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►► BEST ◄◄ Fiat Hitachi D180 Dozer Complete Workshop / Service / Repair Manual - PDF SUMMARY GENERALITIES ENGINE TRANSMISSION FINAL DRIVES STEERING CLUTCHES - BRAKES UNDERC
SUMMARY
GENERALITIES
ENGINE
TRANSMISSION
FINAL DRIVES
STEERING CLUTCHES - BRAKES
UNDERCARRIAGE
DOZER EQUIPMENT
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM
SAMPLE CHAPTER:
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 moving
parts. Wear proper safety equipment as recommended
for the job. Examples: hard hat, heavy gloves,
ear protection, safety glasses or goggles, reflector
vests, respirator. Consult your employer for specific
safety equipment requirements.
- Keep operators compartment, stepping points, grabrails
and handles clear of foreign objects, oil, grease,
mud or snow accumulation to minimise the danger of
slipping or stumbling. Clean mud or grease from shoes
before attempting to mount or operate the machine.
- Do not jump on or off the machine. Keep two hands and
one foot, or two feet and one hand in contact with step
grab rails and handles at all times.
- Do not use controls or hoses as hand holds when
climbing on or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
controls may be inadvertently moved causing accidental
machine or equipment movement.
- Never attempt to operate the machine or its tools from
any position other than seated in the operators seat.
- Keep head, body, limbs, hands and feet inside operators
compartment at all times, to reduce exposure to
hazards outside the operators 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 MACHINE.
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 any
malfunctioning part or system.
- Be sure all protective guards or panels are in place, and
all safety devices provided are in place and in good
operating conditions.
- Be sure exposed personnel in the area of operation are
clear of the machine before moving it or its attachments.
WALK COMPLETELY AROUND the machine before
mounting. Sound horn.
- Before starting machine, check, adjust and lock the
operators 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 FLAMMABLE.
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
places, 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 machines
without ROPS.
- Make sure the Operators compartment is free of foreign
objects, especially if not firmly secured. Never use the
machine to transport objects, unless proper securing
points are provided.
SAFETY RULES
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 OPERATORs COMPARTMENT
OF MACHINES INVOLVED ARE PROPERLY
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
- Be alert to soft ground conditions close to newly constructed
walls. The fill material and weight of the machine
may cause the wall collapse under the machine.
- 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 maintenance
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 machine
if they have been removed.
- Overtaking manoeuvres must be performed only when
absolutely necessary and unavoidable. Beware of possible
uneven terrains, poor visibility conditions, the
presence of other machinery or persons out of sight.
- Operate the machine at a speed adequate to the
working conditions in the site and slow enough to ensure
complete 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).
- 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-
- Check monitoring instruments at start-up and frequently
during operations. in case the brake pressure gauge
shows a pressure lower than the minimum operating
pressure, stop immediately the machine .
- DO NOT CARRY RIDERS ON MACHINE
- Study and familiarise with escape routes alternate to
normal exit routes.
- Seat belts are required by current regulations to be
provided with Roll Over Protection Structures or cabs.
Keep safety belts fastened around you during operation.
- For your personal protection, do not climb on or off
machine while machine is in motion.
- Make sure that exposed persons in the area of operation
are clear of the machine, before starting the engine and
operating the equipment. Sound horn. Obey all indications
provided by flags and signals.
- NEVER COAST the machine down grades and slopes
with the transmission in neutral or neutralised.
Choose and shift into the most appropriate gear to keep
the speed required, thus preventing any loss of control.
- Do not operate machinery in a condition of extreme
fatigue or illness. Be especially careful towards the end
of working shift.
- Do not operate machine with brakes out of adjustment.
- Operate the machine at speeds slow enough to ensure
complete control at all times.
- Travel slowly over rough terrain, on slopes or near dropoffs,
in congested areas or on ice or slippery surfaces.
- When backing, always look to where the machine is to
be moved. Be alert to the position of exposed personnel.
DO NOT OPERATE if exposed personnel enter the
immediate work area. STOP THE MACHINE.
