Case 1650k Tier 2

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1650K
(Tier 2)
CRAWLER DOZER
Workshop
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manual
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Print No. 9-54970 English
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THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

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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.
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You will find this symbol in the text of this Manual referred to the following key words:
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WARNING - Cautions directed to avoid improper repair interventions involving potential consequences for the
safety of the personnel performing the repairs.
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DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other persons
directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recom-
mended 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.
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AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the

farm, at home or on the road, are caused by the failure
of some individuals to follow simple and fundamental
safety rules and precautions. For this reason MOST
ACCIDENTS CAN BE PREVENTED by recognising
the real cause and doing something aboiut it before the
accident occurs.
Regardless of the care used in the design and
construction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without interfering in the reasonable
accessibility and efficient operation.
A carefull operator is the best insurance against an
accident. The complete observance of one simple rule
would prevent many serious accidents.
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The rule is simple: never attempt to clean, lubricate or
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maintain a machine while it is in motion.
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WARNING
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Prior to engaging in any maintenance, adjustment

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or repair operation on machines having

hydraulically, mechanically, and/or cable
controlled equipment (such as shovels, loaders,
dozers, excavators etc.) be certain the equipment is
lowered to the ground.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items, be sure
the equipment is suitably supported by means
other than the devices used for controlling the
equipment.
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SUMMARY
GENERALITIES SECT. 0
ENGINE SECT. 1
TRANSMISSION SECT. 2
FINAL DRIVES SECT. 3
BRAKES AND STEERING SECT. 4
UNDERCARRIAGE SECT. 5
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DOZER EQUIPMENT SECT. 6
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HYDRAULIC SYSTEM
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ELECTRICAL SYSTEM SECT. 7
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1850-2M105
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SECTION 0
GENERALITIES
TABLE OF CONTENTS
SUBJECT PAGE
SAFETY RULES ...................................................................................................................................... I - VIII
IDENTIFICATION DATA ............................................................................................................................ 0-1
TABLE OF FLUIDS USED ....................................................................................................................... 0-2
POSSIBLE ARRANGEMENTS OF THE 1650K ....................................................................................... 0-3
STABILITY ............................................................................................................................................... 0-3
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MAIN DIMENSIONS ................................................................................................................................ 0-4
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TABLES OF TECHNICAL DATA ................................................................................................................ 0-8
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CHECK DATA ON THE MACHINE ............................................................................................................ 0-19
EQUIPMENT MANOEUVRE TIMES ........................................................................................................ 0-20
LEAKAGES ............................................................................................................................................. 0-21

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GENERAL INSTRUCTIONS ..................................................................................................................... 0-22

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TROUBLE SHOOTING ............................................................................................................................. 0-28
UNITS OF MEASURE ............................................................................................................................. 0-29

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TABLE OF TIGHTENING TORQUES ........................................................................................................ 0-31

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SAFETY RULES
WARNING
Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the
machine.
Read and heed all safety rules before any intervention.
SAFETY RULES
- Do not allow unauthorised personnel to operate service - Check brakes, steering and attachment controls before
or maintain this machine. moving. Advise the proper maintenance authority of any
malfunctioning part or system.
- Do not wear rings, wrist watches, jewellery, loose or
- Be sure all protective guards or panels are in place, and
hanging apparels, such as ties, torn clothing, scarves,
all safety devices provided are in place and in good
unbuttoned or unzipped jackets that can catch on mov-
operating conditions.
ing parts. Wear proper safety equipment as recommend-
ed for the job. Examples: hard hat, heavy gloves, ear - Be sure exposed personnel in the area of operation are
protection, safety glasses or goggles, reflector vests, clear of the machine before moving it or its attachments.
respirator. Consult your employer for specific safety WALK COMPLETELY AROUND the machine before
equipment requirements. mounting. Sound horn.
- Keep operator's compartment, stepping points, grab-
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- Before starting machine, check, adjust and lock the
rails and handles clear of foreign objects, oil, grease, operator's seat for maximum comfort and control of the
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mud or snow accumulation to minimise the danger of machine.
slipping or stumbling. Clean mud or grease from shoes
before attempting to mount or operate the machine. - Fasten your seat belt (when provided).
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- Do not jump on or off the machine. Keep two hands and - Obey all flag signals and signs.
one foot, or two feet and one hand in contact with step
grab rails and handles at all times. - Due to the presence on the machine of flammable fluids,
never check or fill fuel reservoirs or batteries near open
- Do not use controls or hoses as hand holds when flames, smoking materials or sparks.
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climbing on or off machine. Hoses and controls are

movable and do not provide a solid support. Also, - REMEMBER THAT STARTING FLUID IS FLAMMA-
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controls may be inadvertently moved causing acciden- BLE. Follow strictly the recommendations printed on
tal machine or equipment movement. containers and in the Operation and Maintenance
Manual.
- Never attempt to operate the machine or its tools from
any position other than seated in the operator's seat. - DO NOT PUNCTURE OR BURN CONTAINERS.
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- Keep head, body, limbs, hands and feet inside opera- - Containers must be stored in fresh, well ventilated plac-
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tor's compartment at all times, to reduce exposure to es, out of reach of unauthorised persons. Follow strictly
hazards outside the operator's compartment. the instructions provided by the Manufacturer.
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- Be careful of slippery conditions on stepping points, - Never use these products near open flames, smoking
hand rails, and on the ground. Wear safety boots or materials or sparks.
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 OPERATION
that could lead to failure, replace it. - 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.
STARTING
- Make sure the Operator's compartment is free of foreign
- NEVER START NOR OPERATE AN UNSAFE MA- objects, especially if not firmly secured. Never use the
CHINE. Before operating a machine, always ensure that machine to transport objects, unless proper securing
any unsafe condition has been satisfactorily remedied. points are provided.
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SAFETY RULES
- Check monitoring instruments at start-up and frequently - Be sure chains and cables are anchored and the anchor
during operations. in case the brake pressure gauge points are strong enough to handle the expected load.
shows a pressure lower than the minimum operating Keep exposed personnel clear of anchor points and
pressure, stop immediately the machine . cables or chains.
- DO NOT CARRY RIDERS ON MACHINE - DO NOT PULL UNLESS OPERATOR's COMPART-

MENT OF MACHINES INVOLVED ARE PROPERLY
- Study and familiarise with escape routes alternate to
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
normal exit routes.
BACKLASH.
- Seat belts are required by current regulations to be
provided with Roll Over Protection Structures or cabs. - Be alert to soft ground conditions close to newly con-
Keep safety belts fastened around you during operation. structed walls. The fill material and weight of the machine
may cause the wall collapse under the machine.
- For your personal protection, do not climb on or off
machine while machine is in motion. - In darkness, check area of operation carefully before
moving in with machine. Use all lights provided. Do not
- Make sure that exposed persons in the area of operation move into area of restricted visibility.
are clear of the machine, before starting the engine and
operating the equipment. Sound horn. Obey all indica- - If engine has a tendency to stall for any reason under
tions provided by flags and signals. load or idle, report this for adjustment to proper mainte-
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- NEVER COAST the machine down grades and slopes nance authority immediately. Do not continue to operate
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with the transmission in neutral or neutralised. machine, until condition has been corrected.
Choose and shift into the most appropriate gear to keep - On machines supplied with suction radiator fans, be sure
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the speed required, thus preventing any loss of control. to periodically check engine exhaust parts for leaks, as
exhaust fumes are dangerous to the operator.
- Do not operate machinery in a condition of extreme
fatigue or illness. Be especially careful towards the end - In case of closed type cabs, always keep an opening with
of working shift. the outside, to ensure a constant air circulation.
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- Do not operate machine with brakes out of adjustment.

- Operators must know thoroughly the performances of
the machine they are operating. When working on
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- Operate the machine at speeds slow enough to ensure

complete control at all times. slopes or near sudden level drops of the terrain, avoid
areas where ground is loose or soft since rolling-over or
- Travel slowly over rough terrain, on slopes or near drop- loss of control of machine could result.
offs, in congested areas or on ice or slippery surfaces.
- Where noise exposure exceeds 90 dBA for 8 hours, wear
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- When backing, always look to where the machine is to approved ear protection.
be moved. Be alert to the position of exposed personnel.
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DO NOT OPERATE if exposed personnel enter the - When counterweights are provided, do not work ma-
immediate work area. STOP THE MACHINE. chine if they have been removed.
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- Maintain a safe distance from other machines. Provide

- Overtaking manoeuvres must be performed only when
sufficient clearance for ground and visibility conditions.
absolutely necessary and unavoidable. Beware of pos-
Yield right-of-way to loaded machines.
sible uneven terrains, poor visibility conditions, the pres-
- Maintain clear vision of areas of travel or work. Keep cab ence of other machinery or persons out of sight.
windows clean and repaired.
- Operate the machine at a speed adequate to the working
- When machines are operating in tandem, the pusher conditions in the site and slow enough to ensure com-
(rear) must be equipped with the appropriate deflectors plete control at all times.
to protect the unit in front from the air stream coming from
the radiator. - Never use the machine as a work platform or scaffolding,
nor other inappropriate operations (i.e. pushing railway
- When pulling or towing through a cable or chain, do not cars, trucks or other machines).
start suddenly at full throttle; take-up slack carefully.
Inspect carefully for flaws or troubles before using. - Be alert of people in the operating area of the machine.
- Avoid kinking chains or cables. Do not pull through a - When operating a machine, know in advance what
kinked chain or cable to the high stresses and possibility clearances will be encountered, overhead doors, ca-
of failure of the kinked area. Always wear heavy gloves bles, pipes, bearing load limitations of ground, bridges,
when handling chains or cables. floors or ramps.
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SAFETY RULES
- When roading, find-out what conditions are likely to be - Working in virgin and rough terrains is characterised by
encountered, clearances, traffic congestion, type of road the presence of all the perils and risks listed above. In
surfacing, etc. Beware of fog, smoke or dust elements these conditions, it is emphasised the danger represent-
that obscure visibility. ed by large tree limbs (possibly falling on the machine),
large roots (acting as a leverage under the machine
- When crossing gullies or ditches, move at an angle with when up-rooted causing the roll-over of the unit) etc..
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,
STOPPING
ravines, ditches, soft terrain, heavy traffic, crowded park-
ing areas, closed ambients. In such conditions, proceed
with extreme care. - When the machine is stopped for whatever reason,
follow the instructions of chapters "Stopping the ma-
- Whenever possible, avoid going over obstacles such as
chine" and "Stopping the engine" of the Operation and
rough terrain, rocks, logs highly irregular ground, steps,
Maintenance Instruction Manual.
ditches, railroad tracks. When obstructions must be
crossed, do so with extreme care at an angle, if possible. - Always remember to position the transmission drive
Reduce speed, shift-down. Ease up to the break over
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control in neutral and engage the control lock to secure
point, pass the balance point slowly on the obstruction the machine.
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and ease down on the other side.
- The parking brake is automatically set, when the trans-
- In steep down-hill operation, do not allow engine to over-
mission safety lever is lowered.
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speed. Select proper gear before starting down grade.
- NEVER LEAVE THE MACHINE UNATTENDED with the
- Avoid side hill travel, whenever possible. Drive up and
engine running.
down the slope. Should the machine slipping sideways,
turn it immediately downhill.
- Always, before leaving the operator's seat and after
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- The grade of slope you should attempt will be limited by making sure all people are clear of the machine, slowly
lower the attachments or tools flat to the ground in a
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factors such as condition of the ground, load being

handled, type of machine, speed of machine and visibil- positive ground support position.
ity.
- Return the controls to rest position. Place the gearshift
- There is no substitute for good judgement when working lever in neutral. Disconnect the master switch and ex-
tract the key.
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on slopes.
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- Avoid operating equipment too close to an overhang or - Park in a non- operating and no-traffic area or as instruct-
high wall, either above or below the machine. Be on the ed. Park on firm level ground if possible. Where not
look-out for caving edges, falling objects and slides. possible, position machine at a right angle to the slope,
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Beware of concealment by brush and undergrowth of making sure there is no danger of uncontrolled sliding
these danger. movements.
- When pushing-over trees, the machine must be - If parking in traffic lanes cannot be avoided, provide
equipped with proper overhead guarding. Never allow appropriate flags, barriers, flares and signals as re-
a machine to climb up on the root structure particularly quired. Also provide advance warning signals in the
while the tree is being felled. Use extreme care when traffic lane of approaching traffic.
pushing over any tree with dead branches.
- Keep head, body, limbs, feet, fingers or hands away from
- When pushing trees with dead limbs, proceed with bucket, blade or ripper when in raised position.
extreme care. Avoid brush piles, logs or rocks.
- Always disconnect the master switch before any inter-
- NEVER DRIVE OVER THEM or other surface irregular- vention (i.e. cleaning, repairing, maintaining, refuelling
ities that brake traction with the ground, especially when etc.). Do the same when parking for prolonged periods
on slopes or near drop-offs. of time to avoid accidental or unauthorised starting.
- Be alert to avoid changes in traction conditions that could - Never lower attachments or tools other than seated in
cause loss of control. DO NOT DRIVE on ice or frozen operator's seat. Sound horn. Make sure area near the
ground conditions when working the machine on steep attachment is clear. Lower the attachment slowly. DO
slopes or near drop-offs. NOT USE FLOAT POSITION of hydraulic system.
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SAFETY RULES
- Place master switch in OFF, securely block the machine - Never attempt to operate the machine or its tools from
and lock it every time you leave it unattended. Return any position other than seated in the operator's seat.
keys to authorised security. Heed all shut-down opera-
tions of the Operation and Maintenance Instruction - When maintenance operations require moving hydrau-
Manual are followed. 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.
MAINTENANCE
- Always block booms or parts of the machine which must
be raised to perform interventions under them with
GENERALITIES
external devices. Do not allow persons to move into the
- Before operating or performing any intervention on the vicinities nor standing under equipment not being
machine: blocked. Unless you are totally sure about your safety,
avoid staying under raised equipment, even in case it is
• read carefully all the rules contained by this Manual; blocked.
• read and obey all safety related plates and instruc- - Do not place the body, limbs or fingers into sharp articu-
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tions located on the machine. lation uncontrolled openings of the machine and without
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proper protections, unless they are blocked in a safe
- Do not allow unauthorised personnel to perform any manner.
maintenance operation. Do not perform maintenance
operation without prior authorisation. Follow all recom-
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- Never perform interventions with engine running, ex-
mended maintenance and service procedures. cept as called for in a Manual. Do not wear loose clothing
or jewellery near moving parts.
- Keep operator's compartment free of all loose objects
that are not properly secured. - When servicing or maintenance require access to areas
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that cannot be reached from the ground, use a ladder or

- Do not wear rings, wrist watches, jewellery, loose or
step platform that meet local and national regulations, to
hanging apparels, such as ties, torn clothing, scarves,
reach the service point. If such ladder or platform are not
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unbuttoned or unzipped jackets that can catch on mov-

available, use the machine hand holds and steps as
ing parts. Wear proper safety equipment as recommend-
provided. Perform all service or maintenance carefully.
ed for the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector vests, - Shop and/or field service platforms or ladders must be
respirator. Consult your employer for specific safety
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constructed and maintained in accordance with local

equipment requirements. and national regulations.
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- Do not use controls or hoses as hand holds when

- Disconnect batteries and tag all controls according to
climbing on or off machine. Hoses and controls are
current regulations to warn that work is in progress. Block
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movable and do not provide a solid support. Also,

machine and all attachments that must be raised accord-
controls may be inadvertently moved causing acciden-
ing to current regulations.
tal machine or equipment movement.
- Due to the presence of flammable fluids, never check or
- Do not jump on or off the machine. Keep two hands and
fill fuel tanks, batteries, nor use starting fluid near lighted
one foot, or two feet and one hand in contact with step
smoking materials or open flames.
grab rails and handles at all times.
- Do not perform any service operation on the machine - Brakes are inoperative when manually released for
with a person seated in the operator's compartment, servicing. Provisions must be made to maintain control
unless he is an authorised operator co-operating in the of the machine by blocking or other means.
operation to be performed.
- The fuel filling nose must be kept constantly inside the
- Keep operator's compartment, stepping points, grab- filling neck. Keep this contact from the beginning to the
rails and handles clear of foreign objects, oil, grease, end of the fuelling operation to avoid the possibility that
mud or snow accumulation to minimise the danger of sparks due to static electricity are generated.
slipping or stumbling. Clean mud or grease from shoes
- Use only designated towing or attaching points. Use
before attempting to mount or operate the machine.
care in making attachments. Make sure pins and/or locks
- Keep shoes free of mud or grease before climbing or are secure before pulling. Stay clear of drawbars, cables
driving the machine. or chains under load.
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SAFETY RULES
- To move a disabled machine, use a trailer or a low-boy, - KEEP HANDS AND CLOTHING AWAY FROM MOVING
if available. In case towing is needed , use all necessary PARTS.
signals required by local and national regulations, and
follow the directions provided in this Manual. - For field service, move machine to level ground, if
possible, and block it. If work on an incline is absolutely
- To load/unload a machine from transporter, choose a necessary, first block machine and its attachments se-
level surface ensuring firm support to the wheels of truck curely, than move it to level ground as soon as possible.
or trailer. Use strong access ramps, with adequate
height and angle. Keep surface free of mud, oil or - Do not trust worn and /or kinked chains and cables: do
slippery materials. not use them for lifting or pulling operations. To handle
them, always use heavy gloves.
- Anchor the machine securely to the bed of truck or trailer
and block wheels or tracks with appropriate wedges. - Be sure chains and cables are anchored and the anchor
points are strong enough to handle the expected load.
- Never align holes with fingers or hands; always use Keep exposed personnel clear of anchor points and
appropriate aligning tools. cables or chains.
- Eliminate all sharp edges and burrs from re-worked - No bystanders are allowed near the hooking points,
parts. chains or cables.
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- Use only approved grounded auxiliary power sources - DO NOT PULL UNLESS OPERATOR's COMPART-
for heaters, chargers, pumps and similar equipment to MENT OF MACHINES INVOLVED ARE PROPERLY
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reduce the hazards of electrical shocks. GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
- Lift and handle heavy parts with a lifting device of proper
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- Keep the area where maintenance operations are per-
capacity. Be sure parts are supported by proper slings
formed CLEAN and DRY. Eliminate immediately all
and hooks. Use lifting eyes if provided. Watch-out for
water and oil spillages.
people in the vicinity.
- Do not pile oily or greasy rags; they represent a fire
- Never pour gasoline or diesel fuel into open, wide and
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hazard. Store in closed metal container.

low containers. Never use gasoline, solvent or other
flammable fluid to clean parts. Use exclusively qualified,
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- Before starting machine, check, adjust and lock the

non-flammable, non-toxic commercial solvents.
operator's seat for maximum comfort and control of the
- When using compressed air for cleaning parts, use machine. Be sure exposed personnel in the area of
safety glasses with side shields or goggles. Limit pres- operation are clear of the machine before moving it or its
sure to 2 bar, in accordance with local and national attachments. Sound horn.
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regulations.
- Rust inhibitors are volatile and flammable Use only in
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- Do not run the engine in closed areas without proper well ventilated areas. Keep open flames away - DO NOT
ventilation to remove deadly exhaust fumes. SMOKE - Store containers in a cool well ventilated place,
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secure against unauthorised personnel.

- Do not smoke or permit any open flames or spark near
when re-fuelling or handling flammable materials. - Do not carry loose objects in pockets that might fall
unnoticed into open compartments.
- Do not use an open flame as a light source to look for
leaks or for inspection anywhere on the machine. - Wear proper protective equipment such as safety gog-
gles or safety glasses with side shields, hard hat, safety
- Make sure that all mechanic's tools are in good condi- shoes, heavy gloves when metal or other particles are
tions. NEVER USE tools with mushroomed heads or apt to fly or fall.
frayed. Always wear eye protections.
- Wear welders protective equipment such as dark safety
- Move with extreme care when working under the ma- glasses, helmets, protective clothing, gloves and safety
chine, its attachments and or on or near them. Always shoes, when welding or burning. Wear dark safety
wear protective safety equipment as required, such as glasses near welding zones. DO NOT LOOK AT ARC
hard hat, goggles, safety shoes, ear plugs. WITHOUT PROPER EYE PROTECTION.
- When performing operations requiring running of the - Know your jacking equipment and its capacity. Be sure
engine, have a qualified operator in the operator's seat the jacking point used on the machine is appropriate for
at all times with the mechanic on sight. Place the trans- the load to be applied. Be sure the support of the jack at
mission in neutral and set the brakes and safety lock. the machine and under jack is appropriate and stable.
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SAFETY RULES
- The load lifted by jacks is always dangerous: it is neces- ELECTRICAL SYSTEM

sary to transfer loads to appropriate blocking as a safety
measure, before proceeding with service or mainte- - Disconnect batteries prior to any intervention on ma-
nance work, according to local or national regulations. chine or electrical system (cleaning, repair, mainte-
nance).
- Steel cables are frayed after prolonged use; always
wear appropriate protections (heavy gloves, goggles - Should booster batteries be used, remember to connect
etc.). both ends of the booster cables in the proper manner (+)
with (+) and (-) with (-). Avoid short-circuits of the termi-
- Handle all parts carefully. Keep hands and fingers away nals. Follow thoroughly the instructions of this Manual.
from structures, gears or moving parts. Use and wear
always the appropriate protections - Before any intervention, make sure that the main switch
is OFF.
- Compressed air systems can have water deposits creat-
ed by moisture condensation due to changes of atmos- - BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery
pheric conditions. If required, discharge deposits, as box open to improve ventilation when recharging batter-
instructed. 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.
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- Before any intervention, make sure that there are no fuel
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or electrolyte leakages; eliminate them before proceed-
ing with further work. When recharging batteries in
STARTING
closed ambients, make sure that there is appropriate
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- Do not run the engine in closed areas without proper ventilation to prevent possible accidental explosions
ventilation to remove deadly exhaust fumes. due to the accumulation of gases generated during the
recharge.
- Do not place head, body, limbs, feet, hands or fingers,
near rotating fans or belts. Be especially alert near
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pusher fans.
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HYDRAULIC SYSTEM
- Fluid escaping under pressure from a very small hole

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ENGINE can be almost invisible and can have sufficient force to

- Loosen the radiator cap very slowly, to release pressure
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penetrate the skin. Use a piece of cardboard or wood to

from the system, before removing it. All coolant level top- search for suspected pressure leaks. DO NOT USE
ups must be performed with engine OFF. HANDS. If injured by escaping fluid, see a doctor at once.
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Serious infection or reaction can develop if proper med-

- Avoid that flammable materials touch exhaust parts.
ical treatment is not administered immediately.
Should this be possible, provide the necessary protec-
tions. - Stop the engine and release all pressures in the system
before removing panels, housings, plugs or covers.
- Do not run engine when refuelling and use care if the
engine is hot due to the increased possibility of a fire if - In case pressures must be measured, use instruments
fuel is spilled. of adequate capacity. Always follow the recommended
procedures.
- 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.
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SAFETY RULES
TOOLS
- Keep head, body, limbs, feet, fingers or hands away from - Clutches and brakes of this machine and eventual
bucket, blade or ripper when in raised position. auxiliary equipment and attachments (such as operat-
Prior to any intervention, install all safety devices according cylinder or winches control valves) must always be
ing to current rules and regulations. properly adjusted in accordance with the instructions
provided by the Manuals of the Manufacturer.
- In case equipment on the machine must be operated by
hydraulic systems, remember to proceed only after seat- - Never perform adjustments with engine running, except
ing in the operator's compartment. Make sure that there when called for by the above instructions.
are no persons in the operating area of the machine.
Alert people before operating using the horn and by - When changing work shift, check that wheel or rim
voice. Move the equipment very carefully. securing screws and brackets are not loosen; if neces-
sary, retighten to the prescribed torque.
- Do not use machine to transport loose objects, unless
proper devices for this purpose are provided.
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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.
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SAFETY RULES
SAFETY RULES FOR SEALS
VITON SEALS (fluoroelastomer)
Seals, especially VITON O-Rings, (normally coloured red) 2) identify the type of material of the seals, if they are
are used in systems operating at high temperatures, since VITON, performing the test illustrated below, on the
this materials resists the effects of heat. However, in the spare parts;
event this material is subject to heat exceeding 315 °C (in 3) in case it is verified, or there is a reasonable doubt that
practice, only in case of fire or when using welding flames) the components are made of VITON, the contaminated
fluoridic acid is generated. This acid is highly corrosive area MUST be decontaminated before proceeding
and could cause severe burns, if in contact with the skin. with further operations;
Every time it is necessary to intervene on components 4) wear neoprene rubber or PVC gloves and protection
equipped with VITON rings, for which an exposure to goggles or face screen, and wash accurately the
excessive temperatures is suspected, the following proce- contaminated zone with a solution of hydraulic lime
dures must be applied: (found at building stores) and water, so that a milky
liquid is obtained. Rinse carefully with steam or run-
1) inspect visually, without touching them, all seals show- ning water;
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ing signs of damage due to high temperature. They 5) dispose of the materials removed and the protective
look black and tacky; gloves in a safe manner, without burning them.
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TEST FOR THE DISCRIMINATION OF RUBBER (BUNA N) MATERIALS

AND "VITON" (FLUOROELASTOMER) MATERIAL
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WATER WATER
TRICHLORO-
ETHYLENE
NITRILIC/BUNA N RUBBER VITON"

FLUOROELASTOMER
FLOATS
SINKS
VIII
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1650K
(Tier 2)
DOZER
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TECHNICAL DATA TABLES
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1650K GENERALITIES 0-1
IDENTIFICATION DATA
A. Engine data plate

The engine data plate is visible by opening the engine left side
panel and it includes all the identification data and other
important information related to the engine.
1. Engine serial number

(E.S.N. Engine Serial Number Cummins)
C.I.D./L CPL Engine Serial No.

