NEW HOLLAND D150 CRAWLER DOZER Service Repair Manual

D150
CRAWLER DOZER
Workshop Manual
Print No. 604.13.517.00 English
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING-Cautionsdirectedtoavoidimproperrepairinterventionsinvolvingpotentialconsequencesforthe
safety of the personnel performing the repairs.
DANGER -Thesewarningsqualifyspecificallypotentialdangersforthesafetyoftheoperatororotherpersons
directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.
Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national, regional
or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts
and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or
merchandised by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandised by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.

Most accidents, whether they occur in industry, on the
farm, at home or on the road, are caused by the failure
of some individuals to follow simple and fundamental
safety rules and precautions. For this reason MOST
ACCIDENTS CAN BE PREVENTED by recognising
the real cause and doing something aboiut it before the
accident occurs.
Regardless of the care used in the design and
construction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without interfering in the reasonable
accessibility and efficient operation.
A carefull operator is the best insurance against an
accident. The complete observance of one simple rule
would prevent many serious accidents.
The rule is simple: never attempt to clean, lubricate or
maintain a machine while it is in motion.
AVOID ACCIDENTS
WARNING
Prior to engaging in any maintenance, adjustment
or repair operation on machines having
hydraulically, mechanically, and/or cable
controlled equipment (such as shovels, loaders,
dozers,excavatorsetc.)becertaintheequipmentis
lowered to the ground.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items, be sure
the equipment is suitably supported by means
other than the devices used for controlling the
equipment.

SUMMARY
GENERALITIES SECT. 0
ENGINE SECT. 1
TRANSMISSION SECT. 2
FINAL DRIVES SECT. 3
BRAKES AND STEERING DIFFERENTIAL SECT. 4
UNDERCARRIAGE SECT. 5
DOZER EQUIPMENT
SECT. 6
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM SECT. 7
D150-2M079
4
5
23
6
17

SUBJECT
SAFETY RULES .......................................................................................................................................I - VIII
IDENTIFICATION DATA ................................................................................................................................. 0-1
TABLE OF FLUID CAPACITIES .................................................................................................................... 0-2
TABLE OF CENTRE OF GRAVITY ............................................................................................................... 0-3
MAIN DIMENSIONS AND WEIGHTS............................................................................................................ 0-4
TABLES OFTECHNICAL DATA..................................................................................................................... 0-8
CHECK DATA ONTHE MACHINE ................................................................................................................0-19
EQUIPMENT MANOEUVRE TIMES ............................................................................................................0-20
LEAKAGES .................................................................................................................................................0-21
GENERAL INSTRUCTIONS .........................................................................................................................0-22
DIAGNOSTIC CHECKS ...............................................................................................................................0-28
UNITS OF MEASURE .................................................................................................................................0-29
TABLE OFTIGHTENING TORQUES............................................................................................................0-31
PAG.
SECTION 0
GENERALITIES
TABLE OF CONTENTS

SAFETY RULES
I
Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the
machine.
Read and heed all safety rules before any intervention.
SAFETY RULES
- Do not allow unauthorised personnel to operate service
or maintain this machine.
- 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 mov-
ing parts. Wear proper safety equipment as recommend-
ed for the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector vests,
respirator. Consult your employer for specific safety
equipment requirements.
- Keep operator's compartment, stepping points, 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 jump on or off the machine. Keep two hands and
one foot, or two feet and one hand in contact with step
grab rails and handles at all times.
- Do not use controls or hoses as hand holds when
climbing on or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
controls may be inadvertently moved causing acciden-
tal machine or equipment movement.
- Never attempt to operate the machine or its tools from
any position other than seated in the operator's seat.
- Keep head, body, limbs, hands and feet inside opera-
tor's compartment at all times, to reduce exposure to
hazards outside the operator's compartment.
- Be careful of slippery conditions on stepping points,
hand rails, and on the ground. Wear safety boots or
shoes that have a high slip resistant sole material.
- Do not leave the machine until it is completely stopped.
- Check the seat safety belt at least twice a year. If there
are signs of wear or fraying or other signs of weakness
that could lead to failure, replace it.
STARTING
- NEVER START NOR OPERATE AN UNSAFE MA-
CHINE. Before operating a machine, always ensure
that any unsafe condition has been satisfactorily
remedied.
- Check brakes, steering and attachment controls before
moving. Advise the proper maintenance authority of
anymalfunctioning part or system.
- Be sure all protective guards or panels are in place, and
all safety devices provided are in place and in good
operating conditions.
- Be sure exposed personnel in the area of operation are
clear of the machine before moving it or its attachments.
WALK COMPLETELY AROUND the machine before
mounting. Sound horn.
- Before starting machine, check, adjust and lock the
operator's seat for maximum comfort and control of the
machine.
- 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 FLAMMA-
BLE. Follow strictly the recommendations printed on
containers and in the Operation and Maintenance
Manual.
- DO NOT PUNCTURE OR BURN CONTAINERS.
- Containers must be stored in fresh, well ventilated plac-
es, out of reach of unauthorised persons. Follow strictly
the instructions provided by the Manufacturer.
- Never use these products near open flames, smoking
materials or sparks.
OPERATION
- Do not run the engine of this machine in closed areas
without proper ventilation to remove deadly exhaust
gases.
- Roll Over Protective Structures are required on loaders,
dozers, graders, excavators. NEVER OPERATE ma-
chines without ROPS.
- 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.
WARNING

SAFETY RULES
- 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.
- 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 PULL UNLESS OPERATOR's COMPART-
MENT OF MACHINES INVOLVED ARE PROPERLY
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
- Be alert to soft ground conditions close to newly con-
structed walls. The fill material and weight of the machine
may cause the wall collapse under the machine.
- In darkness, check area of operation carefully before
moving in with machine. Use all lights provided. Do not
move into area of restricted visibility.
- If engine has a tendency to stall for any reason under
load or idle, report this for adjustment to proper mainte-
nance authority immediately. Do not continue to operate
machine, until condition has been corrected.
- 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.
- In case of closed type cabs, always keep an opening with
the outside, to ensure a constant air circulation.
- 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.
- Where noise exposure exceeds 90 dBA for 8 hours, wear
approved ear protection.
- When counterweights are provided, do not work ma-
chine if they have been removed.
- Overtaking manoeuvres must be performed only when
absolutely necessary and unavoidable. Beware of pos-
sible uneven terrains, poor visibility conditions, the
presence of other machinery or persons out of sight.
- Operate the machine at a speed adequate to the working
conditions in the site and slow enough to ensure com-
plete control at all times.
- Never use the machine as a work platform or scaffolding,
nor other inappropriate operations (i.e. pushing railway
cars, trucks or other machines).
- Check monitoring instruments at start-up and frequently
during operations. in case the brake pressure gauge
shows a pressure lower than the minimum operating
pressure, stop immediately the machine .
- DO NOT CARRY RIDERS ON MACHINE
- Study and familiarise with escape routes alternate to
normal exit routes.
- Seat belts are required by current regulations to be
provided with Roll Over Protection Structures or cabs.
Keep safety belts fastened around you during operation.
- For your personal protection, do not climb on or off
machine while machine is in motion.
- Make sure that exposed persons in the area of operation
are clear of the machine, before starting the engine and
operating the equipment. Sound horn. Obey all indica-
tions provided by flags and signals.
- NEVER COAST the machine down grades and slopes
with the transmission in neutral or neutralised.
Choose and shift into the most appropriate gear to keep
the speed required, thus preventing any loss of control.
- Do not operate machinery in a condition of extreme
fatigue or illness. Be especially careful towards the end
of working shift.
- Do not operate machine with brakes out of adjust-
ment.
- Operate the machine at speeds slow enough to ensure
complete control at all times.
- Travel slowly over rough terrain, on slopes or near
drop-offs, in congested areas or on ice or slippery
surfaces.
- When backing, always look to where the machine is to
be moved. Be alert to the position of exposed personnel.
DO NOT OPERATE if exposed personnel enter the
immediate work area. STOP THE MACHINE.
- Maintain a safe distance from other machines. Provide
sufficient clearance for ground and visibility conditions.
Yield right-of-way to loaded machines.
- Maintain clear vision of areas of travel or work. Keep cab
windows clean and repaired.
- When machines are operating in tandem, the pusher
(rear) must be equipped with the appropriate deflectors
to protect the unit in front from the air stream coming from
the radiator.
- When pulling or towing through a cable or chain, do not
start suddenly at full throttle; take-up slack carefully.
Inspect carefully for flaws or troubles before using.
II

SAFETY RULES
- 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, ca-
bles, pipes, bearing load limitations of ground, bridges,
floors or ramps.
- 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.
- When crossing gullies or ditches, move at an angle with
reduced speed after ensuring ground conditions will
permit a safe traverse.
- Explore the working area to identify potential risks such
as: slopes, overhangs, pits, demolition rubble, fires,
ravines, ditches, soft terrain, heavy traffic, crowded park-
ing areas, closed ambients. In such conditions, proceed
with extreme care.
- 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 steep down-hill operation, do not allow engine to over-
speed. Select proper gear before starting down grade.
- Avoid side hill travel, whenever possible. Drive up and
down the slope. Should the machine slipping sideways,
turn it immediately downhill.
- The grade of slope you should attempt will be limited by
factors such as condition of the ground, load being han-
dled, type of machine, speed of machine and visibility.
- There is no substitute for good judgement when working
on slopes.
- 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.
- 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.
- When pushing trees with dead limbs, proceed with
extreme care. Avoid brush piles, logs or rocks.
- NEVER DRIVE OVER THEM or other surface irregular-
ities that brake traction with the ground, especially when
on slopes or near drop-offs.
- 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 represent-
ed by large tree limbs (possibly falling on the machine),
large roots (acting as a leverage under the machine
when up-rooted causing the roll-over of the unit) etc..
STOPPING
- When the machine is stopped for whatever reason,
follow the instructions of chapters "Stopping the ma-
chine" and "Stopping the engine" of the Operation and
Maintenance Instruction Manual.
- Always remember to position the transmission drive
control in neutral and engage the control lock to secure
the machine.
- The parking brake is automatically set, when the trans-
mission safety lever is lowered.
- 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.
- Return the controls to rest position. Place the gearshift
lever in neutral. Disconnect the master switch and ex-
tract the key.
- Park in a non- operating and no-traffic area or as instruct-
ed. 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.
- If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and signals as re-
quired. Also provide advance warning signals in the
traffic lane of approaching traffic.
- 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 inter-
vention (i.e. cleaning, repairing, maintaining, refuel-
III