- Maintain a safe distance from other machines. Provide
sufficient clearance for ground and visibility conditions.
Yield right-of-way to loaded machines.
- Maintain clear vision of areas of travel or work. Keep cab
windows clean and repaired.
- When machines are operating in tandem, the pusher
(rear) must be equipped with the appropriate deflectors
to protect the unit in front from the air stream coming
from the radiator.
- When pulling or towing through a cable or chain, do not
start suddenly at full throttle; take-up slack carefully.
Inspect carefully for flaws or troubles before using.
- Avoid kinking chains or cables. Do not pull through a
kinked chain or cable to the high stresses and possibility
II
SAFETY RULES
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
parking 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 overspeed.
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
handled, 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 irregularities
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 represented
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 machine
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 transmission
safety lever is lowered.
- NEVER LEAVE THE MACHINE UNATTENDED with the
engine running.
- Always, before leaving the operators 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
extract the key.
- Park in a non- operating and no-traffic area or as
instructed. Park on firm level ground if possible. Where
not possible, position machine at a right angle to the
slope, making sure there is no danger of uncontrolled
sliding movements.
- If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and signals as required.
Also provide advance warning signals in the
traffic lane of approaching traffic.
- Keep head, body, limbs, feet, fingers or hands away
from bucket, blade or ripper when in raised position.
- Always disconnect the master switch before any intervention
(i.e. cleaning, repairing, maintaining, refuelling
etc.). Do the same when parking for prolonged periods
of time to avoid accidental or unauthorised starting.
III
SAFETY RULES
- Never lower attachments or tools other than seated in
operators 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 operations
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 instructions
located on the machine.
- Do not allow unauthorised personnel to perform any
maintenance operation. Do not perform maintenance
operation without prior authorisation. Follow all recommended
maintenance and service procedures.
- Keep operators 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 moving
parts. Wear proper safety equipment as recommended
for the job. Examples: hard hat, heavy gloves,
ear protection, safety glasses or goggles, reflector
vests, respirator. Consult your employer for specific
safety equipment requirements.
- Do not use controls or hoses as hand holds when
climbing on or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
controls may be inadvertently moved causing accidental
machine or equipment movement.
- 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 operators compartment,
unless he is an authorised operator co-operating in the
operation to be performed.
- Keep operators compartment, stepping points, grabrails
and handles clear of foreign objects, oil, grease,
mud or snow accumulation to minimise the danger of
slipping or stumbling. Clean mud or grease from shoes
before attempting to mount or operate the machine.
- 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 operators seat.
- When maintenance operations require moving hydraulically
operated attachments by means of machines
hydraulic system remember that all manoeuvres must
be made only when seated in the operators 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
articulation uncontrolled openings of the machine and
without proper protections, unless they are blocked in a
safe manner.
- Never perform interventions with engine running, except
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
according 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.
- 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.
IV
SAFETY RULES
V
- 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 pressure
to 2 bar, 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 mechanics tools are in good conditions.
NEVER USE tools with mushroomed heads or
frayed. Always wear eye protections.
- Move with extreme care when working under the machine,
its attachments and or on or near them. Always
wear protective safety equipment as required, such as
hard hat, goggles, safety shoes, ear plugs.
When performing operations requiring running of the
engine, have a qualified operator in the operators seat
at all times with the mechanic on sight. Place the
transmission in neutral and set the brakes and safety
lock.
- KEEP HANDS AND CLOTHING AWAY FROM MOVING
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
securely, 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 OPERATORs COMPARTMENT
OF MACHINES INVOLVED ARE PROPERLY
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
- Keep the area where maintenance operations are performed
CLEAN and DRY. Eliminate immediately all
water and oil spillages.
- 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
operators 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 - Store containers in a cool well ventilated
place, secure against unauthorised personnel.
- Do not carry loose objects in pockets that might fall
unnoticed into open compartments.
- Wear proper protective equipment such as safety goggles
or safety glasses with side shields, hard hat, safety
shoes, heavy gloves when metal or other particles are
apt to fly or fall.
- 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.
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