Cummins
ins Engine Company Inc.
mm Box 3005 Family Cust. Spec.
Cu Columbia, Indiana
47202-3005 Engine Model
Low idle RPM

Warning injuty result and warranty is voided
it fuel rate or rpm or altitudes exceed published
maximum values for this model and application. Valve lash cold Engni Engin Fuel rate at rated HP mm3/st
Firing Order Timing-TDC

Date of Mfg
Made in Great Britain by
Cummins Engine Co. Ltd. Rasted HP/KW st RPM
D150-2M002
D150-2M005
IMPORTANT ENGINE INFORMATION
This engine conforms to 2003 U.S. EPA
And California Tier 2 and EU Stage II
regulations for heavy duty non-road
compression ignition diesel cycle
engines as applicable.
THIS ENGINE IS CERTIFIED TO OPERATE
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ON DIESEL FUEL
IN
B. Machine identification plate
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The identification plate includes the main data of the
machine and it is visible under the operator's seat.
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1850-2M0005
1850-2M0004
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C. Marking and serial number
On the right side of the transmission housing it is

possible to read, etched on the upper side, the MARK-
ING of the machine, composed of:
- manufacturer code (first 3 digits);
- machine code (01651S)
- serial number (last 8 digits)
MODEL MARKING
1650K LT PAT-T2 PS ★HHA01651Sxxxxxxxx★
1650K LT BD-T2 PS ★HHA01651Sxxxxxxxx★
1650K XLT PAT-T2 PS ★HHA1651STxxxxxxxx★
1650K LGP PAT-T2 PS ★HHA1651SPxxxxxxxx★

1850-2M0006
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1650 K -Table of fluids used 0-2
QUANTITY Fluids and lubrificants VISCOSITY Outdoor temperatures International

ITEM
(litres) AKCELA GRADE of reference Classification
Agriflú Mixture of water and antifreeze at

mixed with 50% 50%. The mixture provides
Premium Down to - 35 °C
Cooling system 18 (20) water protect oxidation, foaming, corrosion,
Anti-Freeze (-31 °F)
down to scaling and freezing protection
MS 1710 properties down to - 35 °C (- 31 °F).
- 35 °C (- 31°F)
DIESEL FUEL ASTM No. 2D

Fuel reservoir 270
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quality and make
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T SAE 15W - 40 - 15 / 40 °C ( -5 / 104 °F)
Engine 14.2 (17) CASE NO. 1 Engine Oil* API CH4 and ACEA E5
SAE 10W - 30 - 25 /25 °C (- 13 / 77 °F)
Torque converter/Transmission CNH MS1209
31 (40) SAE 10W All season ATF Type A Suffix A
(Front Transmission Housing) Hy-Tran® Ultra
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Rear Transmission housing
94 CASE NO. 1 Engine Oil R SAE 10W - 30 All season API CF-4
Planetary steering / brakes
GENERALITIES
DIN 51524 PART-1

CASE Hydraulic Excavator
Equipment Hydraulic Reservoir 63 Grade NT - 20 / 50 °C ( - 4 - 122 °F) DIN 51524 PART-2
Fluid - MS 1230
ISO VG-46
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Final drives (each) 24 CASE GEAR 135 HEP SAE 80W - 90 All season API GL5 or MIL-L-2105 D
Idlers Rollers
4 CASE NO. 1 Engine Oil SAE 10W - 30 All season API CF-4
and track chains
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CASE Molydisulfide Grade 251 H - EP,
Grease fittings
Grease Spec B-27
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CNH MS 1209,
Cab tilting pump 0.5 SAE 10W All season ATF Type A Suffix A
Hy-Tran® Ultra
If the content of sulphur of the fuel exceeds 0.5%, change the engine oil as follows:
Note: Oil quantities indicated are those required for periodical changes.
as 0.5% sulphur Normal Service interval
{ } First fill quantity.
* In case of use of engine oil classified "CH4" the change interval can be 0.5 to 1% Half normal interval
extended to 500 hours providing that the ambient temperature does not
1650K
up to 1% One quarter normal interval

exceed 38 °C (100 °F) and the fuel sulphur content does not exceed 0.5%.
Copyright ©
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POSSIBLE ARRANGEMENTS OF THE 1650K
LT BD LT PAT XLT PAT LGP PAT
Blade HS
HSU
x – – –
Blade PAT – x x x
Undercarriage 7 rollers x – – –
Undercarriage 8 rollers – x x x
Shoes 500 mm (20 in)
550 mm (22 in)
x x x –
Shoes 800 mm (32 in) – – – x

STABILITY
Basic machine (carriage LT) + HS blade + Ripper Basic machine (carriage LT) + HS blade
Configuration Hg Lg Configuration Hg Lg
Blade and ripper on the ground 845 1160 Blade on the ground 805 1260
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(33.26 in) (45.66 in) (31.69 in) (49.60 in)
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Blade on the ground and ripper 870 1175 Blade at max height 845 1360
at max height (34.25 in) (46.25 in) (33.27 in) (53.54 in)
Blade at max height and ripper 868 1145
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on the ground (34.17 in) (45.07 in)
Blade at max height and ripper 1005 1150 Basic machine (carriage LT) + PAT blade
at max height (39.56 in) (45.27 in) Configuration Hg Lg
Blade on the ground 750 1470
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(29.53 in) (57.87 in)

Basic machine (carriage LT) + PAT blade + Ripper
Blade at max height 926 1360
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Configuration Hg Lg (36.46 in) (53.54 in)

Blade and ripper on the ground 800 1175
(31.49 in) (46.25 in)
Blade on the ground and ripper 825 1205 Basic machine (carriage LT) (without blade and
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at max height (32.48 in) (47.44 in) without ripper)

Blade at max height and ripper 820 1160 Configuration Hg Lg
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on the ground (32.28 in) (45.66 in) Without blade and without ripper 965 1130
Blade at max height and ripper 875 1195 (37.99 in) (44.49 in)
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at max height (34.44 in) (47.05 in)
Lg = Distance from the sprocket centre

Hg = Height from the ground
Hg
Lg
1650-2M005
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0-4 GENERALITIES 1650K
COLD STARTING (Optional) AUXILIARY APPLICATIONS

Optional, a cold starting device is available, allowing Some of the equipment described and illustrated in
the starting of the machine at particularly low this manual are supplied in determined markets to
temperatures. satisfy specific requirements.
Other devices and applications can be provided as an
option, in agreement with the sales organization.
Some optional accessories are listed:
Air conditioner, Blade: HS pliant for LGP version, or
HSU, or PAT, Ripper,
1 kg Fire Extinguisher, Diagnostics, Forest (sweeps)
ROPS, Outer sound suppression, 550 mm (22 in)
shoes.
MAIN DIMENSIONS
TYPE Blade Blade Blade capacity Tilt Pitch Digging Blade raising Length Weight
OF width height SAE J1265 (in) depth from ground with blade with
BLADE mm (in) mm (in) m3 (foot3) mm mm (in) mm (in) mm (in) blade (lb)
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(HS) 3180 1100 3,10 550 ±10° 406 1105 4750 14811 (*)
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(125.20) (43.30) (109.47) (21.65) (15.98) (4350) (187) (32652)
Semi-U 3180 1320 4,12 550 ±6° 480 1105 5025 15011 (*)
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(HSU) (125.20) (51.96) (145.50) (21.6) (18.89) (4350) (197) (33093)
LT 3200 1100 3,15 450 ±5° 490 950 4955 14915 (*)
PAT (126) (43.3) (111.24) (17.71) (19.29) (37.40) (195.07) (32881)
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XLT 3200 1100 3,15 450 ±5° 490 950 5315 15677 (*)
PAT (126) (43.3) (111.24) (17.71) (19.29) (37.40) (209.25) (34561)
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LGP 4000 1000 3,15 550 ±5° 590 900 5315 16810 (**)
PAT (157.48) (39.37) (111.24) (21.65) (23.22) (35.43) (209.25) (37059)
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* Included in the weight: cab-operetor, blade and cylinders, lubricants, coolant and 10% fuel and 500 mm (20 in)
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shoes.
** Included in the weight: cab-operetor, blade and cylinders, lubricants, coolant and 10% fuel and 800 mm (32 in)
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shoes.
TRACK CONTACT GROUND

ON GROUND SHOES WEIGHT AREA PRESSURE
mm (in) mm (in) kg (lb) mm2 (in2) kPa (p.s.i.)
2550 500 550 15011 15126 2550000 2805000 57,7 52,9
LT BD (HSU) (100.39) (20) (22) (33093) (33347) (3952) (4347) (8.36) (7.67)
2550 500 550 14915 15030 2550000 2805000 57,4 52,6
LT PAT (100.39) (20) (22) (32881) (33135) (3952) (4347) (8.32) (7.62)
2985 500 550 15677 15805 2985000 3283500 51,5 47,2
XLT PAT (117.51) (20) (22) (34561) (34844) (4626) (5089) (7.46) (6.84)
2985 800 16810 4776000 34,5
LGP PAT (117.51) (32) (37059) (7402) (5)
Copyright ©
BULLDOZER HS
3080 mm (121.25 in)

3060 mm (120.47 in)
500 mm
(19.68 in)
370 mm
(14.56 in)
2550 mm (100.40 in) 1900 mm (74.80 in)
3650 mm (143.70 in)
4750 mm (187 in) 2400 mm (94.48 in)
1650-2M001
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BULLDOZER HSU
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3080 mm (121.25 in)
3060 mm (120.47 in)
500 mm
(19.68 in)
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370 mm
(14.56 in)
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2550 mm (100.40 in) 1900 mm (74.80 in)
3650 mm (143.70 in)
5025 mm (197 in) 2400 mm (94.48 in)
1650-2M001
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MAIN DIMENSIONS LT PAT

3060 mm (120.47 in)
3080 mm (121.25 in)

(17.71 in)
450 mm
1100 mm
(43.30 in)
(37.40 in)
950 mm
(19.29 in)
490 mm
5° 3200 mm (125.98 in)

2550 mm (100.39 in)
3650 mm (143.70 in)

5°
4950 mm (194 in)
(1.37 in)
35 mm
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25° 25° ~ 400 mm (15.74 in)
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1900 mm (74.80 in)
PR 2400 mm (94.48 in)

2950 mm (116.14 in)
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5470 mm (215.35 in)
1650-2M002
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MAIN DIMENSIONS XLT PAT

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3060 mm (120.47 in)
3080 mm (121.25 in)

1180 mm (46.45 in)
(37.40 in)
950 mm
(19.29 in)
490 mm
450 mm
(17.71 in) 2140 mm (84.25 in)
2985 mm (117.51 in)
800 mm
23° 4750 mm (187 in)
(31.50in)
5315 mm (209.25 in) 2940 mm (115.74 in)
3200 mm (126 in)
1650-2M003
Copyright ©
MAIN DIMENSIONS LGP PAT
3060 mm (120.47 in)
3080 mm (121.25 in)

(35.43 in)
900 mm
(23.22 in)
590 mm
550 mm
5° 2985 mm (117.51 in) (21.65 in) 2140 mm (84.25 in)
4010 mm (158 in) 800 mm

5° (31.50 in)
2940 mm (115.74 in)
5315 mm (209.25 in)
1650-2M004
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TABLES OF TECHNICAL DATA

DIMENSIONS Total length (base tractor) mm (in) 3890 (153.1)
Total length (w/ blade HS) mm (in) 4750 (187)
Total length (w/ blade semi-U HSU) mm (in) 5025 (197.8)
Total length ("LT PAT" version) mm (in) 4950 (194.9)
Total length ("XLT PAT" version) mm (in) 5315 (209.2)
Total length ("LGP PAT" version) mm (in) 5315 (209.2)
Total width (base tractor w/ 550 mm shoes) mm (in) 2450 (96.5)

Total width (w/ blade HS) mm (in) 3180 (125.2)
Total width (w/ blade semi-U HSU) mm (in) 3180 (125.2)
Total width ("LT PAT" version) mm (in) 3200 (126)
Total width ("XLT PAT" version) mm (in) 3200 (126)
Total width ("LGP PAT" version w/800 mm, 32 in shoes) mm (in) 4000 (157.5)
Total height (at top of exhaust pipe) mm (in) 3060 (120.5)

Total height (W/ ROPS canopy) mm (in) 3080 (121.3)
Gauge (BD, LT PAT) mm (in) 1900 (74.8)

Gauge (XLT PAT, LGP PAT) mm (in) 2140 (84.2)
Min. ground clearance (SAE J1234) mm (in) 370 (14.6)
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Length of track chain on ground (BD, LT PAT) mm (in) 2550 (100.4)
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Length of track chain on ground (XLT PAT, LGP PAT) mm (in) 2985 (117.5)
Width of track shoe (standard) mm (in) 500 (19.7)
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MASS Weight in shipping order (including ROPS,
500 mm (20 in) shoes, lubricants, engine coolant, kg (lb) 13505 (29773.4)
10 % fuel)
Weight in work order (w/ PAT blade, ROPS cab,

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500 mm (20 in) shoes, lubricants, engine coolant, kg (lb) 14880 (32804.8)
10 % fuel and operator)
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Speed / Pull
PERFORMANCES 1st forward Km/h / daN (mph/lbf) 4.3 / 21300 (2.7 / 4788.4)
2nd forward Km/h / daN (mph/lbf) 7.0 / 12100 (4.4 / 2720.2)
3rd forward Km/h / daN (mph/lbf) 11.0 / 6800 (6.8 / 1528.7)
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SPEEDS / PULL
1st forward Km/h / daN (mph/lbf) 5.4 / 16770 (3.4 / 3770)
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2nd forward Km/h / daN (mph/lbf) 8.7 / 9420 (5.4 / 2117.7)

3rd forward Km/h / daN (mph/lbf) 13.0 / 5230 (8.1 / 1175.7)
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(Standard shoes 500 mm, 20 in wide)

PRESSURE
ON GROUND w/ blade "PAT" and ROPS cab Kpa (psi) 57.4 (8.3)
60% (in 1st speed forward) Km/h (mph) 3.0 (1.9)

CLIMBING
30% (in 2nd speed forward) Km/h (mph) 5.0 (3.1)
FEATURES
10% (in 3rd speed forward) Km/h (mph) 9.0 (5.6)
Copyright ©

ENGINE Engine CUMMINS 6BTAA 5.9
Type 4-stroke, in-line vertical, direct injection

turbocharged, after-cooled, low
emission
Bore and stroke 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 (511.7 ft.lb.) (at 1300 rpm)
Maximum power speed 2000 rpm
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Maximum idle speed 2460 rpm
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Idle speed 850 rpm
Fuel consumption (at max. power) 25 kg/h (55 lb/h)

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Starter motor 24 Volt - 6.8 kW (9.1 HP)
Alternator 24 Volt - 70 Amp
Batteries - std 2x12 Volt - 100 Amph

extra size 2 x 12 Volt - 160 Amph
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Radiator Air-water with in-line tubes

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and core
Dimensions of radiator core 930 x 453 x 114 mm
Radiator cap pressure 1.0 bar (14.5 psi)

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Delivery of water pump (at 2200 rpm) 157 lt/min (41.5 gpm)
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Fan Blowing, 6-blade, diam. 28".
Air cleaner DONALDSON - Dry, 2-stage with safety

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element and centrifugal separator, clogging

indicator
Horizontal,
Silencer 655 x diam. 228 mm (9500 x diam. 3306.8 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
shifting the transmission into neutral. AL
function button and As function button.
Modulating valves on For and REV, speed
engaging modulating valve.
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0 - 10 GENERALITIES 1650K
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

capacity 100 micron.
Transmission filters
Delivery Cartridge type (SPIN ON) with paper
cartridge and by-pass valve, filtering
capacity 25 micron.
Pressure relief valve Mounted on converter cover
Pressure relief valve (at flow of 10 lt/min, 2.6 gpm) 10 ± 0.5 bar (145 ± 7 psi)
Transmission pressure (at flow of 10 lt/min, 2.6 gpm) 13.75 ± 0.5 bar (199.4 ± 7 psi)
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Transmission pressure (at flow of 70 lt/min, 18.4 gpm) 17.0 ± 0.5 bar (246.6 ± 7 psi)
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Safety lever valve In the locked position, it prevents the
shifting of gears and the starting of the
engine and it engages the parking brake.
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Controls:
Joystick, Shift up-down slider button.
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FWD & REV actuated thru pressure switches on the joystick.

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Selection of operating mode - AS automatic AUTO - SHIFT

- AL automatic AUTO - LOW
Description of auto mode

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AL Downshifting when the engine drops to a pre-determined speed.

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AS It provides the operator with the pre-selection of the 1st gear forward and 2nd gear
reverse when shifting direction.
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Propeller shaft With two universal joints and sliding

shaft.
Nominal length (in) mm 265.5 (10.4)
Copyright ©
1650K GENERALITIES 0 - 11

STEERING The machine uses a differential steering system; this consists of a hydraulic pump, a hydraulic
SYSTEM 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 a pilot valve located on the left side of the driver's
compartment.
The pilot valve controls the steering section of the control 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).
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Displacement cm3/rev (in3/rev) 63 (3.8)
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Maximum operating pressure bar (psi) 350 (5076.3)
Steering control valve:
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- Closed centre.
- load sensing.
- This section is included in the equipment control valve.
Steering control:
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- Electro-Hydraulic control with two proportional valves.

- Integrated CPU for steering and Tm control.
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Priority valve:
- It provides priority to the steering over the equipment cont
(blade lifting).
Make-up valve:
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- It provides pressure to both equipment control

pilot valves and the electro proportional valves bar (psi) 31.5 to 35 (457 to 507.6)
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Setting of minimum pressure valve, hydraulic motor bar (psi) 5 (72.5)

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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)
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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)
2 2
Total friction area cm (in ) 2045 (317)
Friction material sintered
No. of springs 12
Max. braking torque daNm (ft.lb.) 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:
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Spin-on Micron 25 abs.
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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)
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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)
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Steering compartment
Fabricated housing.
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FINAL Counter shaft, double reduction, modular assembly.

DRIVES Total ratio 1:10.8
SPROCKET Sectors 7
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No. of teeth 28
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Pitch diameter mm (in) 790.94 (31.1)

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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 (lb/ft) 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 (LT version) 7

Sequence of rollers from sprocket SF-DF-SF-DF-SF-DF-SF
Copyright ©
UNDERCARRIAGE Diameter of rollers mm (in) 195 (7.7)
No of track rollers (version XLT/LGP) 8

Sequence of rollers from sprocket 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)
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UNDERCARRIAGE Pivot shaft (near sprocket) and fixed front cross. beam.
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SUSPENSION All joints permanently lubricated.
SYSTEM Diameter of pivot shaft mm (in) 100 (3.9)
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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 FRAME Fabricated structure, with two main members.
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Bolted to steering compartment housing.

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Width of main frame mm (in) 900 (35.4)

Section mm (in) 264 x 108 (10.4 x 4.2)
UPPER FRAME Fabricated structure, with two main members.
With integral mudguards.
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Total width of main frame mm (in) 1984 (78.1)

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TOW BAR Bolted to steering compartment housing.

Diameter of pin mm (in) 56 (2.2)
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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
proportional 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) 190/350 (2759.7/5076.3)
Piloting pressure bar (psi) 31.5 to 35 (1.2 to 1.4)
Main pump
Axial piston pump.
Regulators:
constant power control kW (HP) 58 (77.8) at 2000rpm
CUT-OFF pressure bar (psi) 350 (5076.3)
pressure sensor (load sensing) bar (psi) 21 (304.6)
Brand Rexroth
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HYDRAULIC Model A11V075

SYSTEM Max. displacement 3
cm /rev 75
Pump speed at maximum engine speed rpm 2000
Pump max. delivery lt/min (gpm) 150
3
Min displacement cm /rev 15
Discharge valve setting bar (psi) 30±2
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)
nd
2 spool
- Blade tilt (left, right) lt/min (gpm) 50/70 (13.2/18.5)
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3rd spool
- Blade (raising/lowering /floating control) lt/min (gpm) 150 (39.6)
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th
4 spool
- Angle lt/min (gpm) 150 (39.6)
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5th spool
- Steering hydraulic motor lt/min (gpm) 150 (39.6)
Pilot valve
Single lever for 2nd and 3rd spool + button
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Brand Rexroth
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Model 5THF6
Auxiliary lever
Single lever for auxiliary spool
Brand Rexroth
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Model 2TH6
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Lift cylinder
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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)
Diameter of rod mm (in) 50 (2)
Stroke mm (in) 826 (32.5)
Tilt (Bulldozer blade)

Bore mm (in) 125 (4.9)
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HYDRAULIC Tilt (PAT blade)
SYSTEM Bore mm (in) 125 (4.9)
Angle (PAT) LT/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)
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IN
Hydraulic tank
Total capacity of tank lt (gal.) 78 (20.6)
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Oil tank capacity (max. level) lt (gal.) 63 (16.6)
Strainer
Medium: metal mesh.
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Filtering capacity micron 250

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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)
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Return filter
Medium: inorganic glass fibre paper.
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Filtering capacity micron 10

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Differential switch setting bar (psi) 2.2 (31.9)
2 2
Surface cm (in ) 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:
Support with Pilot Valve (Steering and Transmission controls).
The console includes: Auto T/M switches, left safety lever, Climate regulation controls.
Right console:
Front equipment control pilot valve and 3rd function lever, right safety lever, armrest, starter
key, horn, ashtray.
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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
Adjusting range mm (in) 150 (5.9)
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Height range mm (in) 60 (2.4)
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Other features:
Cloth lining, with safety belt and connections for cab
and PVC for ROPS.
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Heater group
Heating capacity Kcal -
Filter
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Medium: inorganic fibre glass paper

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Efficiency > 89%

Capacity micron 20
Dimensions cm2 (in2) 13680 (2120.4)
Air conditioner group

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Max. gas charge gr (lb.) 1800 (3968.3)

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Compressor
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Brand SANDEN
Model SD7H1SMD7948
Condenser
Brand CR-CLIMA
3 3
Air flow m /h (ft /h) 1570 (55444)
No. of fans 2
Cab tilting system

Double stroke tilt cylinder with stroke-end valves.
Brand POWER PACKER
Diameter mm (in) 25x45 (1 x 1.8)
Hand pump
Double stroke with oil tank.
Brand POWER PAKER
Nominal displacement cm3/stroke (in3/stroke) 4 (0.2)
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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 12 V Ah 100/160 Ah - 12V
Discharge Amp 440/650
Lighting system
No. of elements -
2 front lights + 2 side work lights W 70
2 rear work lights W 70
Other main components
Main switch manual
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Engine cut-off solenoid FV 9187
Link fuses Amp 50 & 80
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Fuse boxes 2x11 fuses
Four position starter key Hitachi
Dashboard 24 V MC Elettronica
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Engine rpm counter digital
Hour meter digital
Fuel level level indicator
Coolant temperature level indicator
Steering/transmission display digital
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Steering valves (q.ty 2) proportional

Transmission control solenoids (q.ty 4) on-off
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Back-up alarm 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.
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Ball joint
Diameter mm (in) 110 (4.3)
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HS blade:
Width (blade) mm (in) 3180 (125.2)
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Height mm (in) 1100 (43.3)

Nominal capacity m3 (ft3) 3.1 (109.5)
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) 3180 (125.2)
Height mm (in) 1320 (52)
Nominal capacity mm (in) 4.1 (0.2)
Max. lifting m3 (ft3) 1105 (39023)
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) -
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PAT "C" frame hinged to the track frame by ball joints.
EQUIPMENT Hydraulically actuated tilt and mechanical pitch.
Front ball joint

Diameter mm (in) 130 (5.2)
PAT blade
Width (blade) 3200 (126)
Height 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) -
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- Break-up force (tilt cylinder) -
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MULTI TEETH Multiple teeth parallelogram ripper
RIPPER Brand RECO
PR
Model RP10F
No. of teeth 3
Thickness of teeth mm (in) -
Ripping width mm (in) 1700 (66.9)
Ripping depth mm (in) 365 (14.4)
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Ground clearance under tooth with ripper raised mm (in) 474 (18.7)
Ground clearance under tooth beam with ripper lowered mm (in) 164 (6.4)
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Total width mm (in) 1890 (74.4)

Dimension of ripper beams mm (in) 170 x 220 (6.7 x 8.7)
Break-up force daNm (ft.lb.) 13980 (103074)
Penetration force daNm (ft.lb.) 4867 (35884.4)
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Multiple teeth parallelogram ripper

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Brand RECO
Model RP12F
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One double stroke cylinder.

Bore x diameter of piston rods mm (in) 125 x 70 (4.9 x 2.8)
Cylinder support and equipment arms in welded boxed structure.

H.D. semi-curved teeth w/replaceable tips.
No. of teeth 3
Thickness of teeth mm (in) 45 (1.8)
Ripping depth mm (in) 495 (19.5)
Ripping width mm (in) 1800 (70.9)
Ground clearance under tooth with ripper raised mm (in) 460 (18.1)
Ground clearance under tooth beam with ripper lowered mm (in) 170 (6.7)
Total width mm (in) 2040 (80.3)
Dimension of ripper beams mm (in) 220 x 255 (8.7 x 10)
Break-up force daNm (ft.lb.) 10350 (76310.5)
Penetration force daNm (ft.lb.) 5190 (38265.9)
Weight Kg (lb) 1552 (3421.6)
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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 1825 to 2025
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)
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Torque converter safety valve bar (psi) 10.5 (152.3)
IN
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)
PR
2nd speed clutch pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
3rd speed clutch pressure bar (psi) 16.5 to 17.5 (239.3 to 253.8)
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)
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BRAKE SYSTEM
Brakes powering bar (psi) 22.5 to 27.5 (326.3 to 398.8)
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Pressure regulated by brake pedal valve bar (psi) 18 to 22 (261 to 319)
HYDRAULIC SYSTEM
Power pressure bar (psi) 31.5 to 35.0 (456.9 to 507.6)
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Maximum pressure (equipment/steering) bar (psi) 190/350 (2755.7/5076.3)

Waiting @ neutral bar (psi) 33 to 37 (478.6 to 536.6)
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Waiting @ floating bar (psi) 33 to 37 (478.6 to 536.6)

Delta LS bar (psi) 21 (304.6)
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Floating selection bar (psi) 25 (362.6)

Setting of discharge valve (@ 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)
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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)
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IN
TILT (PAT version)
Left side of blade from max. to min. height 1.3 (sec)

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Right side of blade from max. to min. height 1.2 (sec)
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ANGLE (PAT version)

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Right side of blade from rear to forward position 3.3 (sec)
Left side of blade from rear to forward position 3.3 (sec)

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RIPPER LIFTING (mod. RP12F)

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From ground level to max. height 1.2 (sec)
RIPPER LOWERING (mod. RP12F)
From max. height to ground level 1.1 (sec)
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LEAKAGES
NOTE PRIOR TO STARTING ANY TEST IT IS NECESSARY TO WARM-UP THE HYDRAULIC OIL TO
60 to 65 °C (140 to 149 °F) PERFORMING SEVERAL HYDRAULIC STALLS (MAX. DURATION OF EACH
SINGLE STALL 5 sec.) INTERVALLED BY MOVEMENT OF THE EQUIPMENT.
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.
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≤ 40 mm
Evaluate the movement of the blade cylinder rod,
(1.6 in)
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3 With blade on the ground actuate the right tilt control
to stroke-end.
≤ 15 mm
(0.6 in)
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4 With blade on the ground actuate the left tilt control

to stroke-end.
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≤ 15 mm
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5 Raise the rear side of the machine to max. by

actuating the ripper lowering.
≤ 15 mm
(0.6 in)
6 Raise the ripper to max. height.

≤ 15 mm
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GENERAL INSTRUCTIONS
INSTALLATION OF SEALS FOR ROTATING - when pressing the seal, make sure that it is entered
SHAFTS perpendicularly to its seat and once the pressing is
over, make sure, when requested, that is seated
Please comply with the following advises:
against the shoulder;
- prior to installation, keep the seals half an hour
- in order to avoid damaging the sealing seat with
dipped into the same oil they are going to seal;
the shaft, it is recommended, during the installation
of the two parts, to insert an appropriate seal.
- clean accurately the shaft and make sure that its
working surface is undamaged;
- direct the sealing lip towards the fluid; in case of an

INSTALLATION OF O-RINGS
hydro dynamic lip, the grooves must be oriented
so that the rotating direction of the shaft, tend to Lubricate the seals before placing them into the rel-
return the oil inside the seal; evant seats so as to avoid that, during the installa-
tion, they tend to roll, thus altering their correct posi-
- smear the sealing lip with a film of lubricant (oil is tioning, being furled, causing prejudice to their seal-
preferred to grease); ing function.
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- install the seal into its seat by pressing it or using a
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punch with a flat contact face; absolutely avoid
hammering it;
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REMOVAL AND INSTALLATION OF ELASTIC

RINGS FOR ROTATING SEALING
Remove the rings as follows:
- press the ring so that one end and part of the inner
circumference contact the bottom of the relevant
seat (a);
- keep the ring in the position above and, acting with

a scriber on the other end, free the catches, as
indicated in the figure (a).
Re-install the elastic rings as follows:
- press the ring so as to have one end and part of

a
the inner circumference touching the bottom of the 1850-2R0378
relevant seat (b);
- install the ring in the position describe above and
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lift the free end (b) moving it until the two catches
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engage correctly (c). PR
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b
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1850-2R0379
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1850-2R0380
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RECOMMENDATIONS FOR THE DISASSEMBLY DISASSEMBLY

AND REASSEMBLY OF GROUPS
It is always recommended, for any intervention on
The following information, of a general nature, are in- engines or other assemblies removed form the ma-
tended to facilitate the disassembly and reassembly chine, that appropriate stands are used.
of groups. Make available baskets or containers sufficient to
store all the smaller size parts disassembled. Take
Consequently, read and heed them when performing particular care of machined faces of the components,
this type of operations. placing them, after the disassembly, on shelves or
wooden blocks.
When identical parts are disassembled, such as
CLEANING valves, tappets etc., place them in appropriate con-
tainers to ensure the same mating order when reas-
After disconnecting the electrical system, clean ac-
sembling.
curately all the parts to be disassembled, preferably
using steam.
ASSEMBLY
In many repair or service workshops, caustic com-
pounds are used to eliminate all traces of grease, dirt, Clean accurately all the components to be reassem-
paint or remains of sealing materials etc. from the bled, as described by the various chapters of the
parts. These compounds are very useful and efficient Manual.
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when used correctly; however they can cause con- The use of the proper special tools shown in the Manual
siderable damages to certain components. is recommended.
IN
Materials such as aluminium, rubber, fibres, sintered
bronze and alloying elements are particularly sensi-
PR
tive to all highly concentrated caustic compounds. Note – When applying sealing adhesive compounds,
Some heat exchangers are made with aluminium fins. comply with the instructions provided with commer-
To clean internally or outside these parts, the use of cial products.
solvents not reacting with aluminium are recom-
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mended.
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The manufacturer, prescribes, unless differently

specified, the following adhesive compounds:
RHODOSIL CAF 1, or LOCTITE 510.
Whenever possible, press bushes into their correct

position using a press.
In the event it is necessary to use a hammer to install
a bush, use an appropriate punch to avoid damaging
the bush. Max = 0.6 mm (0.02 in)
Lubricate ball bearings prior to their installation. Lubri-
cate the sealing lip of all seals, prior to their installa-
tion.
Whenever possible, install new seals; in particular new
gaskets must be used on engine cylinder heads. D350R0406
Use screws with the dimensions and grade indicated,

referring to the part number of the Spare Parts Cata-
logue.
When indicated, safety washers, split pins and lock-
ing wires etc. must be used.
Comply with the prescribed tightening torques indi-
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cated in the "Tightening torques" section of this
Manual, using an appropriate torque wrench.
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Self-locking nuts must be replaced at each disassem-
bly, to ensure a constant good performance against
loosening.
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Wrong Correct
HIGH PRESSURE PIPES, CONNECTIONS,
HOSES AND PIPES
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D350R0407
This chapter provides correct recommendations and

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procedures to be followed during the disassembly of

pipes and relevant connections.
- Keep all internal and external threads clean.