SAFETY RULES
ling etc.). Do the same when parking for prolonged
periods of time to avoid accidental or unauthorised
starting.
- 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.
- 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 opera-
tions of the Operation and Maintenance Instruction
Manual are followed.
MAINTENANCE
GENERALITIES
- Before operating or performing any intervention on the
machine:
• read carefully all the rules contained by this Manual;
• read and obey all safety related plates and instruc-
tions located on the machine.
- Do not allow unauthorised personnel to perform any
maintenance operation. Do not perform maintenance
operation without prior authorisation. Follow all recom-
mended maintenance and service procedures.
- Keep operator's compartment free of all loose objects
that are not properly secured.
- 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 mov-
ing parts. Wear proper safety equipment as recommend-
ed 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.
- 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 acciden-
tal machine or equipment movement.
- Do not jump on or off the machine. Keep two hands and
one foot, or two feet and one hand in contact with step
grab rails and handles at all times.
- Do not 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.
- 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.
- Keep shoes free of mud or grease before climbing or
driving the machine.
- Never attempt to operate the machine or its tools from
any position other than seated in the operator's seat.
- When maintenance operations require moving hydrau-
lically 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.
- 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.
- Do not place the body, limbs or fingers into sharp articu-
lation uncontrolled openings of the machine and without
proper protections, unless they are blocked in a safe
manner.
- Never perform interventions with engine running, ex-
cept as called for in a Manual. Do not wear loose clothing
or jewellery near moving parts.
- 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.
- Shop and/or field service platforms or ladders must be
constructed and maintained in accordance with local
and national regulations.
- 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 accord-
ing to current regulations.
- 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.
IV

SAFETY RULES
V
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- When using compressed air for cleaning parts, use
safety glasses with side shields or goggles. Limit pres-
sure to 2 bar (29 psi), in accordance with local and
national regulations.
- 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.
- Do not use an open flame as a light source to look for
leaks or for inspection anywhere on the machine.
- Make sure that all mechanic's tools are in good condi-
tions. NEVER USE tools with mushroomed heads or
frayed. Always wear eye protections.
- Move with extreme care when working under the ma-
chine, its attachments and or on or near them. Always
wear protective safety equipment as required, such as
hard hat, goggles, safety shoes, ear plugs.
- When performing operations requiring running of the
engine, have a qualified operator in the operator's seat
at all times with the mechanic on sight. Place the trans-
mission in neutral and set the brakes and safety lock.
- KEEPHANDSANDCLOTHINGAWAYFROMMOVING
PARTS.
- 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 se-
curely, than move it to level ground as soon as possible.
- 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.
- 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.
- No bystanders are allowed near the hooking points,
chains or cables.
- DO NOT PULL UNLESS OPERATOR's COMPART-
MENT OF MACHINES INVOLVED ARE PROPERLY
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
- Keep the area where maintenance operations are per-
formed CLEAN and DRY. Eliminate immediately all
water and oil spillages.
- Do not pile oily or greasy rags; they represent a fire
hazard. Store in closed metal container.
- 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.
- Rust inhibitors are volatile and flammable Use only in
well ventilated areas. Keep open flames away - DO NOT
SMOKE- Storecontainersinacoolwellventilatedplace,
secure against unauthorised personnel.
- Do not carry loose objects in pockets that might fall
unnoticed into open compartments.

SAFETY RULES
- Wear proper protective equipment such as safety gog-
gles or safety glasses with side shields, hard hat, safety
shoes, heavy gloves when metal or other particles are
apt to fly or fall.
- 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.
- 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.
- The load lifted by jacks is always dangerous: it is neces-
sary to transfer loads to appropriate blocking as a safety
measure, before proceeding with service or mainte-
nance work, according to local or national regulations.
- Steel cables are frayed after prolonged use; always
wear appropriate protections (heavy gloves, goggles
etc.).
- Handle all parts carefully. Keep hands and fingers away
from structures, gears or moving parts. Use and wear
always the appropriate protections
- Compressed air systems can have water deposits creat-
ed by moisture condensation due to changes of atmos-
pheric conditions. If required, discharge deposits, as
instructed.
STARTING
- Do not run the engine in closed areas without proper
ventilation to remove deadly exhaust fumes.
- Donotplacehead,body,limbs,feet,handsorfingers,near
rotating fans or belts. Be especially alert near pusher fans.
ENGINE
- Loosen the radiator cap very slowly, to release pressure
from the system, before removing it. All coolant level top-
ups must be performed with engine OFF.
- Avoid that flammable materials touch exhaust parts.
Should this be possible, provide the necessary protec-
tions.
- 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.
- Never attempt to check or adjust fan belts when engine
is running.
- Do not adjust engine fuel pump when machine is mov-
ing.
- Do not lubricate the machine with engine running.
- Do not run the engine with air intakes, door or protections
open.
ELECTRICAL SYSTEM
- Disconnect batteries prior to any intervention on ma-
chine or electrical system (cleaning, repair, mainte-
nance).
- Should booster batteries be used, remember to con-
nect 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.
- Before any intervention, make sure that the main switch
is OFF.
- BATTERYGASISHIGHLYFLAMMABLE.Leavebattery
box open to improve ventilation when recharging batter-
ies. Never check charge by placing metal objects across
the posts. Keep sparks or open flames away from batter-
ies. Do not smoke near battery to guard against the
possibility of causing an explosion.
- Before any intervention, make sure that there are no fuel
or electrolyte leakages; eliminate them before proceed-
ing 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.
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 adminis-
tered immediately.
- Stop the engine and release all pressures in the
system before removing panels, housings, plugs or
covers.
- In case pressures must be measured, use instruments
of adequate capacity. Always follow the recommended
procedures.
VI

SAFETY RULES
VII
TOOLS
- Keep head, body, limbs, feet, fingers or hands away from
bucket, blade or ripper when in raised position.
Prior to any intervention, install all safety devices accord-
ing to current rules and regulations.
- In case equipment on the machine must be operated by
hydraulic systems, remember to proceed only after seat-
ing 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.
- 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 operat-
ing cylinder or winches control valves) must always be
properly adjusted in accordance with the instructions
provided by the Manuals of the Manufacturer.
- 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 neces-
sary, retighten to the prescribed torque.
WARNING
On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels,
loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground before servicing,
adjusting and/or repairing. If it is necessary to have the hydraulically, mechanically, and/or cable control-
led 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.

SAFETY RULES
SAFETY RULES FOR SEALS
VITONSEALS(fluoroelastomer)
Seals, especially VITON O-Rings, (normally coloured red)
are used in systems operating at high temperatures, since
this materials resists the effects of heat. However, in the
event this material is subject to heat exceeding 315 °C (in
practice, only in case of fire or when using welding flames)
fluoridic acid is generated. This acid is highly corrosive
and could cause severe burns, if in contact with the skin.
Every time it is necessary to intervene on components
equipped with VITON rings, for which an exposure to
excessive temperatures is suspected, the following proce-
dures must be applied:
1) inspect visually, without touching them, all seals show-
ing signs of damage due to high temperature. They
look black and tacky;
2) identify the type of material of the seals, if they are
VITON, performing the test illustrated below, on the
spare parts;
3) in case it is verified, or there is a reasonable doubt that
the components are made of VITON, the contaminated
area MUST be decontaminated before proceeding
with further operations;
4) wear neoprene rubber or PVC gloves and protection
goggles or face screen, and wash accurately the con-
taminated zone with a solution of hydraulic lime (found
at building stores) and water, so that a milky liquid is
obtained. Rinse carefully with steam or running water;
5) dispose of the materials removed and the protective
gloves in a safe manner, without burning them.
TEST FOR THE DISCRIMINATION OF RUBBER (BUNA N) MATERIALS
AND"VITON"(FLUOROELASTOMER)MATERIAL
WATER WATER
TRICHLORO-
ETHYLENE
VITON"
FLUOROELASTOMER
SINKS
NITRILIC/BUNA N RUBBER
FLOATS
VIII

D150
CRAWLER DOZER
TECHNICAL DATA TABLES

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0 - 1GENERALITIESD150
IDENTIFICATION DATA
A. Engine data plate
Theenginedataplateisvisiblebyopeningtheengineleftside
panel and it includes all the identification data and other
important information related to the engine.
1. Engineserialnumber
(E.S.N. Engine Serial Number Cummins)
B. Machine identification plate
The identification plate includes the main data of the
machine and it is visible under the operator's seat.
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 FNH);
- machine code (150LT);
- check letter "N";
- year of production “5” for 2005;
- manufacturing plant H (Lecce Plant);
- product line “C” (Dozer);
- serial number (last 5 digits).
Depending upon the configuration of the machine, the
marking is one of the following:
Cummins
Warning injuty result and warranty is voided
it fuel rate or rpm or altitudes exceed published
maximum values for this model and application.
Date of Mfg
Made in Great Britain by
Cummins Engine Co. Ltd.
Cummins
Engine Company Inc.
Box 3005
Columbia, Indiana
47202-3005
C.I.D./L CPL
Low idle RPM
Family
Valve lash cold
Firing Order
Rasted HP/KW
Engine
Engine Serial No.
Cust. Spec.
Engine Model
Fuel rate at rated HP
Timing-TDC
st RPM
mm /st3
D150-2M005
D150-2M002
D150-2M003
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
D150-0R001
D150-0R002
MODEL
D150 STD PAT PS
D150 STD BD PS
D150 XLT PAT PS
D150 LGP PAT PS
MARKING
*FNH150LTN5HC20001*
*FNH150BDN5HC21001*
*FNH150XTN5HC22001*
*FNH150LPN5HC23001*

