0097

If the spray pattern of nozzles S is defective, clean the holes with a needle.

If necessary, re-adjust the spray nozzle orientation so that the fluid will strike the windshield uniformly.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

67

MAINTENANCE MAINTENANCE SAFETY WARNINGS Do not allow unauthorised personnel to perform any maintenance operation. Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine.

Always place the starter switch in lock position prior to perform cleaning, repair or any other intervention on the machine and after parking it, to prevent personal injuries.

Never perform lubrication, repair or adjusting operations with engine running, except as specifically called for in this Manual, to avoid being caught by moving parts or being crushed by the machine.

Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Follow the instructions of chapters "Stopping the machine" and "Stopping the engine" of the Operation and Maintenance Instruction Manual, before lubricating or performing any other intervention.

Always lower the equipment to the ground and release pressure from all systems prior to proceeding with any maintenance or repair work.

The equipment and attachments can be lowered by moving the control lever with engine running or inoperative.

Every time components and groups of the machine must be removed, be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under jack is appropriate and stable.

Transfer load to appropriate blocking as a safety measure, before proceeding with service or maintenance work.

Never work over or under a machine or its components being supported only by jacks or other lifting devices, in accordance with current national and/or local regulations.

DO NOT USE HANDS to search for suspected pressure leaks. Fluid escaping under pressure nd can have sufficient force to penetrate the skin.

When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully.

Use only grounded auxiliary equipment to power heaters, battery charges, pumps or similar equipment, to reduce the risk of electrocution.

Warn all personnel which could be performing repairs or in the vicinity of the machine prior to starting the engine.

Keep hands, limbs and face away from loosen connections of pipes when performing efficiency or leakage tests of injectors or systems. Also, wear proptective glasses with side shields.

NEVER ALIGN HOLES WITH FINGERS OR HANDS; always use appropriate aligning tools.

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine, due to the presence of flammable fluids.

Never work under or near the equipment of a machine or its components nit adequately supported and blocked.

Always move the safety levers into Neutral position (raised)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

68

LIST OF ON-BOARD TOOLS

- Double head wrench

mm 24 + mm 27

- Double head wrench

mm 19 + mm 22

- Double head wrench

mm 13 + mm 17

- Double head wrench

mm 12 + mm 14

- Double head wrench

mm 8 + mm 10

- Allen wrench

mm 12

- Allen wrench

mm 10

- Allen wrench

mm 8

- Universal pliers

- Hammer

0,5 Kg

- Flat screwdriver

- Phillips screwdriver

- Grease gun with hose extension

- Filter chain wrench

Complying with standard ISO 4510.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

69

MAINTENANCE OPERATIONS The service intervals indicated herein refer to normal operating conditions; during the initial break-in period and under particularly severe conditions, other intervals may be needed.

Use this list to co-ordinate maintenance scheduled at the same intervals.

Before proceeding with any service operation, lower the equipment to the ground and shut-off the engine.

It is advisable to change oil immediately after stopping the machine as warm oil will drain out more easily, along with any suspended deposit or scale.

Before and after lubrication operations, accurately clean all fittings, covers, plugs to prevent dirt from entering the system.

Lubrication is an essential part of preventive maintenance, controlling to a great extent, the useful life of the unit. Different components require different lubricants, and some components in the unit require more frequent lubrication than others. It is important that the instructions regarding types of lubricant, and the frequency of their application, be followed. Periodic lubrication of moving parts reduces to a minimum, the probability of mechanical failures.

Notice – Do not temper with the calibration of the injection device. Otherwise the manufacturer is exonerated from any responsibility under the conditions of warranty.

WALK AROUND INSPECTION (to be performed daily) By quickly responding to initial troubles, required maintenance and downtime will be reduced. It is recommended to check the machine each day, before beginning work or to make a walk around inspection at the completion of each day to check: A. Side final drive oil leakages B. Ineffective or broken instruments C. Engine oil/coolant leakages

D. Hydraulic system leaks and damaged hoses E. Caked dirt on radiator grill F. Blade wear or damage H. Track rollers and idler wheel oil leakages I. Track tensioner grease leakages L. Caked dirt and mud on track frames M. Loosen fixtures on various components of the machine and relevant attachments.

C

B

D E

H M

F

A

L

I G D150-2M079

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

70

NOTES FOR MAINTENANCE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

71

MAINTENANCE TABLE When indicator lights come ON or when required

40 28

34

32 23

25

37

31 28 27

24 17

11

10

19

10 5

38

Every 1000 hours

30

2

4

41

33 26

35

22

36

29

16 17

Every 250 hours

12

9 6

Every 2000 hours

Every 500 hours 18

39

15 18

21

23 20 13

14

Every 100 hours

8

Every 10 hours

1

7

3

D150-2M179

EVERY 10 WORK HOURS 1. Engine oil check engine oil level.

2. Torque converter-transmission circuit: check oil level.

3. Fuel filter: draining condensation.

4. Radiator: check coolant level.

5. Brake indicator light: check efficiency.

EVERY 100 WORK HOURS 6. Bevel gear set Steering and brakes: check oil level.

7. Final drives: check oil level.

8. Fuel tank: draining condensation.

9. Equipment hydraulic system: check oil level.

10. Blade cylinder articulations: greasing the articulations.

11. Ripper linkage articulations: greasing the articulations.

EVERY 250 WORK HOURS 12. Undercarriage: check track chain sag.