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- Remove the plugs just before connecting the pipes

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and plug at once all open connections.
- Do not use or reuse semi flanges out of shape more

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Wrong Correct
than 0.6 mm in the centre (see figure).
- Make sure that the seats of O-Rings are undamaged.
- Lubricate all O-Rings. D350R0408
- Make sure that O-Rings are in place in the relevant

seat.
- Tighten regularly so as to avoid distortions or dam-

ages to O-Rings.
- Install pipes and support bands letting the latter

slightly loosen (tighten the band only after tighten-
ing the connections).
Copyright ©
- Make sure that the hoses reach the corresponding

part to be connected to without forcing their posi- Wrong
tion.
- In the event a hose is mounted straight, let enough

space to absorb contractions caused by pressure.
- Hoses must not be rolled (see figure) or touching Correct

one another or touching other parts, especially if
moving.
- Make sure that the dimension of the bands is

appropriate for the outer diameter of the pipe to be
tighten to avoid possible rubbings (see figure). D350R0410
- Do not install bands on small diameter curves, to

avoid that, under pressure, forces are generated in
the pipe (see figure: the dotted lines indicate the
contraction that the hose could be subject to under
the action of the pressure).
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- Make sure that bands are installed in a correct po-
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sition so that the hose is kept away from obstacles
(see figure).
PR
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D350R0409
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O-RINGS FIELD of application
DESIGNATION BASE ELASTOMER TEMPERATURE FIELD OF APPLICATION

of OPERATION
(*)
- 40 to 120 °C MINERAL OIL AND GREASE, COOL-

(- 40 to 248 °F) ANTS, FUEL, WATER UP TO 70 °C
(158 °F), AIR UP TO 100 °C (212 °F)
NBR NITRIL BUTADIENE
SAME COMPATIBILITY OF NBR 60" 75
- 30 to 125 °C IRHD, BETTER RESISTANCE TO EX-
(- 22 to 257 °F) TRUSION, USED ONLY AS STATIC
SEAL
GENERAL FUELS, NON FLAMMABLE

- 40 to 200 °C FLUIDS, ACIDS, SOLVENTS, MIN-
FLUOROCARBON ERAL OIL
FPM (- 40 to 392 °F)
(VITON) TO BE USED WITH TEMPERATURES
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> 100 °C (212 °F)
IN
BRAKE FLUID (DOT 3), STEAM, HOT
- 40 to 150 °C WATER, SILICON OIL AND GREASE.
EPDM ETHYLENE PROPYLENE
(- 40 to 302 °F) WARNING: NOT TO BE USED WITH
PR
MINERAL OIL AND GREASE
AIR, GAS, WATER, HIGH ANILINE

- 60 to 200 °C
MVQ SILICON POINT MINERAL OIL, STEAM USED
(- 76 to 392 °F)
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AS STATIC SEAL ONLY

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Note – (*) Temperature indicated for static applications, provided as indication only.
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O-RING PROPERLY O-RING O-RING O-RING

INSTALLED PRESSURISED EXTRUDED BROKEN
Copyright ©
TROUBLESHOOTING
GENERALITIES d) Inspection of the machine

For a fast troubleshooting, we recommend the com- After the test of item c, stop the machine and have a
pliance with the following rules: visual inspection. Check whether the various groups
show leakages of fluids, loosen bolts, failures of de-
formations etc.
a) Knowing the machine
It is impossible to research the causes and formula
e) Diagnosis
te a diagnosis of troubles without having a good knowl-
edge of the machine. Thus it is recommended Once the trouble is identified. prepare a list of the
that the descriptions regarding the arrangement and possible causes with the help of the suggestions of
the operation of the various groups provided by the the chapter for the group involved and identify the
Repair Manuals are carefully read. correct one, using practical tests, starting from the
most probable causes and the easiest tests.
b) Inspection with the operator

Many trouble originate from a bad use or insufficient
maintenance. Check with the operator if the machine
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was previously subject to the current trouble and even-
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tual interventions have been performed with appropri-
ate equipment and genuine spare parts. Also,
check the environmental working conditions of the
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machine and make sure that current maintenance is
performed.
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c) Operating the machine

The best way to ascertain the conditions of the
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machine is to test it under real working conditions.

During such test, check:
- the correct operation of the monitoring instrumenta-

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tion;
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- the performance of the machine;

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- eventual odours or signs of overheating;
- noises different from normal operation noises; iden-

tify their origin and the operating conditions during
which they occur.
Copyright ©
UNITS OF MEASURE
The units of measure used in this Manual are those CLASSIFICATION OF STANDARD COMPONENTS
adopted by the International System (I. S.) supersed- TO DETERMINE THE TIGHTENING TORQUES
ing those previously used by the M.K.S. system.
Force: decanewton (daN) supersedes kilogram

(kg) Note – In case, in the different sections, the tighten-
Pressure: bar, supersedes kg/sqcm ing torque is not listed, refer to the table "TIGHTEN-
Torque: decanewton x meter (daN meter) super- ING TORQUES", only after identifying exactly the com-
sedes kg-m ponent.
To convert the units of measure, the following table

applies: The latter is identified by a coded eight digit number,
allowing a complete description of the item.
multiply by to obtain
Force Kg 0.9807 daN Example:

Pressure Kg/cm2 0.9807 bar I / a b c d e / f g
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Torque Kg m 0.9807 daNm
IN
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I - Standard index digit
Note – For current repair needs, the following equiva- It is always represented by the digit 1. This number
lencies can be considered valid: indicates that the item can be fabricated in different
kg = daN; kg/sqcm = bar; kgm = daNm. versions, differing for the material and coating.
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FO
a - b - c - d - e - Standard base digit

To convert the units of measure of the International
It is a number always composed of five digits identi-
System into an Anglo Saxon system, please refer to
fying the dimensional specifications of the item
the following table:
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multiply f - Material index digit

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by to obtain
This digit indicates the material used fro a defined
Mass Kg 2.205 Ib
N
item. Its meaning is indicated in the table to follow.

Length mm 0.03937 in.
Pressure bar 14.5 p.s.i. g - Coating index digit
Torque daNm 7.373 lb.ft. It indicates the coating applied to a defined item.
Flow l/min 0.2642 gal/min (US)
Temperature °C °C + 32 °F
9
Power kW 1.341 HP
5
Capacity l 0.2642 gal. (USA)
Speed Km/h 0.6213 mph
Copyright ©
Class of strength and type of material

Index no. of
material (f) FIAT UNI DIN SAE BSI BNA
0 R 40 D - 4S - 4A 1 A 42
1 R 50 5S - 6S 3 P 56
2 R 80 8G 5 T 80
3 R 100 100 10K 8 V 100
4 Brass Brass Messing Brass Brass Laiton
5 Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium
6 Copper Copper Kupfer Copper Copper Cuivre
7 Free from other metal materials
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IN
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NOTICES
- Lubricate with engine oil the fixtures up to diameter

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24, with tallow for larger diameters.

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- The tolerance on tightening torques is ± 5%.

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- The strength classes R80, R100, R120, must be

intended as follows:
10.9 supersedes R 100
12.9 " R 120

} for screws
10
12
supersedes R 80
supersedes R 100
} for nuts
CDT = cadmium plated; FOSF = phosphatised;

ZNT = zinc plated.
Copyright ©
TABLE OF TIGHTENING TORQUES

In the event, the tightening torque of bolts and nuts is not specifically indicated in the single sections, the same
can be found in the table listed here below:
NUTS (ZNT) SCREWS (ZNT / DEIDR)
Class of strength: 10 (R 80) Class of strength: 10,9 (R 100)
Diameter normal low type with polyamaide ring Diameter normal autoblocc.
and pitch and pitch ZNT ZNT
normal low type daNm daNm
mm daNm (lb.ft.) daNm (lb.ft.) daNm (lb.ft.) daNm (lb.ft.) mm (lb.ft.) (lb.ft.)
M6 x 1 1.3 (9.6) 1.2 (8.8) - - M6 x 1 1.3 (9.6) -
M8 x 1.25 3.2 (23.6) 2.6 (19.2) 3.9 (28.7) 3.2 (23.6) M8 x 1.25 1.3 (9.6) 3.5 (25.8)
M10 x 1.25 7.2 (53) 5.2 (38.8) 8.2 (60.4) 6.2 (45.7) M10 x 1.25 7.1 (52.3) 7.9 (58.2)
M10 x 1.5 6.5 (47.9) 5 (36.8) 7.7 (56.8) 6 (44.2) M10 x 1.5 6.5 (47.9) 7 (51.6)
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M12 x 1.25 13 (95.8) 8.7 (64.1) 14.5 (106.9) 10.2 (75.2) M12 x 1.25 12.7 (93.6) 13.9 (102.5)
M12 x 1.75 11 (81.1) 8.1 (59.7) 12.9 (95.1) 9.6 (70.8) M12 x 1.75 11 (81.1) 12 (88.5)
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M14 x 1.5 19.5 (143.8) 13 (95.8) 21.6 (159.2) 15 (110.6) M14 x 1.5 20 (147.5) 22 (162.2)
M14 x 2 18 (132.7) 12.5 (92.2) 20 (147.5) 14.6 (107.6) M14 x 2 18 (132.7) 19 (140.1)
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M16 x 1,5 30 (221.2) 17 (125.3) 34 (250.7) 20 (147.5) M16 x 1.5 30 (221.2) 33 (243.3)
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M16 x 2 - - - - M16 x 2 - -
M18 x 1.5 45 (331.8) 25 (184.3) 50 (368.6) 29 (213.8) M18 x 1.5 45 (331.8) 48 (353.9)
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M18 x 2.5 - - - - M18 x 2.5 - -

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M20 x 1.5 60 (442.3) 30.5 (224.9) 64.5 (475.5) 35 (258) M20 x 1.5 60 (442.3) 65 (479.2)
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M20 x 2.5 - - - - M20 x 2.5 - -
M22 x 1.5 80 (589.8) 41 (302.2) - - M22 x 1.5 80 (589.8) 90 (663)
M22 x 2.5 - - - - M22 x 2.5 - -
M24 x 2 100 (737.3) 47 (346.5) 108 (796.2) 52.5 (387) M24 x 2 100 (737.3) 110 (811)
M24 x 3 - - - - M24 x 3 - -
M27 x 2 95 (700.4) 40.1 (295.6) - - M27 x 2 100 (737.3) -
M30 x 2 130 (958.4) 49.9 (368) - - M30 x 2 140 (1032) -
M33 x 2 170 (1253.4) - - - M33 x 2 190 (1400.9) -
M36 x 3 220 (1622.1) - - - M36 x 3 240 (1769.5) -
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SECTION 1
ENGINE
TABLE OF CONTENTS
CHAPTER SUBJECT PAGE
1.1 GENERAL SPECIFICATIONS OF SERIES B ENGINE .......................................... 1-1

1.1.1 Engine main specifications .................................................................................. 1-1
1.1.2 Engine identification ............................................................................................. 1-2
1.2 DESIGN FEATURES .............................................................................................. 1-3
1.3 SERVICEABILITY .................................................................................................. 1-8
1.4 SECURING THE ENGINE TO THE FRAME ............................................................ 1-9
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1650K ENGINE 1-1
For the disassembly, inspection, overhaul and re-assembly

of the series B5.9 engine, please refer to the Cummins publications
to be provided from the service department
The main specifications and data of the engine installed on 1650K 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
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Net flywheel power (ISO 9249) 142 HP/105 kW
Net flywheel power (EEC 80/1289) 142 HP/106 kW
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Engine weight dry less flywheel and electrical equipment 432 kg (952.4 lb)
Firing order 1-5-3-6-2-4
Idle speed 850 rpm
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Maximum no-load speed 2460 rpm
Maximum torque speed 1500 rpm
Maximum power speed 2200 rpm
Maximum torque 650 Nm at 1300 rpm
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Clearance between valves and rocker arms

Intake 0.25 mm (0.009 in)
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Exhaust 0.51 mm (0.020 in)

Compression ratio 17.5 : 1
Direction, seen from the front side of engine clockwise
Air intake turbo charged with aftercooler
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Lubrication system
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Lube pressure at low idle 0.69 bar (10 psi)

Lube pressure at setting speed 2.07 bar (30 psi)
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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 H2O
Exhaust system
Maximum allowable restriction on intake at rated speed
and load 76.2
Copyright ©
1-2 ENGINE 1650K
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)
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D150-2R0098
Fig. 1-1
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Engine are designated as follows:

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The first digit indicates the number of cylinders, the

Model nomenclature of
letter to follow identifies the series of the engine, the industrial engine
remaining alpha digits indicate the air intake (T = turbo
No. of
6 B T A 5. 9
charged) and the last digits indicate the total displace-
T
ment in litres. cylinders

Series B
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Turbocharger
Aftercooler
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Total displacement
D150-2R0099
Fig. 1-2
The total displacement of the engine is 5.9 litres
(360 in3), the bore is 102 mm (4.01 in) and the stroke
120 mm (4.72 in). Specifications of engine 6B 5.9
The firing order is the same as for all other 6-cylinder,
in-line Cummins engines, 1-5-3-6-2-4. Total
displacement litres 5.88 (1.55 US gal)
Bore mm 102 (4.01 in)
Stroke mm 120 (4.72 in)
Firing order 1-5-3-6-2-4
D150-2R0100
Fig. 1-3
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1650K ENGINE 1-3
1.2 DESIGN FEATURES
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, Belt automatic
industrial and marine applications are available. This tensioner
front view of the engine illustrates a belt driven fan
hub.
Fan hub
D150-2R0101
Fig. 1-4
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This is the gear train available on Series B engines.
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All gears are hardened and of an helicoidal teeth type
for strength and silent operation. The alignment with
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reference marks is used between crankshaft gear and
camshaft gear. On engines equipped with rotary in-
jection pumps, the timing alignment occurs between
the injection pump gear and the camshaft gear. En- Camshaft gear
gines equipped with in-line injection pump do not re- with injection
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quire a timing between injection pump and camshaft. pump drive gear
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Crankshaft gear
with camshaft
gear
D150-2R0102
Fig. 1-5
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The cylinder block incorporates several innovative

design features. The block casting includes arrange-
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ments for: Coolant by-pass duct

• Oil heat exchanger housing.
• Water pump intake.
• Oil pump housing. Oil heat
• Water pump chamber. exchanger
• Coolant by-pass duct.
Water
pump
Water pump inlet chamber
Oil pump housing
D150-2R0103
Fig. 1-6
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1-4 ENGINE 1650K
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. Rimmed
block
Piston cooling
nozzle
D150-2R0104
Fig. 1-7
The cylinder head is a single piece designed for a
crossed flow with two valves per cylinder. This fea- Crossed flow
ture maintains the exhaust energy, cooling slightly, cylinder hea
the short exhaust gaps.
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D150-2R0105
Fig. 1-8
An exhaust manifold of a pulsation type coupled to
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the turbine housing with twin intake is used to im- Twin intake
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prove the efficiency of the engine. turbine

housing
Pulsation
exhaust
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manifold
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D150-2R0106
Fig. 1-9
The design of the cylinder head includes:
• Integral intake manifold. Intake
manifold Fuel filter
• Integral thermostat housing. supports
• Integral fuel filter housing.
Thermostat
housing
D150-2R0107
Fig. 1-10
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1650K ENGINE 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. Integral
valve guide
Rocker arm
group
D150-2R0108
Fig. 1-11
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.
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D150-2R0109
Fig. 1-12
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The timing is composed of a camshaft, tappets, push

rods and rocker arm group. Besides the intake and Rocker
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exhaust valve cams, the camshaft has a special cam armgroup

to power the fuel pump. Fuel pump
Push rods
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Camshaft
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Tappets
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D150-2R0110
Fig. 1-13
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.
Camshaft
bush
Camshaft
journal
D150-2R0111
Fig. 1-14
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1-6 ENGINE 1650K
The power components of the engine are distinguished

Power components
for special features
• Piston.
• Conrods.
Piston
• Crankshaft.
Conrod
Crankshaft
D150-2R0140
Fig. 1-15
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 Small end
employs a larger surface bearing, thus improving the
wear resistance. A piston ceiling oil jet lubricates the
bush of the conrod small end. Conrod
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Large end
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D150-2R0113
Fig. 1-16
Naturally aspirated engines use aluminium conrod
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bearings lined, at the rear, by steel, whereas turbo Conrod bearings

charged engines use tri-metal bearings lined at the
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back by steel. Service bearings are of the tri-metal

type with steel back lining.
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Aluminium with steel Tri-metal with steel

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back lining back lining

D150-2R0114
Fig. 1-17
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.
D150-2R0115
Fig. 1-18
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1650K ENGINE 1-7
Turbocharged engines use pistons with three ring

seats. A single high nickel content insert with a Key-
stone profile ensures optimised anti-wear features to
the upper ring seat. The most powerful turbocharged
Insert Nlresist
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.
Piston turbocharged
D150-2R0116
Fig. 1-19
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 crank-
shafts.
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D150-2R0117
Fig. 1-20
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Another technical feature is the use of pressed steel

parts to reduce the engine weight. These light compo-
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nents include the timing gear cover, valve cover with

breather group and engine sump.
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D150-2R0118
Fig. 1-21
The design objectives are:
• Simplicity.
• Reliability.
• Durability.
• Reduction of components.
• Better serviceability.
D150-2R0119
Fig. 1-22
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1-8 ENGINE 1650K
1.3 SERVICEABILITY
No special tools are required for routine overhauls on

series B engines. The tools required are those illus-
trated hereby.
D150-2R0120
Fig. 1-23
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No special repair/rebuild procedures are required for
series B engines. Normal high quality standards ap- Rebuilding procedure:
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plicable for engines of similar power are adequate.
· Disassembly
· Replacement of worn parts
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· Grinding the valves
· De-glassing of sleeve walls
· Cleaning the cylinder head and
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cylinder block
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· Re-assembly
D150-2R0121
Fig. 1-24
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The Cummins engine Company developed repair tools

usable to maintain, ovehaul and repair series B en-
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gines: Please refer to CUMMINS Manuals to

toubleshoot failures and to define the tooling.
Attrezzatura per le
Repair tools
riparazioni
D150-2R0122
Fig. 1-25
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1650K ENGINE 1-9
1.4 SECURING THE ENGINE TO THE FRAME
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IN 7
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15 2
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9
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7 10
16 13,14
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9
12
10
D150-2R0095
Fig. 1-26
N. Description Tightening torque N. Description Tightening torque
1 L. h. support 9 Washer 16x30x3
2 R. h. support 10 Nut 16x1.5x18
3 Block 11 Stud 47.5 to 52.5 daNm
4 Nut 24x2x28 (350.31 to 387.19 ft lb)
5 Screw 24x2x80 41 to 45 daNm 12 Nut
(302.38 to 331.88 ft lb) 13 Support - rear left
6 Screw 12x1.75x30 17 to 18.5 daNm 14 Support - rear right
(125.38 to 136.44 ft lb) 15 Screw 12x1.75x40
7 Washer 12x24 16 Screw 12x45
8 Screw 16x1.5x50 32.5 to 35.5 daNm
(239.69 to 261.81 ft lb)
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1 - 10 ENGINE 1650K
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SECTION 2
TRANSMISSION
TABLE OF CONTENTS
2.1 GENERAL DESCRIPTION ........................................................................................ 2-2

2.1.1 Transmission torque 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 .......................................................................... 2-11
2.3.3 Transmission gearshifting electric control valve .................................................... 2-12
2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER ........................ 2-14
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2.4.1 Removal ............................................................................................................... 2-14
2.4.2 Re-Installation ....................................................................................................... 2-15
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2.4.3 Disassembly ......................................................................................................... 2-16
2.4.4 Reassembly .......................................................................................................... 2-25
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2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION .................................. 2-26
2.5.1 Removal ............................................................................................................... 2-26
2.5.2 Re-Installation ....................................................................................................... 2-27
2.5.3 Disassembly ......................................................................................................... 2-28
2.5.4 Overhaul of forward the speed clutch .................................................................... 2-42
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2.5.5 Overhaul of 3rd speed ............................................................................................ 2-44

2.5.6 Overhaul of the rev speed clutch .......................................................................... 2-49
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2.5.7 Modulating valves (disassembly/assembly) .......................................................... 2-52

2.5.8 Pressure relief valve (disassembly/assembly) ...................................................... 2-53
2.6 SPECIFICATIONS AND DATA .................................................................................... 2-57

2.6.1 General data ......................................................................................................... 2-57
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2.6.2 Tightening torques (Torque converter) ........................................................... 2-58

(Transmission housing) .................................................... 2-59
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2.6.3 Data and dimension

transmission (Transmission clutches) ................................................... 2-60
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(Transmission clutch discs) ............................................. 2-62

(1st - 2nd - 3rd speed transmission clutch modulating
valves) ............................................................................ 2-62
(Lube oil pressure relief valve) ......................................... 2-63
(Forward/reverse modulating valves) ............................... 2-64
(Transmission pressure relief and torque converter
safety valve) .................................................................... 2-65
(Torque converter - transmission feeding pump) .............. 2-66
(Oil filters) ....................................................................... 2-67
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1650K TRANSMISSION 2-1
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2-2 TRANSMISSION 1650K
2.1 GENERAL DESCRIPTION
2.1.1 TRANSMISSION TORQUE The oil flowing out the torque converter, passes through
CONVERTER HYDRAULIC DIAGRAM the heat exchanger, the manifold and it is distributed
to the lube and cooling ducts of the transmission
The transmission is of a "power-shift" type with three clutches.
forward and three reverse speeds. The system is pow- The maximum lube pressure is limited by valve (15)
ered by a dual pump feeding the transmission and the set at 3 bar (43.5 psi).
torque converter (1). Modulating valves (9) make the engagement of the
The pump sucks oil from the transmission housing clutches progressive, regulating the pressure incre-
through filter (6) and circulates it purifying further ment in the control circuits.
through filter (2). A valve (set at 2.5 bar) (36.25 psi) A low engine lube oil pressure or an excessive lube
protects filter (2) against over pressures due to the oil temperature are indicated on the dashboard in the
clogging of the cartridge or excessively thick oil. cab.
The oil delivered by feeding pump (1) after being puri- Quick discharge valves on the 2nd and 3rd speed
fied by filter (2) reaches pressure relief valve (3) es- clutches, during the speed engagement phase, are in
tablishing and maintaining the pressure setting of the closed position, under the action of pressurised oil.
oil controlling the transmission clutches. When shifting from one speed to another, the relevant
Safety valve (16) protects the torque converter and control cylinder is connected to the discharge and the
the heat exchanger against accidental pressure in- pressure drop causes the centrifugal force to prevail
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crements, normally due to cold and excessively thick over the action of the oil, moving the balls outwards,
oil, discharging the flow excess into the pump deli- facilitating a quick discharge.
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very line (1).
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2-3
L T
F AS
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AL
P
S
MICROCONTROLLER
12 9
11
10
T
16 18 17
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7
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1
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26
4 25
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To brakes/clutches
feeding valve B
3
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23
B 22
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14 2
13 24
1 2
21
24
5 24
From transmission housing 20
15 19
Transmission lubrication
KSM0003
Fig. 2-1 Torque converter hydraulic diagram
B. To transmission housing - F. Forward speed - R. Reverse speed - P. Upshifting - S. Downshifting - N. Neutral - AS. Auto-shift function - AL. Auto kick-down function - L. Transmission control manipulator - T. Up-Down Shifting Button - 1. Dual transmission/torque converter
feeding pump 67 to 50 lt/min (17.70 to 13.21 gpm) - 2. Oil filter (delivery) - 3. Pressure relief valve (17 bar, 246.5 psi) - 4. TWIN-DISC torque converter - 5. Heat exchanger - 6. Oil filter (suction) - 7. Control valve - 8. Transmission housing - 9. FORWARD speed solenoid -
10. REVERSE speed solenoid - 11. 1st speed solenoid - 12. 3rd speed solenoid - 13. Steering torque converter scavenging pump (53 to 22 lt/min) (13.21 to 5.81 gpm) - 14. Mesh filter - 15. Lube oil pressure relief valve (3 bar, 43.5 psi) - 16. Torque converter safety valve -
17. FORWARD/REVERSE control valve spool - 18. 1st - 3rd control valve spool - 19. To 1st speed clutch pack - 20. To 3rd speed clutches pack - 21. 2nd speed clutch pack - 22. To FOR speed clutch pack - 23. To REV speed clutch pack - 24. 1st - 2nd - 3rd speed modulating
valves - 25. Filter clogging valve - 26. FOR/REV modulating valves.
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Transmission Brakes oil

oil filler neck suction filter
and oil dipstick
Control valve
solenoid
Transmission
control valve
Transmission Transmission oil

oil suction filter level sensor
1850-2R0105
Fig. 2-2 Transmission housing
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Torque converter
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Transmission/torque
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converter propeller
shaft
1850-2R0106
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Fig. 2-3 Propeller shaft

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Oil inlet
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Torque converter safety valve,

setting: 10 bar (145 psi) Pressure relief valve
(it provides 17 bar,
246.5 psi) for the
Equipment/steering operation of the
pump transmission)
Oil outlet at 17 bar
(246.5 psi), actuating
Brakes pump (53 lt/min,
the transmission
13.2 gpm)
Scavenger pump Transmission pump
(22 lt/min, 5.8 gpm) (67 lt/min, 17.7 gpm)
Torque converter pump
It recovers the oil at the
(50 lt/min, 13.2 gpm)
bottom of the torque
converter cover and Torque converter
flows it into the discharge
transmission Lube pressure switch
1850-2R0107
Fig. 2-4 Torque converter
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2.2 TROUBLESHOOTING
TROUBLE PROBABLE CAUSE TOOLS REQUIRED TEST SOLUTION
Low lube oil pres- Transmission oil level Instruction Manual. Pull-out the dipstick Top-up oil up to pre-
sure. The indica- low. and check the level. scribed level.
tor light is ON with
engine running.
Torque conver ter Clean the filter.
pump suction filter
clogged.
Outer crack allowing If the oil is foaming, Eliminate the crack.

the seeping of air into check if a crack is
the pump. present.
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Hose defective. Suction pipe clog- Change or clean the
ged. pipe.
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Oil of a wrong type. Instruction Manual. Check oil speci- Drain the oil and
fications with data change it with oil of
provided by Manu- the prescribed type.
facturer.
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Control oil pres- Transmission oil level Instruction Manual. Check oil level on Top-up with pre-
sure low at al low. dipstick. scribed oil to cor-
speeds with trans- rect level.
mission in neutral.
Transmission pump Clean the filter.
suction filter clogged.
Outer crack allowing If the oil is foaming, Eliminate the lea-

the seeping of air into check if a crack is kage.
the pump. present.
Suction pipe. Suction pipe clog- Change or clean the

ged. pipe.
Pressure relief valve Check pressure of Correct the pres-

out of setting. system. sure setting.
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Feeding pump deli- Check delivery of Replace pump, if
very insufficient. pump. defective.
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Control oil pres- Transmission pump Check and wash
sure low at high suction filter clogged. the mesh filter.
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engine speed with
transmission in Outer crack allowing If the oil is foaming, Eliminate the lea-
neutral. the seeping of air into check if a crack is kage.
the pump. present.
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Tr a n s m i s s i o n Orifice of direction Clean the orifice.

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pressure is nor- modulating valve

mal in neutral and plunger clogged.
low with speeds
engaged. The ma- Direction modulating Eliminate condition
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chine starts with valve plunger seized. for seizure between

difficulty in one plunger and seat.
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direction and the

torque is insuffi-
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cient.
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High transmission Pressure relief valve Eliminate seizure.

oil pressure at all seized open.
engine speeds.
High transmission Transmission oil level Instruction Manual. Check level on dip- Top-up with pre-
oil temperature. low. stick. scribed oil to cor-rect
level.
Transmission heat Measure tempera- Clean or replace the

exchanger clogged ture differential bet- heat exchanger.
keeps the safety ween inlet and out-
valve open. let of heat exchang-
er. With a clogged
unit, the differential
is marginal.
Operation pressure Measure operating Refer to remedies for
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low. pressure of trans- low oil pressure fault.
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mission.
Clutch discs burnt, Replace defective

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seized with clutches components.
disengaged.
Transmission oil Oil pump delivery in- Test pump.

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is normal, but the sufficient.

machine moves
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only at high en-

gine speed.
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Transmission pres- Discs worn or war-ped. Replace defective

sure normal; low components.
power in certain
speeds and oil
overheating.
Transmission pres- Leakages in piping of Check if seals or Overhaul the trans-

sure low in a given defective speed. pipes are damaged. mission and re-
speed. place defective
parts.
Engine oil level in- Together with trou- Clean scavenger

creases and trans- ble for low power filter.
mission oil level output.
drops.
Crankshaft sealing Replace crankshaft
ring damaged. sealing ring.
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Replace pump.
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2 - 10 TRANSMISSION 1650K
2.3 TESTS
2.3.1 TORQUE CONVERTER STALL TEST 2. Block the transmission output shaft, keeping the
brake pedal pressed, then engage the forward high
The stall test must be performed when the power group
speed range checking that the engine is at full
(engine and transmission) do not operate satisfacto-
speed. Record the engine speed. DO NOT let the
rily. The scope of the test is to determine if the trans-
temperature on the outlet of the torque converter
mission is defective. It is performed with the engine
exceed 120 °C (248 °F).
running at maximum speed and the transmission out-
put stalled. Perform the torque converter stall test pro-
Note – Let the transmission operate in neutral for
ceeding as follows:
an interval of about 2 minutes between the vari-
ous stall tests, to avoid overheating. During these
two minutes do not let the engine speed drop, ex-
cept when shifting through the neutral.
WARNING
3. Engage the other speeds and check that the en-
Do not run the engine of this machine in closed gine speeds drops the same value, independently
areas without proper ventilation to remove deadly from the speed being engaged. In the event the
exhaust gases. engine speed does not drop with a given speed
Be sure exposed personnel in the area of opera- engaged, it is probable that the relevant clutch slips.
T
tion are clear of the machine before moving it or In the event the engine speed does not drop with
its attachments. WALK COMPLETELY AROUND the
IN
all speeds, as indicated, this could be due to:
machine before mounting. Sound horn. Obey flag - the transmission, if the shaft between torque
man, safety signals and signs. converter and transmission is operating, or
PR
Comply with all procedures for the starting and - the torque converter, if said shaft is inoperative
stopping of the machine and the "NOTICES" listed
in the Operation and Maintenance Manual. Result – Under stall test conditions, a compari-
son between the effective engine speed and the
normal one prescribed for such conditions, indi-
R
cates that the trouble is in the engine or in the

FO
transmission.
1. Connect a precision revolution counter to the en- Note – Ambient conditions, such as ambient tem-
gine and bring the transmission housing to the op- perature, elevation, variations in the loss of en-
gine accessories, influence the power transferred
T
erating temperature: DO NOT PERFORM this test

with cold oil. Record the engine speed (rpm). to the torque converter: These conditions can
O
cause variations in the stall speed of 50 rpm, with

Note – The stall conditions must not be kept for respect to the normal value. When the difference
over 30 seconds, in any case, to avoid excessive can be assigned to such causes, the effective
N
temperatures. speed can be accepted as normal.
Copyright ©
1650K TRANSMISSION 2 - 11
2.3.2 DELIVERY PRESSURE TEST Check the temperature and pressure gauges on the
PROCEDURE instrument panel. If the main pressure stays within
the limits (or in case the trouble persists after inter-
Prior to measuring the pressures and the oil flow of ventions to correct the main pressure) measure and
the torque converter and transmission, it is neces- record all pressures for a comparison.
sary to proceed with the following preliminary check.
The pressure gauge pick-up points of the pressures
Check the oil level of the transmission, with the oil at of the entire system are located on the control valve
normal operating temperature: DO NOT perform this illustrated at page 2-12. All connections can be made
test with cold oil: To bring the oil temperature to the simultaneously. The pressure gauge connected to each
prescribed value, it is necessary to operate the ma- point must have a capacity sufficient to measure the
chine or stall the converter. pressure involved; however it must not by so high to
make the reading of the correct pressure difficult.
WARNING
Keeping the stall speed too long, overheats the
torque converter.
Do not run the engine of this machine in closed
areas without proper ventilation to remove deadly
exhaust gases.
T
Prior to starting the engine, warn all persons
IN
nearby the machine.
NEVER LEAVE THE MACHINE UNATTENTED with
the engine running.
PR
R
FO
T
O
N
Copyright ©
2.3.3 TRANSMISSION GEARSHIFTING

ELECTRIC CONTROL VALVE
Specifications and data
- Normal operating temperature 50 to 120 °C (122 to 248 °F)
- Engine max. rated speed (idle) 2260 to 2360 rpm
- Torque converter stall engine speed 1940 to 2080 rpm
- Total stall engine speed 1660 to 1860 rpm
- Main pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)
1 - 1st speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)
2 - 2nd speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)
T
3 - 3rd speed clutch pressure 16.5 to 17.5 bar (239.2 to 253.7 psi)
IN
F - Forward speed clutch pressure 14.5 to 15.5 bar (210.2 to 224.7 psi)
PR
R - Reverse speed clutch pressure 14.5 to 15.5 bar (210.2 to 224.7 psi)
L - Lube oil pressure 3 bar (43.5 psi)

R
FO
T
O
N
Pressures
SPEED LUBE
1 SPEED FORWARD
L
2 F
SPEED RESERVE
3 R
1850-2R0013
Fig. 2-5 Transmission pick-up point for machine arranged with diagnostic panel (optional)
Copyright ©
2nd gear
Forward gear
Lubrication
Trasmission
control valve
T
IN
Slow speed
Fast
speed
PR
Reverse gear F14329
Fig. 2-6 Pressure pick-up points on transmission

R
FO
P
T
O
N
SM9011
Fig. 2-7 Pressure pick-up points on torque converter
Copyright ©
2.4 PROCEDURES FOR THE REPAIR OF THE TORQUE CONVERTER
2.4.1 REMOVAL
ON
Turn the main switch into position "OFF". Place a "DO
Key
NOT OPERATE" warning signal on the machine. please
refer to the Section "CAB" of this Manual to tilt the OFF DO NOT
cab. OPERATE
SM9261
Fig. 2-8
Remove the central lower guard.
T
IN
PR
1850-2R0014
Fig. 2-9
R
Drain the transmission oil through the draining plug.