0 - 2 GENERALITIES D150
ITEMQUANTITYFluidsandlubricantsVISCOSITYOutdoortemperat.International
LitriGRADEofreferenceClassification
Note:Thequantitiesofoilindicatedarethoserequiredforperiodicchanges.
-()Quantityoffirstfilling.
Intheeventengineoilwithclassification“CH4”isused,thechangeintervalcanbeextendedto500hoursproviding
thattheambienttemperaturedoesnotexceed38°C(100°F)andthatthepercentageofsulphurinthefueldoesnot
exceed0.5%.Incaseofparticularlyheavydutyoperation,reducethegreasingintervals.
APICF-4/SG
MIL-L-2104E
ACEAE2
SAE15W-40-15to40°C(5to104°F)
SAE10W-3-25to20°C(-13to68°F)
SAE15W-40-15to40°C(5to104°F)
SAE10W-30-25to20°C(-13to68°F)
TABLEOFFLUIDCAPACITIES
Downto0.5%sulphurPeriodicalchange
From0.5to1%Halfnormalinterval
Over1%Onequarternormalinterval
Equipmenthydraulicsystem63
Ifthecontentofsulphurofthefuelexceeds0.5%,
changetheengineoilasfollows:
Mixtureofwaterandantifreezeat
50%.Themixtureprovidesoxida-
tion,foaming,corrosion,scaling
andfreezingprotectionproperties
downto-35°C(-31°F).
DIN51524PART-1
DIN51524PART-2
ISOVG46
Coolingsystem18(20)AgriflùAgriflùmixedwith50%
waterprotectsdownto
-35°C(-31°F)
Downto-35°C
Fuelreservoir270–––DIESELFUELASTMNo.2D
GradeTTofreputablequalityandmake
Engine14.2(17)SuperGold
SuperGoldHSP*
APICH4
ACEAE3
15W-40
10W-30
-10to+50
-30to+20
15W-40-10to+50
TorqueconverterTransmission31(40)HydropowerSAE10WAllseasonATFTypeASuffixA
Transmissionhousing
steering/brakes
94SuperGold
APICF-4/SGoppure
CCMCD4oppure
MIL-L-2104E
HI-TECH46ISO46-20°Cto50°C
Finaldrives(each)24Hypoide90SAE80W-90Allseason
APIGL5oppure
MIL-L-2105
Idlers
Rollersandtrackchains
4Super
APICEoppure
CCMCD4oppure
MIL-L-2104E
Greasefittings
Cabtiltingpump
MG2
0.5Hydropower
NLGI2consistency
SAE10W
Allseason
Allseason
–
ATFTypeASuffixA

TABLE OF CENTRE OF GRAVITY
Machine configuration:
HG
LG
Base machine + blade HS + Ripper
Blade on the ground and ripper on the ground 845 (33.26 in) 1160 (45.66 in)
Blade on the ground and ripper at max. height 870 (34.25 in) 1175 (46.25 in)
Blade at max. height and ripper on the ground 868 (34.17 in) 1145 (45.07 in)
Blade at max. height and ripper at max. height 1005 (39.56 in) 1150 (45.27 in)
Base machine + blade PAT + ripper
Blade on the ground and ripper on the ground 800 (31.49 in) 1175 (46.25 in)
Blade on the ground and ripper at max. height 825 (32.48 in) 1205 (47.44 in)
Blade at max. height and ripper on the ground 820 (32.28 in) 1160 (45.66 in)
Blade at max. height and ripper at max. height 875 (34.44 in) 1195 (47.05 in)
Base machine + blade HS
Blade on the ground 805 (31.69 in) 1260 (49.60 in)
Blade at max. height 845 (33.27 in) 1360 (53.54 in)
Base machine + blade PAT
Blade on the ground 750 (29.53 in) 1470 (57.87 in)
Blade at max. height 926 (36.46 in) 1380 (53.54 in)
Basic machine (without blade and without ripper) 965 (37.99 in) 1130 (44.49 in)
Note: LG
= Horizontal distance from sprocket C/L
HG
= Ground clearance
Lg
Hg
D150-2M010

COLDSTARTING(Optional)
Upon request, a cold starting device facilitating the
starting of the machine at particularly low tempera-
tures is available.
AUXILIARYAPPLICATIONS
Some of the equipment described and illustrated in
this Manual is provided in determined markets to
satisfy specific requirements.
Additional devices and special applications can be
provided upon request, in agreement with the Sales
Organisation. Some accessories upon request are
listed here below:
Air conditioner, Cold starting, Blade: HS or folding HS
for LGP version, HSU or PAT, Ripper, 1 kg fire
extinguisher,Diagnostics,ForestRops(sweeps),Outer
sound suppression, 550 mm shoes.
MAIN DIMENSIONS AND WEIGHTS
* Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 500 mm
(20 in).
** Are included in the weight: cab, operator, blade and cylinders, lubricants, coolant and 10% fuel, with 800 mm
(32 in).
MACHINE SHOES WEIGHT GROUND PRESSURE ON
BASE BEARING AREA GROUND
mm (in) mm (in) kg (lb) cm2
(in2
) kPa
STD BD (HSU) 2550 500 550 15.011 15.126 25.500 28.050 57.7 52.9
(87.7) (19.5) (21.6) (33.095) (33.277)
STD PAT 2550 500 550 14.915 15.030 25.500 28.050 57.4 52.6
(87.7) (19.5) (21.6) (32.280) (33.065)
XLT PAT 2985 500 550 15.677 15.805 29.850 32.835 51.5 47.2
(116.4) (19.5) (21.6) (34.560) (34.770)
LGP PAT 2985 800 16.810 47.760 34.5
(116.4) (31.50) (37.060)
TYPE Blade Blade Blade capacity Tilt Pitch Digging Blade Width Weight
OF width width SAE J1265 mm depth max. lift withblade withblade
BLADE mm (in) mm (in) cu m (cu yd) (in) mm (in) mm (in) mm (in) kg (lb)
(HS) 3180 1100 3.10 550 ±10° 406 1105 4750 14.811 (*)
(125.19) (43.34) (4.0) (21.6) (16.0) (43.5) (187.0) (32.650)
Semi-U 3180 1320 4.12 550 ±6° 480 1105 5025 15.011 (*)
(HSU) (125.19) (52) (5.36) (21.6) (18.9) (43.5) (197.7) (33.095)
STD 3200 1100 3.15 450 ±5° 490 950 4950 14.915 (*)
PAT (126) (43.34) (4.05) (17.7) (19.30) (37.4) (194.9) (32.280)
XLT 3200 1100 3.15 450 ±5° 490 950 5315 15.677 (*)
PAT (126) (43.34) (4.05) (17.7) (19.30) (37.4) (209.28) (34.560)
LGP 4000 1000 3.15 550 ±5° 590 900 5315 16.810 (**)
PAT (157.5) (39.4) (4.05) (21.6) (21.66) (35.43) (209.28) (37.060)

Bulldozer HS arrangement
D150-2M007
3060mm
2550 mm
3650 mm
4750 mm
3080mm
500
mm
370mm
1900 mm
2400 mm
HSU Bulldozer arrangement
D150-2M007
3060mm
2550 mm
3650 mm
5025 mm
3080mm
500
mm
370mm
1900 mm
2400 mm

STD PAT Arrangement
XLT PAT Arrangement
D150-2M008
D150-2M133
2550 mm
3650 mm
4950 mm
5°
5°
950mm
3060mm
450mm
3200 mm
3080mm
25° 25°
~400mm
2950mm
1900mm
5470 mm
950mm
5°
5°
2985 mm
4010 mm
5315 mm
450mm
3080mm
2140 mm
2940 mm
800
mm
490mm
1100mm
2400mm
35mm
3060mm
1180mm
3200 mm
490mm

LGP PAT Arrangement
D150-2M009
3060mm
900mm
5°
5°
2985 mm
4010 mm
5315 mm
550mm
3080mm
2140 mm
2940 mm
800
mm
590mm

DIMENSIONS Total length (basic tractor) mm (in) 3890 (153)
Total length (with HS blade) mm (in) 4750 (187)
Total length (with semi-U HSU blade) mm (in) 5025 (198)
Total length ("STD PAT" version) mm (in) 4950 (195)
Total length ("XLT PAT" version) mm (in) 5315 (209)
Total length ("LGP PAT" w/ 800 mm, 32 in shoes version) mm (in) 5315 (209)
Total length (basic tractor w/500 mm shoes) mm (in) 2450 (96)
Total length (with HS blade) mm (in) 3180 (125)
Total length (with semi-U HSU blade) mm (in) 3180 (125)
Total length ("STD PAT" version) mm (in) 3200 (126)
Total length ("XLT PAT" version) mm (in) 3200 (126)
Total length ("LGP PAT" w/ 800 mm, 32 in shoes version) mm (in) 4000 (157)
Total height (BD, STD PAT) mm (in) 3060 (120)
Total height (with ROPS canopy) mm (in) 3080 (121)
Track gauge (BD, STD PAT) mm (in) 1900 (75)
Track gauge (XLT PAT, LGP PAT) mm (in) 2140 (84)
Minimum ground clearance (SAE J1234) mm (in) 370 (15)
Track chain length bearing on ground (BD, STD PAT) mm (in) 2550 (100)
Track chain length bearing on ground (XLT PAT,LGP PAT) mm (in) 2985 (117)
Width of track shoe (standard) mm (in) 500 (20)
MASS Weight in shipping order (including ROPS, 500 mm,
20 in shoes, lubricants, engine coolant, 10 % fuel)
kg (lb) 12865 (28362)
Weight in work order (w/ PAT blade, ROPS cab, 500 mm,
20 in shoes, lubricants, engine coolant, 10 % fuel and kg (lb) 14915 (32882)
operator)
Speed / Pull
PERFORMANCES 1st
forward Km/h / daN (mph/lbf) 4.3 / 21300 (2.7 / 47884)
2nd
3rd
SPEEDS / PULL
1st
2nd
3rd
PRESSURE
(Standard shoes 500 mm, 20 in wide)
ON GROUND w/ blade "PAT" and ROPS cab Kpa (psi) 57.4 (8.3)
CLIMBING
(1st
forward) Km/h (mph) 3.0 (1.9)
CAPACITY
(2nd
(3rd
TABLES OF TECHNICAL DATA
60%
30%
10%

ENGINE Model CUMMINS 6BTAA 5.9
Type
Bore and stoke 102 x 120 mm (4 x 4.7 in)
Total displacement 5.9 litres (360 in3
)
Number of cylinders 6
Net power at flywheel (SAE J1349) 140 HP /104 kW (at 2200 rpm)
Net power at flywheel (DIN 6270) 142 HP / 106 kW (at 2200 rpm)
Net power at flywheel (ISO 9249) 142 HP / 105 kW (at 2200 rpm)
Net power at flywheel (EEC 80/1269) 142 HP / 106 kW (at 2200 rpm)
Maximum torque 650 Nm (146.1 lbf) (at 1300 rpm)
Maximum power speed 2000 (rpm)
Maximum idle speed 2460 (rpm)
Low idle speed 850 (rpm)
Fuel consumption (at max. power) 25 kg/h (55 lbs/h)
Starter motor 24 Volt - 6.8 kW (9.1 HP)
Alternator 24 Volt - 70 Amp
Batteries - std 2 x 12 Volt - 100 Amph
oversized 2 x 12 Volt - 160 Amph
Radiator Air - water with tubes and in
line core
Dimensions of radiator core 930 x 453 x 114 mm (36.6 x 17.8 x 4.5 in)
Pressure of radiator cap 1.0 bar (14.5 psi)
Water pump flow (at engine 2200 rpm) 157 lt/min (34.5 gpm)
Fan Blower, 6-blade, diam 711.2 mm (28 in)
Air cleaner DONALDSON - Dry, 2-stage twith safety ele-
ment and centrifugal separator, clogging in-
dicator
Horizontal,
Exhaust silencer dimensions 655 x diam 228 mm (25.8 x diam 9 in)
TRANSMISSION/ Single stage, single phase, diam. 13"
TORQUE Stall ratio 2.33 : 1
CONVERTER The propeller shaft actuates through a gear
Torque converter train:
– equipment pump
– transm. pump + converter pump
– oil scavenger pump + brake pump
Transmission "Power shift" transmission, 3 forward and 3
reverse speeds with FINGERTIP CONTROL
type electric control. Neutral button allowing
disengaging directly the speed engaged shift-
ing the transmission into neutral. AL function
button and As function button. Modulating
valves on For and REV, speed engaging modu-
lating valve.
4-stroke, in-line vertical, direct
injection turbocharged, after-
cooled, low emission