13. Braking system: check operation.

14. Mesh fuel filter: replacement.

EVERY 500 WORK HOURS

EVERY 1000 WORK HOURS

EVERY 2000 WORK HOURS

15. Fuel filter: replace filter.

16. Steering-brakes circuit oil delivery filter: replace filter.

17. Torque converter-transmission circuit: change oil and delivery filter cartridge.

18. Engine sump: change the oil.

19. Engine oil filter: replace filtering cartridge.

20. Cab ventilation air filter: replace.

21. Cab: lubricate door-window hinging. .

22. Engine valves: check the valve clearance with cold engine.

23. Bevel gear set steering and brakes: change oil and clean suction filter.

24. Torque converter-transmission hydraulic circuit: was suction filter and magnetic rod.

25. Batteries: check electrolyte level.

26. Air conditioner compressor: check state and sag of belt.

27. Drive belt: inspection/replacement.

28. Drive belt: check sag.

29. Track suspension: grease swinging cross-bar.

30. Crankshaft pulley: check.

31. Belt tensioner: check.

32. Radiator: change coolant.

33. Engine air cleaner: replace cartridges.

34. Equipment hydraulic circuit: change oil and clean suction magnetic rod and filter.

35. Final drives: change oil.

36. Propeller shaft between torque converter and transmission: grease spiders.

37. Front equipment grease fittings: cylinder support.

38. Vibration damper: inspection.

AS REQUIRED 39. Engine air cleaner clogged: clean cartridges.

40. Oil filter on equipment hydraulic circuit return: replace cartridge.

41. Ventilation system: clean filters.

D150

73

2.

EVERY 10 WORK HOURS ENGINE: 1.

ENGINE OIL - Check oil level

Open the upper left engine compartment panel. with the machine on flat ground and engine inoperative since at least 5 minutes, check that the oil level on dipstick A is included between the two marks indicated. top-up the oil as required through filler neck B up to maximum level, paying attention to prevent exceeding the corresponding mark.

TORQUE CONVERTER/TRANSMISSION HYDRAULIC CIRCUIT - Check oil level

Open the engine panel indicated on the right side of the machine.

With the engine inoperative since at least 15 minutes and the machine on flat ground, loosen the screw located on cap S and remove the cap complete with the oil dipstick. Check that the oil level is near the upper mark MAX. etched on the dipstick.

WARNING Never operate the engine with the oil level below the lower mark (MIN.).

B A

S

D150-2M081

MAX MIN.

B D150-2M083

A Top-up with oil as required through filler neck B checking the level after running the engine at low idle for a few minutes, and shifting the transmission a few times.

MAX MIN.

D150-2M082

A. Engine oil dipstick B. Engine oil filler neck

The correct oil level must be included between the two marks, near the upper mark MAX. etched on the dipstick.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

74

3.

FUEL FILTER - Draining condensation

Open the left upper panel and the lower side panel to the engine compartment. Drain water and sediments from filter (A) with engine inoperative loosening draining valve (V) located under the filter, about 3 ÷ 4 full turns.

Let the water and sediments get out until clean fuel only flows.

Push the valve upward and tighten it, preventing an excessive torque.

Note – The frequency of draining operations can be increased or decreased as a function of the presence of water and the quality of the fuel.

4.

RADIATOR - Check coolant level

Open upper panel S indicated and the right side engine compartment panel. Check the engine coolant level through sight gauge A that should be included between the marks MIN. and MAX. The coolant level must never get below level MIN. Top-up with coolant through the filler neck indicated, with engine inoperative, with the engine inoperative since at least 1 hour, in order to release the pressure inside the circuit.

S

D150-2M086

A D150-2M084

It is recommended to fill the circuit with AGRIFLU' liquid dilute 50% with water, to obtain maximum protection against: - the effect of freezing down to - 40 °C (- 40 °F); - the formation of scale; - overheating during hot spells up to + 100 °C (230 °F); - the corrosion of metal components.

A

A V

MAX MIN D150-2M085

A. Water separation fuel filter - V. Draining valve.

D150-2M087

WARNING AVOID POLLUTING THE ENVIRONMENT Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

5.

75

BRAKING SYSTEM - Indicator light

The activation of the indicator light is a symptom of an abnormal operation of the brake system. Under these conditions, cut-off the engine and have the system inspected by specialised personnel.

15 20

10 50 40

70 90 120 25

5 C RPM x 100

D150-2M088

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

76

7.

EVERY 100 WORK HOURS 6.

BEVEL GEAR SET - STEERING AND BRAKES - Check oil level

FINAL DRIVES - Check oil level

Check that the oil level reaches the plug indicated (one level plug for each final drive); top-up with oil, as required, through the same plug.

Check the level with the engine on flat ground and the engine inoperative since at least 5 minutes proceeding as follows: 1. Open the right panel indicated under the cab.

D150-2M091

A. Final drive oil level filler and level plug D150-2M089

2. Loosen the screw on cap A complete with dipstick.

Extract it and check that the oil level is included between the mark MIN and the mark MAX etched on it. Top-up with oil as required through filler neck B.

8.

FUEL TANK - Draining condensation

Remove the rear guard of the machine under the tank indicated to drain impurities (water and sediments) accumulated on the bottom and collected in the well.

A

B

MAX MIN. D150-2M090

A. Brake-steering clutch oil cap and dipstick D150-2M092

To do this, loosen valve R indicated in the figure and let the liquid drain from the pipe into a container, until clean fuel flows out. Drain more frequently when operating under wet conditions, cold climate or strong temperature differentials. If required, clean the mesh filter in the fuel filler neck.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

77

When the temperature exceeds 0 °C (32 °F) the draining can be performed prior to starting the engine.