FO
T
O
N
1850-2R0015
Fig. 2-10
Drain the oil from the torque converter housing through
the draining plug.
1850-2R0016
Fig. 2-11
Copyright ©
Tilt the cab and perform the following operations.

Disconnect the transmission temperature sensor wire.
Disconnect the return piping between heat exchanger

and torque converter.
Disconnect the breather piping between torque con-

verter and transmission.
Disconnect the piping between the main pressure re-

lief valve and valve blocking in neutral.
Disconnect the feeding piping between brake pump

and steering and brake control valve.
Remove the propeller shaft between transmission

housing and torque converter.
Disconnect the brake pump suction pipe and the de-

livery and scavenger pipes from the torque converter
T
scavenger pump.
IN
Remove the scavenger and brake pump from the
torque converter.
Disconnect the connection pipe from the front part of
PR
the torque converter.
Make a lifting bracket and secure it to the propeller

shaft flange on the torque converter. Holding the torque
R
converter with an appropriate lifting device, remove

the securing screws to the flywheel housing and re-
FO
move the torque converter.
WARNING
T
Lift and handle all heavy parts with a lifting de-

O
vice of appropriate capacity.

Make sure that the parts are secured by appropri-
N
ate slings and hooks.
2.4.2 RE-INSTALLATION
The re-installation of the torque converter is performed
reversing the removal operations, with the following
exceptions.
Install the dowels on the flywheel housing.
1850-2R0017
Fig. 2-12
Copyright ©
Smear with sealant the mating surfaces between

torque converter and flywheel housing.
Install the torque converter securing screws, tighten-

ing them at a torque of 6.8 to 7.4 daNm (50.15 to
54.58 ft lb).
1850-2R0108
Fig. 2-13
2.4.3 DISASSEMBLY
Remove the engine/torque converter adapter ring.
WARNING
T
It is dangerous hitting hardened steel parts with
tools different from hammers made of mild steel
IN
or non ferrous metals. When these components
are remove or installed, always wear safety glasses
PR
with side shields, heavy gloves etc., to reduce the
chances of injuries. 1850-2R0109
Fig. 2-14
Place the torque converter on a rotary stand.
R
FO
T
O
N
1850-2R0110
Fig. 2-15
Remove the hub.
1850-2R0018
Fig. 2-16
Copyright ©
Loosen and remove the screws securing the retaining

plate, then pull-out the plate, the O-Ring and the shaft
flange.
SM9023
Fig. 2-17
Remove the pressure relief valve assembly.
T
IN
PR
1850-2R0019
Fig. 2-18
Loosen the support securing screws, then turn the

R
torque converter with its bottom side upwards, so that

FO
the securing screws can me removed from the sup-

port.
T
O
N
1850-2R0020
Fig. 2-19
Remove the screws securing the equipment pump

driven gear, lift the gear from the nose of the shaft
and put it aside.
1850-2R0111
Fig. 2-20
Copyright ©
Secure a lifting chain to the torque converter; lift just

enough to rotate the support so that the remaining
gears are free, then pull the torque converter out the
housing.
WARNING
ate slings and hooks. 1850-2R0112
Fig. 2-21
Pull the equipment pump driven gear out the housing.
T
IN
PR
1850-2R0022
Fig. 2-22
R
Remove the circlips from the driven gears, then re-

move the gears from the shaft.
FO
T
O
N
1850-2R0023
Fig. 2-23
Loosen the securing screws and remove the bearing
retaining plate.
WARNING
Fig. 2-24
Copyright ©
Using an appropriate punch and a soft metal hammer,

pull-out the pump drive shafts from the bearings.
WARNING
Fig. 2-25
Pull-out the bearings and spacers from the housing.
WARNING
T
IN
PR
Fig. 2-26
Remove the equipment pump drive shaft circlip.
R
FO
T
O
N
1850-2R0027
Fig. 2-27
Pull-out the shaft and bearing from the housing.
1850-2R0028
Fig. 2-28
Copyright ©
Pull-out the bearing left in the housing.
1850-2R0113
Fig. 2-29
Pull-out the seal assembly from the housing.
T
IN
PR
1850-2R0029
Fig. 2-30
Remove the bearing circlip from the equipment pump

R
drive, and pull-out the spacer and the bearing from

the shaft.
FO
T
O
N
1850-2R0030
Fig. 2-31
Place the equipment pump drive shaft on a vertical
press of appropriate capacity to remove the inner race
of the bearing from the shaft.
SM9039
Fig. 2-32
Copyright ©
Place the torque converter assembly on an appropri-

ate work bench.
1850-2R0114
Fig. 2-33
Remove the front bearing retaining plate.
T
IN
PR
SM9041
Fig. 2-34
Remove the screws securing the wheel.
R
FO
T
O
N
1850-2R0031
Fig. 2-35
Using puller screws, separate the turbine from the

housing, then lift the turbine.
WARNING
1850-2R0032
Fig. 2-36
Copyright ©
Separate the turbine from the shaft prying it, in case

the turbine comes out with the shaft.
1850-2R0115
Fig. 2-37
Otherwise, in case the turbine is not coming out with
the shaft, lift it from the housing.
T
IN
PR
1850-2R0033
Fig. 2-38
Remove the shoulder disc from the housing.
R
FO
T
O
N
1850-2R0034
Fig. 2-39
Pull-out the front bearing from the housing, hammer-

ing it.
WARNING
Fig. 2-40
Copyright ©
Place the pump wheel over blocks, remove the circlip

and pull-out the shaft from the wheel.
1850-2R0035
Fig. 2-41
Remove the screws securing the stator.
T
IN
PR
1850-2R0036
Fig. 2-42
Separate the stator from the pump wheel.
R
FO
T
O
N
1850-2R0037
Fig. 2-43
Disassemble the bearing support from the pump wheel
and remove the sealing rings from the support.
Remove the bearing race from the support only in
case its replacement is required.
1850-2R0038
Fig. 2-44
Copyright ©
Remove the pump drive gear from the wheel.
1850-2R0039
Fig. 2-45
Using a proper punch and a soft hammer, pull-out the

bearing support from the pump wheel.
WARNING
T
IN
PR
Fig. 2-46
Remove the sealing ring from the shaft.

R
FO
T
O
N
1850-2R0040
Fig. 2-47
Pull-out the rear bearing from the shaft, using an ap-

propriate press.
SM9055
Fig. 2-48
Copyright ©
2.4.4 REASSEMBLY
To reassemble, reverse the disassembly procedures,
with the following modifications:
In case the dowels, the sleeve or the sealing ring have

been removed, install new parts.
Always install new O-Rings and seals.
In the event the heating of a bearing is required, use

an appropriate heater and warm-up at 121 °C
(250 °F).
In the event the freezing of a bearing of its compo-

nents is required, place the part in dry ice 4 hours
prior to the installation.
Pay attention to the correct installation of the oil de-

flector.
T
IN
PR
R
FO
T
O
N
Copyright ©
2.5 PROCEDURES FOR THE REPAIR OF THE TRANSMISSION
2.5.1 REMOVAL
ON
Turn the main switch into position "OFF". Place a "DO Key
NOT START" warning signal on the machine. Please
refer to the Section "CAB" of this Manual to tilt the OFF DO NOT
cab. Drain the transmission oil through the draining OPERATE
plug.
Remove the central lower guards.
SM9261
Fig. 2-49
Drain the oil from the torque converter housing through

the draining plug.
Remove the propeller shaft between torque converter
T
and transmission housing.
IN
PR
1850-2R0014
R
Fig. 2-50
FO
Disconnect the hydraulic pump pipes (delivery and

return) to the distributor.
Disconnect the forward and 2nd speed pressure test

T
pipes between transmission and test panel.

O
Disconnect and label the three pipes between the upper

part of the control valve and the pilot valve.
N
Disconnect and label the 4 pipes on the rear side of

the transmission control valve: 2 run to the test panel,
one runs to the manual pilot valve and one runs to the 1850-2R0041
brake unlocking valve. Fig. 2-51
Hold the transmission housing with an appropriate

winch: its mass is about 450 kg (992.25 lb).
Copyright ©
Remove the screws and nuts retaining the transmis-

sion housing.
Note – It could be necessary to disconnect the

cylinder pipe on the hydraulic control valve to be able
loosening the nuts on the right upper side of the
transmission housing.
SM9059
Fig. 2-52
Remove the transmission housing from the pinion

support and lift it away from the machine.
WARNING
T
IN
PR
1850-2R0145
Fig. 2-53
R
FO
T
O
N
2.5.2 RE-INSTALLATION
The installation is done reversing the removal proce-
dure.
Copyright ©
2.5.3 DISASSEMBLY
Place the transmission assembly on a rotary stand.
WARNING
1850-2R0146
Fig. 2-54
Remove the lube manifold cover.
T
IN
PR
1850-2R0042
Fig. 2-55
Remove the modulating valves cover.

R
FO
T
O
N
1850-2R0161
Fig. 2-56
Remove the modulating valves from the housing.
1850-2R0162
Fig. 2-57
Copyright ©
Remove the covers of the forward and medium range

clutch spools.
1850-2R0043
Fig. 2-58
Pull-out the clutch spools from the shafts.
T
IN
PR
1850-2R0044
Fig. 2-59
Remove the input shaft drive flange.
R
FO
T
O
N
1850-2R0045
Fig. 2-60
Turn the transmission assembly and remove the trans-

mission control valve assembly, loosening the screws
(q.ty 5).
1850-2R0046
Fig. 2-61
Copyright ©
Remove the side covers.
1850-2R0047
Fig. 2-62
Remove the screws securing the front cover (please

note that 2 screws must be removed from the bot-
tom).
T
IN
PR
SM9069
Fig. 2-63
Remove the front cover of the housing, lifting it with
R
an appropriate winch.
FO
WARNING
T

O
ate slings and hooks. Use the lifting eyes provided

for this purpose.
N
1850-2R0147
Fig. 2-64
Turn the housing and remove the high range control

and lube pipes.
SM9071
Fig. 2-65
Copyright ©
Remove the low and high range clutches distribution

spools and pull them out from the shafts.
1850-2R0048
Fig. 2-66
Remove the low range clutch housing cover.
T
IN
PR
1850-2R0049
Fig. 2-67
Remove the rear cover.
R
FO
T
O
N
SM9074
Fig. 2-68
Remove the reverse clutch pipe holder.
1850-2R0050
Fig. 2-69
Copyright ©
Pull-out the reverse clutch distribution spool.
1850-2R0051
Fig. 2-70
Remove the reverse clutch shaft bearing holder.
T
IN
PR
1850-2R0052
Fig. 2-71
Remove the oil sump and the oil pipes with the
R
bracket, recording the position of the pipes for the

installation.
FO
T
O
N
1850-2R0053
Fig. 2-72
Loosen the nuts securing the forward and medium
range clutch shafts.
WARNING
Fig. 2-73
Copyright ©
Block the transmission gears through the access panel

to prevent the shaft from turning, then loosen the for-
ward speed clutch shaft securing nut.
1850-2R0149
Fig. 2-74
Remove the forward speed piston assembly.
T
IN
PR
1850-2R0054
Fig. 2-75
Remove the forward speed clutch hub-pack assem-
R
bly.
FO
T
O
N
1850-2R0055
Fig. 2-76
Loosen and remove the low range clutch shaft secur-

ing nut (blocking the transmission gears to prevent
the rotation of the shaft).
1850-2R0150
Fig. 2-77
Copyright ©
Remove the low range clutch piston assembly.
1850-2R0056
Fig. 2-78
Remove the low range clutch hub-pack assembly.
T
IN
PR
1850-2R0057
Fig. 2-79
Remove the low range clutch drum-stop assembly.
R
FO
T
O
N
1850-2R0058
Fig. 2-80
Pull-out the clutch shaft taper spacer.
Please keep in mind that when reassembling, the ta-

per part of the spacer must be placed in front of the
bearing.
1850-2R0159
Fig. 2-81
Copyright ©
Lift the low range and forward speed clutches shaft

from the transmission housing.
1850-2R0060
Fig. 2-82
Remove the gears and spacers through the access

panel.
T
IN
PR
1850-2R0061
Fig. 2-83
Remove the circlip from the driven gear of the forward

R
speed clutch drum.

FO
T
O
N
1850-2R0062
Fig. 2-84
Remove the drum and the forward speed clutch gear,

using an appropriate punch, extracting the drum
through the gear and the housing.
1850-2R0063
Fig. 2-85
Copyright ©
Install three clamps (P/N 75291531) on the high range

clutch assembly.
SM9092
Fig. 2-86
Remove the medium range clutch shaft securing nut.
T
IN
PR
1850-2R0151
Fig. 2-87
Remove the medium range clutch piston.
R
FO
T
O
N
1850-2R0064
Fig. 2-88
Remove the medium range clutch hub-pack assem-

bly.
1850-2R0065
Fig. 2-89
Copyright ©
Remove the medium range clutch hub circlip.
SM9096
Fig. 2-90
Remove the medium/high range clutch shaft.
T
IN
PR
1850-2R0066
Fig. 2-91
Remove the medium range clutch drum.
R
FO
T
O
N
1850-2R0067
Fig. 2-92
Remove the medium range clutch gear.
1850-2R0068
Fig. 2-93
Copyright ©
Remove the medium range clutch assembly.
1850-2R0069
Fig. 2-94
To pull-out the medium range clutch drum bearing,

use an appropriate punch, after removing the two
screws with retaining nut.
WARNING
T
IN
PR
1850-2R0070
chances of injuries.
Fig. 2-95
Remove the screws securing the input drive gear seal
R
and the bearing support, then extract the shaft prying

FO
it.
T
O
N
1850-2R0071
Fig. 2-96
Remove the input drive gear using a pry bar and ham-
mering the shaft.
WARNING
1850-2R0072
Fig. 2-97
Copyright ©
Remove the bearing and the retaining wing of the rel-

evant spacer.
1850-2R0153
Fig. 2-98
Remove the bearing spacer using a securing screw.
T
IN
PR
SM9105
Fig. 2-99
Remove the output shaft nose bearing circlip.
R
FO
T
O
N
1850-2R0073
Fig. 2-100
Remove the output shaft gear circlip.
1850-2R0074
Fig. 2-101
Copyright ©
Remove the output shaft and the bearing using an

appropriate punch.
WARNING
Fig. 2-102
Using an appropriate punch, pull-out the output shaft

through the bearing and the gear.
WARNING
T
IN
PR
1850-2R0076
Fig. 2-103
Remove the output shaft gear.
R
FO
T
O
N
1850-2R0077
Fig. 2-104
Remove the PTO shaft securing screws and seal
holder.
1850-2R0078
Fig. 2-105
Copyright ©
Install two clamps (P/N 75291531) on the reverse

clutch.
1850-2R0079
Fig. 2-106
Loosen and remove the reverse clutch shaft locking

nut.
WARNING
T
IN
PR
D150-2R0081
Fig. 2-107
R
Pull-out the reverse shaft/PTO shaft through the clutch

and the housing.
FO
T
O
N
1850-2R0154
Fig. 2-108
Remove the input gear and the reverse spacer.
1850-2R0080
Fig. 2-109
Copyright ©
Pull-out the reverse clutch assembly.
1850-2R0155
Fig. 2-110
Remove the bearing remaining in the housing.
WARNING
T
IN
PR
1850-2R0156
Fig. 2-111
2.5.4 OVERHAUL OF THE FORWARD
R
SPEED CLUTCH
FO
Note – The procedures for the overhaul of the low and

medium range clutches are the same as for the forward
speed clutch.
T
Remove the piston from the housing, then check that

these two elements are satisfying the prescribed re-
O
quirements. Reinstall the piston into the housing with

new sealing rings.
N
1850-2R0157
Fig. 2-112
Remove the clutch pack from the hub.
1850-2R0081
Fig. 2-113
Copyright ©
Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.
1850-2R0158
Fig. 2-114
Press the spring using a long threaded stud.
T
IN
PR
1850-2R0082
Fig. 2-115
Remove the circlip.
R
FO
T
O
N
SM9122
Fig. 2-116
Remove the spring cup and the spring from the hub;
check that the spring complies with the prescribed
requirements.
1850-2R0083
Fig. 2-117
Copyright ©
Reinstall the spring and the relevant cup on the hub;

press the cup and install the circlip.
1850-2R0084
Fig. 2-118
Reinstall the friction discs, the spacer springs and
the steel discs, alternatively, on the hub.
T
IN
PR
1850-2R0159
Fig. 2-119
To measure the height of the clutch pack, place the
R
clutch assembly on a press and load it at 197 daNm

FO
(1452.88 ft lb), measuring as illustrated.

T
O
N
SM9126
Fig. 2-120
2.5.5 OVERHAUL OF THE 3RD SPEED

Remove the blocks holding the high range clutch.
1850-2R0085
Fig. 2-121
Copyright ©
Separate the high range gear housing and the piston

from the clutch assembly.
1850-2R0086
Fig. 2-122
Remove the high range piston from the relevant hous-

ing.
Check that the piston and housing satisfy the pre-
scribed requirements. Install a new sealing ring on
the piston and housing hub, then reinstall the piston
into the relevant housing.
T
IN
PR
1850-2R0087
Fig. 2-123
Remove the hub and the high range clutch pack from
R
the clutch drum.

FO
Note – In the event it is necessary to replace the

bearings in the clutch drum assembly, it is imperative
that the shoulder washer with lube holes is properly
mounted, with the inner taper side on the opposite side
T
of the bearings.
O
N
1850-2R0088
Fig. 2-124
1850-2R0081
Fig. 2-125
Copyright ©
Measure the thickness of all friction and steel discs;

replace them if not within the prescribed requirements.
1850-2R0160
Fig. 2-126
Press the return spring using a long thread screw.
T
IN
PR
1850-2R0082
Fig. 2-127
Remove the circlip.

R
FO
T
O
N
SM9134
Fig. 2-128
Remove the spring and the relevant cup from the hub;
check that the spring complies with the prescribed
requirements.
1850-2R0083
Fig. 2-129
Copyright ©
Insert the spring cup and the spring into the hub; press
the spring and install the circlip.
1850-2R0084
Fig. 2-130
Reinstall the friction discs, return springs and steel

discs, alternatively on the hub.
T
IN
PR
1850-2R0159
Fig. 2-131
R

FO

T
O
N
SM9126
Fig. 2-132
Install the central hub assembly and clutch pack on

the high range clutch drum.
1850-2R0089
Fig. 2-133
Copyright ©
Install the alignment tool (P/N 75291532) in the hub

grooves.
1850-2R0090
Fig. 2-134
Arrange the gear assembly on the hub assembly and

align the relevant grooves with the grooves on the
hub.
T
IN
PR
SM9137
Fig. 2-135
Check the alignment of the grooves using the high
R
range shaft, prior to introducing the high range clutch

FO
assembly into the transmission housing.
Note – It is important that the grooves are perfectly

aligned, otherwise they could be damaged during the
installation of the shaft.
T
O
N
1850-2R0091
Fig. 2-136
Install three brackets (P/N 75291531)on the high range

clutch assembly.
1850-2R0092
Fig. 2-137
Copyright ©
2.5.6 OVERHAUL OF THE REV SPEED

CLUTCH
Remove the locking tools from the reverse clutch as-
sembly.
1850-2R0093
Fig. 2-138
Separate the reverse clutch drum from the clutch as-

sembly.
T
IN
PR
1850-2R0094
Fig. 2-139
Remove the clutch pack-hub from the piston-housing
R
assembly.
FO
T
O
N
1850-2R0095
Fig. 2-140
1850-2R0251
Fig. 2-141
Copyright ©
Measure the thickness of all the friction and steel

discs; replace them if they are not within the toler-
ance limits.
1850-2R0160
Fig. 2-142
Press the return spring using a long thread screw.
T
IN
PR
1850-2R0082
Fig. 2-143
Remove the circlip.
R
FO
T
O
N
SM9134
Fig. 2-144
Pull-out the spring stop and the return spring from the
hub; check that the spring complies with the pre-
scribed requirements.
1850-2R0083
Fig. 2-145
Copyright ©
Insert the return spring and the relevant stop in the

hub; press the stop and install the circlip.
1850-2R0084
Fig. 2-146
Install the friction discs, the spacer springs and the

steel discs, alternatively, on the hub.
T
IN
PR
1850-2R0159
Fig. 2-147
R

FO

T
O
N
SM9126
Fig. 2-148
Pull-out the piston from the housing and check that

the two components comply with the prescribed re-
quirements. Install new sealing rings on the piston
and reinstall the piston into the housing.
1850-2R0157
Fig. 2-149
Copyright ©
Install the hub-clutch assembly on the reverse clutch

hub-housing assembly. Check that the outer steel ring
is correctly oriented with respect to the housing.
1850-2R0095
Fig. 2-150
Install the reverse clutch drum on the clutch assem-

bly.
T
IN
PR
1850-2R0094
Fig. 2-151
Install two brackets (P/N 75291531) on the reverse
R
clutch assembly.
FO
T
O
N
1850-2R0093
Fig. 2-152
2.5.7 MODULATING VALVES

(disassembly / assembly)
Note – The three modulating valves are identical.
Remove the circlip from the modulating valve.
1850-2R0096
Fig. 2-153
Copyright ©
Pull-out the cup, the springs, the plunger and the valve
from the valve body.
Check that the springs comply with the prescribed

requirements.
SM9148
Fig. 2-154
Assembly
Insert the valve, the plunger, the springs the cup into
the valve body; block with the circlip.
T
IN
PR
1850-2R0096
Fig. 2-155
R
FO
2.5.8 PRESSURE RELIEF VALVE

(disassembly / assembly)
The pressure relief valve is located on the torque con-
T
verter. It is equipped with two spools: one controls the

main pressure, the other operates as a safety valve,
O
protecting the torque converter against pressure over-

loads, which could occur with oil cold or too thick.
N
Disassembly
Disconnect the pressure sender.
Note – Record the number of shims located under the

sender, which shall be the same when reinstalling it.
1850-2R0097
Fig. 2-156
Copyright ©
Remove the plug.
1850-2R0098
Fig. 2-157
Pull-out the spool assembly from the valve body.
T
IN
PR
1850-2R0099
Fig. 2-158
Disassemble the spool assembly.

R
FO
Check that the spring complies with the prescribed

requirements.
Re-install the spool assembly, as illustrated in the fig-

T
ure.
O
For the moment, do not tighten the setting ring.

N
1850-2R0100
Fig. 2-159
Remove the valve seat from the valve body.
1850-2R0101
Fig. 2-160
Copyright ©
Push the plunger retaining ring out its seat.
1850-2R0102
Fig. 2-161
Pull-out the plunger, the spring and the shims from

the seat.
Check that the spring complies with the prescribed

requirements.
T
IN
Assembly
Install the shims, the spring and the plunger into the
PR
seat, press the spring and secure the pin.
1850-2R0103
Fig. 2-162
Install a new O-Ring and a new washer on the seat.
R
FO
T
O
N
SM9156
Fig. 2-163
Place the seat assembly into the valve body.
SM9158
Fig. 2-164
Copyright ©
Place the spool assembly into the valve body.
SM9152
Fig. 2-165
Install the plug on the valve body.
T
IN
PR
D150-2R0087
Fig. 2-166
Set the pressure, actuating the valve, as indicated.
R
FO
T
O
N
D150-2R0088
Fig. 2-167
Copyright ©
2.6 SPECIFICATIONS AND DATA
2.6.1 GENERAL DATA
TORQUE CONVERTER
Make ................................................................................................................................................ TWIN-DISC

Model .................................................................................................................................. PX-1615 - C MS335
Number of elements ...................................................................................................... 3 (pump, turbine, stator)
Torque ratio at stall .................................................................................................................................... 2.33:1
TORQUE CONVERTER AND TRANSMISSION PROPELLER SHAFT
Type ...................................................................................................... Tubular with universal joints at the ends

Technical description ......................................................................................................... Italcardano 148 - M70
Working angle ............................................................................................................................................... 10°
Lube fittings ..................................................................................................................................................... 2
Tightening torque of universal joint screws ............................................... 12.8-14.2 daNm (94.4 to 104.73 ft lb)
T
IN
TRANSMISSION HOUSING
PR
Type ........................................................................................................................................... Full Power Shift
No of speeds ....................................................................................................................... 3 forward, 3 reverse
No of clutches .................................................................................................................................................. 5
R
FO
SPEED POWER-SHIFT CLUTCHES ENGAGED RATIO

T
1st Forward Low - Forward 1:2.531

O
2nd Forward Medium - Forward 1:1.484

3rd Forward High - Forward 1:0.888
N
1st Reverse Low - Reverse 1:2.016

2nd Reverse Medium - Reverse 1:1.182
3rd Reverse High - Reverse 1:0.707
QUANTITY
CLUTCH DISCS Forward 3rd 2nd 1st Reverse
Bimetal discs with outer toothing 10 6 8 8 8
Intermediate toothed steel discs 9 5 7 7 7

Shoulder toothed steel discs 1 1 1 1 1
Spacer springs 10 6 8 8 8
Copyright ©
2.6.2 TIGHTENING TORQUES - Torque converter
DESCRIPTION daNm (*) ft lb
1. Securing screws, front bearing stop 4.1 to 4.9 30.24 to 36.14

2. Securing screws, shaft hub stop 4.1 to 4.9 30.24 to 36.14
3. Securing screws, drive shaft 10.8 to 11.7 79.65 to 86.29
4. Securing screws, torque conv. housing 6.8 to 7.4 50.15 to 54.57
5. Securing screws, rear wheel 2.3 to 2.8 16.96 to 20.65
6. Securing screws, stator 3.4 to 3.9 25.07 to 28.76
7. Securing screws, pump drive gear 4.1 to 4.9 30.24 to 36.14
8. Securing screws, steering-brakes pump 1.2 to 1.4 8.85 to 10.32
9. Securing screws, pressure relief valve 6.8 to 7.4 50.15 to 54.58
10. Securing screws, rear bearing support 8.0 to 8.8 59 to 64.9
11. Secur. screws, rear output flange stop 4.1 to 4.9 30.24 to 36.14
12. Securing screws, oil deflector 3.0 to 3.3 22.13 to 24.34
13. Securing screws, oil deflector support 6.8 to 7.4 50.15 to 54.57
Screws, equipm. pump driven gear 7.5 to 8.3 55.31 to 61.21

Sec. screws, trans./torque conv. pump 6.8 to 7.4 50.15 to 54.57
Nut, pump drive hub 2.1 to 2.3 15.49 to 16.96
Secur. screws, hydraulic pump
T
4
IN
PR
9
R
5
FO
2 3
T
O
6
N
1
10
7 11
12 13 8
SM9259
Fig. 2-168 Section view of torque converter housing
Copyright ©
Transmission housing
Thread daNm (*) ft lb
1. Nuts, rear cover studs 10 x 1.25 6.1 to 7.7 44.99 to 58.79

2. Screws and nuts, low range clutch cover and housing 10 x 1.25 6.1 to 7.7 44.99 to 58.79
3. Screws, reverse clutch front bearing cover 10 x 1.25 6.2 to 6.8 45.73 to 50.15
4. Screws, reverse clutch spool 10 x 1.25 5.7 to 6.3 42.04 to 46.46
5. Screws, reverse clutch seal 10 x 1.25 4.8 to 6.0 35.4 to 44.25
6. Screws, side cover 10 x 1.25 4.8 to 6.0 35.4 to 44.25
7. Screws, clutch spool cover 10 x 1.25 3.4 to 5.7 25.08 to 42.04
8. Screws, rear bearing holder 10 x 1.25 5.4 to 6.8 39.83 to 50.15
9. Self-locking screws, high range driven gear and
medium/high ranges drive gear 12 x 1.25 11 to 12 81.13 to 88.5
10. Nuts and screws, securing the transmission
housing to bevel gear pinion housing 16 x 1.5 24 177
11. Nuts, transmission shafts locking 40 x 1.5 92 to 95.5 (**) 679 to 704.31
T
IN
(*) Lubricate with engine oil - (**) Apply Loctite 242
PR
8 1
R
9
FO
7 11
T
7
O
2
N
11
11
7
3
2
4
5
10 SM9260
Fig. 2-169 Section view of transmission housing
Copyright ©
2.6.3 DATA AND TRANSMISSION DIMENSION