TRANSMISSION/ Torque converter - transmission group Pump combined with converter
TORQUE powering oil pump and oil scavenger
CONVERTER pump.
Transmission pump delivery lt/min (gpm) 70 (18.5) (17 bar, 246.6 psi)
(at max. power speed)
Converter pump lt/min (gpm) 53 (14) (3 bar, 43.5 psi)
(at max. power speed)
Suction Metal mesh and magnetic rod, filtering
Transmission filters
capacity 100 micron.
Delivery Cartridge type (SPIN ON) with paper car-
tridge and by-pass valve, filtering capacità
capacity 25 micron.
Pressure relief valve Mounted on converter cover
Pressure relief valve (at flow of (psi) bar 10 ± 0.5 (2.6 ± 0.1)
10 lt/min, 2.6 gpm)
Transmission pressure (at flow of (psi) bar 13.75 ± 0.5 (3.6 ± 0.1)
10 lt/min, 2.6 gpm)
Transmission pressure (at flow of (psi) bar 17.0 ± 0.5 (4.5 ± 0.1)
70 lt/min, 18.5 gpm)
Safety lever valve In the locked position, it prevents the shift-
ing of gears and the starting of the engine
and it engages the parking brake.
Transmission gearshift Electro-hydraulic of a FINGER TIP CON-
TROL type with semi-open pattern.
Controls:
Fingertip type, FNR pivoting control, Shift-up/down neutral switch.
Safety lever.
election of operating mode - AS automatic AUTO - SHIFT
- AL automatic AUTO - LOW
Description of auto mode
AL Downshifting when the engine drops to a pre-determined speed.
AS It provides the operator with the pre-selection of the 1st
gear forward and 2nd
gear
reverse when shifting direction.
Propeller shaft With two universal joints and sliding shaft
Nominal length mm (in) 265.5 (10.4)
F
N
R
UP
1st
- 2nd
-3rd
3rd
- 2nd
- 1st
DOWN

The machine uses a differential steering system; this consists of a hydraulic pump, a hydrau-
lic motor, two epicyclical control modules and steering gear train. The rear transmission has
two power inputs. One from the bevel gear set for the speeds and forward & reverse, the other
from the motor to steer.The steering system is actuated by two "finger top" potentiometric
levers located on the left side of the operator's compartment.
The levers send an electric signal to the microprocessor that controls the two electro propor-
tional valves. These valves convert the electric signal into a hydraulic signal, to pilot the
steering section of the main valve.This section controls the pump flow to the hydraulic motor
that, through the steering gear train, actuates the two epicyclical modules and the right track
chain.
Open hydrostatic circuit includes:
main pump
The same of the equipment
(see hydraulic system) cm3
/rev (in3
/rev) 75 (4.6)
Hydraulic motor
Bent axle design, axial pistons, fixed displacement motor
(with bolted movement control valve)
Displacement cm3
/rev (in3
/rev) 63 (3.8)
Maximum operating pressure bar (psi) 350 (5076.3)
Steering control valve
- Closed centre - load sensing.
- Load sensing.
- This section is included in the equipment control valve
Steering control
- Electro-Hydraulic control with two proportional valves
- Integrated CPU for steering and Tm control
Priority valve
- it provides priority to the steering over the equipment cont
(blade lifting).
Make-up valve
- It provides pressure to both equipment control
pilot valves and the electro proportional valves bar (psi) 31.5 to 35 (456.9 to 507.6)
Setting of minimum pressure valve, hydraulic motor bar (psi) 5 (72.5)
Epicyclical modules
Gear ratio straight –
travel conditions 1.33
Steering
Gear ratio –
Hydraulic motor to sprocket 215
Performance
Min. steering radius m (ft) 1.6 (5.2)
Max. diff. speed of track chain
unloaded condition Km/h (mph) 3.0 (1.9)
Max. diff. torque track chain
at 350 bar (5076.3 psi) KNm (ft.lb.) 57 (4.2)
STEERING
SYSTEM

BRAKES Single, multiple-disc brake, spring actuated and oil cooled.
No
. of brake discs 6
Outer diameter mm (in) 227.6 (8.9)
Inner diameter mm (in) 173.5 (6.8)
Total friction area cm2
(in2
) 2045 (317)
Friction material sintered
No
. of springs 12
Max. braking torque daNm (ftlb) 460 (3391.6)
Pump delivery (@ engine max. speed) lt/min (gpm) 53 (14)
System pressure bar (psi) 25 (362.6)
Steering filters
Suction
Metal mesh + magnetic rod mesh 100
Line:
Spin-on Micron 25 abs.
By-pass valve setting bar (psi) 3.44 (49.9)
Accumulation capacity @ 3.44 bar (49.9 psi) (ISO 4572) gr (lb) 50 (0.11)
Filtering area cm2
(in2
) 3075 (476.6)
Pressure drop @ 80 lt/min (21.1 gpm) bar (psi) 0.71 (10.3)
Nominal pressure of element bar (psi) 34.5 (500.4)
Breaking pressure of element bar (psi) 70 (1015.3)
Steering compartment
Fabricated housing.
FINAL Counter shaft, double reduction, modular assembly.
DRIVES Total ratio 1:10.8
SPROCKET Sectors 7
No
. of teeth 28
Pitch diameter mm (in) 790.94 (31.1)
TRACK Fabricated structure with two closed boxes.
FRAME Sealed track tensioner compartment
UNDERCARRIAGE Link pitch mm (in) 176 (6.9)
No
. of links 43
Link height mm (in) 106 (4.2)
Shoe height mm (in) 55 (2.2)
Weight of shoe per meter Kg/m 26 (17.7)
Width of standard shoe mm (in) 500 (19.7)
Width of optional shoe mm (in) 550 (21.6)
No
of rollers per track (STD version) 7
Sequence of rollers from sprocket SF-DF-SF-DF-SF-DF-SF

UNDERCARRIAGE Diameter of rollers mm (in) 195 (7.7)
No
of track rollers (version XLT/LGP) 8
Sequence of rollers from sprocket mm (in) SF-DF-SF-SF-DF-SF-DF-SF
Diameter of rollers mm (in) 195 (7.7)
No
of track rollers 2
Diameter of rollers mm (in) 165 (6.5)
Diameter of idler wheel mm (in) 660 (26)
TRACK Sliding track tensioner guides with replaceable wear strips.
TENSIONER Sealed track tensioner compartment. Grease piston to regulate the track chain tension.
Single spring.
Nominal load of spring assembly daN (lbf) 13500 (3034.9)
Outer diameter of spring mm (in) 200 (7.9)
Diameter of rod mm (in) 44.5 (1.7)
Diameter of grease piston mm (in) 75 (2.9)
Pressure relief valve setting bar (psi) 950 (13778.6)
UNDERCARRIAGE Pivot shaft (near sprocket) and fixed front cross beam.
SUSPENSION All joints permanently lubricated.
SYSTEM Diameter of pivot shaft mm (in) 100 (3.9)
Thickness of cross-member mm (in) 70 (2.7)
Swing travel (track) deg ± 3.5
Travel of idler wheel (total) mm (in) 245 (9.6)
MAIN Fabricated structure, with two main members.
FRAME Bolted to steering compartment housing.
Width of main frame mm (in) 900 (35.4)
Section mm (in) 264 x 108 (10.4 x 4.2)
UPPER Fabricated structure, with two main members.
FRAME With integral mudguards.
Total width of main frame mm (in) 1984 (78.1)
TOW BAR Bolted to steering compartment housing.
Diameter of pin mm (in) 56 (2.2)
Bar width mm (in) 90/55 (3.5/2.2)
HYDRAULIC Load sensing system with piloted variable displacement pump with flow partition.
SYSTEM The power valve block provides the pressure to both pilot valve controls and electro propor-
tional valves.
A priority valve provides priority to the steering over the equipment control (blade lifting).
System pressure
Setting of dual pressure relief valve (equipment/steering) bar (psi) 160/350 (2320.6/5076.3)
Piloting pressure bar (psi) 31.5 to 35 (456.9 to 507.6)
Main pump
Axial piston pump
Regulators:
constant power control kW (HP) 58 (78) at 2000rpm
CUT-OFF pressure bar (psi) 350 (5076.3)
pressure sensor (load sensing) bar (psi) 21 (304.6)
Brand Rexroth

HYDRAULIC Model A11V075
SYSTEM Max. displacement c3
/rev (in3
/rev) 75 (4.6)
Pump speed at maximum engine speed rpm 2000
Pump max. delivery lt/min (gpm) 150 (39.6)
Min displacement c3
/rev (in3
/rev) 15 (0.9)
Discharge valve setting bar (psi) 30±2 (435±29)
Control valve
Closed centre, flow partition, 4-spool or 5-spool for PAT version
with piloted discharge valve.
Brand Rexroth
Model 5M6 - 15
1st
spool:
- Ripper (raising, lowering control) lt/min (gpm) 120/150 (31.7/39.6)
2nd
spool:
- Blade tilt (left, right) lt/min (gpm) 50/70 (13.2/18.5)
3rd
spool:
- Blade (raising/lowering /floating control) lt/min (gpm) 150 (39.6)
4th
spool:
- Angle lt/min (gpm) 150 (39.6)
5th
spool:
- Steering hydraulic motor lt/min (gpm) 150 (39.6)
Pilot valve
Single lever for 2nd
and 3rd
spool + button.
Brand Rexroth
Model 5THF6
Auxiliary lever
Single lever for auxiliary spool.
Brand Rexroth
Model 2TH6
Lift cylinder
Blade (HS/HSU)
2 w/ quick drop valves and stroke limiting valves
Bore mm (in) 80 (3.1)
Diameter of rod mm (in) 45 (1.8)
Stroke mm (in) 1185 (46.6)
Lift cylinder
Blade (PAT).
Bore mm (in) 90 (3.5)
Stroke mm (in) 826 (32.5)
Tilt (Bulldozer blade)
Bore mm (in) 125 (4.9)

HYDRAULIC Tilt (PAT blade)
SYSTEM Bore mm (in) 125 (4.9)
ANGLE (PAT) STD/XLT
Bore mm (in) 100 (3.9)
Diameter of rod mm (in) 50 (2)
Stroke mm (in) 509 (20)
ANGLE (PAT) LGP
Bore mm (in) 110 (4.3)
Ripper
Bore mm (in) 125 (4.9)
Hydraulic tank
Total capacity of tank lt (gal.) 78 (20.6)
Oil tank capacity (max. level) lt (gal.) 63 (16.6)
Strainer
Medium: metal mesh.
Filtering capacity micron 250
Max. nominal delivery lt/min (gpm) 210 (55.5)
Surface cm2
(in2
) 1940 (300.7)
Pressure drop at max. flow bar (psi) 0.016 (0.2)
Return filter
Medium: inorganic glass fibre paper.
Filtering capacity micron 10
Differential switch setting bar (psi) 2.2 (31.9)
Surface cm2
(in2
) 9000 (1395)
Max. nominal delivery lt/min (gpm) 440 (116.2)
SAFETY Cab:
CAB Fully enclosed cab, modular, tiltable 60° leftward. ROPS-FOPS structure w/ 4 vertical
beams.
Two doors, to side windows. 4 elastic supports
Description of cab arrangement
Left console:
With armrest (satellite) fully adjustable, including the Steering and Gearshift controls.
The console includes also: Auto T/M switches and left safety lever.
Right console:
Front equipment control pilot valve and 3rd
function lever, right safety lever, armrest, starter
key, horn and ashtray.