At temperatrures lower than 0 °C (32 °F) the draining must be performed at the end of the work shift, since water could freeze, thus it would not be drained.

9.

EQUIPMENT HYDRAULIC SYSTEM Check oil level WARNING

Fluid under pressure. Prior to removing the cap, turn it slowly to release internal pressure.

Open the right rear panel and check that the oil is in the middle of sight gauge B of the max. level.

This check must be done with machine standing on flat ground, the equipment resting on the ground, cold oil and engine operating at low idle.

R

T

D150-2M093

B R. Fuel draining valve

Max. Min.

A

D150-2M094

When the level drops until it appears through lower gauge A, remove filler cap T and top-up until the level reaches the middle of upper gauge B.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

78

10. BLADE CILINDER LINKAGE Greasing the articulations

11. RIPPER LINKAGE ARTICULATIONS Greasing the articulations

Pump grease into the blade cylinder articulation grease fittings.

Pump grease into the linkage lubrication fittings of the ripper control linkage.

The black arrows indicate that the grease fitting is visible on the opposite side.

WARNING Stop the machine in accordance with the procedures described by this Operation and Maintenance Manual prior to lubricating or performing any intervention. Always rest the equipment on the ground, prior to performing any kind of maintenance operations.

D150-2M096

D150-2M095

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

79

EVERY 250 WORK HOURS 12. ENGINE SUMP - Change the oil (the oil change is done together with the filter) Note – Strictly comply with the 250 hour or 3 month oil change interval. The oil change and the replacement of the filter have the purpose of eliminating contaminants suspended in the oil.

3. To facilitate the draining , open the left front engine compartment panel and loosen the cap from oil filler neck B.

B A

Note – When the fuel used has a sulphur percentage exceeds 1% the oil of the engine oil must be performed every 150 hours.

Note – Drain the oil when hot and the contaminants are suspended, then proceed as follows:

D150-2M081

A D150-2M097

MAX MIN.

1. Run the engine until the temperature of the coolant reaches 60 °C (140 °F), then cut-off the engine.

2. Remove draining plug T at the bottom of the machine using a 10 mm Allen wrench.

D150-2M082

A. Engine oil dipstick B. Engine oil filler neck

To drain the oil, use a collecting pan with a capacity of at least 20 l (5 174 U.S. G.)

WARNING Use authorised disposal sites or centres for the collection of used oils. In case of doubts on the procedures for the administration and elimination of used engine oils, please contact local authorities responsible for the protection of the environment.

T WARNING D150-2M098

T. Engine oil draining plug

Prevent prolonged and extended contacts of the skin with used engine oil, that could cause skin irritation or other injuries.

- Prevent excessive contacts. wash accurately the parts affected by contact.

- Keep away from the reach of children.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

80

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Note – It is possible that the gasket sticks to the filter head, thus , prior to installing a new filter, make sure that the old one is removed.

2. fill the new filter with new oil and lubricate the relevant gasket; 3. hand tighten the filter. After the gasket contacts its seat on the cylinder block, then tighten ¾ turn further.

Once the oil stops flowing, refill with oil of the prescribed type and grade (see "TABLE OF CAPACITIES") 4. retighten draining plug T and refill with new oil through filler neck B, until the maximum level etched on dipstick A is reached; 5. operate the engine at low idle; 6. cut-off the engine and after a few minutes, top-up, as required.

Oil sump capacity

System total capacity

14.2 litres (2.7 USG)

16.3 litres(4 ¼ USG)

D150-2M100

WARNING An excessive mechanical tightening can deform the threads and damage the seals inside the filter.

13. ENGINE OIL FILTER Replacing the filtering cartridge Open the upper and lower panels of the engine right compartment.

The replacement of the filter must be performed at the prescribed intervals, since in the event of clogging, the oil circulated cold be unfiltered. replace the filter proceeding as follows: 1. clean the supporting zone of the filter and loosen it using a 90 - 95 mm filter wrench;

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

D150-2M099

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

81

14. UNDERCARRIAGE - Check the track chain sag DANGER WARNING Fluid under pressure. To reduce the tension of the track chain, follow the procedure described in the "Operation and Maintenance Manual".

When the sag of the track chains in tract C included between the support roller and idler exceeds 30 - 40 mm (1.18 - 1.57 in)

Fluid under pressure. Do not reduce the tension of the track chain loosening pressure relief valve VS. Do not remove the grease fitting installed on adjusting valve VR. Pump grease into grease fitting I indicated of valve VR of the adjusting cylinder, until the track chain is tensioned correctly.

When the sag is lower, discharge grease from the cylinder, loosening slightly adjusting valve VR retracting, if required, the machine a few yards.

C

Re-tighten valve VR. 3÷4 cm MAX.

I VR D150-2M101

Remove the guard indicated removing the four securing screws.

VS D150-2M103

I. Grease fitting; VR. Track chain tension adjusting valve; VS. Pressure relief valve.

Note – When operating in muddy, claysh, very wet ground or sand, gravel, snow and ice, the track chains must be less tensioned.

15. BRAKING SYSTEM - Check operation D150-2M102

Check the correct operation of the braking system performing a series of tests with the machine at maximum speed downhill. When actuating the brake pedal, the machine must stop within a space sufficiently short and such to ensure an adequate operational safety.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

82

16. FUEL GLASS FILTER - Clean mesh filter WARNING WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

1. Remove the rear guard under the fuel tank and close fuel shut-off valve S.

Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

S

D150-2M104

2. On the left side of the machine, open the upper and lower panels of the engine compartment.

3. Remove the mesh filter included in glass filter B loosening screw C and clean it with an appropriate solvent. Make sure that no open flames or sparks are present in the vicinity.