Transmission clutches
DATA mm in
A Ø Out. diameter of forward-reverse speeds 169.894 to 169.957 6.688 to 6.691

and 1st - 2nd ranges clutches fixed piston (large)
Ø Inner diameter forward speed mobile piston (large) 170.000 to 170.063 6.692 to 6.695
Piston play 0.043 to 0.169 0.001 to 0.006
B Ø Out. diameter of forward-reverse speeds 59.924 to 59.970 2.359 to 2.361
and 1st - 2nd ranges clutches fixed piston (small)
Ø Out. diameter of forward-reverse speeds 60.000 to 60.046 2.362 to 2.364
and 1st - 2nd ranges mobile piston (small)
Piston play 0.030 to 0.122 0.001 to 0.004
C Ø Outer diameter of 3rd range drive piston 194.600 to 194.700 7.661 to 7.665
Ø Inner diameter of high range on 1st range gear piston 195.000 to 195.072 7.677 to 7.679
Piston play 0.300 to 0.472 0.011 to 0.018
D Ø Inner diameter of 3rd range drive piston 80.036 to 80.066 3.151 to 3.152
Ø Out. diameter of high range 79.940 to 79.970 3.147 to 3.148
T
on 1st, 2nd and 3rd ranges drive gear hub
IN
Piston play 0.066 to 0.126 0.002 to 0.004
E Ø Outer diameter of clutch control spools 19.770 to 19.800 0.778 to 0.779
Ø Inner diameter of clutches control spools 20.016 to 20.020 0.788 to 0.788
PR
Clearance between seat and spool 0.22 to 0.25 0.008 to 0.009
G Specifications of clutch springs
Spring free length (3rd speed) 83.5 3.29
Spring free length (1st, 2nd, FOR, REV) 83.0 3.27
R
Press. load at 35 mm (1.378 in) 3rd 65.5 to 72.5 daNm 261.8 to 534.7 lbft
Press. load at 65 mm (2.559 in) (1 - 2 - FOR - REV) 315.5 to 348.5 daNm 2327 to 2570.18 lbft
FO
T
DATA OF CLUTCH DISCS PACK ASSEMBLY

O
Clutch (X) Piston stroke (*) (Y) Clutch pack dimens. (**)
N
mm in mm in
FORWARD 4 to 5 0.16 to 0.20 60.4 to 60.8 2.38 to 2.39
REVERSE 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
1st SPEED 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
2nd SPEED 3 to 4 0.12 to 0.16 48.25 to 48.65 1.90 to 1.91
3rd SPEED 2 to 3 0.08 to 0.12 36.1 to 36.5 1.42 to 1.44
(*) Check by measuring the stroke of the mobile piston.
(**) Check pre-loading the clutch pack with a load of 197 daNm (1452 ft lb). When the discs are worn,
spare discs are available to reastablish the setting, to be used in lieu of as many inner toothed
discs.
Copyright ©
X Y Y X X Y
G G
G
A D
C
SM9163
Fig. 2-170 Section 1st Speed Section 3rd Speed Section FORWARD
2nd Speed
T
REVERSE
IN
PR
R
FO
T
O
N
Copyright ©
Transmission clutch discs

A
C D
B SM9164
Fig. 2-171 Section view of clutch discs
DATA mm in
A Thickness of inner toothed intermediate discs 2.42 to 2.58 0.09 to 0.10
B Thickness of inner toothed driving discs 2.42 to 2.58 0.09 to 0.10

3.4 to 3.6 0.13 to 0.14
C Thickness of outer toothed friction discs

wear tolerance of syntherised friction discs 0.90 to 1.20 0.03 to 0.04
T
D Length of return springs without permanent deformation 3.8 to 4.2 0.15 to 0.16
IN
PR
1st - 2nd - 3rd Speed transmission clutch modulating valves
R
FO
C B A
T
O
SM9165
N
Fig. 2-172 Section view of modulating valve
DATA mm in
A Ø Outer diameter of piston 19.987 to 20.000 0.787 to 0.787

Diameter of piston seat in valve body 10.020 to 20.033 0.394 to 0.788
Installation tolerance between piston and seat 0.020 to 0.046 0.001 to 0.002
B Specifications of outer spring:

Free length 65 2.56
Load for spring compressed at 47 mm (1.85 in) 2.47 to 2.73 daNm 18.22 to 20.13 ft lb
C Specifications of outer spring:

Free length 48 1.89
Load for spring compressed at 32.5 mm (1.28 in) 9.11 to 10.11 daNm 67.19 to 74.56 ft lb
Copyright ©
Lube oil pressure relief valve
A Specifications of outer spring:

Free length 40 mm (1.57 in)
Load for spring compressed at 14 mm (0.55 in) 7.31 to 8.09 daN (16.44 to 18.20 lb)
B Valve pressure setting 3 bar (43.5 psi)
T
IN
PR
R
FO
T
O
Lube pressure
N
relief valve
Valve section
SM9166
Fig. 2-173 Pressure relief valve
Copyright ©
Forward reverse modulating valves
Transmission control valve
T
IN
FORWARD REVERSE B A
C
PR
MODULATING VALVES VALVE SECTION
SM9167
Fig. 2-174 Transmission control valve and modulating valves

R
FO
T
O
DATA mm in
N
A Specifications of modulating valve inner spring:

Free length 48 1.89
B Ø Outside diameter of plunger 23.987 to 24.000 0.944 to 0.945

Ø Inner diameter of modulating valve body 24.020 to 24.041 0.946 to 0.946
Clearance between plunger and seat 0.020 to 0.054 0.001 to 0.002
C Specifications of modulating valve outer spring:

Free length 64 2.52
Copyright ©
Transmission pressure relief valve and torque converter safety valve
A C E P B D S
Q
Q P SM9168
Fig. 2-175 Section of pressure relief valve Section of torque converter safety valve
T
DATA mm in
IN
A Ø Outside diameter of valve spool 19.979 to 20.000 0.786 to 0.787
Ø Inner diameter of spool seat in body 20.020 to 20.041 0.788 to 0.789
PR
Clearance between spool and seat 0.020 to 0.062 0.001 to 0.002
B Ø Outside diameter of piston 13.982 to 14.000 0.550 to 0.551

Ø Inner diameter of piston seat 14.016 to 14.043 0.553 to 0.552
Clearance between piston and seat 0.016 to 0.061 0.001 to 0.002
R
C Specifications of spool return spring:

FO
Free length 48 1.89

Load for spring compressed at 37 mm (1.46 in) 45.6 daN 102.37 lb
D Specifications of spool return spring:

T
Free length 43.5 1.71

Load for spring compressed at 32 mm (1.26 in) 15.64 to 17.30 daN 35.19 to 32.92 lb
O
E Pressure change setting ringnut

N
Setting of transmission pressure relief valve
- Adjust ringnut (E) so that the valve opens under a pressure in "Q" of 13.75 ± 0.5 bar (199.37 ± 7.25 psi)
with an oil flow at 40 °C (104 °F) of 10 lt/min (2.64 gpm).
- Each turn of the ringnut changes the pressure 1.5 bar (21.75 psi).
- Operating pressure: 17 bar (246.5 psi) with a flow of 66 lt/min (17.45 gpm).
Setting of torque converter safety valve
- Shim spring (D) so that the valve opens under a pressure in "P" of 10.5 ± 0.5 bar (152.25 ± 7.25 psi)
with an oil flow at 40 °C (104 °F) of 10 lt/min (2.64 gpm).
- Each shim changes the pressure 0.7 bar (10.15 psi) (thickness 1 mm) (0.03937 in).
Copyright ©
Torque converter / transmission feeding pump (Ref. 1 hydraulic diagram)
Twin gear pumps, one feeding the transmission, the other feeding the torque converter.
Maximum speed .......................................................................................... 2650 rpm

Bench test of transmission/torque converter pumps:
- Nominal output (at max. speed) ................................................ 117 lt/min (30.9 gpm)
- Nominal output of transmission feeding section ......................... 67 lt/min (17.7 gpm)
- Nominal output of torque converter feeding section.................... 50 lt/min (13.2 gpm)
- Oil temperature ............................................................... 45 to 55 °C (113 to 131 °F)
(*) The torque converter oil scavenger pump is connected to the steering clutches pump,
thus it is described in the Steering Clutch Section.
Torque converter Transmission feeding
T
feeding section section
IN
PR
R
FO
T
The arrow indicates the rotation direction

O
of the shaft and the delivery side

SUCTION
N
SUCTION
DELIVERY DELIVERY
SM9169
Fig. 2-176 Torque converter - transmission feeding pump
Copyright ©
Oil filters
Filter on the total flow transmission torque converter F2
delivery with paper filtering element, replaceable every
500 hours work (25 µ - nominal tightening torque 4
daNm (29.5 ft lb) and by-pass valve set at 2.5 bar
36.25 psi).
D150-2R0082
Fig. 2-177 Oil filter on delivery line

F2. Transmission/torque converter oil filter.
T
1
4
IN
PR
2
R
FO
SM9171
Fig. 2-178 Oil filter section on delivery line

1. Filter support - 2. Filter cartridge - 3. Filtering element -
4. Cover - 5. O-Ring.
T
Total flow filter on torque converter-transmission pump

O
suction line, with steel mesh filtering element (to be 2

1
cleaned every 1000 hours work) and magnetic plug 4
N
(100 µ nominal, without by-pass). 6 7
3 Fa
5
8
9
SM9172
Fig. 2-179 Oil filter on suction line

Fa. Steel mesh filtering element - 1. Cover locking nut -
2. O-Ring - 3. Cover - 4. Stud - 5. Magnetic rod - 6. Filtering
element retaining spring - 7. Circlip - 8. Gasket - 9. Support.
Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
SECTION 3
FINAL DRIVES
TABLE OF CONTENTS

3.1.1 Final drive (exploded view and sectional view) ...................................................... 3-2
3.2 REPAIR PROCEDURES ............................................................................................ 3-4

3.2.1 Final drive (removal / disassembly) ...................................................................... 3-4
3.2.2 Pulling the housing cover ...................................................................................... 3-8
3.2.3 Driven gear (bearing removal) ............................................................................... 3-9
3.2.4 Driving gear shaft (bearing removal) ...................................................................... 3-9
3.2.5 Description of installation of front seals (long life) ................................................. 3-10
3.2.6 Final drive (assembly) ........................................................................................... 3-11
T
IN
3.3.1 Final drive shaft and bearing fittings ..................................................................... 3-20
PR
R
FO
T
O
N
Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
1650K FINAL DRIVES 3-1
The final drives are of a double reduction type, with

straight spur gears and a 1 : 10.8 reduction ratio.
Specifications of final drive oil: must meet MIL-2105

or Api Service GL5 (SAE 80W-90). 4 1 2
Quantity to fill with oil final drives: 38 litres (10.04
gal.).
The 1650K final drives have two features, one of a

technical type, the other service oriented.
The technical feature consists of a different arrange-
ment of the final drives, being isolated from the stress
generated by the undercarriage, which, on the other
hand, is directly connected to the transmission hous-
ing, absorbing the majority of the loads on the track
chains through the hinging on the two shafts (PIVOT -
SHAFTS).
The service feature consists of the reduction of the
T
service time required to intervene on the machine,
since the modular type final drives are individually
IN
removable from the unit, without involving the trans-
mission housing.
PR
5 3
D150-2R0001
R
Fig. 3-1 Final drive installed

FO
1. Final drive - 2. Sprocket - 3. Track frame - 4. Transmission

housing - 5. Pivot shaft.
T
O
N
Copyright ©
3-2 FINAL DRIVES 1650K
3.1.1 FINAL DRIVE

(exploded view and sectional view)
185 173 174 172 179

168
168 175 176 169

178
170
159
181 G 182
194
172 167
166 V1
158
157
190
165
V2
171
161 183
180 162
T
164 187 186
IN
184
189 C
V1 1 S
PR
V2
188 163
R
160
FO
M V
D150-2R0002
T
Fig. 3.2 Final drive exploded view

O
C. Final drive cover - G. Dowel - R. Final drive upper guard - V. Sprocket hub securing screw (M20x1.5) - V1. Final drive
securing screw to PIVOT SHAFT (M24x2x260) (M24x2x130) - V2. Final drive securing screw to transm. housing (M16x1.5) -
N
C1. Segment securing screws (M22x1.5) - S. Sprocket segments - M. Sprocket hub - 157. Housing - 158. Cover -
159. Bearing housing - 160. Sprocket shaft - 161. Driven or idle gear - 162. Bearing - 163. Housing - 164. Spacer -
165. Spacer - 166. Spacer - 167. Sprocket gear - 168. Plate - 169. Driving gear - 170. Bearing housing - 171. O-Ring
3.53x171 - 172. O-Ring 3.53x142.50 - 173. O-Ring 3.53x183.7 - 174. O-Ring 3.53x190.1 - 175. Screw TE M16x1.5x65 -
176. Washer 16x30x3 - 178. Roller bearing 40x90x33 - 179. Roller bearing 70x150x35 - 180. Roller bearing 70x150x51 -
181. Roller bearing 55x120x43 - 182. Bearing - 183. Plug M27x2x16 - 184. O-Ring 3x24 - 185. Seal - 186. Screw TE
M12x50 - 187. Washer 12x24 - 188. O-Ring 3.53x215.5 - 189. Front seal - 190. Beaded ringnut - 194. Circlip 170.
Copyright ©
168
173-174
175-176
157-183-184
170-185
Driving
178
161
179
180
181
Idle
167
T
IN
159-168-172
188
PR
189
R
158-171
164
190
FO
160
TORQUE TIGHTENING
170 to 190 daNm
T
(1253.75 to 1401.25 ft lb)

162
O
182
N
194
165
187-186-163
166
D150-2R0084
Fig. 3-3 Final drive sectional view

(for the components, refer to fig. 3-2)
Copyright ©
3.2 REPAIR PROCEDURES
3.2.1 FINAL DRIVE

(removal / disassembly)
Removal
To remove the final drive, proceed as follows:
Drain the oil from the final drive through draining plug
B (fig. 3-4). Remove plug A to facilitate the draining. A
Remove the cover on the track frame, loosen the ten-

sion of the track chain, loosening slightly setting screw
VR and moving the machine backward, if required, a
few yards.
B
D150-2R0004
Fig. 3-4
T
IN
DANGER A. Oil filler plug - B. Oil draining plug.
Fluid under pressure. Do not relieve the track ten-
PR
sion by loosening pressure relief valve VS. Do not
remove grease fitting (I) installed on adjusting valve
VR .
R
FO
VS
T
O
N
I VR
D150-2R0004
Fig. 3-5 Adjustment of the track chain
VR. Tension adjusting valve - VS. Pressure relief valve - I. Grease fitting - C. Cover.
Copyright ©
Remove the track chain as described in SECTION 5

M
- UNDERCARRIAGE. 157
V
WARNING
Never work under or in the vicinity of equipment
or parts of the machine not adequately supported
and blocked.
Lift and handle all heavy parts with lifting devices

of adequate capacity. Make sure that parts are prop-
erly slinged and hooked. Use the lifting eyes pro-
vided for this purpose. Pay attention to persons
in the vicinity of the parts to be lifted.
T C1 S D150-2R0006
To disassemble the final drive assembly, it is advis- Fig. 3-6

able to remove first the sprocket, then proceed as
T
follows: C1. Sectors securing screws - M. Sprocket - S. Toothed
IN
sectors - V. Sectors securing screws - T. Track frame
housing - 157. Final drive housing.
- Remove at least three tooted sectors S from the
upper part of the sprocket, removing screws C1 (fig.
PR
3-6).
- Move the machine just enough to place the sprocket

without toothed sectors corresponding to the inter-
R
ference with track frame T, so that the sprocket can

be removed form the final drive. V1
FO
- Hold sprocket M using a hoist a lifting hook and 157

remove it, loosening the screws securing V it to the V2
hub.
V1
T
C1
O
S
N
Pull-out the two securing screws V1. Remove the cap.

Sling and hold the final drive assembly to be removed
(weight of the final drive complete with sprocket about
530 kg - 1170 lb). Loosen screws V2 securing the final
drive and remove it from the transmission housing.
Place the final drive on a bench for the full disassem- A
bly operation.
V2
V
M
D150-2R0007
Fig. 3-7 Final drives, sprocket and guards
Copyright ©
Disassembly
168 169 170
Remove the two seals (185) from driving shaft (169).
Pull out safety plates (168) from the seat on the cover
and bearing housing.
Remove bearing housing (170).
185 D150-2R0008
Fig. 3-8
Install two eye screws A into holes B of bearing

A 170
housings (158 and 159) and remove them complete
with bearings and O-Rings.
B 158
T
159
IN
PR
D150-2R0009
Fig. 3-9
Remove screws (175) on the final drive cover; remove

R
the dowels.
FO
T
O
N
D150-2R0010
Fig. 3-10
Tighten three eye screws on cover (C) and remove it

as indicated the figure.
D150-2R0011
Fig. 3-11
Copyright ©
Remove beaded ringnut (190).

190
D150-2R0012
Fig. 3-12
Remove driving gear (169) and driven gear (161) from

the final drive housing, as illustrated in the figure.
161
T
IN
PR
D150-2R0013
Fig. 3-13
Separate the components and place them on a proper

R
supporting surface, sufficient for all the parts to be

removed.
FO
T
O
N
D150-2R0014
Fig. 3-14
Install tool A as indicated in the figure, to block the

driven gear on the final drive housing.
D150-2R0028
Fig. 3-15
Copyright ©
Turn the final drive upside down and remove screws

(186) retaining the sprocket shaft and remove the
assembly from the final drive housing, as indicated in
the figure.
D150-2R0015
Fig. 3-16
Turn the final drive upside down, remove the blocking

tool and remove the driven gear, as indicated in the
figure.
T
IN
PR
D150-2R0016
Fig. 3-17
3.2.2 PULLING THE HOUSING COVER

R
Remove the outer straight roller bearings from the

FO
cover with the appropriate puller, only in the event

they must be replaced.
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O
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SM9340
Fig. 3-18
Copyright ©
3.2.3 DRIVEN GEAR

(bearing removal)
E
Pull-out the bearing races from each end of the gear
shaft, using puller (E), as illustrated in the figure.
D150-2R0090
Fig. 3-19
Warm-up races (P) of the new bearings and install

P
them on the shaft as illustrated.
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IN
PR
D150-2R0017
Fig. 3-20
3.2.4 DRIVING GEAR SHAFT

R
(bearing removal) P P E
FO
Using an appropriate puller (E), remove the bearing

races from the driving gear shaft, as illustrated in the
figure.
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D150-2R0018
Fig. 3-21
Warm-up the races of the new bearings (P) and install

them on the shaft as illustrated. P
D150-2R0019
Fig. 3-22
Copyright ©
3 - 10 FINAL DRIVES 1650K
3.2.5 DESCRIPTION OF INSTALLATION

OF FRONT SEALS
1
(long life)
Examine accurately the metal rings, checking that
the relevant faces are free from scratches, dents and
signs of wear, due to misalignment or planarity errors.
a
2
3 3
Replace both metal rings 1 figure and rubber rings 2,

even if one only is defective. b
T
Absolutely avoid mating a used metal ring with a new
one and rings salvaged from different seal pairs.
IN
PR 4
R
To install the seals, comply with the following rules:

FO
1. Eliminate all sharp corners and burrs; clean accu-

rately the rubber ring seats.
T
2. Clean accurately the rubber rings.

O
3. Press each metal ring 1 onto the relevant rubber

ring 2 (see detail a). d
N
D150-2R0020
4. Make sure that the metal ring is properly installed,
by checking that dimension 3 (detail b) isconstant Fig. 3-23
on the entire circle.
5. Install manually each pair of rings into the rel-

evant seats on the rubber ring, as illustrated (see
detail c).
6. Before completing the assembly (detail d) clean

with a lint free rag sealing faces 4 and smear a
thin film of fluid oil on them.
Copyright ©
1650K FINAL DRIVES 3 - 11
3.2.6 FINAL DRIVE

(assembly)
Clean and wash with an appropriate solvent all the
components prior to reassemble. 157
WARNING
erly slinged and hooked. Use the lifting eyes pro-
vided for this purpose. Pay attention to persons
in the vicinity of the parts to be lifted.
D150-2R0021
Fig. 3-24
Place final drive housing (157) on an appropriate

bench, facing the inner side upward, as illustrated in
the figure.
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IN
PR
Install the outer race of bearings (178) and (180) us-
R
ing an appropriate punch.

178 161 180
FO
SM9341
Fig. 3-25
161. Driven gear - 178. Gear roller bearing - 180. Sprocket

T
gear roller bearing.

O
N
Lift with a tool as illustrated and install driven gear

(161) into the final drive housing.
161
D150-2R0016
Fig. 3-26
Copyright ©
Arrange sprocket shaft (160) and install long-life seal

(189) in the relevant seat on the shaft. 160
Prepare housing (163) and install the second long-life
seal.
Note – Prior to the installation, lubricate adequately

the seals with oil or vaseline.
163
189
D150-2R0022
Fig. 3-27
Install he housing onto the shaft and insert spacer

164
(164).
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IN
PR
D150-2R0023
Fig. 3-28
Block the housing - sprocket shaft assembly proper-

R
ly, as per figure and warm-up twin bearing (162) to 162

about 110 °C (230 °F).
FO
Install the bearing on the shaft.

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D150-2R0024
Fig. 3-29
Install a tool (A) on the housing to secure the driven

gear, as illustrated in the figure, and turn the final drive A
housing upside down.
D150-2R0025
Fig. 3-30
Copyright ©
Lubricate adequately with oil or vaseline the contact

surfaces of the sprocket shaft assembly.
D150-2R0026
Fig. 3-31
Install O-Ring (188) in its seat.
188
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IN
PR
SM9314
Fig. 3-32
Install spacer (166) and insert the shaft into the hous-
R
ing, paying attention, during the centring phase, that

the assembly sets-in in a uniform manner.
FO
Install the 8 securing screws (M12x50) and tighten 166

them to the prescribed torque (see Torque Tightening
Table of SECTION 0 at the beginning of this Manual).
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D150-2R0027
Fig. 3-33
Turn the housing upside down and remove the driven
gear retaining tool.
Install spacer (165) on the shaft.
D150-2R0028
Fig. 3-34
Copyright ©
Prepare bearing housing (159) of idle shaft (161) and

install bearing (181) using a press.
181
159
D150-2R0029
Fig. 3-35
Warm-up inner races (P) of bearings (179) of driving P

gear (169) at about 110 to 120 °C (230 to 248 °F).
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IN
PR
D150-2R0030
Fig. 3-36
Install races (P) onto the relevant seats on both sides

R
of the shaft. P
FO
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D150-2R0031
Fig. 3-37
Hold the shaft and idle gear (161) assembly and in-
stall it inside bearing housing (159) inside the final
drive. 161
D150-2R0032
Fig. 3-38
Copyright ©
Also, install driving gear (159) matching it with idle

shaft (161). Rotate the gear train a few turns, to set in 161 159
the movement of the components.
D150-2R0033
Fig. 3-39
Warm-up the bearing inner race (182) to 110 °C

182
(230 °F) and install it on the seat on sprocket bearing
(160).
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IN
PR
D150-2R0034
Fig. 3-40
Prepare bearing housing (158) for reassembly.

R
182
Press mount bearing (182) outer race into the hous-
ing complete with O-Ring.
FO
Install the assembly on the cover and drive it with a

soft metal hammer until fully mounted.
158
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D150-2R0035
Fig. 3-41
Install circlip (194).
194
D150-2R0036
Fig. 3-42
Copyright ©
Screw ring nut (190) retaining the sprocket shaft.
190
D150-2R0037
Fig. 3-43
Block the gaer train and place the ringnut tighten-

ing tool complete with torque wrench (A) and multi- B
plier (B).
Tighten the nut to 100 daNm (737.5 ft lb). A
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IN
PR
D150-2R0038
Fig. 3-44
Bead the tip of the ex of nut (190).

R
190
FO
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D150-2R0012
Fig. 3-45
Smear a film of sealing compound (LOCTITE 518) on

the mating face with the cover.
Install the cover on the final drive housing, lifting it as
shown in the figure.
D150-2R0011
Fig. 3-46
Copyright ©
Install two guide screws (V) to centre the cover on

the housing and insert dowels (G). V
Drive the dowels until fully seated.
WARNING
Use a soft non ferrous hammer.
D150-2R0039
Fig. 3-47
Install the cover securing screws and tighten them

(12 daNm) (88.5 ft lb).
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IN
PR
D150-2R0010
Fig. 3-48
Lubricate with oil or petroleum jelly, driving shaft bear-

R
170
ing housing (170), complete with bearing (179) and
O-Ring (172).
FO
Install the housing into the seat oriented in such a

manner to coincide the seat for the installation of the
key.
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D150-2R0040
Fig. 3-49
Lubricate the idle shaft housing with oil or vaseline

and install it into the set on the cover.
D150-2R0041
Fig. 3-50
Copyright ©
Adjust the seat, if required to install the key.