SAFETY CAB Dashboard (monitor) with control switches, manual throttle.
Pedal support:
- Brake central pedal, decelerator, pedal, and footrest.
Cab accessories:
- Rear mirror.
- Front wiper, door window wiper.
- Rear window wiper.
- Ashtray and cigarette lighter.
- Ceiling light (2).
- FM-AM radio (12 Volt).
- Drink holder.
- Fridge 12 Volt socket.
No
. of air ducts 12
Seat
Brand Kab
Model 301 C/ROPS
865 C/COND. CAB
Range of adjustment mm (in) 150 (5.9)
Height of adjustment mm (in) 60 (2.4)
Other features:
- Cloth upholstery, with safety belt and connections for cab
and PVC for ROPS
Heater group
Heating capacity Kcal -
Filter:
Medium: inorganic fibre glass paper.
Efficiency >89%
Capacity micron 20
Dimensions cm2
(in2
) 13680 (2120.4)
Air conditioner group
Max. gas charge gr (lb) 1800 (3.9)
Compressor
Brand Sanden
Model SD7H1SMD7948
Condenser
Brand AUTOCLIMA
Air flow m3
/h (gpm) 1570 (5755)
No. of fans 2
Cab tilting system
Double stroke tilt cylinder with stroke-end valves.
Brand POWER PACKER
Diameter mm (in) 25 x 45 (1 x 1.8)
Hand pump
Double stroke with oil tank.
Brand POWER PACKER
Nominal displacement c3
/stroke (in3
/stroke) 4 (0.2)

ELECTRICAL Alternator
SYSTEM Brand Delco-Remy
Model EE9059 Delco
Capacity 24V - 70A
Starter motor
Brand Delco-Remy
Model ST 9181
Batteries
No
. of elements 2 (in series)
Brand Magneti Marelli
Capacity Ah 100/160 Ah - 12V
Discharge Amp 440/650
Lighting system
No
. of elements -
2 front lights + 2 side work lights (all on cab) W (HP) 70 (0.09)
2 rear work lights W (HP) 70 (0.09)
Other main components
Master switch manual
Engine cut-off solenoid FV 9187
Link fuses Amp 50 & 80
Fuse boxes 2 x 11fuses
Starter key four position
Dashboard 24 V MC Elettronica
Engine rpm counter digital
Hourmeter digital
Fuel level level indicator
Coolant temperature temperature gauge
Steering/transmission display digital
Steering valves (q.ty. 2) proportional
Transmission gearshifting solenoids (q.ty 4) on-off
Reverse indicator P.I. 109 dB(A)-1000Hz
Transmission and Steering electronic controller Rexroth
BULLDOZER Two push beams pivoting on the track frame through a ball joint. Tilt hydraulic regulation
EQUIPMENT and pitch mechanical regulation. Equistatic compensator.
Ball joint
Diameter mm (in) 110 (4.3)
HS blade:
Width (blade) mm (in) 3180 (125.2)
Height mm (in) 1100 (43.3)
Nominal capacity m3
(ft3
) 3.1 (109.4)
Max. lifting mm (in) 1105 (43.5)
Digging depth mm (in) 406 (16)
Max. tilt mm (in) 550 (21.6)
Max. angle deg ± 10
Semi-U HSU blade
Width (blade) mm (in) 3180 (125.2)
Height mm (in) 1320 (52)
Nominal capacity mm (in) 4.1 (144.8)
Max. lifting m3
(ft3
) 1105 (43.5)
Digging depth mm (in) 480 (18.9)
Max. tilt mm (in) 550 (21.6)
Max. angle deg ± 6
Wear components:
Two corners + two reversible cutting edges
Thickness of cutting edges mm (in) 25 (0.9)
Break-up force (lift cylinders) -
Break-up force (tilt cylinder) -

PAT C-frame hinged to track frame.
EQUIPMENT Tilt hydraulic control and pitch mechanical adjustment.
Front ball joint
Diameter mm (in) 130 (5.2)
PAT blade
Width (blade) mm (in) 3200 (126)
Height mm (in) 1100 (43.3)
Nominal capacity m3
(ft3
) 3.15 (111.2)
Max. lift mm (in) 950 (37.4)
Digging depth mm (in) 490 (19.3)
Max. tilt mm (in) 450 (17.7)
Max. pitch deg ± 5
Wear components:
- Two corners + two reversible cutting edges
- Thickness of cutting edges mm (in) 20 (0.8)
- Break-up force (lift cylinders) -
- Break-up force (tilt cylinder) -
MULTI-SHANK Multi-shank parallelogram ripper
RIPPER Brand RECO
Model RP10F
No. of teeth 3
Thickness of shank mm (in) -
Ripping width mm (in) 1700 (66.9)
Ripping depth mm (in) 365 (14.4)
Ground clearance under shank with ripper lifted mm (in) 474 (18.7)
Ground clearance under crossbar with ripper lowered mm (in) 164 (6.4)
Total width mm (in) 1890 (74.4)
Dimension of tool carrier bar mm (in) 170 x 220 (6.7 x 8.7)
Break-up force daNm (ft.lb.) 13980 (103074)
Penetrating force daNm (ft.lb.) 4867 (35884.4)
Multi-shank parallelogram ripper
Brand RECO
Model RP12F
One double stroke cylinder.
Bore x diameter piston rod mm (in) 125 x 70 (4.9 x 2.8)
Cylinder support and equipment arms in welded boxed structure.
H.D. semi-curved shanks and replaceable tips.
Q.ty of shanks 3
Thickness of shanks mm (in) 45 (1.8)
Ripping depth mm (in) 495 (19.5)
Ripping width mm (in) 1800 (70.9)
Ground clearance under shank with ripper lifted mm (in) 460 (18.1)
Ground clearance under crossbar with ripper lowered mm (in) 170 (6.7)
Total width mm (in) 2040 (80.3)
Dimension of tool carrier bar mm (in) 220 x 255 (8.7 x 10)
Break-up force daN (lbf) 10350 (76310.5)
Penetrating force daN (lbf) 5190 (38265.9)
Weight kg (lb) 1552 (3421.6)

CHECK DATA ON THE MACHINE
ENGINE
Net power at flywheel (ISO 9249) HP/kW 141 / 105
Low idle rpm 750 to 950
High idle rpm 2320 to 2460
Equipment stall rpm 2310 to 2450
Converter/transmission stall rpm 1960 to 2100
Total stall rpm 1850 to 2050
Lubrication
At low idle (minimum allowed) bar (psi) 0.69 (10)
At high idle (minimum allowed) bar (psi) 2 (29)
Filter by-pass pressure bar (psi) 1.68 (24.4)
Thermostat temperature °C (°F) 81 to 83 (177.8 to 181.4)
Thermostat maximum temperature setting °C (°F) 95 (203)
BOSH injector setting bar (psi) 260 to 270 (3771 to 3916)
TRANSMISSION
Pressure relief valve bar (psi) 17 (246.6)
Torque converter safety valve bar (psi) 10.5 (152.3)
Lube oil pressure relief valve bar (psi) 3 (43.5)
Main pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
1st
speed clutch pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
2nd
3rd
Forward clutch pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
Reverse clutch pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
BRAKE SYSTEM
Brakes powering bar (psi) 22.5 to 27.5 (326.3 to 398.8)
Pressure regulated by brake pedal valve bar (psi) 18 to 22 (261 to 319)
HYDRAULIC SYSTEM (equipment/steering)
Operating pressure bar (psi) 31.5 to 35.0 (456.9 to 507.6)
Maximum pressure (equipment/steering) bar (psi) 190/350 (2755.7/5076.3)
Wait @ neutral bar (psi) 33 to 37 (478.6 to 536.6)
Wait @ float bar (psi) 33 to 37 (478.6 to 536.6)
Delta LS bar (psi) 21 (304.6)
Float selection bar (psi) 25 (362.6)
Unloading valve setting (@ 10 lt/min, 2.6 gpm) bar (psi) 28 to 32 (406.1 to 464.1)
UNDERCARRIAGE
Setting of pressure relief valve bar (psi) 900 (13053.4)

EQUIPMENT MANOEUVRE TIMES
BLADE LIFTING (PAT version)
From ground level to max. height 2.3 (sec)
BALDE LOWERING (PAT version)
From max. height to ground level in power down 1.3 (sec)
From max. height to max, depth in power down –
From max. height to ground level in float 1.3 (sec)
From max. height to max. depth in float –
Waiting time machine w/ blade 0 (sec)
TILT (PAT version)
Left side of blade from max. to min. height 1.3 (sec)
Right side of blade from max. to min. height 1.2 (sec)
ANGLE (PAT version)
Right side of blade from rear to forward position 3.3 (sec)
Left side of blade from rear to forward position 3.3 (sec)
RIPPER LIFTING (mod. RP12F)
From ground level to max. height 1.2 (sec)
RIPPER LOWERING (mod. RP12F)
From max. height to ground level 1.1 (sec)

No. TEST Machine LIMIT
configuration
1 Lift the front side of the machine to max. height by
lowering the blade.
≤ 60 mm
Evaluate the movement of the blade cylinder rod, (2.4 in)
keeping the unit in the conditions described here
above, with engine inoperative, for 15 minutes.
2 Raise the blade to max. height.
Evaluate the movement of the blade cylinder rod, ≤ 40 mm
keeping the unit in the conditions described here (1.6 in)
3 With blade on the ground actuate the right tilt control
to stroke-end.
≤ 15 mm
4 With blade on the ground actuate the left tilt control
to stroke-end.
≤ 15 mm
5 Raise the rear side of the machine to max. by
actuating the ripper lowering.
≤ 15 mm
6 Raise the ripper to max. height.
Evaluate the movement of the blade cylinder rod, ≤ 15 mm
keeping the unit in the conditions described here (0.6 in)
LEAKAGES
NOTE PRIORTO STARTING ANYTEST IT IS NECESSARYTOWARM-UPTHE HYDRAULIC OILTO 60 to 65 °C
(140 to 149 °F) PERFORMING SEVERAL HYDRAULIC STALLS (MAX.DURATION OF EACH SINGLE STALL 5
sec.s) INTERVALLED BY MOVEMENT OF THE EQUIPMENT.