After reinstalling the glass filter, re-open valve S and actuate priming pump P e few times.

B

C P

D150-2M105

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

83

3. Loosen the filter indicated in the figure using a filter wrench.

4. Clean the support face of the filter gasket with a dry rag.

EVERY 500 WORK HOURS ENGINE: 17. FUEL FILTER - Replacement 1. Remove the rear guard under the fuel tank and close fuel shut-off valve S (see item 16).

2. Open the engine compartment rear left panel and clean the base of the filter.

A D150-2M084

5. Replace the gasket, fill the new filter with new oil and smear a film of clean engine oil on the gasket, then tighten it until it touches the support.

6. Then, tighten it half a turn further.

D150-2M106

WARNING WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

WARNING To prevent fuel spills, make sure that the fuel filter is firmly tightened, without exceeding. A mechanical tightening of the filter could damage it.

WARNING The bleeding of small quantity of air penetrated during the replacement of filters or injection pump supply pipe occurs automatically when the replacement of the filter is done in accordance with the instructions provided here above.

For a typical bleeding, please refer to item 36.

After installing new filters, open valve R.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

84

18. OIL FILTER ON STEERING/BRAKES DELIVERY CIRCUIT Replacing the cartridge 1. Clean the base of the support and the surrounding zone.

2. Remove filter F1 and replace it with a new one.

Prior to installing the new filter, lubricate the gasket with engine oil, then install it on the support. Once the gasket touches the base, tighten 3/4 turn further. The tightening must be done exclusively by hand.

T F1

D150-2M107

T. Torque converter/transmission oil draining plug

To facilitate the draining, open the engine panel indicated on the right side of the machine.

Loosen cap S from transmission oil filler neck B. 1850-2M0127

When require, top-up with oil as described in item (6) of the MAINTENANCE TABLE.

19. TORQUE CONVERTER/TRANSMISSION HYDRAULIC CIRCUIT Change oil and delivery filter cartridge Draining the oil Remove plug T (10 mm Allen wrench) from the bottom of the machine while the oil is hot and let the oil drain into a 40 l (10 1/2 U.S.G.) at least capacity pan.

S

B D150-2M108

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

85

Replacing the delivery transmission/torque converter oil filter 1. Clean the support base and the surrounding zone.

2. Remove filter F2 and replace it with a new one. Prior to installing the new filter, lubricate the gasket with engine oil, then install it on the support.

3. Once the gasket touches the base, tighten 3/4 turn further. The tightening must be done exclusively by hand.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Be sure exposed personnel in the area of operation are clear of the machine and equipment before moving it or its attachments. walk completely around the machine before mounting. Sound horn.

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

F2

1850-2M0129

F2. Transmission/torque converter (delivery) oil filter

Oil refilling Retighten draining plug T at the bottom of the machine after cleaning it thoroughly and refill with oil through filler neck C up to the level of the upper mark etched on the dipstick.

Start the engine and let it run at low idle for a few minutes.

Cut-off the engine and after a few minutes, top-up to the correct level checking it as described in item (2) of the MAINTENANCE TABLE.

D150-2M109

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

86

20. CAB VENTILATION AIR FILTER AND RE-CIRCULATION AIR FILTER – Replace To reach the filter, open the panel under the cab on the left side of the machine. remove the retaining device and extract frontally filter E using the appropriate handles.

Note – Prior to reinstalling the filter clean the inside of the canister.

WARNING Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

E

D150-2M134

RECIRCULATION AIR FILTER

21. CAB – Lubricate the window hinges

Replace filter (F) located behind the operator’s seat: - Loosen the two knobs (1) retaining the filter canister; - Install a new filter into the canister and retighten the two knobs.

Lubricate the door hinges pumping grease into the grease fittings indicated.

1

1 2

F

D150-2M074

D150-2M111

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

87

Cleaning the suction filter and magnetic rod

EVERY 1000 WORK HOURS 22. ENGINE VALVES Check the valve clearance with cold engine Have the valve clearance checked by specialised personnel.

The adjustment of the valve clearance must be made with cold engine or in any case at an engine temperature not exceeding 60 °C (140 °F).

Valve clearance - Intake ..................................... 0.25 mm (.0098 in) - Exhaust ................................ 0.50 mm (.01965 in)

A

B

Tilt the cab remove nut 1 and extract mesh filter 4 with magnetic rod 5.

Wash both of them with solvent. Clean the inside of the canister.

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

Reinstall the filter, magnetic rod and cover. Check and top-up the oil level after changing it.

1 2

C

D150-2M112

A. Feeler gauge - B. Clearance adjusting screw - C. 14 mm wrench.

Tighten the nut to a torque of 24 Nm and re-check the valve clearance.

4 3

5 F

23. BEVEL GEAR SET STEERING AND BRAKES Changing the oil and washing the suction filter Draining the oil Place a container of at least 65-70 l (17 U.S.G.) under the transmission housing.

Remove plugs A and B and let the oil drain completely.

Retighten the plugs after cleaning them as appropriate.