Repeat the same operations for the sprocket shaft
bearing housing, as well.
SM9323
Fig. 3-51
Smear LOCTITE 518 on the lock race seats and in-

stall them.
T
IN
PR
D150-2R0092
Fig. 3-52
Install the two seals on the driving shaft, using punch

R
(B), with the faces oriented as indicated in detail A for B

the installation of the seals.
FO
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D150-2R0042
Fig. 3-53
Seals
Driving
shaft
Bearing
housing
SM9324
Fig. 3-54
Detail A - Seal installation.
Copyright ©
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3.3.1 FINAL DRIVE SHAFT AND BEARING FITTINGS
Driving shaft
N M A B
Idle shaft
T
L I
IN C D
PR
Sprocket shaft
R
FO
T
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H G E F
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D150-2R0091
Fig. 3-55 Sectional view of final drive
Copyright ©
BEARING SPECIFICATIONS AND DATA
Nominal value
A. Bearing inner diameter .................................................................................... 55 mm (2.16 in)
B. Bearing outer diameter .................................................................................... 120 mm (4.72 in)
C. Bearing inner diameter .................................................................................... 50 mm (1.97 in)
D. Bearing outer diameter .................................................................................... 110 mm (4.33 in)
E. Bearing inner diameter .................................................................................... 55 mm (2.16 in)
F. Bearing outer diameter .................................................................................... 120 mm (4.72 in)
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G. Bearing inner diameter .................................................................................... 110 mm (4.33 in)
IN
H. Bearing outer diameter .................................................................................... 180 mm (7.09 in)
PR
I. Bearing inner diameter .................................................................................... 60 mm (2.36 in)
R
L. Bearing outer diameter .................................................................................... 150 mm (5.90 in)

FO
M. Bearing inner diameter .................................................................................... 40 mm (1.57 in)
N. Bearing outer diameter .................................................................................... 90 mm (3.54 in)

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SECTION 4
BRAKES AND STEERING DIFFERENTIAL

TABLE OF CONTENTS

4.1.1 Brakes hydraulic diagram ..................................................................................... 4-1
4.1.2 Main components of brakes circuit ....................................................................... 4-5
Brakes power pump ......................................................................................... 4-5
Brakes power valve block ................................................................................ 4-6
Brakes pedal valve .......................................................................................... 4-7
Steering-brakes filters ...................................................................................... 4-9
4.1.3 Steering hydraulic system diagram ....................................................................... 4-11
4.1.4 Main components of steering circuit ..................................................................... 4-14
Hydraulic motor ............................................................................................... 4-14
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Steering piloting valve block ............................................................................ 4-15
IN
4.2.1 Diagnosis on the display ....................................................................................... 4-17
PR
4.3 TESTS ...................................................................................................................... 4-19
4.3.1 Checking circuit pressures on diagnostics ............................................................ 4-19
4.3.2 Adjusting the brake pedal ..................................................................................... 4-20
4.3.3 Checks and setting on brake power valve block ................................................... 4-21
R

FO
4.4.1 Brake pedal valve (removal/disassembly) ............................................................. 4-22

4.4.2 Brake power pump (removal/disassembly/re-assembly) ........................................ 4-24
4.4.3 Steering side group ............................................................................................... 4-26
Removal (preliminary operations) ..................................................................... 4-26
T
Disassembly of transmission housing cover .................................................... 4-28

Removal of steering side group........................................................................ 4-31
O
Removal of crown gear .................................................................................... 4-33

Disassembly of crown gear .............................................................................. 4-34
N
Disassembly of steering side group ................................................................. 4-35

Disassembly of the differential planet carrier ................................................... 4-35
Disassembly of planetary group ....................................................................... 4-36
Disassembly of bearing housing from the steering side assembly ................... 4-37
Assembly of the steering side assembly ......................................................... 4-39
Reassembly of planetary group........................................................................ 4-41
Reassembly of planet carrier assembly ........................................................... 4-42
Reassembly and installation of the crown gear assembly ................................ 4-44
Reassembly of steering side group into the transmission housing ................... 4-46
4.4.4 Bevel gear set (removal/disassembly of bevel pinion and crown gear) .................. 4-48
Removal .......................................................................................................... 4-48
Disassembly of bevel pinion ............................................................................ 4-50
Disassembly of the crown gear ........................................................................ 4-53
Reassembly of crown gear .............................................................................. 4-54
Assembly of bevel pinion ................................................................................. 4-55
4.4.5 Brake group and pinion on brake side ................................................................... 4-60
Removal of the brake group ............................................................................. 4-60
Disassembly of the brake group ...................................................................... 4-61
Copyright ©
4.4.6 Procedure and inspection for brake pack .............................................................. 4-63

Installation of brake group ................................................................................ 4-64
Removal of brake pinion .................................................................................. 4-65
Disassembly of brake pinion ............................................................................ 4-66
Reassembly of brake pinion ............................................................................. 4-67
Re-installation of bevel gear crown .................................................................. 4-69
Re-installation of the pinion .............................................................................. 4-70
4.4.7 Procedure for the setting of the bevel pinion bearings pre-load (transmission side) ...... 4-71
T
4.4.8 Procedure for the setting of the bevel gear set ...................................................... 4-72
Re-installation of brake pinion .......................................................................... 4-73
IN
Re-installation of brake group .......................................................................... 4-74
Installation of the rear transmission cover ....................................................... 4-76
Pre-load of the gear support ............................................................................ 4-76
PR
4.4.9 Installation of housing cover ................................................................................. 4-84

4.5.1 Reduction bevel gear set ...................................................................................... 4-85
R
4.5.2 Pinion brake side .................................................................................................. 4-87

4.5.3 Brakes .................................................................................................................. 4-88
FO
4.5.4 Brake pedal valve ................................................................................................. 4-89

4.5.5 Rear transmission (transmission side section) ...................................................... 4-91
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Copyright ©
1650K BRAKES AND STEERING DIFFERENTIAL 4-1
4.1.1 BRAKES HYDRAULIC DIAGRAM A brake pedal valve (directly actuated by the central
pedal in the cab) actuates directly the brakes by cut-
The hydraulic circuit of the brakes is totally separated
ting-off pressure from the circuit.
from the steering circuit and it is mainly composed of:
Rear housing (8) is composed of the bevel gear set
- A double pump powering the brakes and transmis- (directly powered by the transmission), the brake discs
sion circuit (ref. 1 on hydr. diagram) (oil-bath) and the steering differential. The transmis-
sion housing becomes the reservoir collecting the oil
- Suction filter (10) (metal) and on delivery (paper)
that is used both to pilot the pack and to lubricate all
(ref. 2)
the components in the housing.
- Power valve block (ref. 3) The brake is engaged when the pedal in the cab is
pressed, since this subtracts pressure from the cir-
- Brake pedal valve (ref. 4)
cuit, thus the force of the springs locks the baking
- Rear transmission housing (ref. 8) device on the brake disc pack.
Power pump (1) sucks the oil from rear transmission The machine brakes under the following conditions:
housing (8) through a metal mesh filter (10) and for- - when standing with engine inoperative (parking
wards it to port (P) of power valve block (3) through brake);
filter (2).
Pressure relief valve (6) provides the circuit a pres- - when standing with engine in operation and the safety
T
sure of 25 ± 2 bar (362.6 ± 29 psi). Accumulator (5) levers in raised position;
IN
provides pressure to the circuit in case of engine fail- - when moving and the central brake pedal is pressed
ures. (service brake).
PR
R
FO
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4-2 BRAKES AND STEERING DIFFERENTIAL 1650K
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IN
PR
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4-3
4
7
2
1
6
T
5
IN
1
PR
BRAKE DISC
BRAKE DISC BRAKE
2 LUBRICATION 11
LUBRICATION CONTROL
R
10
FO
8
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9
KSM0004
Fig. 4-1 Brakes hydraulic diagram
1. Power double pump - 2. Oil filter (delivery) - 3. Power valve block - 4. Brake pedal valve - 5. Accumulator - 6. Pressure relief valve - 7. Directional solenoid valve - 8. Transmission housing - 9. Brake discs - 10. Oil filter (suction) - 11. Pressure pick-up point - A. From converter -
B. To transmission housing.
Copyright ©
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4.1.2 MAIN COMPONENTS OF BRAKES Gear type double pump mounted on the converter
CIRCUIT cover. One section powers the brake circuit; the other
scavenges the oil form the converter and returns it
Brakes power pump into the transmission.
(Ref. 1 hydraulic diagram) Delivery at max speed (2650 rpm) with engine at max.
power rate of 2000 rpm.
Delivery of section (1) powering the brakes 53 lt/min
Pump type ...................................................... gear (13.2 gpm).
Brand ................................ SAUER SUNDSTRAND Delivery of section (2) scavenging the oil from the
Model ........................................ PNN 19+8S SC 41 converter 22 lt/min (5.8 gpm).
The arrow indicates the direction of the

movement of the shaft and the delivery side
SUCTION
DELIVERY
T
IN
2650 RPM
Sez.1 19.2 CC/REV
53 l/min
2650 RPM
PR
Sez.2 8.4 CC/REV
22 l/min
SUCTION
DELIVERY
R
Section 1: Converter oil Section 2: Brake circuit C

scavenger pump power pump
FO
P1
2 1
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SM9174 P DSM 0123
Fig. 4-2
P. Brakes pump - C. Torque converter - P1. Equipment/steering piston pump.
Copyright ©
Brakes power valve block

(Ref. 3 brakes hydraulic diagram) 3
DR
The power valve block is installed on the left side, 7

under the cab. To reach it, just open the left panel Set 25 bar (362,6 psi)
1
under the cab. 3
P 1 2
1. Brakes power pump 2

2
3. Power valve block 3
5. Accumulator (pre-charge 13 bar, 188.5 psi) 6
6. Pressure relief valve (set at 25 bar, 362.6 psi) 1
1
7. Directional solenoid valve
11. Pressure pick-p points
C 5
Ports on block: PP 11
SM1406
DR. Draining
P. From power pump Fig. 4-3
C. Brakes lubrication
T
PP. Pressure pick-up point
1. To brake pedal valve
IN
2. To brake pedal valve PR
5
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3
6
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PP 2
N
DR P
D350R0091
Fig. 4-4
Copyright ©
Brakes pedal valve

(Ref. 4 hydraulic diagram)
The brake pedal valve is installed in the lower side of

the cab and it is actuated by a linkage directly by the
brake pedal.
DR
Ports on the valve
P. To brakes (delivery)
DR. To brakes (draining) P
T. To housing (discharge)
A. To power valve block (pos. 1)
B. To power valve (pos. 2) D350R0089
Fig. 4-5
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IN
PR
A
R
B
FO
T D350R0090
Fig. 4-6
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DR
(M12 x 1,5)
T
(M22 x 1,5)
A
(M16 x 1,5) P
(M22 x 1,5)
B
(M14 x 1,5)
SM9186
Fig. 4-7 Valve hydraulic diagram
Copyright ©
24 1 2 3 4 5 6 7 8 9 10 25
11
P
12
13
14
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IN
B A
PR
30 20 19 18 17 29 16 15 23
21
R
33 26 26 28 27 24
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22 31 32
D150-2R0064
Fig. 4-8 Brake pedal valve section view
1. Cover - 2. Spring - 3. Washer - 4. Piston - 5. Body assembly - 6. Rod - 7. Inner cup - 8. Washer - 9. Spring - 10. Outer cup -
11. Guide - 12. Pushing pin - 13. Cover - 14. Cam - 15. Washer - 16. Gasket - 17. Piston spring - 18. Piston - 19. Spacer -
20. Gasket - 21. Pin - 22. Dowel - 23. Spring pin - 24. Shaft seal - 25. O-Ring 2.62x34.59 - 26. Spring washer - 27. Screw
M8x55 - 28. Screw M8x35 - 29. O-Ring 2.62x20.29 - 30. O-Ring 2.62x18.72 - 31. Gasket - 32. Plug M10x1.25 - 33. Screw
M8x75.
Copyright ©
Steering-brakes filters
Delivery filter (2)

(Ref. 2 hydraulic diagram)
F
The delivery filter on the steering-brakes circuit can
be reached by opening the panel of the engine com-
partment on the left side of the machine.
Full flow paper type, replaced every 500 hours work

(30 µ nominal and by-pass valve set at 2.5 bar,
36.2 psi).
Tightening torque 4 daNm (29.5 ft.lb.).
D150-2R0126
Fig. 4-9
F. Steering-brakes oil filter.
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IN
PR 5
3
1
4
R
FO
2
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SM9171
Fig. 4-10
1. Filter support - 2. Filter cartridge - 3. Filtering element -

4. Cover - 5. O-Ring.
Copyright ©
4 - 10 BRAKES AND STEERING DIFFERENTIAL 1650K
Suction filter
(Ref. 10 hydraulic diagram) 1 2
The suction filter of the brakes circuit is accessible 6 4

by tilting the cab. 7
Full flow, with steel mesh filtering element (not to be 3
replaced, but cleaned every 1000 hours work) and
magnetic rod 100 µ nominal w/out by-pass). 5 Fa
9 8
SM9172
Fig. 4-11
T
Fa. Steel mesh filtering element - 1. Cover locking nut -
IN
2. O-Ring - 3. Cover - 4. Stud - 5. Magnetic rod - 6. Filter-
ing element retaining spring - 7. Circlip - 8. Gasket -
9. Support.
PR
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Copyright ©
1650K BRAKES AND STEERING DIFFERENTIAL 4 - 11
4.1.3 STEERING HYDRAULIC SYSTEM When pilot valve (Ms) is actuated, oil is forwarded to
DIAGRAM steering piloting block (Vp), thus piloting directly steer-
ing spool (1) on control valve (D).
The steering and equipment hydraulic systems are a Piston pump (P) driven by the torque converter pow-
single circuit and use the same oil. ers both the steering circuit and the equipment circuit
The two systems, although sharing some hydraulic through the control valve. The regulation of the flow
components, are described separately. distribution system operates under priority logic for
The equipment system is described in SECTION 6 - the steering, through the Load Sensing between con-
EQUIPMENT HYDRAULIC SYSTEM. trol valve and pump.
The two systems are separated by the operating pres-
sures and operate at:
- steering system max. pressure 350 ± 5 bar When high performance is required by the steering,
(5076.3 ± 72 psi); when operating the steering and equipment at the same
- equipment system max. pressure 190 ± 5 bar time, it would occur that at a high pressure of 190 bar
(2755.7 ± 72 psi). (2755.7 psi), the flow to the equipment is zeroed, since
it is fully absorbed by the hydraulic motor.
The steering system is mainly composed of: Thus, the advancing speed remains unchanged, since
- Piston type power pump for steering/equipment cir- the power subtracted from one track chain is added in
cuits (ref. P). the same entity to the other, providing a constant steer-
- Hydraulic motor (ref. M). ing without locking the track chain and with a precise
- Steering/equipment control valve (ref. D). control on the trajectory.
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- Steering piloting valves block (ref. Vp). When the travel is straight without operating the equip-
IN
- Power valve block (ref. Va) (see section: Equipment ment, the power flows fully to the bevel gear set and
hydraulic system). thus the track chains that being linked to move at the
- A pilot valve Ms (ref. Ms). same speed, since the hydraulic motor is, in this case,
PR
- Microcontroller (ref. C). inoperative.
In the vent the pilot valve is actuated in neutral, the
The 1650K is equipped with a steering differential let- pump delivery flows entirely toward the hydraulic motor
ting a dozer to transmit constantly power while steer- without actuating the equipment.
ing to both track chains, changing the speed without This makes provides the two track chains to be mov-
R
never blocking the track. The speed of one track chain ing in opposite directions (counter rotation) at a speed
FO
increases or decreases in the same entity with re- of 0 through 2 km/h. Thus the machine is capable of
spect to the other, without any loss of power while turning on itself providing a rightward counter rotation
pushing. It is particularly advantageous also for fin- when the right pilot valve is actuated and leftward when
ishing jobs, especially in particularly closed spaces. the left pilot lever is actuated.
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4 - 13
Ma Ms HYDRAULIC STEERING DIAGRAM 76072083

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12
4 2
T 3
T P
P
A1 S B1
b5 b2 b1
D
877109
877109
877109
3
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
x b3 γ1
230 bar (3385.3 psi)
T
R S X L
73074729
TR 40 bar (580.2 psi)
IN
TL.
230 bar
321141
321141
396467
396467
STEERING
9
0 (5656.5 psi 0 )
230 bar (3385.8 psi)
230 bar (3385.8 psi)
230 bar (3385.8 psi)
230 bar (3385.8 psi)
+72
C
A
PR
396467
396467
396467
396467
B MT
PS
10 Vp 2
390 bar+5
30±2 bar (435.1±29 psi) a 15 lt/min (4 gpm)
T
5 bar (72 psi)
PM D 5 bar (72 psi)

4 1
898999
719176
723216
719176
723199
0.7 Lt/min (0.2 gpm)
938489
R
T
190/360 bar
P
76074300
FO
R1 L1
560952
P
LS
MP
O = 150 lt/min (39.6 gpm)
O = 150 lt/min (39.6 gpm)
O = 70 lt/min (18.5 gpm)
O = 50 lt/min (13.2 gpm)

B5
O = 150 lt/min (39.6)

877109
B3 A3 B2 A2 B1 A1 MLS
877109
877109
877109
O = 150 lt/min (39.6 gpm) O = 150 lt/min (39.6 gpm)
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
O = 120 lt/min.
O = 150 lt/min (39.6 gpm)
RIPER
T
TILT
LIFT
a5 a3 a2 a1
11
O
N
5
BLOCK CHECK POINT
76073165
6 Va P
8 X
35 bar
S
(507.6 psi) F
45 bar
(652.7 psi)
7
P2 T PR
KSM0001
Fig. 4-12 Hydraulic steering diagram

KSM0001
D. Equipment/steering control valve - F. Oil suction filter - M. Steering hydraulic motor - Ma. Blade control pilot valve - Ms. Steering/gearshift pilot valve - P. Variable displacement pump - Va. Power valve block - Vp. Steering piloting valve block - 1. Steering control spool -
2. Plug - 3. Reduction valves (40 bar, 580.2 psi) - 4. Distribution valve - 5. Accumulator - 6. Pressure reduction valve (35 bar, 507.6 psi) - 7. Power cut-off solenoid valve - 8. Power block pressure relief valve (45 bar, 652.7 psi) - 9. Selector valve - 10. Piloting valve -
11. Pressure compensators - 12. Steering spool safety value.
Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
4.1.4 MAIN COMPONENTS OF STEERING Hydraulic motor

CIRCUIT Brand ...................................................... REXROTH
Note – For the following components:
Type ........................................... fixed displacement
- Variable displacement piston type hydraulic pump A2 FE 63/61W - VAL 180-S
(ref. P)
- Control valve (ref. D)
- Power valve block (ref. Va)
Please refer to SECTION 6 EQUIPMENT HYDRAU-
LIC SYSTEM of this Manual.
T
IN
3
MA MB
PR
R
3
FO
1 A1 S B1
T
2
Hydraulic motor diagram
O
N
D350R0088
Fig. 4-13
A. To steering/equipment control valve - B. To steering/equipment control valve - S. To heat exchanger - 1. REXROTH

hydraulic motor - 2. Seal - 3. Screw 16x1.5x45.
Copyright ©
Steering piloting valve block

(Ref. Vp hydraulic diagram)
It is mounted on the frame on the left side of the ma-
chine. To reach it, it is necessary to tilt the cab.
Ms
4 2
T
P
T
3
IN
R S X L
A
40 bar (580.2 psi)

TR
9
PR
TL
T P
C A
Vp
B
PS
10
B
C
4
PM 5 bar (72.5 psi)
R
D
FO
P R1 L1
1850-2R0288
T
Fig. 4-14 Hydraulic diagram

O
Vp. Piloting valves block - 3. Pressure relief valve (40 bar, 580.2 psi) - 4. Electro proportional valves - 9. Selector valve -
N
10. Piloting valve.
Copyright ©
Ports on the piloting valves block
PM
T
X
T
IN
PR S
L R
R
FO
1850-2R0290
Fig. 4-15
T
O
N
P
L1 R1
1850-2R0289
Fig. 4-16
P. From powering block - T. To reservoir - L. To b1 of control valve - R. To a1 of the control valve - X. To y1 of the control
valve - S. To b4 of the control valve.
Copyright ©
4.2 TROUBLESHOOTING
4.2.1 DIAGNOSIS ON THE DISPLAY

The display has 5 text field digits signalling the fol- 5 text field digits
lowing messages:
A. Work hourmeter signal

The engine hours are signalled by coming ON for
about 1 second when the general test of the in-
strument panel is performed. To repeat the reading
of the engine hours, it is necessary to cut-off and
to energise again the system with the starter switch
key. The hours stay ON until the engine is started. SM9191
Fig. 4-17
or
B. Speed engaged + failure code signal
T
- The first digit indicates the speed engaged. Failure code E = Failure
IN
- The second digit indicates E in the event of a
failure. Speed engaged Code failure
PR
1st speed
- The 3rd - 4th and 5th digits indicate the code of the
type of failure and they are distinguished by two
types.
R
Failure codes of a single component of the brakes

FO
and transmission control system

(see table 1).
Failure codes for more than one component
Failure example
(see table 2). SM9192
T
Fig. 4-18
O
N
Copyright ©
When the display shows one of the failure codes here below, identify the corresponding failed component,
as per table 1.
TABLE 1
Failure
Failed component
code
Forward speed "F" solenoid 004
Reverse speed "R" solenoid 008
1st speed solenoid 016
3nd speed solenoid 032
TABLE 2
T
Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of Sol. of
IN
left prop. right prop. Forw. Rev. 1st speed 3rd speed left steer. right steer.
Failed component solen. solen. speed "F" speed "R" lever lever
valve valve
PR
Forward speed "F" solenoid 004 012 020 036 068 132
Reverse speed "R" solenoid 008 024 040 072 136

R
1st speed solenoid 016 048 080 144

FO
3rd speed solenoid 032 096 160

T
O
Failure code of reverse speed "R" solenoid = 008

Failure code addition on display Failure code of 1st speed solenoid = 016
N
In the event the failed components are two, refer to The crossing in TABLE 2 of the two components de-
TABLE 2 where the code is determined by the addi- termines the failure code given by the addition of the
tion of the two single failure codes listed in TABLE 1. two single codes 024.
As an example, code 024 indicates that the failed
parts are two: the top digit of the column identifies the Reverse speed "R" failure code = 008 +
solenoid of the "1st speed", whereas the left digit iden- 1st speed failure code = 016
tifies the solenoid of the "reverse speed R". Failure code for both on the display = 024
Copyright ©
4.3 TESTS
4.3.1 CHECKING CIRCUIT PRESSURES

ON DIAGNOSTICS WARNING
Remove the caps on the diagnostic panel. Before operating the machine or its equipment
Connect a pressure gauge with engine inoperative make sure that all bystanders are away from the
(30 bar, 290 psi capacity) to pressure pick-up points operating range of the unit. Walk around the ma-
(6-7-8) indicated in the figure. chine before climbing on it. Sound horn.
While proceeding with the test of the circuits, make Bring the engine to max. speed (2100 to 2200 rpm)
sure that the single pressure gauges are adequate for and measure the relevant pressures that must coin-
the pressures to be measured. cided with the values of nominal pressures listed in
the table here below.
Start the engine and perform a few forward/reverse
manoeuvres, actuating at the same time, the steer- Table of nominal pressures
ing levers to warm-up the oil.
1. Pump pressure 190/350 bar
(2755.7/5076.3 psi)
2. Load sensing pressure 210 to 370 bar
(3045.8 to 5366.4 psi)
T
WARNING 3. Port A1 hydraulic motor
pressure 350 ± 5 bar
IN
Do not operate the engine of this machine in closed (5076.3 ± 72 psi)
spaces without proper ventilation removing deadly 4. Port B1 hydraulic motor
exhaust fumes. pressure 350 ± 5 bar
PR
(5076.3 ± 72 psi)
5. Pilot valve power pressure 31.5 to 35 bar
(456.9 ± 507.6 psi)
6. Brakes pressure 20 ± 2 bar
(290 ± 29 psi)
R
7. Steering piloting pressure a5 30 ± 2 bar

(290 ± 29 psi)
FO
8. Steering piloting pressure b5 30 ± 2 bar

(290 ± 29 psi)
T
3
2
O
1
N
5 6 7 8
D150-2R0127
Fig. 4-19 Pressure pick-up points on diagnostic board
Copyright ©
4.3.2 ADJUSTING THE BRAKE PEDAL

Place brake pedal (1) at dimension L = 175 mm
(6.9 in) from the cab floor, actuating block (2).
Connect link (3) to fork (4). 4

2 1
Adjust the length of rod (3) until it connects with lever
(5) placed at stroke-end. 6
Lock locknut (6).
Loosen block (2) until play on the pedal is almost elimi-

nated and block it with the relevant nut. L
CAB FLOOR
Run the entire stroke of brake pedal (1) avoiding over-
running the stroke-end of lever (5). 7
Move screw (7) against brake pedal (1).

3
Release the brake pedal, loosen screw (7) two turns
T
and tighten the nut.
IN
5
PR
R
1850-2R0292
Fig. 4-20
FO
T
O
4
N
2
3
1850-2R0293
Fig. 4-21
Copyright ©
4.3.3 CHECKS AND SETTING ON BRAKE

POWER VALVE BLOCK Left side
under
(ref. 3 on brakes hydraulic diagram)
cab panel
Open the left side panel indicated and connect a pres-
sure gauge (30 bar, 290 psi capacity) to pressure quick
release coupling PP on the power valve block.
Start the engine at max. power speed (2100 to 2200

rpm) and read on the gauge if the pressure setting of
the pressure relief valve is 25 ± 2 bar (362.6 ± 29 psi)
at an oil flow of 53 lt/min (14 gpm).
In the event the pressure is not as prescribed, pro-

ceed as follows: PP
Pressure quick
- Loosen locknut (2) and loosen or tighten screw (1) release coupling
to change the pressure, setting it at 25 ± 2 bar
(362.6 ± 29 psi).
- Tighten locknut (2).
T
IN
PR PP 2
WARNING
SM9204
Disconnect and connect all connections with en-
R
gine and system inoperative. The spillage of oil

under pressure from loosen connections can re- Fig. 4-22
FO
sult in personal injuries and damages.

Wear protective glasses with side shields.
T
O
Pressure relief valve

N
1850-2R0294
Fig. 4-23
Copyright ©
4.4.1 BRAKES PEDAL VALVE

(removal/disassembly)
Removal
Disconnect and label all hoses from the control valve,
by removing the two screws (2) with washers secur-
ing the control valve to support bracket (3).
Remove brakes valve (1).
Disassembly
4
Disconnect all connections and washers, remove
screws (4) and the relevant washers. Remove cover
(5) from the valve body. 5
1
3 2 SM9207
T
Fig. 4-24 Brakes pedal valve linkage
Brakes pedal valve linkage
IN
1. Brakes controlling valve - 2. Valve securing screw
Remove dowel (9) securing shaft (10) from the cover M10x1.5 - 3. Valve support - 4. Upper cover screws
using an appropriate screw (4 mm diam x 0.75 mm). M8x1.25 - 5. Cover.
PR
10 6 5
R
7
8
FO
Section view of valve (5)

Remove plug (7) and copper gasket (8) from cover (5)
to reach pin (23) retaining cam (14). Pull-out the lever
using a punch and the relevant shaft. Remove the
T
key from the shaft and the relevant seal. 9

O
Form the other side of the valve, remove screws (24,

fig. 4-26) from cover (1). Hold the cover while loosen-
N
SM9208
ing the last two screws since spool is loaded by a
spring. Then remove the cover and the O-Ring; spring Fig. 4-25 Section view of valve
(2) and cup.
6. Seal - 7. Plug M10 x 1.25 - 8. Gasket 10 x 16 x 1 - 9.
Retaining dowel - 10. Shaft.
Copyright ©
From the other side, remove guide (11) pushrod (12) remove the spacer, spring (9) cup (10). Pull-out washer
and O-Ring (25) then remove pushrod assembly (6). (15) O-Ring (29) extract spring (17) and the large and
Press spring (9) and extract rod retaining washer (8), small plunger (18 and 19).
24 1 2 3 4 5 6 7 8 9 10 25
P
11
12
13
14
T
IN
30 20 19 18 17 29 15 23
PR
B A
SM9188
Fig. 4-26 Brake pedal valve section

R
1. Cover - 2. Spring - 3. Washer - 4. Piston - 5. Body assembly - 6. Pushrod - 7. Inner cup - 8. Washer - 9. Spring - 10. Outer
cup - 11. Guide - 12. Pushrod - 13. Cover - 14. Cam - 15. Washer - 16. Gasket - 17. Piston spring - 18. Piston - 19. Spacer
FO
- 20. Gasket - 23. Spring pin - 24. Cover securing screw M8x75 - 25. O-Ring 2.62x34.59 - 29. O-Ring 2.62x20.29 - 30. O-
Ring 2.62x18.72.
T
O
N
Copyright ©
4.4.2 BRAKE POWER PUMP 4 13

3 5
(Removal/disassembly/re-assembly)
For the pump powering the steering differential circuit 11
and the equipment hydraulic pump, please refer to
SECTION 6 EQUIPMENT HYDRAULIC SYSTEM of
this Manual for the disassembly operations.
Removal
To remove the pump from the converter cover it is
necessary:
- to tilt the cab and to disconnect the pump connect-

ing pipes. 12 7 6 10 8 9
1 2
- to remove the screws securing the front cover to SCREWS TIGHTENING

TORQUE: 50 Nm
torque converter cover (C) and to remove the pump. DSM 0142
Disassembly Fig. 4-27 Brake power pump

To disassemble the parts of the pump remove screws
T
1. Pump securing screw - 2. Rear cover - 3. O-Ring -
(1), remove the front and rear covers and pull-out sup- 4. Pump body - 5. Centring dowel - 6. Supports - 7 and
IN
ports (6) complete with gears (7 and 8). 8. Pump gears - 9. Front cover - 10. Centring ring -
11. Circlip - 12. Bushes - 13. Oil seal.
PR
Inspection of parts
R
WARNING
FO
Never use gasoline, solvent or other flammable

fluid to clean parts. Use exclusively qualified, non-
flammable, non-toxic approved commercial sol-
vents.
T
O
Clean all parts carefully and dry them with dry com-
pressed air.
N
Check the pump gear support bushing; if they are

scored, pitted or excessively worn, replace them.
Check that the pump body (4) in the zone near the
gears is not worn. Replace the parts if damaged. Re-
place the seals.
Copyright ©
Reassembly C
Reassemble the pump reversing the disassembly
sequence. Lubricate freely the inner parts and make
sure that gears (7 and 8) turn freely without jamming.
Secure the pump to the converter cover smearing the
contact faces with an appropriate sealing compound.
Connect the pipes.
P DSM 0123
Fig. 4-28 Torque converter cover
C. Torque converter - P. Brake pump.
T
IN
PR
R
FO
T
O
N
Copyright ©
4.4.3 STEERING SIDE GROUP

Removal (preliminary operations)
Prior to any disassembly operation, move the main
switch into position "OFF" and place a "DO NOT
ON
START SIGN" on the engine starter switch key in the
cab.
OFF
WARNING
Make sure that lifting cables are secured to points
strong enough to handle the load. Keep all by-
standers away from the securing point, cables or
chains.
DSM 0130
Fig. 4-29
T
Drain the fuel from draining pipe T as indicated, actu-
T
ating valve R. Drain completely the fuel tank.
IN
Capacity of fuel tank 270 litres (71 gal.).
Disconnect the duel-feeding pipe to the injection pump; R
remove the eight screws (1) securing the base of the
PR
tank.
Lift the tank with a hoist equipped with lifting hooks,
using the eyes as indicated in fig. 4-31. Remove the
two screws (2) securing the side to the hydraulic tank
R
that it is not necessary to remove.

FO
WARNING
T
D150-2R0128
Avoid kinking chains and steel cables. Always wear

O
Fig. 4-30
protective gloves when handling cables and
chains.
N
2
Remove the fuel tank.
1 D150-2R0129
Fig. 4-31
Copyright ©
- Drain the oil from the transmission housing, by re-

moving plug A from the rear side of the machine
and let the oil drop completely (capacity of housing
about 46 litres - 12 gal.).
- Remove the track chains as described in SECTION

5 - UNDERCARRIAGE of this Manual.
- Remove the final drive as described in SECTION 3

- FINAL DRIVE of this Manual.
A 1850-2R0298
Tilt the cab as described in the Operation and Main-

Fig. 4-32
tenance Manual.
Note – Label the pipes before disconnecting them. 1

Disconnect all pipes connected to the housing and
from hydraulic motor (5) the relevant pipes (1 - 2 - 3 -
4). 4
2
T
Remove all screws (6) securing housing cover (7). 3 5
IN
6
7
PR
R
FO
D150-2R0130
Fig. 4-33
T
Arrange a hoist to remove the cover, equipped with

O
appropriate lifting hooks.

Install three eyes in the holes as indicated in the fig-
ure and lift the transmission housing cover assembly.
N
DSM 0004
Fig. 4-34
Copyright ©
Disassembly of transmission housing cover

Install lifting rig (1) on the hydraulic motor and remove
the securing screws.
DSM 0005
Fig. 4-35
Lift the hydraulic motor with a hoist to pull it out from
the seat on the cover.
T
IN
PR
DSM 0006
Fig. 4-36
Remove the securing parts and the gears from the
R
hydraulic motor following the sequence:

FO
2. Screw
3. Disc
4. Shim
5
5. Gear
4
T
3
O
WARNING
2
N
vice of appropriate capacity. Make sure that heavy DSM 0007

parts are held by appropriate slings and hooks.
Fig. 4-37
Note – Move the cover upside down to remove the

components.
DSM 0008
Fig. 4-38
Copyright ©
Remove screws (6) and pull-out gear support (7) from

the cover.
6 6
7
DSM 0010
Fig. 4-39
Remove screw (8) and extract washer (9) and disc 9 8

(10).
10
T
IN
PR
D150-2R0131
Fig. 4-40
Then, remove gear (11) and spacer (12).
R
11
FO
12
T
O
N
D150-2R0132
Fig. 4-41
Using a press, pull-out from gear support (13) the shaft
with gear (14) and two bearings (15) salvaging spacer 14
(16) as well.
13
16
15 DSM 0013
Fig. 4-42
Copyright ©
Remove securing screws (17) of the two shaft gears

and remove washers (18) and discs (19).
19
17
18 DSM 0014
Fig. 4-43
Then, remove the two gears (20).
20 20
WARNING
Handle all heavy parts with the utmost attention.
T
Never place hands and fingers between one part
and another. Wear approved personal protection
IN
devices such as glasses, gloves and safety shoes. PR
DSM 0015
Fig. 4-44
Remove spacer (21) on the mobile race bearing side,

R
right side.
FO
21
T
O
N
DSM 0016
Fig. 4-45
Remove the two spacers (22) and (23) on the fixed
race bearing side, left side.
23
22
DSM 0017
Fig. 4-46
Copyright ©
Remove the bearing safety circlip and repeat the op-

eration on the opposite side of the shaft.
DSM 0018
Fig. 4-47
After pulling the mobile race bearing, on the left side,
remove the shaft from the bearing supports. Then re-
move the second bearing as well.
Clean accurately all parts disassembled from the cover
assembly.
T
WARNING
IN
PR
flammable, non-toxic approved commercial sol- DSM 0019
vents.
Fig. 4-48
Disconnect the brake control and lubrication pipes from
R
the connections as indicated.