GENERAL INSTRUCTIONS
INSTALLATION OF SEALS ON ROTATING
SHAFTS
Please follow these cautions:
- prior to the installation, keep the seals soaking in
the same oil they shall work with for half an hour;
- clean accurately the shaft and make sure that its
working surface is undamaged;
- direct the sealing lip toward the fluid; in case of a
hydro dynamic lip, the rifling must be oriented con-
sidering the movement direction of the shaft, mov-
ing the fluid toward the inside of the seal;
- smear the sealing lip with a film of lubricant (oil is
preferred over grease);
- insert the seal into the relevant seat pressing it or
using a punch with a flat face; avoid absolutely to
strike it with a hammer or a mallet;
- during the pressing, make sure that the seal is in-
troduced perpendicular to the seat and once the in-
stallation is completed, that it contacts the bottom
face;
- to prevent that the sealing lip is damaged by the
shaft, it is suggested that during the installation an
appropriate seal be placed in between.
INSTALLATION OF O-RINGS
Lubricate the seals prior to inserting them in the rel-
evant seats that, during the installation phase, tend
to twist thus altering the correct positioning, jeopard-
ising the sealing function.

Re-install the elastic rings as follows:
- press the ring so that one end and part of the inner
circumference adhere to the bottom of the relevant
seat (a);
- install the ring in the above mentioned position and
lift and move the free end (b) until the two detents
(c) are correctly hooked.
REMOVAL AND INSTALLATION OF ROTATING
SEALING RINGS
Remove the rings as follows:
- press the ring so that one end and part of the inner
circumference adhere to the bottom of the relevant
seat (a);
- keep the ring in the above position and, using a
scriber on the opposite end, free the detent as shown
in figure (a).
1850-2R0378
b
1850-2R0379
c
1850-2R0380
a

RECOMMANDATIONS FORTHE DISASSEMBLY
AND REASSEMBLY OF GROUPS
The following information, of a general type, have the
purpose of facilitating the disassembly and reassembly
of groups.
Thus please read and heed them carefully when per-
forming the work.
CLEANING
After disconnecting the electrical system, clean ac-
curately all the parts to be disassembled, preferably
with a jet of steam.
In many repair or service shops caustic compounds
are used to eliminate traces of grease, dirt, paint and
remains of seals etc.from the parts.These compounds
are very useful and effective when properly used, but
can cause serious damages to certain materials.
Materials such as aluminium, rubber, fibres sintered
bronze and alloying agents are sensitive to all highly
concentrated caustic compounds.
Some heat exchangers are built with aluminium fins.
To clean them both internally and externally these parts
the use of solvents not reacting with aluminium is
recommended.
DISASSEMBLY
It is always recommended for any intervention on the
engine or other groups removed from the machine,
use the appropriate supporting rigs.
Always make available boxes and containers capa-
ble of holding small parts removed. Take particular
care that machined surfaces of various parts are rest-
ing, after the removal, on wooden blocks or shelves.
When disassembling similar parts, such as valve tap-
pets etc. are placed in appropriate containers, so that
the same installation sequence is re-established.
ASSEMBLY
Clean accurately all components to assemble as de-
scribed in the various paragraph of the manual.
The use of special tools illustrated in the manual is
recommended.
Note – For the applications of sealing compounds
please comply with the instructions prescribed on the
various commercial products.

D350R0406
Max = 0.6 mm (0.02 in)
D350R0407
Wrong Correct
D350R0408
Wrong Correct
The manufactured prescribes, unless differently
specified, the following sealing compounds: VIT
type C or RHODORSIL CAF 1, or LOCTITE 510.
Whenever possible, press the bushes into a correct
position, using a press. If the use of a hammer is
required to install a bush, use an appropriate punch to
prevent damaging the bushes.
Lubricate ball bearings and bushes before installing
them in the relevant pins. Lubricate the sealing lip of
new seals. In particular, new seals must always be
used for engine cylinder heads.
Use fittings of dimensions and specifications as indi-
cated referring to the part numbers listed in the Parts
catalogue.
When prescribed, use safety washers, split pins, lock-
ing wires etc.
Comply with the prescribed tightening torques as in-
dicated in the "tightening torque" section of this
Manual, using an appropriate toque wrench.
Self-locking nuts must be replaced at each installa-
tion to ensure constantly a good resistance to the
loosening.
HIGH PRESSURE PIPES, CONNECTIONS, HOSES
AND STEEL PIPES
This chapter explains recommendations to be followed
during the installation of pipes and the relevant con-
nections.
- Keep all inner threads clean.
- Remove immediately the caps before connecting
the pipes and plug all open ends.
- Never use or re-use flanges or half-flanges deformed
more than 0.6 mm (0.02 in) in the centre (see fig-
ure).
- Make sure that the seat of O-Rings is not damaged.
- Lubricate the O-Rings.
- Make sure that the O-Rings are well seated.
- Tighten regularly to prevent distortions or damages

D350R0409
Correct
D350R0410
Wrong
- Tighten regularly to prevent distortions or damages
to the O-Rings.
- Install pipes and supporting straps letting the latter
slightly loosen (tighten the strap after tightening the
connections).
- Ensure that the pipes can reach the opposite side
to be connected without being forced.
- If a pipe is installed in a straight position, allow suf-
ficient room to absorb contractions due to the pres-
sure.
- Pipes must not be twisted (see figure) nor touch
one another nor touching other parts, especially
moving parts.
- Make sure that the dimensions of bands is correct
in relation to the diameter of the pipe to be secured
to prevent possible rubbing (see figure).
- Do not install a band over a minimal curve to pre-
vent that under pressure, the hose is stressed (see
figure: the dotted part indicates the contraction that
the pipe can be subject to under the effect of the
pressure).
- Make sure that bands are installed in the right posi-
tion so that the hose is kept away from obstacles
(see figure).

NBR
FPM
EPDM
MVQ
NITRIL BUTADIENE
FUORO CARBON
(VITON)
ETIL PROPILENE
SILICON
-40 to 120 °C
(-40 to 248 °F)
-30 to 125 °C
(-22 to 257 °F)
-40 to 200 °C
(-40 to 392 °F)
-40 to 150 °C
(-40 to 302 °F)
-60 to 200 °C
(-76 to 392 °F)
MINERAL OIL AND GREASE, COOL-
ANT, FUEL WATER UP TO 70 °C
(158 °F) AIR UP TO 100 °C (212 °F)
SAME COMPATIBILITY OF NBR 60 " 75
IRHD, BETTER RESISTANCE TO EX-
TRUSION USED ONLY AS STATIC
SEAL
FUELS IN GENERAL, NON FLAMMA-
BLE FLUIDS, ACIDS, SOLVENTS,
MINERAL OILS. TO BE USED WITH
TEMPERATURE > 100 °C (212 °F)
BRAKE LIQUID (DOT 3) STEAM. HOT
WATER. SILICON OIL AND GREASE
WARNING: DO NOT USE WITH MIN-
ERAL OIL AND GREASE
AIR, WATER GAS, HIGH ANILINE
POINT MINERAL OIL, STEAM. USED
AS STATIC SEAL ONLY
DESIGNATION BASE ELASTOMETER WORKING FIELD OF OPERATION
TEMPERATURE
(*)
NOTE:
(*) Temperatures prescribed for static applications, provided as indication only.
O-RING PROPERLY O-RING UNDER EXTRUSION FAILURE
INSTALLED PRESSURE OF O-RING OF O-RING
O-RINGS - Fields of application

DIAGNOSTIC CHECKS
GENERALITIES
For a fat troubleshooting, please follow these rules:
a) Knowing the machine.
It is impossible to perform any troubleshooting and to
formulate a diagnosis without knowing well the ma-
chine. Thus it is recommended that the descriptions
contained in the Repair Manual about the configura-
tion and the operation of the different groups be read
carefully.
b) Check with the operator.
Many troubles are originated by an improper opera-
tion or insufficient maintenance. Check with the op-
erator whether the machine experienced previously
troubles similar to the ones in progress and whether
any intervention was performed using appropriate tool-
ing and genuine spare parts.Also, check the ambient
working conditions of the machine and make sure that
current maintenance is performed.
c) Operating the machine.
The best way to check the conditions of a machine is
to operate it under normal working conditions. In do-
ing this check:
- the correct operation of the monitoring instrumenta-
tion;
- the performance of the machine;
- possible odours or signs of overheating;
- abnormal noises; identify their origin and the oper-
ating conditions when they occur.
d) Inspecting the machine.
After the test of item c, stop the machine and have a
visual inspection. Check whether the various groups
show signs of leakage of fluids, loose fixtures, fail-
ures or deformations etc.
e) Diagnosis
Once the trouble is identified, make a list of possible
causes with the help of the suggestions in the chap-
ter relative to the group involved and identify the cor-
rect one by performing the appropriate tests, starting
from the most probable causes and from the easiest
tests.