1850-2M0134

F. Transmission torque converter suction filter - 1. Nut 2. Cover - 3. Gasket - 4. Mesh filter - 5. Magnetic rod

A

B

1850-2M0133

A - B Steering and brakes draining plugs

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

88

Oil refilling Refill with oil up to the prescribed level, indicated by the mark etched on dipstick A. Start the engine and let it run at about 1000 rpm.

Actuate the steering clutch levers a few times.

Cut-off the engine and, after a few minutes, loosen the cap indicated and check that the oil level reaches the mark etched on the dipstick. top-up, as required, through the filler cap.

24. TORQUE CONVERTER TRANSMISSION HYDRAULIC CIRCUIT - Cleaning the suction filter and magnetic rod Tilt the cab remove nut 1 and extract mesh filter 4 with magnetic rod 5.

Wash both of them with solvent. Clean the inside of the canister.

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

D150-2M109

Dipstick The correct level must be included between the two marks.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Reinstall the filter, magnetic rod and cover. Check and top-up the oil level after changing it (as described in item 2) of the MAINTENANCE TABLE.

1 2

4

3 5 F

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

1850-2M0136

F. Transmission torque converter suction filter - 1. Nut 2. Cover - 3. Gasket - 4. Mesh filter - 5. Magnetic rod

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

89

25. BATTERIES Checking the electrolyte level WARNING Batteries contain SULPHURIC ACID. Protect the eyes when working on batteries against possible splashes of acid solution. in the event acid contacts the skin, eyes or clothing, RINSE IMMEDIATELY WITH WATER FOR AT LEAST 15 MINUTES. Seek immediate medical help.

Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-).Avoid short circuiting the terminals.

BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion. Do not test betteries by sparking.

With engine inoperative and the machine on flat ground.

Check that the level of the electrolyte reaches the reference mark on the side of the battery.

To top-up the electrolyte level, add de-mineralised water through the topping-up holes.

NOTICE – To keep batteries efficient, please comply with the following rules: - do not keep lights On for prolonged periods with the engine inoperative or at low idle; - for short stops it is preferable not to cut-off the engine, but let it run at low idle, since each starting demands a considerable supply of power; - make sure that the cable terminals are well secured to the terminals of the batteries and are smeared with a light film of pure vaseline; - keep batteries clean, especially the top side; - prior to interventions on the terminals, disconnect the end of the ground cable.

NOTICE – to prevent possible damages to the electrical system: - do not exchange the connection of cables on the batteries; - do not operate the engine while the batteries are disconnected; - when due to partially discharged batteries, it is necessary to use booster batteries remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-).

D150-2M113

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

90

26. AIR CONDITIONER COMPRESSOR Checking the conditions of the belt and adjusting the sag

Acceptable condition

Open the engine compartment access panel on the left side of the machine.

1. Check the conditions of the compressor belt.

Should the belt be worn or damaged, replace it with a new one.

The belt should sag 15 to 20 mm (0.59 to 0.79 in) under a force of 110 N. 2. Loosen the screw securing the compressor and the bracket adjusting screw.

3. To obtain a correct tension of the belt, move the compressor outward. tighten the compressor securing screw and the bracket adjustment screw.

Recheck the adjustment of the belt.

4. Repeat phase 2 and 3 as required.

Belt to be replaced

D150-2M114

WARNING Do not check the tension or replace belts with the engine in operation. Be particularly aware of the presence of fans.

Never place your head, body, limbs, feet or hands near belts or moving blades. be particularly aware of the presence of blowing fans.

Replacement 3/8 in square drive To remove or install a belt, use drive square 1 to lift arm 4 of belt tensioner 2 and the pulley.

1 1850-2M0138

27. DRIVE BELTS Inspection/Replacement Open the right and left engine compartment panels to visually inspect the belts. Check whether crossing cracks are present: cross-way cracks (across the width of the belt) are allowed, whereas longitudinal ones (in length-wise) crossing cross-way cracks are not allowed.

Replace the belt when worn due to rubbing or when the material is not perfectly sound.

D150-2M115

Service recommendation: In case of difficulty during the installation of the drive belt (belt apparently too short), place the belt on the fan hub pulley, the slide the belt over the water pump keeping the belt tensioner raised.

Applying an excessive force in the direction opposite to the tightening direction or after tightening the belt tensione through a mechanical lock, could cause the failure of the belt tensioner.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

91

D150

Check also that screw (3) securing the tensioner is tightened to a torque of 4.3 daNm. 3

29. TRACK SUSPENSION Lubricate the swing cross-member Pump grease into the two lubricating fittings of the swing cross-member (one each side).

2

4

D150-2M116

28. DRIVE BELT - Checking the tension D150-2M119

Measure the sag of the belt tension in correspondence with the longest span.

Max. sag: 9,5-12,7 mm (3/8 - 1/2 in) Note – The Cummins ST-1293 belt tension measure dynamometer can be used.

Tension limit: 267-578 N (60-130 ft lbs).

30. CRANCKSHAFT PULLEY - Inspection Check that the screws securing the crankshaft pulley are tightened to a torque of 137 Nm.

31. BELT TENSIONER - Inspection Make sure that the pulley of the belt tensioner turns freely. Check the belt tensioner bearing.

D150-2M117

D150-2M118

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

92

EVERY 2000 WORK HOURS 32. RADIATOR – Changing the coolant DANGER Fluid under pressure. prior to removing the cap, turn it slowly to release the pressure. To prevent burns, do not loosen the radiator cap with hot engine.

Open the panel on the upper side of the engine compartment and remove the filler cap located on the radiator.

A

- Dissolve a “radiator de-scaling compound” or other equivalent product always complying with the proportions indicated on the container. pour the solution into the radiator when the engine is cold.