FO
T
O
N
DSM 0020
Fig. 4-49
Removal of steering side group
Remove screws (C2) securing the steering side as- C2
sembly from the transmission housing.
D150-2R0069
Fig. 4-50
Copyright ©
T
IN
PR
R
FO
DSM 0022
Fig. 4-51 Section view of transmission housing

T
O
N
Copyright ©
Install the lifting tool as indicated in the figure to re-

move the steering side assembly from the housing.
Place the steering assembly on a bench equipped

with an adequate support for the disassembly of parts.
SM9216
Fig. 4-52
Removal of crown gear
Remove the circlip from the crown support.
T
IN
PR
DSM 0023
Fig. 4-53
Install the lifting tool and using a hoist remove crown
R
support (1) from the top of the housing.

FO
T
O
N
DSM 0024
Fig. 4-54
Copyright ©
Disassembly of crown gear

Remove the spacer from the crown shaft.
DSM 0025
Fig. 4-55
Remove the elastic ring from the seat of the crown
gear.
T
IN
PR
DSM 0026
Fig. 4-56
Remove the crown support from the crown gear.
R
FO
T
O
N
DSM 0027
Fig. 4-57
Parts removed from the crown gear group 4 1
1. Crown gear
2. Elastic ring
3. Circlip
4. Crown support
Clean and wash accurately all disassembled parts.
WARNING
flammable, non-toxic approved commercial sol- 3 2 DSM 0028
vents.
Fig. 4-58
Copyright ©
Disassembly of steering side group

Remove retaining circlip (1) from the assembly. 1
DSM 0029
Fig. 4-59
Using a hoist equipped with two lifting hooks, remove
the planet carrier assembly as in the figure.
WARNING
T
vice of appropriate capacity. Make sure that heavy
IN
PR
DSM 0030
Fig. 4-60
Disassembly of the differential planet carrier
R
assembly
FO
Remove the three retaining circlips.

T
O
N
DSM 0031
Fig. 4-61
Then remove the pins and all the components of the
planet carrier group.
DSM 0032
Fig. 4-62
Copyright ©
Exploded view of planet carrier assembly. 1

1. Carrier 4. Planet gear 8. Carrier disc 2
2. Pin 5. Washers 9. Circlip
3. Thrust 6. Screw 10. Needle cage
washer 7. Ball 11. Dowel
3
Clean and wash accurately all components disassembled.
8
11
WARNING 9 7 4
fluid to clean parts. Use exclusively qualified, non- 10
6 5 DSM 0033
vents. Fig. 4-63
Disassembly of planetary group
Remove the spacer from the drum of the steering side
assembly.
T
IN
PR
DSM 0034
Fig. 4-64
Remove the planetary from the steering side assem-
R
bly.
FO
T
O
N
DSM 0035
Fig. 4-65
Remove the retaining circlip.
DSM 0036
Fig. 4-66
Copyright ©
Also, remove the bearing form inside the planetary.
DSM 0037
Fig. 4-67
Disassembly of the bearing housing from the steer-
ing side assembly
Remove circlip (1) to free shaft (2). 2
T
IN
1
PR
DSM 0038
Fig. 4-68
Remove the carrier shaft.
R
FO
T
O
N
DSM 0039
Fig. 4-69
Remove bearing housing (4) from support disc (3) re-
moving the securing screws. 3
4
DSM 0040
Fig. 4-70
Copyright ©
Remove the O-Ring from the support disc.
DSM 0041
Fig. 4-71
Remove circlip (5) to free the bearings.
5
T
IN
PR
DSM 0042
Fig. 4-72
Remove the 1st bearing from the housing.
R
FO
T
O
N
DSM 0043
Fig. 4-73
Remove the two spacers.
DSM 0044
Fig. 4-74
Copyright ©
Then proceed with the removal of the 2nd bearing from

the housing.
Wash accurately all parts disassembled.
WARNING
vents.
DSM 0045
Fig. 4-75
Assembly of the steering side assembly

Install the 1st bearing into the housing using a hydrau-
lic press.
T
IN
PR
DSM 0045
Fig. 4-76
Install the 1st and 2nd spacer rings into the bearing
R
housing.
FO
WARNING
T

O

N
devices such as glasses, gloves and safety shoes.

DSM 0044
Fig. 4-77
The, install the 2nd bearing.
DSM 0043
Fig. 4-78
Copyright ©
Install the safety circlip to block the bearings in the

seat.
DSM 0046
Fig. 4-79
Install housing assembly (2) on disc (1). 1
T
IN
PR
DSM 0040
Fig. 4-80
Install the screws complete with washers using a
R
centring punch and tighten with a torque wrench to

7.2 daNm (53.1 ft.lb.).
FO
Note – Lubricate adequately all O-Rings and contact

parts before the instal.
T
O
N
D150-2R0070
Fig. 4-81
Insert the first outer O-Ring in the seat on the support
disc.
DSM 0048
Fig. 4-82
Copyright ©
Install the carrier shaft.
DSM 0039
Fig. 4-83
Install blocking circlip (3) on carrier shaft (4).
4
T
IN
3
PR
DSM 0038
Fig. 4-84
Reassembly of planetary group
R
Install the bearing in the seat on the satellite.

FO
T
O
N
DSM 0037
Fig. 4-85
Install the bearing retaining circlip.
DSM 0036
Fig. 4-86
Copyright ©
The install the planetary assembly on the group.
DSM 0035
Fig. 4-87
Install the spacer.
T
IN
PR
DSM 0034
Fig. 4-88
Reassembly of planet carrier assembly.
R
1
Exploded view of planet carrier assembly 2
FO
1. Carrier 7. Ball
2. Pin 8. Carrier disc
3. Thrust washer 9. Circlip 3
4. Planet gear 10. Needle cage 8
T
5. Washers 11. Dowel 11

6. Screw 4
9 7
O
Lubricate freely all components, gears, pin, thrust

N
washers and needles. 10 6 5 DSM 0033
Fig. 4-89
Place the needle cage inside the gear using grease.
DSM 0049
Fig. 4-90
Copyright ©
Place the thrust washers on the sides of the gear and

repeat the operation for the three planet gears.
D150-2R0133
Fig. 4-91
Arrange the first planet gear into the carrier and install
the pin.
Pay the utmost attention that the needles stay inside

the planet gear.
T
Repeat the operation for the other 2 planet gears.
IN
PR
DSM 0032
Fig. 4-92
Install the pin securing circlips in their seats.

R
FO
T
O
N
DSM 0050
Fig. 4-93
Turn slightly the circlip with a point to ensure a correct

installation in the seat.
DSM 0051
Fig. 4-94
Copyright ©
Using an appropriate hoist equipped with two lifting

hooks as illustrated, lift and install the planet carrier
assembly in the brake drum.
WARNING
chains
DSM 0030
Fig. 4-95
Install the blocking circlip.
T
IN
PR
DSM 0029
Fig. 4-96
Reassembly and installation of the crown gear 1
R
assembly
FO
Exploded view
1. Epicyclic gear crown
2. Elastic ring
3. Circlip 4
T
4. Crown support.
O
N
3 2 DSM 0028
Fig. 4-97
Install the crown gear in the support.
DSM 0027
Fig. 4-98
Copyright ©
Install the securing elastic ring in the seat on the crown.
DSM 0026
Fig. 4-99
Install the spacer on the crown shaft paying attention

that the flared part is inward.
T
IN
PR
DSM 0052
Fig. 4-100
Install the crown support assembly in the transmis-

R
sion housing.
FO
T
O
N
DSM 0024
Fig. 4-101
Copyright ©
Install the retaining circlip in its seat using pliers and

check that it is properly installed (turning the circlip
with a punch and mallet).
DSM 0023
Fig. 4-102
Reassembly of steering side group into the trans-

mission housing.
WARNING
T
IN
vents. PR
WARNING
DSM 0053
Use appropriate tools to align holes.
NEVER USE HANDS OR FINGERS. Fig. 4-103
R
Lift the steering group with a hoist and the lifting rig.
FO
Lubricate adequately mating parts of the assembly

and housing.
WARNING
T
Clean accurately the mating surfaces in the trans-

O
mission housing.
N
DSM 0054
Fig. 4-104
Install the two centring guides in the housing to facili-
tate the insertion of the steering assembly.
SM1494
Fig. 4-105
Copyright ©
Install the steering side group into the transmission

housing, paying attention to prevent damaging the
components.
Make sure that the gears are properly matched.
SM1495
Fig. 4-106
Tighten some screws slowly to ensure a proper set-
ting of the steering group.
T
IN
PR
D150-2R0071
Fig. 4-107
Install the remaining screws C2 and tighten them
R
diagonally and alternatively to ensure a uniform C2

tightening (Tightening torque of screws C2 110 Nm,
FO
811 ft.lb.).
T
O
N
D150-2R0069
Fig. 4-108
Copyright ©
4.4.4 BEVEL GEAR SET

(removal/disassembly of bevel pinion
and crown gear)
Preliminary operations:
WARNING
chains.
WARNING
Avoid kinking chains and steel cables. Always wear
protective gloves when handling cables and
chains.
T
IN
Removal
Tilt the cab as described in the Operation and Mainte-
nance Manual.
PR
Remove the fuel and hydraulic oil tank as described
in SECTION 6 - EQUIPMENT HYDRAULIC SYSTEM
in this Manual.
Remove the transmission group as described in SEC-
R
TION 2 - TRANSMISSION.
FO
Drain the oil from the rear transmission housing, by

removing the plug placed at the bottom as described
in item 4.4.3.
T
REMOVE THE STEERING SIDE GROUPS AS INDI-

O
CATED IN ITEM 4.4.3 OF THIS SECTION.

N
Copyright ©
Then, proceed as follows: 1 2
Remove cover (1), remove O-Ring (2).
D150-2R0072
Fig. 4-109
Remove adjusting shims (3) and secure with cables
or chains the bevel pinion support group assembly
and remove it using puller screws. 3
T
IN
PR
D150-2R0073
Fig. 4-110
Remove the bevel pinion from the housing.
R
FO
T
O
N
D150-2R0074
Fig. 4-111
Remove the screws securing the bearing housing.
D150-2R0075
Fig. 4-112
Copyright ©
Install a puller to remove the bearing housing from Right hand housing
the bevel gear crown shaft until it gets out the taper
splines, complete with the seat.
Repeat the operation on the opposite side of the hous-
ing.
D150-2R0134
Fig. 4-113
Remove the shaft complete with crown gear lifting it

with the tool as indicated in the figure.
T
IN
PR
DSM 0056
Fig. 4-114
Disassembly of bevel pinion

R
Secure the pinion in the appropriate bracket and place

FO
it in a vice.
T
O
N
T-86964
Fig. 4-115
Remove the cover using a screwdriver inserted in the

appropriate notches on the cover itself.
T-86961
Fig. 4-116
Copyright ©
Remove the O-Ring from the cover.
D150-2R0076
Fig. 4-117
Install two holders on the appropriate bracket.
T
IN
PR
D150-2R0077
Fig. 4-118
Lift the safety wing.
R
FO
WARNING
It is dangerous to strike hardened steel parts with
tools different from mild steel or non-ferrous met-
T
als. When removing or installing these compo-

nents, always wear safety glasses with side shields,
O
gloves etc, to reduce the possibility of personal

injuries.
N
T-86965
Fig. 4-119
Remove the securing ringnut using a wrench and
torque multiplier, then remove the safety washer.
T-86967
Fig. 4-120
Copyright ©
Extract the pinion shaft complete with bearings.
T-86970
Fig. 4-121
Install a bearing puller and extract the shaft from the
larger bearings.
Recover the spacers and adjusting shims of the bear-
ings.
T
IN
PR
T-86971
Fig. 4-122
Install a puller and remove the small bearing race from
R
the shaft.
FO
T
O
N
T-86989
Fig. 4-123
Remove the small bearing securing screw in the hous-
ing.
T-86979
Fig. 4-124
Copyright ©
Using a punch, push-out the bearing from the hous-

ing.
WARNING
T-86981
injuries.
Fig. 4-125
Disassembly of the crown gear

1
WARNING
T
IN
Using a puller, remove bearings (1) from the crown
gear shaft.
PR
D150-2R0135
1
Fig. 4-126
Place the gear crown assembly on a bench equipped

R
with a vice and remove the securing screws.

FO
Remove the gear crown from the shaft.

T
O
N
DSM 0058
Fig. 4-127
Exploded view of bevel pinion/gear crown group. 5

1 2 3 4
Pinion:
1-2. Bearing
3. Bevel gear pinion
4. Bearing housing 10
5. Cover
6. Safety washer
7
7. Ringnut 6
8. Adjusting shims 11
9. O-Ring
10-11. Spacer
9 8 DSM 0059
Fig. 4-128
Copyright ©
Gear crown:
1. Gear crown shaft 1
2. Bevel gear crown
3. Bearings
2
3
DSM 0060
Fig. 4-129
Reassembly of crown gear
Install the gear crown on the shaft.
T
IN
PR
DSM 0061
Fig. 4-130
Tighten the gear crown on the shaft with the 14 self-
R
tightening screws. Please refer to the table in SEC-

TION 0 - SPECIFICATIONS AND DATA.
FO
T
O
N
DSM 0062
Fig. 4-131
Warm-up the taper bearings to 110 °C (248 °F) and
install them individually on the shaft.
Note – Wear gloves.
D150-2R0136
Fig. 4-132
Copyright ©
Assembly of bevel pinion

Warm-up the small bearing and install it in the seat on
the smaller end of the pinion shaft.
T-86990
Fig. 4-133
Stake the smaller end of the shaft.
WARNING
T
IN
injuries.
PR
T-86991
Fig. 4-134
Warm-up the lower bearing race and install it on the
R
shaft.
FO
T
O
N
T-86992
Fig. 4-135
Using a punch, insert the roller bearing in the hous-
ing.
WARNING
injuries.
T-86981
Fig. 4-136
Copyright ©
Block it in the seat using screw and nut, tightening

the nut to the prescribed torque.
T-86979
Fig. 4-137
Bend the safety wing and tighten the nut.
WARNING
T
IN
injuries.
PR
T-86977
Fig. 4-138
Install the bevel pinion in the relevant housing.

R
FO
T
O
N
T-86993
Fig. 4-139
Install the inner spacer.
T-86994
Fig. 4-140
Copyright ©
Install the outer race of the lower bearing.
DSM 0063
Fig. 4-141
Insert the second spacer between the taper bearings.
T
IN
PR
DSM 0064
Fig. 4-142
Insert the adjusting shims.

R
FO
T
O
N
DSM 0065
Fig. 4-143
Install the outer race of the upper bearing.
DSM 0063
Fig. 4-144
Copyright ©
Warm-up and install the upper bearing.
T-86997
Fig. 4-145
Install the ringnut securing winged ring.
T
IN
PR
T-86982
Fig. 4-146
Install the ringnut.

R
FO
T
O
N
T-86983
Fig. 4-147
Install the pinion in the support bracket and secure it

in a vice.
T-86984
Fig. 4-148
Copyright ©
Tighten the ringnut with the appropriate wrench com-

plete with torque multiplier to the prescribed torque.
T-86985
Fig. 4-149
Grease and install the O-Ring in its seat on the hous-

ing cover.
T
IN
PR
T-86987
Fig. 4-150
Install the cover on the housing.
R
FO
T
O
N
T-86988
Fig. 4-151
Copyright ©
4.4.5 BRAKE GROUP AND PINION ON

BRAKE SIDE
Removal of the brake group
Remove the screws from the brake group.
DSM 0066
Fig. 4-152
Insert centring dowels (1) on the transmission hous-

ing through the holes in the brake group.
T
IN
PR
D150-2R0078
Fig. 4-153
Pull-out the brake group using two screws on threaded

R
holes (A). A
FO
WARNING
T
A
O
N
DSM 0068
Fig. 4-154
Insert securing tool (2) on the group and lift it com-
pletely with a hoist.
DSM 0069
Fig. 4-155
Copyright ©
Disassembly of the brake group

Remove brake drum hub (1) from the brake group.
1 DSM 0070
Fig. 4-156
After positioning the brake group on the bench, pro-

ceed with the disassembly of thrust disc (2) by re-
moving securing screws (3).
Note – The screws must be loosened gradually, 3

proceeding with a crossway sequence.
T
IN
PR
2 DSM 0071
Fig. 4-157
Remove central brake drum (4) driven discs (6) and

R
driving discs (5).

6
FO
WARNING
T

4
O

N
5 DSM 0072
Fig. 4-158
Remove securing screws (7) to free guide disc (8)

and brake piston (9) then recover the 12 springs (10). 10 7
9 DSM 0073
Fig. 4-159
Copyright ©
Remove safety ring (11) then remove bearing (12) and

guide disc (13). 13
Recover the two O-Rings (14 - 15).
12
11
15
14 DSM 0074
Fig. 4-160
Remove three outer O-Rings (16) on the central brake.
16
T
IN
PR
DSM 0075
Fig. 4-161
Wash accurately all the parts of the assembly, previ-

R
ously disassembled, seen all together in the exploded

view on the side.
FO
T
O
N
WARNING
vents. DSM 0076
Fig. 4-162
Copyright ©
4.4.6 PROCEDURE AND INSPECTION

FOR BRAKE PACK
Check that the maximum out-of-round, on each disc After inspecting the discs in accordance with the in-
(2) of the clutch packs does not exceed 0.03 mm structions mentioned here above, install each clutch
(0.00118 in). Also check that on driven discs (1): pack (A) (7 driven discs and 6 drive discs) on the
- the maximum thickness difference between the drum and check with a press that the total thickness
faces of sintered materials does not exceed (A) of the pack is 41 ± 1 mm (1.6 ± 0.04 in) under a
0.05 mm (0.00196 in); load of 294 to 392 daN (2167.7 to 2890.2 ft.lb.). If not,
- the above faces do not show abnormal wear, due, add one or more drive disc of a normal or reduced
generally to impurities in the oil or dry operations of type, form the side indicated by the arrow.
the clutches, or pitted zones.
A 41 ± 1 mm (1.6 ± 0.04 in)
1 q.ty 7 driven discs (sintered)
T
IN
PR
P P
R
FO
P = 300 to 400 Kg (661.4 to 881.8 lb)

294 to 392 daN (2167.7 to 2890.2 ft.lb.)
T
O
2 q.ty 6 drive discs (steel) DSM 0077

N
Fig. 4-163
DETERMINATION AND INSPECTION OF THE

P
BRAKE DISC PACK
Obtain a dimension A under a press load P by select-

ing appropriately the thickness of the discs (1 and 2).
SM9126
Q.ty and thickness of brake discs Fig. 4-164

1 - Driven (with sintered lining) ..................................... q.ty 7 discs thickness 4.2 to 4.5 mm (0.165 to 0.177 in)
2 - Drive (steel) .......................................................................... q.ty 6 discs 2.5 to 0.08 mm (0.098 to 0.003 in)
Copyright ©
Installation of brake group

Insert the three outer O-Rings (1) on the central brake 1
drum.
DSM 0075
Fig. 4-165
Insert the two O-Rings (2) and (3) on guide disc (4)
then insert on it bearing (5) securing it with safety ring 3
(6). 2
T
6
IN 4
PR
DSM 0074
Fig. 4-166
Insert the 12 springs (7) on the brake drum then in-
R
sert brake piston (8) and seal (9) securing finally guide 7 9
11
disc (10) with screws (11).
FO
10
WARNING
T

O

N
8 DSM 0073
Fig. 4-167
Insert in central brake drum (12) driven discs (14) and
drive (13).
14
12
13 DSM 0072
Fig. 4-168
Copyright ©
Install thrust disc (15) and secure it with screws (16).

Tighten the screws to 130Nm (958.5 ft.lb.).
Note – The screws must be tightened gradually pro-

ceeding with a crossway sequence.
16
15 DSM 0071
Fig. 4-169
Insert the brake drum hub.
T
IN
PR
DSM 0070
Fig. 4-170
Removal of brake pinion

R
A
Replace the screws indicated in position (A) with two
FO
shorter ones to hold the pinion shims.
A
T
O
N
DSM 0078
Fig. 4-171
Remove all the remaining screws.
DSM 0079
Fig. 4-172
Copyright ©
Remove the pinion from the housing and hold it with

the appropriate lifting rig and recover adjusting shims
(1).
WARNING
1
DSM 0080
Fig. 4-173
Disassembly of brake pinion

Place the pinion on the workbench.
T
IN
PR
DSM 0081
Fig. 4-174
Remove the two screws (1) and remove support cover
R
(2) then recover adjusting shims (3). 3

1
FO
T
O
2
N
DSM 0082
Fig. 4-175
Remove race (4) and taper roller bearing (5).
4
DSM 0083
Fig. 4-176
Copyright ©
Remove pinion (6) from the pinion support.
DSM 0084
Fig. 4-177
Remove the second bearing (7) from the pinion sup-

port. Wash accurately all the parts disassembled from
the brake pinion assembly.
WARNING
T
IN
flammable, non-toxic approved commercial sol- 7
vents.
PR
DSM 0085
Fig. 4-178
Reassembly of brake pinion
R
Place pinion support (1) on a workbench.

FO
T
O
N
1 DSM 0086
Fig. 4-179
Install the first bearing (2) into the pinion support.
DSM 0085
Fig. 4-180
Copyright ©
Install pinion (3) inside the support.

3
DSM 0084
Fig. 4-181
Install the second taper roller bearing inside the pin-

ion support.
T
IN
PR
DSM 0083
Fig. 4-182
Secure cover (4) on the pinion support and secure it
5
R
with two screws (5). 5

FO
T
O
N
4 DSM 0087
Fig. 4-183
Pre-load the roller bearing with a torque wrench

(1 to 2 Nm, 7.4 to 14.7 ft.lb.).
DSM 0088
Fig. 4-184
Copyright ©
Measure the gap between cover and pinion support

with a feeler gauge.
D150-2R0079
Fig. 4-185
Install a quantity of shims such to obtain the dimen-

sion previously measured.
WARNING
T
IN
PR
DSM 0090
Fig. 4-186
Re-installation of bevel gear crown

R
Re-install the bevel gear crown complying with what

FO
listed here below.

Install the lifting tool to the gear crown and insert it
into the bevel gear compartment.
T
WARNING
O

N

DSM 0056
Fig. 4-187
Lubricate adequately the bearings with engine oil.
Pre-install the right and left supports, installing the

bearing outer races using a hydraulic press.
SM9248
Fig. 4-188
Copyright ©
First, install the left support assembly, without ad- Right hand housing
justing shims using 4 screws only tightened to a torque
of 130Nm.
D150-2R0134
Fig. 4-189
Then, install the right support, without adjusting shims,

with two retaining screws, tightening them with incre-
ments of 0.1 daNm (0.73 ft.lb.) up to a final value of
0.7 daNm (5.16 ft.lb.). At the same time, turn a few
times manually the gear crown, to set the taper roll-
ers in the relevant races.
T
IN
PR
SM9250
Fig. 4-190
Re-installation of the pinion
R
Lubricate adequately all the mating faces of the pin-

FO
ion.
Arrange the assembly for the re-assembly on the hous-
ing, slinging it with cables to a hoist.
To facilitate the centring of the pinion, use two guide
screws and adjust the position and the backlash, as
T
described in the previous paragraph for the adjust-

ment of the bevel gear.
O
N
SM1489
Fig. 4-191
Insert adjusting shims (1) then install the pinion into

the housing and set its position and the tooth back-
lash as described in the preceding paragraph for the
setting of the bevel gear crown.
DSM 0091
Fig. 4-192
Copyright ©
4.4.7 PROCEDURE FOR THE SETTING

OF THE BEVEL PINION BEARINGS
PRE-LOAD
(transmission side)
Perform the setting of the pre-load of the bearings, D. After reading this value, loosen the ringnut, re-
complying with the phases as follows: move bearing (1), remove spacer (3) and the
standard spacer.
A. Match bevel pinion (6) to pinion housing (7) com- Deduct from the thickness of the standard spacer
plete with half-bearings (1 and 2). (4 mm) the value measured, then shim using
rings (5) in the point indicated, for the resulting
B. Install spacers (3 and 4) and the standard shim value. Install spacer (3) half-bearing (1) then
4 mm, the inner race of bearing (1) using a press, tighten the ringnut to a torque of 130 to 150 daNm
then tighten ringnut (8). (958.5 to 1106 ft.lb.).
C. Keeping pinion housing (7) steady, measure the E. Check that the rolling torque of the pinion on the
axial movement of the pinion using a feeler gauge transmission side is between 1.5 to 2.5 Nm (11 to
placed on the nose or the tail of it. 18.4 ft.lb.). Then, stake the ringnut on the pinion.
Otherwise, repeat the operation adding or deduct-
ing shims to obtain the rolling torque indicated.
T
IN
PR 5 8
1. Pinion half-bearing 9
1
2. Pinion half-bearing 4
3. Spacer
R
4. Spacer
5. Adjusting shim
FO
6. Bevel pinion
7. Pinion housing
8. Ringnut 2
9. Adjusting shim thickness:
T
1 mm (0.039 in)
0.5 mm (0.019 in) 6
O
0.2 mm (0.008 in)

0.15 mm (0.006 in)
N
10. Adjusting shims 7

11. Bearing housing
12. Bearing housing
DSM 0093
Fig. 4-193 Details of pinion
Copyright ©
4.4.8 PROCEDURE FOR THE SETTING

OF THE BEVEL GEAR SET
Perform the setting of the bearing pre-load complying housings (11) and (12) until a backlash of the
with the phases as follows: teeth between pinion/gear crown is equivalent to
0.25 to 0.33 mm (0.009 to 0.013 in).
A. Shim with rings (10) to obtain a rolling torque on
the gear crown shaft (without the pinion) equiva- D. Check that the total rolling torque measured with
lent to 4.5 to 6 Nm (3.3 to 4.4 ft.lb.). the pinion transmission and gear crown side, is
equivalent to 3 to 5 Nm, 2.2 to 3.7 ft.lb. (total
B. After pre-loading the gear crown shaft bearings rolling torque with pinion transmission side, the
as for item A, install pinion housing (7) using gear crown and pinion brake side must be in-
shims (9) until the pinion/gear crown teeth touch cluded between 4 to 6.5 Nm, 2.9 to 4.8 ft.lb.).
in accordance with the indications of detail "A".
Note – The setting of the bevel gear set occurs
C. After obtaining the contact as specified in phase exclusively between the pinion transmission side and
B split shims (10) between the two bearing the gear crown.
T
From 21 through 28 mm
IN
B (0.82 through 1.1 in) length.
Teeth contact face.
PR
Between 5 through
7.5 mm (0.19 through
R
10 C 0.29 in) from tip of

FO
tooth
11
T
O
N
Teeth contact face
B
C
12
DSM 0092
Fig. 4-194
Copyright ©
Re-installation of brake pinion

Install the two centring pins in the transmission holes.
DSM 0094
Fig. 4-195
Install setting shims (1).
WARNING
T
IN 1
PR
DSM 0095
Fig. 4-196
Lift the pinion with a hoist equipped with the appropri-
R
ate lifting tool, then install the pinion in the transmis-

sion housing with the help of the guide pins.
FO
T
O
N
DSM 0080
Fig. 4-197
Remove the centring pins.
DSM 0096
Fig. 4-198
Copyright ©
Tighten fully some pinion securing screws (2) taking

2
care to replace the two screws in position (A) used to
pre-load the pinion, with two longer screws (2) used to
secure the housings.
2 DSM 0078
Fig. 4-199
Tighten all the pinion screws to 300 Nm (221.2 ft.lb.).
T
IN
PR
DSM 0079
Fig. 4-200
Re-installation of brake group

R
Install the centring pins in the transmission housing.

FO
T
O
N
DSM 0097
Fig. 4-201
Grease with a brush the contact faces on the housing
and on the brake group.
DSM 0098
Fig. 4-202
Copyright ©
Lift the brake group with a hoist equipped with the

appropriate holding tool and check that drum hub (1)
is installed correctly on drive discs (2).
2 DSM 0070
Fig. 4-203
Install the brake group on the transmission housing
using the centring guide pins.
T
IN
PR
DSM 0099
Fig. 4-204
Then remove the holding tool and push the brake group
R
all the way with a puller.