The units of measure in this Manual are those
implemented by the International System (S.I.)
replacing those previously used by the M.K.S. system.
Force: decanewton (daN) supersedes kilogram
(kg)
Pressure: bar, supersedes kg/cm2
Torque: dacanewton x meter (daN m) supersedes
kg m
For the conversion of units of measure, the following
table applies:
Note – For current repair needs, the following
equivalences are considered valid:
kg = daN; kg/cm2
= bar; kg m = daN m.
CLASSIFICATION OF STANDARDISED PARTS FOR
THE DETERMINATION OFTIGHTENINGTORQUES
Note – In the event, in the different sections, no tight-
ening torque is prescribed, please refer to the table
"TIGHTENINGTOQUES" only after identifying exactly
the item.
The latter is identified by an eight-digit coded number
fully designating the part.
Example:
For the conversion of units of measure from the Inter-
national System to British System please refer to the
following table:
UNITS OF MEASURE
I / a b c d e / f g
multiply by to obtain
Mass kg 2.205 Ib
Length mm 0.03937 in
Pressure bar 14.5 psi
Torque daN m 7.373 lb ft
Flow l/min 0.2642 gal/min (US)
Temperature °C 9 °C + 32 °F
Power kW 1.341 HP
Capacity l 0.2642 gal. (USA)
Speed Km/h 0.6213 mph
9
5
multiply by to obtain
Force kg 0.9807 daN
Pressure kg/cm2
0.9807 bar
Torque kg m 0.9807 daN m
I - Index number of standard
It is always indicated by digit 1. This digit indicates
that the part can be made in several versions differ-
ing for the material and coating.
a - b - c - d - e - Bas number of the standard
It is a number always composed of five digits identi-
fying the part and its dimensional specifications.
f - Index number for the material
This digit indicates the material prescribed for a spe-
cific item. Its meaning is indicated in the table to fol-
low.
g - Index number for the coating
It is a digit indicating the coating prescribed for a spe-
cific item.

Resistance class and type of material
Index no. of
material (f)
FIAT UNI DIN SAE BSI BNA
0
1
2
3
4
5
6
7
R 40
R 50
R 80
R 100
Brass
Aluminium
Copper
D - 4S - 4A
5S - 6S
8G
100 10K
Brass Brass
Aluminium Aluminium
Copper Copper
1
3
5
8
Brass
Aluminium
Copper
A
P
T
V
Brass
Aluminium
Copper
42
56
80
100
Brass
Aluminium
Copper
Free for other metal materials
CAUTION
- Lubricate bolts and nuts with engine oil for diameters
up to 24 mm, with tallow for larger diameters.
- The tolerance of tightening torques is ± 5%.
- Strength classes R80, R100, R120 must be
considered as follows:
10.9 supersedes R 100
for screws
12.9 " R 120
10 supersedes R 80
for nuts
12 supersedes R 100
CDT = cadmium plated; FOSF = phosphatised;
ZNT = zinc plated.
}
}

TABLE OF TIGHTENING TORQUES
When the tightening torque of bolts and nuts is not indicated in the single sections, this can be obtained from the
table here below:
normal
daNm (lb.ft.)
Diameter
and pitch
mm
autoblocc.
ZNT
daNm
(lb.ft.)
normal
ZNT
daNm
(lb.ft.)
Diameter
and pitch
mm
low type
daNm (lb.ft.)
low type
daNm (lb.ft.)
with polyamaide ring
normal
daNm (lb.ft.)
M6 x 1
M8 x 1.25
M10 x 1.25
M10 x 1.5
M12 x 1.25
M12 x 1.75
M14 x 1.5
M14 x 2
M16 x 1,5
M16 x 2
M18 x 1.5
M18 x 2.5
M20 x 1.5
M20 x 2.5
M22 x 1.5
M22 x 2.5
M24 x 2
M24 x 3
M27 x 2
M30 x 2
M33 x 2
M36 x 3
1.3 (9.6)
3.2 (23.6)
7.2 (53)
6.5 (47.9)
13 (95.8)
11 (81.1)
19.5 (143.8)
18 (132.7)
30 (221.2)
-
45 (331.8)
-
60 (442.3)
-
80 (589.8)
-
100 (737.3)
-
95 (700.4)
130 (958.4)
170 (1253.4)
220 (1622.1)
-
3.2 (23.6)
6.2 (45.7)
6 (44.2)
10.2 (75.2)
9.6 (70.8)
15 (110.6)
14.6 (107.6)
20 (147.5)
-
29 (213.8)
-
35 (258)
-
-
-
52.5 (387)
-
-
-
-
-
M6 x 1
M8 x 1.25
M10 x 1.25
M10 x 1.5
M12 x 1.25
M12 x 1.75
M14 x 1.5
M14 x 2
M16 x 1.5
M16 x 2
M18 x 1.5
M18 x 2.5
M20 x 1.5
M20 x 2.5
M22 x 1.5
M22 x 2.5
M24 x 2
M24 x 3
M27 x 2
M30 x 2
M33 x 2
M36 x 3
1.3 (9.6)
1.3 (9.6)
7.1 (52.3)
6.5 (47.9)
12.7 (93.6)
11 (81.1)
20 (147.5)
18 (132.7)
30 (221.2)
-
45 (331.8)
-
60 (442.3)
-
80 (589.8)
-
100 (737.3)
-
100 (737.3)
140 (1032)
190 (1400.9)
240 (1769.5)
-
3.5 (25.8)
7.9 (58.2)
7 (51.6)
13.9 (102.5)
12 (88.5)
22 (162.2)
19 (140.1)
33 (243.3)
-
48 (353.9)
-
65 (479.2)
-
90 (663)
-
110 (811)
-
-
-
-
-
NUTS (ZNT) SCREWS (ZNT / DEIDR)
Class of strength: 10 (R 80) Class of strength: 10.9 (R 100)
-
3.9 (28.7)
8.2 (60.4)
7.7 (56.8)
14.5 (106.9)
12.9 (95.1)
21.6 (159.2)
20 (147.5)
34 (250.7)
-
50 (368.6)
-
64.5 (475.5)
-
-
-
108 (796.2)
-
-
-
-
-
1.2 (8.8)
2.6 (19.2)
5.2 (38.8)
5 (36.8)
8.7 (64.1)
8.1 (59.7)
13 (95.8)
12.5 (92.2)
17 (125.3)
-
25 (184.3)
-
30.5 (224.9)
-
41 (302.2)
-
47 (346.5)
-
40.1 (295.6)
49.9 (368)
-
-

SECTION 1
ENGINE
TABLE OF CONTENTS
PARAGRAPH
1.1
1.1.1
1.1.2
1.2
1.3
1.4
SUBJECT PAGE
GENERAL SPECIFICATIONS OF SERIES B ENGINE ............................................ 1-1
Engine main specifications .................................................................................... 1-1
Engine identification............................................................................................... 1-2
DESIGN FEATURES ................................................................................................ 1-3
SERVICEABILITY .................................................................................................... 1-8
SECURING THE ENGINE TO THE FRAME .............................................................. 1-9

ENGINED150 1 - 1
For the disassembly, inspection and reassembly
of the engine series B5.9 please refer to the Cummins publications
that can be procured from the Service organisation
The main specifications and data of the engine installed on D150 are listed here below
1.1 GENERAL SPECIFICATIONS OF SERIES B ENGINE
1.1.1 ENGINE MAIN SPECIFICATIONS 6BT AA5.9
Number of cylinders 6
Bore 102 mm (4 in)
Stroke 120 mm (4.72 in)
Total displacement 5.9 litres (360 in3
)
Net flywheel power (DIN 6270) 142 HP/106 kW
Net flywheel power (SAE J1349) 140 HP/104 kW
Net flywheel power (ISO 9249) 142 HP/105 kW
Net flywheel power (EEC 80/1289) 142 HP/106 kW
Engine weight dry less flywheel and electrical equipment 432 kg
Firing order 1-5-3-6-2-4
Idle speed 850 rpm
Maximum no-load speed 2460 rpm
Maximum torque speed 1500 rpm
Maximum power speed 2200 rpm
Maximum torque 650 Nm (146 lbf) at 1300 rpm
Clearance between valves and rocker arms
Intake 0.25 mm (0.009 in)
Exhaust 0.50 mm (0.020 in)
Compression ratio 17.5:1
Rotation, seen from front side of engine clockwise
Air intake turbocharged w/ aftercooler
Lubrication system
Lube pressure at low idle 0.69 bar (10 psi)
Lube pressure at setting speed 2.07 bar (30 psi)
Cooling system
Coolant capacity 9.8 litres (2.6 gal.)
Setting of thermostat
Start 83 °C (181° F)
Maximum opening 95 °C (203° F)
Radiator cap pressure
with system at 104 °C (220 °F) 1.03 bar (14.9 psi)
Air intake system
Maximum allowable restriction on intake at rated speed
and load with clogged cartridge 635 mm H2
O
Exhaust system
Maximum allowable restriction on intake at rated speed
and load 76.2 mm Hg

ENGINE D1501 - 2
1.1.2 ENGINE IDENTIFICATION
Engine data plate
The engine data plate includes identification data and
other important information relative to the engine.
Always have the following engine data available when
communicating with a Cummins authorised repair
Centre.The information on the data plate are essen-
tial when ordering spare parts.
To order parts it is necessary to specify
Serial number of the engine (E.S.N.)
Check list of the parts (CPL)
Engine are designated as follows:
The first digit indicates the number of cylinders, the
letter to follow identifies the series of the engine, the
remaining alpha digits indicate the air intake (T = turbo
charged) and the last digits indicate the total displace-
ment in litres.
The total displacement of the engine is 5.9 litres
(360 in3
), the bore is 102 mm (4.01 in) and the stroke
is 120 mm (4.72 in).
The firing order is the same of all Cummins in-line
6-cylinder: 1-5-3-6-2-4.
Specifications of engine 6B 5.9
Total
displacement litres 5.9 (360 in3
)
Bore mm 102 (4.01 in)
Stroke mm 120 (4.72 in)
Firing order 1-5-3-6-2-4
Model nomenclature of
industrial engine
6 B T A 5. 9No. of
cylinders
Series B
Turbocharger
Aftercooler
Total displacement
Fig. 1-1
D150-2R0098
Fig. 1-2
Fig. 1-3
D150-2R0099
D150-2R0100

ENGINED150 1 - 3
Belt automatic
tensioner
Fan hub
Coolant by-pass duct
Oil heat
exchanger
Water pump inlet
Oil pump housing
An automatic belt tensioner is used to provide a cor-
rect tension. On series B a variety of mounting posi-
tions for fan hubs and belt tensioners usable for auto,
industrial and marine applications are available.This
front view of the engine illustrates a belt driven fan
hub.
This is the gear train available on Series B engines.
All gears are hardened and of an helicoidal teeth type
for strength and silent operation.The alignment with
reference marks is used between crankshaft gear and
camshaft gear.On engines equipped with rotary injec-
tion pumps, the timing alignment occurs between the
injection pump gear and the camshaft gear. Engines
equipped with in-line injection pump do not require a
timing between injection pump and camshaft.
The cylinder block incorporates several innovative
design features.The block casting includes arrange-
ments for:
- Oil heat exchanger housing.
- Water pump intake.
- Oil pump housing.
- Water pump chamber.
- Coolant by-pass duct.
Crankshaft gear
with camshaft
gear
Camshaft gear
with injection
pump drive gear
Water
pump
chamber
1.2 DESIGN FEATURES
D150-2R0101
D150-2R0102
D150-2R0103
Fig. 1-4
Fig. 1-5
Fig. 1-6