- Operate the machine at work until the engine is well hot.

- Drain the solution. Let the engine cool-off a little, the pour drinking water through the radiator cap while draining it through the bottom of the radiator. Use AGRIFLU mixed 50% water for operation to – 35 ° C (-31 °F) 33. ENGINE AIR CLEANER – Replacing the cartridges Open the left panel of the engine compartment.

Remove the cover of container C loosening the screw.

Extract the two co-axial filtering elements: one inner B and the outer A and replace them.

MAX MIN

E

D150-2M087

Change the coolant proceeding as follows: - with cold engine, drain the engine coolant loosening draining plug T at the bottom of the radiator;

D

D150-2M121

A

T

B

D150-2M120

- reinstall plug T and pour slowly the coolant through the filler cap of the radiator until it covers fully (up to MAX level) sight gauge A; - retighten the filler cap on the radiator; - start the engine and let it operate for a few minutes; - let the engine cool-off, the top-up the coolant through the radiator filler cap.

D150-2M122

Prior to installing the elements, clean inside canister C and check that dust discharge valve D, located in the lower side of the filter is always clean.

Note – In the event the engine cooling system is filled with water in lieu of coolant (with anti-oxidation, anticorrosion, anti-scaling properties) flush the circuit as described here below.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

93

D150

WARNING Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

V

Important – In order to reduce machine down-time, it is appropriate to keep a reserve of spare filters ot the prescribed type obtainable from the Sales Organisation.

34. EQUIPMENT HYDRAULIC SYSTEM Changing the oil and cleaning suction filter and magnetic rod Draining the oil - Place the machine on flat ground, resting the equipment of the ground; - open the right side panel of the hydraulic oil tank; - remove the filler cap from the hydraulic oil tank and loosen lower plug T on the right side to drain the oil form the tank; - clean plug T and magnetic rod Z with solvent.

Fa

D150-2M124

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Loosen screws V securing the filter support. Remove filter Fa and wash it accurately. The filter must be cleaned and inspected at each oil change; Should the filter found to be damaged, replace it with a new one.

Z

Refilling with oil T D150-2M123

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Reinstall the magnetic rod and plug, refill the tank with oil through the filler neck up to maximum level and tighten the cap.

Start the engine and operate slowly the blade a few times as well as the ripper, if mounted, to fill cylinders and pipes with oil. Top-up the tank as many times as required.

Check the level as described at item (9) of the MAINTEANCE TABLE. WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

94

35. FINAL DRIVES - Changing the oil

37. FRONT EQUIPMENT Cylinder support grease fittings

Remove lower plug B (one each final drive) and drain completely the oil. After reinstalling the draining plug, refill with new oil through filler plug A. Repeat the operation on both final drives.

Pump grease into the cylinder support pivot grease fittings. The grease fitting indicated by the arrow is located on the opposite side of the machine, as well.

WARNING A

Stop the machine in accordance with the Operation and Maintenance Manual prior to lubricating or performing any intervention. Always lower the equipment to the ground before starting any maintenance work.

B D150-2M125

Final drive WARNING Prevent polluting the environment. Eliminate hydraulic fluids, lubricants and refrigerants and filtering elements impregnated by these fluids in compliance with current national or local regulations classifying these materials as polluting, noxious and dangerous waste.

36. PROPELLER SHAFT BETWEEN TORQUE CONVERTER AND TRANSMISSION Greasing the spiders Tilt the cab as described in chapter “TILTING THE CAB”. pump grease (three or four strokes) into the appropriate fittings to grease the spiders.

D150-2M126

Note – The operation must be done more frequently when working in very dusty conditions.

Propeller shaft

D350M0117

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

95

D150

38. VIBRATION DAMPER - Inspection Check reference lines (A) of the hub of vibration damper (B) and inertial member (C).

When the -misalignment of the lines exceeds 1.59 mm (1/16 in) replace the damper.

A

B

C D150-2M127

Check that the rubber element is not deteriorated.

Should the rubber be damaged or the elastic element reduced in excess of 3.18 mm (0.125 in) with respect to the metallic face, replace the vibration damper.

Note – Check also that the ring of the vibration damper does not travel forward on the hub. In the event even marginal movements are found, replace the damper.

OK

OK

OK

D150-2M128

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

96

WHEN REQUIRED L

Operations to be performed when the relevant indicator lights come ON: 1. Indicator light - engine air cleaner clogged 3. Indicator light – hydraulic oil filter clogged 1 2 3 4 5 6

7 8 9 10 11 12 13 F

15 20

10 70 90 50 40

120 C

D

25

5 RPM x 100

Coolant temperature

Rpm counter

Display

Fuel level D150-2M129

D350M0122

39. ENGINE AIR CLEANER CLOGGED Clean the cartridges Operation to be performed when indicator light 1, located on the instrument panel indicates that the filter is clogged.

Proceed with the replacement of the filters as described in item (33) of the MAINTENANCE TABLE. 40. EQUIPMENT HYDRAULIC CIRCUIT RETURN OIL FILTER Replacing the cartridge WARNING Fluid under pressure. Turn it slowly before removing it to release the presure.

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

WARNING Avoid polluting the environment. Dispose of batteries, hydraulic fluids, lubricants and coolants, filtering elements and absorbing materials impregnated by these fluids, in compliance with current national regulations, classifying these materials as polluting, noxious and dangerous waste.

Proceed as follows: 1. Tilt the cab as described in point “TILTING THE CAB”; 2. Clean filter cover L on the return line and the surrounding area; 3. Remove the securing screws and remove the cover; 4. Remove return filter F and replace it with a new one; 5. Reinstall cover L. Top-up the oil level as required, through filler neck D.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

97

D150

41. CAB VENTILATION AIR FILTER AND RECIRCULATION AIR FILTER – Clean filters To reach the filter, open the panel under the cab on the left side of the machine. remove the retaining device and extract frontally filter E using the appropriate handles.

Check the filter. If clogged, clean as described here below: - tap the filter smoothly on a flat surface, with the holed side downward; - blow with dry and clean compressed air. travel up and down along the pleats of the elements, until all the dust is eliminated; - reinstall the filter.

1

1 2

F

Notice – Keep the jet of compressed air away from the filter.

Note – Prior to reinstalling the filter, clean the inside of the canister.

E

D150-2M111

WARNING Wear proper protective equipment such as safety goggles or safety glasses with side shields when using compressed air to clean parts to prevent injuries by metal or other particles apt to fly or fall.

Limit the pressure to 2.1 bar in accordance with current local or national regulations.

D150-2M134

AIR RECIRCULATION FILTER Clean filter (F) located behind the operator’s seat proceeding as follows: - Remove the two filter canister securing knobs (1); - Tap smoothly and blow with a jet of clean and dry compressed air, until all dust is eliminated; - Reinstall the filter into the canister and retighten the knobs.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150

98

ELECTRIC SYSTEM Warnings – The electric system is operative only when the MAIN SWITCH is to ON position.

During machine operation, the switch must be ON in order to allow battery recharge and signalling operation. After the engine stopping, prior to leaving the machine, it is recommended to set the main switch on the position OFF.

WARNING - DANGER

Before every cleaning, repairing, servicing intervention, ALWAYS DISCONNECT ELECTRIC SYSTEM MAIN SWITCH. Turn OFF the ELECTRIC SYSTEM MAIN SWITCH located inside the left side door of the cab as shown.

Moving direction

If the batteries of the machine are nearly exhausted and engine starting is therefore performed by using auxiliary batteries, the connection to the batteries of the machine must be performed matching the terminals having the same sign (positive to positive and negative to negative).

This rule must be observed even in the case of battery recharge by external devices.

If the machine is without batteries and engine starting is therefore performed by using auxiliary batteries, it is necessary to disconnect in advance the alternator and keep it disconnected even during the machine operation.

In case of repair interventions on the machine by using electric welders, it is recommended to disconnect the alternator.

MEGAFUSE 200 A (only with cold starting device-optional) To reach the megafuse (1) open the rear door and remove the cover (2) of the electric component box (3), unscrewing the four check screws (4) as shown in the figure below. Remove the pressure-fit cover and then replace the megafuse (1).

ON

OFF

3

4

D150-2M051

2 DANGER

1

FLAMMABLE VAPOURS - Put every fire or free flames out, before checking or topping up the batteries.

DO NOT CHECK the batteries, causing electric arcs.

D150-2M130

WARNING

For heaters, charge battery devices, pumps and other similar devices, use only ground electric energy sources to minimise the risk of shocks.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

99

D150

FUSES Remove the pressure covers on fuse boxes A and B to reach the fuses.

In the event a fuse is blown, it must be replaced. If the trouble reoccurs, have the system checked by a competent technician.

The fuses protect: FUSE BOX A (mounted on the upper side) 1 = Tractor relay solenoid - Cab relay solenoid - 5 Amp 2 = Operator safety proximity sw. - Fuel shutoff solenoid valve - Thermal switch - Excess fuel solenoid valve - 10 amp 3 = Starting relay solenoid - Eng. stop electr. relay solenoid - 5 amp 4 = Buzzer - Monitor - 6W/B solenoid valve - Resistance - Control valve linkage - 5 Amp 5 = Brake safety solenoid valve - I.R.C. block supply solenoid valve - 5 Amp 6 = Horn - 7.5 Amp 7 = Micro Controller (PIN 1,2,33,46) - 7.5 Amp 8 = Micro Controller (PIN 12,13,14,24,39,40, 41,43,52) - 5 Amp 9 = Cab lights - Lighter - Pot. divider - Radio (optional) - 7.5 Amp 10 = Flood lights (side beam) - 7.5 Amp 11 = Rear flood lights (side beam) - 7.5 Amp

A

B

A B D350M0125

on ROPS

on CAB

Fuse box A

Fuse box B

FUSE BOX B 1 = Flood lights (front beam) - Switches lamps 7.5 Amp 2 = CR climate control - 20 Amp 3 = R-H door windshield motor pump - 7.5 Amp 4 = L-H door windshield motor pump - 7.5 Amp 5 = Rear windshield wiper motor 1 speed - 7.5 Amp 6 = Front and rear windshield motor pump - Front windshield wiper motor 1 speed - 7.5 Amp 7 = CR climate control - 20 Amp 8 = Cold starting relay solenoid - Cold starting indicator lamp - 5 Amp 10 = Optional - 7.5 Amp 11 = Empty - 5 Amp

WARNING Always disconnect the battery grounding cable prior to cleaning, repairing, connecting or disconnecting any wire of the electrical system, to prevent personal injuries.

Always keep all lights mounted on the machine in working conditions. Replace all burnt-out bulbs as soon as possible.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350M0183

D150

100

LINK FUSES "Link" fuses are reached by opening the left side engine cowling. They are located on the inner side of the frame beam.