ENGINE D1501 - 4
Other design features of the cylinder block casting
require:
- A block design with a rim for higher strength;
- Bored cylinders for pistons with 120 mm (4.72 in)
centre to centre distance and 18 mm (0.71 in) cylin-
der, so that space is provided to a dry sleeve, if
required by service interventions.
- Piston cooling.
The cylinder head is a single piece designed for a
crossed flow with two valves per cylinder. This fea-
ture maintains the exhaust energy, cooling slightly,
the short exhaust gaps.
An exhaust manifold of a pulsation type coupled to
the turbine housing with twin intake is used to im-
prove the efficiency of the engine.
The design of the cylinder head includes:
- Integral intake manifold.
- Integral thermostat housing.
- Integral fuel filter housing.
Rimmed
block
Piston cooling
nozzle
Crossed flow
cylinder head
Twin intake
turbine
housing
Pulsation
exhaust
manifold
Intake
manifold
Thermostat
housing
Fuel filter
supports
Fig. 1-7
D150-2R0104
Fig. 1-8
D150-2R0105
Fig. 1-9
D150-2R0106
Fig. 1-10
D150-2R0107

ENGINED150 1 - 5
An additional design feature of the cylinder head in-
cludes cast integral valve guides and hardened valve
seat surfaces.Service parts and procedures are avail-
able for grinding operations and installation for valve
guides.
The length of the injection pump requires the reposi-
tioning of the fuel filter toward the rear of the engine.
This is possible by using a distance filter support.
The timing is composed of a camshaft, tappets, push
rods and rocker arm group. Besides the intake and
exhaust valve cams, the camshaft has a special cam
to power the fuel pump.
A single bush of the camshaft, located in the first
shaft bore, is used to support the axial thrust of the
accessory drives.The remaining journals turn in the
camshaft bores in the cast iron block. Service bushes
and the procedure to grind and install bushes for all
journals of the camshaft are available.
Integral
valve guide
Rocker arm
group
Tappets
Rocker
armgroup
Push rods
Fuel pump
Camshaft
Camshaft
bush
Camshaft
journal
Fig. 1-11
D150-2R0108
Fig. 1-12
D150-2R0109
Fig. 1-13
D150-2R0110
Fig. 1-14
D150-2R0111

ENGINE D1501 - 6
The power components of the engine are distinguished
for special features
- Piston.
- Conrods.
- Crankshaft.
The conrod is of an angled split type.This design al-
lows having the largest possible big end, to provide
strength and long life. The design of the angled split
employs a larger surface bearing, thus improving the
wear resistance. A piston ceiling oil jet lubricates the
bush of the conrod small end.
Naturally aspirated engines use aluminium conrod
bearings lined, at the rear, by steel, whereas turbo
charged engines use tri-metal bearings lined at the
back by steel. Service bearings are of the tri-metal
type with steel back lining.
Emissions, applications and power settings determine
the type of pistons to be installed on the engine. Simi-
lar features of the pistons are a high turbulence top
chamber, a free floating pin held by circlips and cast
aluminium bodies.
Power components
Conrod
Piston
Crankshaft
Conrod bearings
Aluminium with steel
back lining
Tri-metal with steel
back lining
Small end
Conrod
Large end
Fig. 1-15
D150-2R0140
Fig. 1-16
D150-2R0113
Fig. 1-17
D150-2R0114
Fig. 1-18
D150-2R0115

ENGINED150 1 - 7
Turbocharged engines use pistons with three ring
seats. a single high nickel content insert with a
Keystone profile ensures optimised anti-wear features
to the upper ring seat.The most powerful turbocharged
engines use an anodised lining on the piston face and
on the head to increase life.
Always check the spare part numbers or be sure about
the right configuration of the piston to be used as a
replacement.
The crankshaft is an integral steel forged balanced
component. Crossed inner drillings provide lubrication
to the conrod bearings.The main and conrod journals
are significantly larger than competitive engine
crankshafts.
Another technical feature is the use of pressed steel
parts to reduce the engine weight. These light
components include the timing gear cover, valve cover
with breather group and engine sump.
The design objectives are:
- Simplicity.
- Reliability.
- Durability.
- Reduction of components.
- Better serviceability.
Stantuffo turbocompresso
Inserto NIresist
Fig. 1-19
D150-2R0116
Fig. 1-20
D150-2R0117
Fig. 1-21
D150-2R0118
Fig. 1-22
D150-2R0119

ENGINE D1501 - 8
1.3 SERVICEABILITY
No special tools are required for routine overhauls on
series B engines. The tools required are those illus-
trated hereby.
No special repair/rebuild procedures are required for
series B engines. Normal high quality standards ap-
plicable for engines of similar power are adequate.
The Cummins engine Company developed repair tools
usable to maintain, ovehaul and repair series B en-
gines: Please refer to CUMMINS Manuals to
toubleshoot failures and to define the tooling.
Rebuilding procedure:
· Disassembly
· Replacement of worn parts
· Grinding the valves
· De-glassing of sleeve walls
· Cleaning the cylinder head and
cylinder block
· Re-assembly
Repair tools
Fig. 1-23
D150-2R0120
Fig. 1-24
D150-2R0121
Fig. 1-25
D150-2R0122

ENGINED150 1 - 9
1.4 SECURING THE ENGINE TO THE FRAME
N. Description Tightening torque
1 L. h. support
2 R. h. support
3 Block
4 Nut 24X2X28
5 Screw 24X2X80 41 to 45 daNm
(302.38 to 331.88 ft lb)
6 Screw 12X1,75X30 17 to 18,5 daNm
(125.38 to 136.44 ft lb)
7 Washer 12X24
8 Screw 16X1,5X50 32,5 to 35,5 daNm
(239.69 to 261.81 ft lb)
D150-2R0095
N. Description Tightening torque
9 Washer 16X30X3
10 Nut 16X1,5X18
11 Stud 47,5 to 52,5 daNm
(350.31 to 387.19 ft lb)
12 Nut
13 Support - rear left
14 Support - rear right
15 Screw 12X1,75X40
16 Screw 12X45
1
4
7
6
2
3
5
7
15
8
9
9
10
13,14
11
3
12
7
16
8
9
9
10
Fig. 1-26

SECTION 2
TRANSMISSION
TABLE OF CONTENTS
PARAGRAPH SUBJECT PAGE
2.1 GENERAL DESCRIPTION ........................................................................................ 2-2
2.1.1 Transmission converter hydraulic diagram ............................................................. 2-2
2.2 TROUBLESHOOTING ............................................................................................... 2-6
2.3 TESTS ...................................................................................................................... 2-10
2.3.1 Torque converter stall test ..................................................................................... 2-10
2.3.2 Delivery pressure test procedure ........................................................................... 2-10
2.3.3 Transmission gearshifting electric control valve ..................................................... 2-11
2.4 PROCEDURES FORTHE REPAIR OFTHE TORQUE CONVERTER ........................ 2-13
2.4.1 Removal ................................................................................................................ 2-13
2.4.2 Re-Installation........................................................................................................ 2-14
2.4.3 Disassembly .......................................................................................................... 2-15
2.4.4 Reassembly........................................................................................................... 2-24
2.5 PROCEDURES FORTHE REPAIR OFTHE TRANSMISSION .................................. 2-25
2.5.1 Removal ................................................................................................................ 2-25
2.5.2 Re-Installation........................................................................................................ 2-26
2.5.3 Disassembly .......................................................................................................... 2-27
2.5.4 Overhaul of forward the speed clutch ..................................................................... 2-41
2.5.5 Overhaul of 3rd
speed............................................................................................. 2-43
2.5.6 Overhaul of reverse speed clutch .......................................................................... 2-48
2.5.7 Modulating valves (Disassembly/Assembly) .......................................................... 2-51
2.5.8 Pressure relief valve (Disassembly/Assembly) ...................................................... 2-52
2.6 SPECIFICATIONS AND DATA.................................................................................... 2-56
2.6.1 General data .......................................................................................................... 2-56
2.6.2 Tightening torques (Torque converter) .................................................................... 2-57
Tightening torques (Transmission housing) ............................................................ 2-58
2.6.3 Transmission Data (Transmission clutches) ........................................................... 2-59
(Transmission clutch discs)...................................................... 2-61
(1st
- 2nd
- 3rd
speed transmission clutch modulating valves) ..... 2-61
(Lube oil pressure relief valve) ................................................. 2-62
(Forward/reverse modulating valves) ........................................ 2-63
(Transmission pressure relief and torque converter safety valve) 2-64
(Torque converter - transmission feeding pump) ....................... 2-65
(Oil filters) ................................................................................ 2-66
2.7 LIST OF OVERHAUL SPECIALTOOLS..................................................................... 2-67

TRANSMISSION
2 - 2 D150
2.1.1 TRANSMISSION TORQUE
CONVERTER HYDRAULIC
DIAGRAM
The transmission is of a "power-shift" type with three
forward and three reverse speeds.The system is pow-
ered by a dual pump feeding the transmission and the
torque converter (1).
The pump sucks oil from the transmission housing
through filter (6) and circulates it purifying further
through filter (2). A valve (set at 2.5 bar) (36.25 psi)
protects filter (2) against over pressures due to the
clogging of the cartridge or excessively thick oil.
The feeding pump of the hydraulic system steering
clutches sucks the oil accumulated in the torque con-
verter support housing, through a mesh filter (14) and
returns it to the transmission housing.
The oil delivered by feeding pump (1) after being puri-
fied by filter (2) reaches pressure relief valve (3) es-
tablishing and maintaining the pressure setting of the
oil controlling the transmission clutches.
Safety valve (16) protects the torque converter and
the heat exchanger against accidental pressure in-
2.1 GENERAL DESCRIPTION
crements, normally due to cold and excessively thick
oil, discharging the flow excess into the pump deliv-
ery line (1).
The oil flowing out the torque converter, passes through
the heat exchanger, the manifold and it is distributed
to the lube and cooling ducts of the transmission
clutches.
The maximum lube pressure is limited by valve (15)
set at 3 bar (43.5 psi).
Modulating valves (9) make the engagement of the
clutches progressive, regulating the pressure incre-
ment in the control circuits.
A low engine lube oil pressure or an excessive lube
oil temperature are indicated on the dashboard in the
cab.
Quick discharge valves on the 2nd
and 3rd
speed
clutches, during the speed engagement phase, are in
closed position, under the action of pressurised oil.
When shifting from one speed to another, the relevant
control cylinder is connected to the discharge and the
pressure drop causes the centrifugal force to prevail
over the action of the oil, moving the balls outwards,
facilitating a quick discharge.

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