Fuse 1 protects the machine 50 Amp. Fuse 2 protects the alternator 80 Amp.

2 1

D150-2M131

F. LINK fuses

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

PROTECTION TREE ELECTRIC DIAGRAM

101

FUSE 50A

STARTER MOTOR

FUSE 200A GRID HEATER FUSE 80A ALTERNATOR F7A - 7.5A PIN 1,2,33,46

TRACTOR RELAY

KEY SWITCH

F8A - 5A PIN 12,13,14,24,39,40,41,43,52

F10A - 7.5A F11A - 7.5A

F3A - 5A STARTING RELAY SOLENOID

F1B - 7.5A ELECTRIC CUT-OFF RELAY SOLENOID

FLOOD LIGHTS (SIDE BEAM) REAR FLOOD LIGHTS (SIDE BEAM) FLOOD LIGHTS (FRONT BEAM) SWITCHES LAMPS

F2A - 10A OPERATOR SAFETY PROXIMITY SW.

F2B - 20A CR CLIMATE CONTROL

FUEL SHUTOFF SOLENOID VALVE

CAB RELAY

THERMAL SWITCH

F3B - 7.5A

EXCESS FUEL SOLENOID VALVE

R-H DOOR WINDSHIELD MOTOR PUMP

F4B - 7.5A

F5A - 5A

L-H DOOR WINDSHIELD MOTOR PUMP

BRAKE SAFETY SOLENOID VALVE ENGINE STOP ELECTR. PULL SOLENOID

SIDE WINDSHIELD WASHER MOTOR PUMP

I.R.C. BLOCK SUPPLY SOLENOID VALVE

F11B - 5A

STARTER MOTOR CONTROL

F5B - 7.5A

REAR WINDSHIELD WIPER MOTOR I SPEED

EMPTY

F6B - 7.5A F4A - 5A

FRONT AND REAR WINDSHIELD MOTOR PUMP

F6A - 7.5A HORN

BUZZER

FRONT WINDSHIELD WIPER MOTOR I SPEED

MONITOR

F9A - 7.5A CAB LIGHTS

6W/B SOLENOID VALVE RESISTANCE

LIGHTER

CONTROL VALVE LINKAGE

POT. DIVIDER

F10B - 7.5A

RADIO - OPTIONAL

OPTIONAL - SEAT COMPRESSOR

F1A - 5A TRACTOR RELAY SOLENOID CAB RELAY SOLENOID

F7B - 20A CR CLIMATE CONTROL

Example of identification of fuses F = FUSE 1 = FUSE no. 1 A = Fuse box A 5A = Ampere à Services relay coil

F8B - 5A COLD STARTING RELAY SOLENOID D150-2M175

COLD START. INDICATOR LAMP

15W-40

- 25 to 20 °C (-13 to 68 °F) -20 °C to 50 °C (- 4 to 122 °F)

SAE 10W - 30

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

The quantities of oil indicated are those required for periodic changes.

- ( ) Quantity of first filling.

In the event engine oil with classification “CH4” is used, the change interval can be extended to 500 hours providing that the ambient temperature does not exceed 38 ° C (100 °F) and that the percentage of sulphur in the fuel does not exceed 0.5 %. In case of particularly heavy duty operation, reduce the greasing intervals.

Note:

Hydropower

Cab tilting pump

SAE 10W

NLGI2 consistency

MG2

Grease fittings

0.5

-25 to 20 °C (-13 to 68 °F)

SAE 10W - 30

ATF Type A Suffix A

–

API CE or CCMC D4 or MIL-L-2104 E

Periodical change Half normal interval One quarter normal interval

Down to 0.5 % sulphur From 0.5 to 1 % Over 1 %

If the content of sulphur of the fuel exceeds 0.5 %, change the engine oil as follows:

All season

All season

-15 to 40 °C ( 5 to 104 °F)

SAE 15W - 40

Super

API GL5 or MIL-L-2105

DIN 51524 PART - 1 DIN 51524 PART - 2 ISO VG 46

-15 to 40 °C (5 to 104 °F)

SAE 15W - 40

ISO 46

API CF-4/SG or CCMC D4 or MIL-L-2104 E

All season

SAE 10W

Idlers Rollers and track chains

4

-10 to +50

15W-40 10W-30

API CF-4/SG MIL-L-2104E ACEA E2 API CH 4 ACEA E3

ATF Type A Suffix A

-10 to +50 -30 to +20

–

All season

Hypoide 90

HI-TECH 46

Mixture of water and antifreeze at 50%. The mixture provides oxidation, foaming, corrosion, scaling and freezing protection properties down to - 35 °C (- 31 °F).

Down to - 35°C (- 31°F)

DIESEL FUEL ASTM No. 2D Grade TT of reputable quality and make

International Classification

Outdoor temperat. of reference

–

Agriflù mixed with 50% water protects down to - 35 °C (- 31 °F)

VISCOSITY GRADE

SAE 80W - 90

24

Final drives (each)

63

Super Gold

94

Transmission housing steering/brakes

Equipment hydraulic system

Hydropower

31 (40)

Torque converter Transmission

Super Gold HSP*

Super Gold

14.2 (17)

Engine

–

Agriflù

270

18 (20)

Cooling system

Fluids and lubricants

Fuel reservoir

QUANTITY Litres

ITEM

TABLE OF FLUID CAPACITIES D150 103

Operation and Maintenance Instruction Manual Print No 604.19.160.00 English - Printed in Italy

Operation and Maintenance Instruction Manual