FO
T
O
N
DSM 0100
Fig. 4-205
Secure the brake group to the transmission housing
with the appropriate screws and tighten them to
130 Nm (95.8 ft.lb.).
DSM 0066
Fig. 4-206
Copyright ©
Installation of the rear transmission cover

Warm-up the two bearing races to expand them.
DSM 0101
Fig. 4-207
Install the two races on the shaft.
WARNING
Handle the parts with protective guides to prevent
injuring the hands with burns.
T
IN
PR
DSM 0102
Fig. 4-208
Pre-load of the gear support
R
Parts disassembled to be reassembled using a hy- 2

1
FO
draulic press.
1. Support
2. Gear
3. Bearings
4. Spacer
T
3
O
4
N
DSM 0013
Fig. 4-209
Install the first bearing (1) using a hydraulic press.
DSM 0103
Fig. 4-210
Copyright ©
Turn the support upside down and install steering gear

(2) on the first bearing.
DSM 0104
Fig. 4-211
Install spacer (3) between the two bearings.
3
T
IN
PR
DSM 0105
Fig. 4-212
Install the second bearing (4) on the support.
R
FO
4
T
O
N
DSM 0106
Fig. 4-213
Install spacer (5).
5
DSM 0107
Fig. 4-214
Copyright ©
Install the second gear (6) on the support.

6
DSM 0012
Fig. 4-215
Install disc (7) washer (8) and securing screw (9).
9
7 8
T
IN
PR
DSM 0011
Fig. 4-216
Install fixed race bearing (10) in the support on the
R
"hydraulic motor" side using an appropriate punch (A). A

FO
10
T
O
N
DSM 0108
Fig. 4-217
Install securing circlip (11) and check that it is prop-
erly in place.
11
DSM 0109
Fig. 4-218
Copyright ©
Install the shaft.
DSM 0019
Fig. 4-219
Install mobile race bearing (12) in the right side sup-
port.
T
IN
PR
12
DSM 0110
Fig. 4-220
Install the bearing blocking circlip.
R
FO
T
O
N
DSM 0018
Fig. 4-221
Check that the circlip is properly installed in its seat.
DSM 0111
Fig. 4-222
Copyright ©
Install spacer (13) on the shaft.
13
DSM 0016
Fig. 4-223
Install the two spacers (14) and (15) on the left side of
the shaft.
T
IN
14
15
PR
DSM 0017
Fig. 4-224
Install the two gears (16) on the shaft.
R
16 16
FO
T
O
N
DSM 0015
Fig. 4-225
Install disc (17) and securing screws (18) on the shaft.
Repeat the operation on the opposite gear.
17 18
DSM 0014
Fig. 4-226
Copyright ©
Tighten the screws on the shaft, 130 Nm (95.8 ft.lb.).
DSM 0112
Fig. 4-227
Install gear support (19) on cover (20) and install the

securing screws.
T
20
IN
19
PR
DSM 0113
Fig. 4-228
Tighten securing screws (21) to a torque of 195 Nm

R
(143.8 ft.lb.).
21
FO
T
O
21
N
DSM 0114
Fig. 4-229
Turn the cover upside down to arrange the installation

of the hydraulic motor.
DSM 0115
Fig. 4-230
Copyright ©
Install the lifting tool.
DSM 0116
Fig. 4-231
Install gear (22) to be tightened with the appropriate

fixtures in sequence.
22. Gear
23. Shim 22
24. Disc
25. Screw 23
T
24
IN
PR 25
DSM 0007
Fig. 4-232
Lift the hydraulic motor, using the hoist, to arrange it

R
in its seat.
FO
T
O
N
DSM 0006
Fig. 4-233
Secure the hydraulic motor with the appropriate

screws.
DSM 0009
Fig. 4-234
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Fill the hydraulic motor with lubricant.

Refer to the lubrication table in the Operation and
Maintenance Manual.
DSM 0117
Fig. 4-235
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4.4.9 INSTALLATION OF HOUSING COVER

Tighten four lifting eyes on the cover and arrange it
for the installation on the housing.
Apply a film of Loctite 548 to the mating faces of the

housing and cover.
WARNING
Lift and handle all heavy parts with a lifting de- DSM 0004
parts are held by appropriate slings and hooks. Fig. 4-236
Use the lifting eyes provided for this purpose. Be
aware of bystanders near the load to be lifted.
Install the centring dowels to facilitate the installation

of the cover.
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DSM 0118
Fig. 4-237
Tighten initially 4 or 5 screws to secure the cover to

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the housing.
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DSM 0119
Fig. 4-238
Tighten all the remaining screws on the cover.
To complete the re-assembly operations, please refer
to item 4.4.3 (preliminary operations) reversing the
procedure described therein.
DSM 0120
Fig. 4-239
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4.5.1 REDUCTION BEVEL GEAR SET

(general data/dimensions)
General data
Type of gears ........................................................................................................................GLEASON teeth
Reduction ratio (15/38) .......................................................................................................................... 1:2.53
Teeth backlash ......................................................................................... 0.25 to 0.33 mm (0.009 to 0.013 in)

average 0.3 mm (0.012 in)
Dimensions - See pinion - gear crown sections
A inner diam. bevel gear crown shaft bearing race ....................... 139.948 to 139.988 mm (5.509 to 5.513 in)
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outer diameter bearing .............................................................. 139.980 to 140.000 mm (5.511 to 5.518 in)
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* B inner diameter bearing .................................................................. 79.850 to 80.000 mm (3.143 to 3.149 in)
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outer diameter bevel gear crown shaft ........................................... 80.020 to 80.033 mm (3.150 to 3.151 in)
C outer diameter bevel gear crown shaft hub ............................... 157.960 to 158.000 mm (6.218 to 6.220 in)
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inner diameter bevel gear crown ................................................ 158.000 to 158.040 mm (6.220 to 6.222 in)
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E inner diameter pinion housing ................................................... 159.932 to 159.972 mm (6.296 to 6.298 in)
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outer diameter pinion bearing .................................................... 159.975 to 160.000 mm (6.298 to 6.299 in)
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D inner diameter pinion support ....................................................... 62.000 to 62.004 mm (2.440 to 2.441 in)
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outer diameter bearing ................................................................... 61.985 to 62.004 mm (2.440 to 2.441 in)
F inner diameter pinion bearing (shaft toller.) .................................................. 90 mm (90.013 to 90.035 mm),
.......................................................................................................................... 3.543 in (3.544 to 3.545 in)
G Inner diameter pinion nose bearing (shaft toller.) ........................................ 30 mm (30.008 to 30.021 mm),
.......................................................................................................................... 1.181 in (1.181 to 1.182 in)
* Note. The dimensions are identical on both sides.
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DSM 0126
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Fig. 4-240 Section view of pinion transmission side

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DSM 0124
Fig. 4-241 Section view gear crown
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4.5.2 PINION BRAKE SIDE
H1
L1
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DSM 0125
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Fig. 4-242 Section view of pinion brake side

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General data
Type of gears ........................................................................................................................ GLEASON teeth

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Reduction ratio (15/38) ............................................................................................................................. 2.53

Teeth backlash ......................................................................................... 0.25 to 0.33 mm (0.009 to 0.013 in)
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average 0.3 mm (0.012 in)

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Cuscinetti pignone freno
H inner diameter pinion support .................................................... 61.985 to 62.004 mm (2.441 to 2.440 in)
outer diameter bearing ................................................................................................... 62 mm (2.441 in)
H1 Shaft tolerance .......................................................................... 30.008 to 30.021 mm (1.181 to 1.182 in)
L inner diameter pinion housing ................................................ 159.972 to 159.932 mm (6.296 to 6.298 in)
outer diameter bearing ................................................................................................. 160 mm (6.299 in)
L1 Shaft tolerance .......................................................................... 90.013 to 90.035 mm (3.544 to 3.545 in)
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4.5.3 BRAKES
General data
TYPE ............................................................................................................................. multiple disc, oil-bath
Number of discs per brake
- Driven (sintered) ...................................................................................................................................... 7
- Drive (steel) ............................................................................................................................................. 6
Specifications of the spring

Number of springs per brake ....................................................................................................................... 12
- Spring free length ................................................................................................................ 83 mm (3.268 in)
- Diameter of wire ......................................................................................... 5.5 ± 0.05 mm (0.216 ± 0.002 in)
- Outer diameter of pack ............................................................................... 30 ± 0.30 mm (1.181 ± 0.012 in)
Compression load at:

66 mm (2.6 in) .................................................................................................. 135 ± 7 daN
61 mm (2.4 in) .................................................................................................. 174 ± 9 daN
Fittings and tolerances

Thickness of brake disc pack ................................. 41 ± 1 mm (1.614 ± 0.04 in) (with a load of 300 to 400 kg,
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......................................................................................................................................... 661.4 to 881.8 lb)
Average travel of thrust disc ................................................................................................ 2.5 mm (0.098 in)
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Average wear ....................................................................................................................... 3.5 mm (0.138 in)
Total travel .............................................................................................................................. 6 mm (0.236 in)
Thickness of steel discs .............................................................................. 2.5 to 0.8 mm (0.098 to 0.031 in)
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Thickness of sintered driven discs .............................................................. 4.2 to 4.5 mm (0.165 to 0.177 in)
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4.5.4 BRAKE PEDAL VALVE

Ref. 3 hydraulic diagram
DATA AND DIMENSIONS

A. Diameter piston seat 20.000 to 20.021 mm (0.787 to 0.788 in)
Outer diameter piston 19.980 to 19.993 mm (0.786 to 0.787 in)
Play 0.007 to 0.041 mm (0.0002 to 0.0016 in)
B. Guide pin seat 40.000 to 40.025 mm (1.574 to 1.576 in)

Outer diameter guide pin 39.936 to 39.975 mm (1.572 to 1.573 in)
Play 0.025 to 0.089 mm (0.0009 to 0.0035 in)
C. Inner diameter rod seat 10.000 to 10.015 mm (0.393 to 0.394 in)
Outer diameter of rod in guide 9.986 to 9.995 mm (0.392 to 0.393 in)

Play 0.005 to 0.029 mm (0.0002 to 0.0011 in)
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D. Diameter of plunger seat 16.000 to 16.018 mm (0.629 to 0.631 in)
Outer diameter of plunger 15.983 to 15.994 mm (0.628 to 0.629 in)

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Play 0.006 to 0.035 mm (0.0002 to 0.0014 in)
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E. Diameter washer seat 26.000 to 26.021 mm (1.023 to 1.024 in)

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Outer diameter washer 25.947 to 25.980 mm (1.021 to 1.022 in)

Play 0.020 to 0.074 mm (0.0008 to 0.0029 in)
F. Diameter seat in cover for small end of pin 13.016 to 13.059 mm (0.512 to 0.514 in)
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Outer diameter control pin small end 12.973 to 13.000 mm (0.511 to 0.512 in)
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Play 0.016 to 0.086 mm (0.0006 to 0.0034 in)

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G. Diameter seal seat in cover 24.000 to 24.033 mm (0.945 to 0.946 in)

Outer diameter in correspondence with seal 13.982 to 14.000 mm (0.550 to 0.551 in)
H. Diameter seat of centring pin 8.013 to 8.049 mm (0.315 to 0.317 in)
Outer diameter centring pin 7.964 to 8.000 mm (0.313 to 0.315 in)
Play 0.013 to 0.085 mm (0.0005 to 0.0033 in)
I. Diameter spring seated in control pin 5.000 to 5.030 mm (0.196 to 0.198 in)
Diameter spring seated in cam 5.000 to 3.030 mm (0.196 to 0.198 in)
Outer diameter spring pin 5.000 mm (0.196 in)
Play 0 to 0.030 mm (0 to 0.0012 in)
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J. Diameter control seated in cam 13.016 to 13.059 mm (0.512 to 0.514 in)
Outer diameter control pin in cam 12.973 to 13.000 mm (0.511 to 0.512 in)
Play 0.016 to 0.086 mm (0.0006 to 0.0034 in)
K. Diameter control seated in control lever 11.995 to 12.006 mm (0.472 to 0.473 in)
Outer diameter control in lever 12.982 to 12.000 mm (0.511 to 0.472 in)
Interference 0.005 int. to 0.024 play mm (0.0001 int to 0.0009 play in)
1. Piston return spring

Number of spring coils 9.5
Free length 76.5 mm (3.012 in)
Force required to press it 45 mm 54.7 to 60.3 daN (40.3 to 44.5 ft.lb.)
2. Piston actuating spring
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3. Plunger return spring

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1 A 2 B C
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G
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D 3 E I
D150-2R0080
Fig. 4-243
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4 - 93
4.5.5 REAR TRANSMISSION (section view transmission side)
Pinion transmission side Bevel gear crown Top view
Steering side group
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Brake assembly Pinion brake side
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Brake control
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Brake lubrication
Final drive Side view final drive
and transmission housing
Sprocket
BRAKES CONTROL DSM 0127

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SECTION 5
UNDERCARRIAGE
TABLE OF CONTENTS

5.1.1 Generalities .......................................................................................................... 5-1
5.1.2 Main components ................................................................................................. 5-2

5.2.1 Slack track chain tension ..................................................................................... 5-5
5.2.2 High track chain tension ....................................................................................... 5-5
5.2.3 Insufficient tightening of the screws securing the shoes
to the track chain .................................................................................................. 5-5
5.2.4 Working on steep slopes ...................................................................................... 5-5
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5.3 INSPECTIONS .......................................................................................................... 5-6
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5.3.1 Inspection and adjustment of track chains ............................................................ 5-6
5.3.2 Setting of the track tensioner pressure relief valve ............................................... 5-7
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5.4.1 Track chain (removal / installation) ........................................................................ 5-8
5.4.2 Replacing a damaged link and re-installation ........................................................ 5-10
5.4.3 Idler (removal / installation / overhaul) .................................................................. 5-12
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5.4.4 Track chain support rollers (removal / installation / overhaul) ................................ 5-15
5.4.5 Track chain bottom rollers (removal / installation / overhaul) ................................. 5-17
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5.5.1 Idler ...................................................................................................................... 5-21
5.5.2 Sprockets ............................................................................................................. 5-22
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5.5.3 Track chains ......................................................................................................... 5-22

5.5.4 Bottom rollers ....................................................................................................... 5-23
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5.5.5 Support rollers ...................................................................................................... 5-24

5.5.6 Track tensioner device .......................................................................................... 5-25
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5.5.7 Front cross-member pivots ................................................................................... 5-26

5.5.8 Wear limits ........................................................................................................... 5-30
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1650K UNDERCARRIAGE 5-1
5.1.1 GENERALITIES Working sideways - The weight of the machines is

bearing on the side located on the downhill side, with
When evaluating the undercarriage conditions, it is
a wear of the flanges and other components guiding
appropriate to consider that an accurate inspection, a
the track chain.
proper preventive maintenance and a correct opera-
tion of the machine, are the elements contributing most
Working on a cat's back - It causes a concentration
to extend the life of components. It is good practice
of the loads on the inner side of the components. It
to clean, lubricate, adjust and repair the undercarriage
increases the wear of the inner side of rollers and
at regular intervals, not limited to quick and incom-
idlers and the inner tip of the grousers.
plete inspections.
Working into a ditch - It causes the concentration of
To evaluate exactly the conditions of components,
loads on the outer flanges of rollers and the outer race
proceed with a systematic and thorough inspection. If
of idlers.
the machine was subject to excessive stress, the track
frames could be deformed. Excessive or strange wear
The environment and the type of materials moved are
patterns on the idlers, the roller edges and the sprocket
the elements determining the life of undercarriage,
segments could be caused by deformed track frames.
since some materials are more abrasive than others.
Also, the abrasive action is generally higher when they
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Also, it is important to consider the conditions under
are. Under this point of view, the most common mate-
which a crawler machine is often compelled to oper-
rials can be classified as follows:
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ated.
Gravel and rocks - intense breakage and wear
TERRAIN
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Obviously, it is not always possible to choose the sand (in water) - fast wear
terrain and the operating conditions, but it is neces- wet sand - packing and high wear
sary to consider the geological configuration and the sand (dry) - high wear
gradients which could influence the wear type and top soil (wet) - moderate wear
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speed the undercarriage shall be subject to.

clay (wet) - light - moderate wear
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Working uphill - It results in moving weights and clay (dry or slightly wet) - slight wear
loads towards the rear end of the machine. The wear
on the rear bottom rollers and the forward motion side talcum
of the sprocket segments and bushings increases.
gypsum
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Working downhill - It results in moving weights and coal - very slight wear
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loads towards the side of the machine facing down- phosphates

hill. There is a higher wear of the components, such
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as flanges a link sides, working in this position.
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5-2 UNDERCARRIAGE 1650K
Also, it is important, when the undercarriage is over- - reduce the load when it is felt that the track chain
hauled, to check the operation of the track tensioner starts slipping;
device. An inefficient tack tensioner can cause a pre-
- avoid parking the machine in mud, water or condi-
mature wear of pins and bushing, the torsion of idler
tions facilitating corrosions;
shafts, and, as a limit, troubles on the sprocket shafts
and the final drives. - inspect daily the components, check the tightening
of bolts and nuts, eventual leakages from seals or
The more components are worn the faster wear oc- signs of abnormal wear;
curs. When components are new, hardened surfaces - clean mud and debris accumulated during the work
are thick and resistant; with the wear progression of shift from the undercarriage.
components between them and contact with the
ground, their harder outer surfaces are replaced by
softer layers of material, thus the wear becomes faster.
What said above can be summarised in a few preven-

tive rules and operations:
5.1.2 MAIN COMPONENTS
- do not operate the machine at high speed, unless The main components making the undercarriage are:
this is strictly necessary. This is particularly true
when operating in reverse;
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5 1 4 3 2 6 7
D150-2R0043
Fig. 5-1 Undercarriage components
1. Track frames - 2. Track frame bottom rollers - 3. Track chain support rollers - 4. Track tensioner device and pressure relief
valve - 5. Idler wheels - 6. Track chains - 7. Sprocket and toothed segments.
Copyright ©
1. Track frames 4. Track chain tensioner device

Each track frame is composed of a frame made with The track tensioner device provides a dual function:
material with high mechanical specifications fabricated keep the track chain tension; absorb the stress trans-
with boxed section bars. Inside, fully enclosed track ferred by the idler.
tensioner devices are mounted, protected from the The track chain tension is provided by an hydraulic
entry of loose materials. device, made of a cylinder and a piston connected to
The two frames are hinged, at the back, on the PIVOT the idler yoke by a rod.
SHAFTS, whereas, in the front, the connection is pro- To stretch a track chain, grease is pumped inside the
vided by a suspended cross-member, hinged centrally cylinder. This causes a forward movement of the pis-
and to the frame of the machine on the sides. ton and the idle, connected to it.
Thus, each track frame is allowed to pivot independ- Please note that the spring is normally compressed,
ently from the other one. but it does not actuate its action against the track
The alignment of the track frames is provided, frontally, chain.
by guides, the position of which is adjusted by shims.
The following components are mounted on the track

5. Idler
frames:
- bottom rollers The idler, of a spring type, located in the front side of
- track chain support rollers each track frame, is connected to the track chain
- idler and track tensioner device. tensioner hydraulic device by a yoke and a rod against
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the adjusting cylinder piston. The tensioner effort and
the absorption of shocks received by the track chain
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2. Track frame bottom rollers
while working, are transferred through this system.
The rollers, for the standard version, are 7.3 of which For this reason, the idler is not rigidly connected to
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double flange and 4 single flange, whereas for the the track frame body, but it is allowed to slide on guides,
LGP version they are 8.3 of which double flange and which must be properly aligned by adjusting shims.
5 single flange. They are made with special steel, The shafts turn on lubricated bushes. The sealing is
surface treated for better standing wear and abrasion. provided by metal (long-life) seals.
These rollers, mounted in the lower side of each track
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frame, support the weight of the machine, the pins

turn on lubricated bushing. The sealing is provided by
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6. Track chain
metal (long-life) seals.
The track chain is essentially, made of:
- Pins
3. Track chain support rollers
- Bushes
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The support rollers support the upper part of the track - Links
chain. Each roller is secured, by supports, to the track - Shoes
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frames. The shafts turn on lubricated bushes and the - Split link
sealing is provided by metal (long-life) seals. - Frontal seals
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Pins and bushing are the components of the track Seals (4) provide the sealing, avoiding the entry of
chain most subject to wear. The symptoms charac- foreign materials and keeping the lubricant. Rubber
terising the wear of pins and bushes are wear of the plug (2) allows the filling with oil and provides sealing.
sides of the links, fast wear of the sprocket teeth and
excessive sagging of the track chains.
Note – On lubricated track chain, it is recommended
Shoes are single ribbed. The ribbing, besides provid- to turn pins and bushing, as well.
ing traction, contribute to reinforcing the shoe. Worn
shoes, besides facilitating the slipping of the track
chains, are more easily deformed. 7. Toothed segment idler
The track chain is permanently lubricated and the wear The idler transfers, directly, to the track chain the ro-
between pin and bushing is greatly reduced. In fact, tation received from the final drive. The sprocket is
each pin (1) see fig. 5-2, has an axial hole (2) and two mounted on the final drive output shaft. There are nine
radial holes (3) perpendicular to the first one, provid- toothed segment bolted to the hub, thus they are indi-
ing a constant and continuos lubrication. The move- vidually replaceable. The profile of the teeth is of a
ment between pin and bushing, ensures the distribu- self-cleaning type. The toothed segments can be re-
tion of lubricant over all the contact surfaces. placed without removing the chains.
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4 1
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SM9351A
Fig. 5-2 Permanent lubrication (SALT) track

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chains
1. Pin with lube oil reserve drilling - 2. Rubber plug -

3. Radial lube drillings - 4. Seal - 5. Thrust ring - 6. Bushing -
7. Link - 8. Pin.
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5.2 TROUBLESHOOTING
The major causes for premature or abnormal wear of 5.2.2 HIGH TRACK CHAIN TENSION
the undercarriage components are listed here below.
Troubles
5.2.1 SLACK TRACK CHAIN TENSION 1. Low speed and insufficient traction power. The
Troubles machine fails to develop the prescribed pushing
capacity.
1. Very fast wear on links, pins and bushings of the
track chain. 2. The machine turns rightward or leftward, caused
by the track chain which is tighter.
2. Fast wear of the sprocket teeth and the rib of the
shoe. 3. Fast wear of pins, bushing's and links.
3. Possible damage or breakage of the sprocket, 4. Wear of the final drive bearings.
idler,idler supports, bottom rollers and guards.
5.2.3 INSUFFICIENT TIGHTENING OF THE
4. The track chain could fail to engage correctly the SCREWS SECURING THE SHOES
sprocket teeth, both when moving forward or TO THE TRACK CHAIN
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reverse. The track chain could jump the idler,
when the machine is steering. Troubles
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Elongation of the screw holes on the link.
5. Noisy track chain.
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Remedies
6. The track chains fills with foreign materials. (*)
The loosening can be caused by a thinning of the
shoe due to wear, or by an incorrect torque tightening
of the screws to the prescribed values. Make sure
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that the mating faces between shoe and track chain

are perfectly clean and free from paint.
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(*) Note – When the machine operates under condi- 5.2.4 WORKING ON STEEP SLOPES
tions facilitating the entry of foreign materials into the
undercarriage components, it is recommended that Troubles
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the tension of the system is checked frequently.

Wear at the tips of pins, on the side of the master
In fact, the tension can increase the rubbish included
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link, on the inner and outer rims of the bottom rollers,

between the track chain components and the idler
the sprockets and idlers.
tensioner device.
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The presence of foreign materials inside, could cause

Remedies
delay or prevent the movement of the idler. This
preclusion could result in a dangerous load on the track Operating on steep slopes, causes strong stress to
chain (pins, bushings, links), on the idler shaft and the the undercarriage components, with subsequent fast
final drives. wear. Whenever possible, change frequently the di-
rection and/or the trajectory of the machine.
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5.3 INSPECTIONS
5.3.1 INSPECTION AND ADJUSTMENT 40 mm (1.181 to 1.574 in). If loosening is required,

OF TRACK CHAINS proceed as follows:
- Remove access cover (C) on the track
In sealed and lubricated track chains, strong phenom- tensioner frame, removing retaining screws (V).
ena of internal wear do not occur, if the track chain
adjustment is done timely, when required. With a 24 mm (0.94 in) wrench, loosen slightly adjust-
When the track chain is too tight, it is subject to use- ment valve (VR) and back-up the machine a few me-
less and dangerous stress. The wear speed increases tres, if required. Re-tighten the valve and check sag
and drawbar traction power is lost. When it is too slack, (L).
the links are hitting the undercarriage, increasing the
wear of all parts involved.
Keep in mind that a normal adjustment is proper for
dry, stony or rocky terrains, whereas it is necessary L = 30 ÷ 40
to slack further the track chains in muddy, very wet
and clay conditions, or when sand, gravel, snow or
ice are present.
Tightening the track chain
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In the event the track chain has become slack, it is
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necessary to increase the tension. Prior to any op-
eration, measure the sagging of the track chains in
section (L Fig. 5-3) between the support roller and the
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idler. If sagging (L) exceeds 30 to 40 mm (1.181 to D150-2R0089
1.574 in) (regular sagging) pump grease into fitting (I
Fig. 5-4) of valve (VR) of the adjustment cylinder, un- Fig. 5-3 Track chain sag
til the correct tension is obtained.
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Loosening the track chain WARNING

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When disassembly operations must be performed or Fluid under pressure. Do not loosen track tension
the track chain is excessively tensioned, the tension by loosening pressure relief valve (VS). Do not re-
must be loosened. Prior to slackening the track chain, move the grease fitting (I) mounted on adjusting
check that the sag on section (L) is lower than 30 to valve (VR).
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Vs
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VR
D150-2R0045
Fig. 5-4 Adjusting the track chain
VR. Adjustment valve - VS. Pressure relief valve - I. Grease fitting - C. Cover - V. Securing screws.
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5.3.2 SETTING OF THE TRACK

TENSIONER PRESSURE RELIEF
VALVE
Disassemble all parts of the valve and clean them A
from all traces of grease. B
Reassemble the valve and proceed as follows:
- secure tool (A) 75291573 (Fig. 5-5) in a vice, screw P

valve (VS) on the tool placing in between the rel-
evant O-Ring;
- fill well (P) of the tool with gasoline or alcohol;

Vs
SM9358
WARNING Fig. 5-5
Extinguish all smoking materials and free flames.
- actuate torque wrench (B) considering that the valve - to obtain the setting value required, change shims
must stay closed, thus the level of the liquid inside (S1 accordingly, or actuate threaded element (1);
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well (P) must not change until value (V1) = 6.41to
6.86 daNm (47.273 to 50.592 ft lb). - reassemble the valve and fill it with AMBRA GR9
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The valve should open and the well drain-out when grease;
a torque value (V2) is applied, equivalent to a set-
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ting of 900 to 950 bar (13050 to 13775 psi). - reinstall the valve on the cylinder and tighten it to
the prescribed torque (see chapt. 5).
Setting of the pressure relief valve:
- Thickness of valve setting shims 0.1
V1 = 6.41 to 6.86 daNm (47.273 to 50.592 ft lb) - 0.2 - 0.5 mm (0.008 - 0.019 in).
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V2 = 6.86 to 7.35 daNm (50.592 to 54.206 ft lb) Setting 900 to 950 bar (13050 to 13775 psi)
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6 1
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S1
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2 1
3 5
4
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S1
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C1
6 2
D150-2R0047
Fig. 5-6 Sectional view, parts and check of the pressure setting of pressure relief valve (Vs) of the hydraulic
adjusting cylinder
C1. Valve cover - P. Gasoline or alcohol well - S1. Adjusting shims - T. Pressure setting marking - 1. Rubber cap - 2. Steel
washers - 3. Disc springs (Bauer type) - 4 and 5. Plunger and ball valve - 6. Cap (1) securing screw.
Copyright ©
5.4.1 TRACK CHAIN (removal/installation)

Removal
Place blocks of an appropriate thickness under the

transmission housing and the cross-member so that
the track chains do not touch the ground.
Remove the cover on the track frame and loosen the

tension of the track chain, as described in item 5.3.1
LOOSENING THE TRACK TENSION.
SM9360
WARNING
Fig. 5-7
Fluid under pressure. Do not loosen track tension
by loosening pressure relief valve VS (Fig. 5-4).
Do not remove the grease fitting mounted on the
adjusting valve.
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Remove the screws securing the shoe indicated
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(Fig. 5-8) from the master link.
Remove the shoe and split the master link.
Using a proper hoist and sling, remove the chain from

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the machine.
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SM9359
Fig. 5-8
WARNING
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erly slung and hooked. Use the lifting eyes pro-

vided for this purpose.
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WARNING
When removing the track chains, sling the two end
links and spread the track chain slowly, using a
hoist. Make sure that the zone where the track chain
is going to be placed is completely free and no SM9361
by-standers are in the vicinities.
Fig. 5-9
Start the machine and moving forward slowly, disen-

gage the track chain from the sprocket, the support
rollers and the idler.
Copyright ©
Re-installation
WARNING
Handle all parts with extreme care. Never place
hands and fingers between one piece and another.
Wear approved personal protection equipment
such as glasses, gloves and safety shoes.
1. Position the track chain so that the junction point

is corresponding to the sprocket (fig. 5-10).
SM9362A
2. Start the machine and move it slowly forward, guid-
ing, at the same time, the track chain over the Fig. 5-10
sprocket, using a strong bar placed through the
holes of a link.
Note – Before installing, degrease screws (C) and the

treaded seats on master link (1). 1
T
Apply LOCTITE Super Rapid 242 on the screw thread
IN
and tighten to the prescribed torque. Lubricate with
engine oil the other screws and tighten to the same
torque.
PR
3. Place a wooden block under the rib of the shoe
nearest the junction point. Connect half links (1), SM9363
R
install the master shoe and tighten the screws to

Fig. 5-11
the prescribed torque indicated in fig. 5-12.
FO
Tighten the master link screws with the relevant shoes

to a torque C = 21 to 30 daNm (154.87 to 221.25 ft lb), 3 C 1 2 C1
plus a further 180° (half turn).
For the screws securing the screws, tighten to a torque
T
C1 = 46 to 54 daNm (339.25 to 398.25 ft lb) plus a

O
further 120° (1/3 turn).

N
4. Reset the correct track chain tension, making ref-

erence to item 5.3.1 TIGHTENING THE TRACK
CHAIN.
SM9364
Fig. 5-12 Track chain master link
1. Master SPLIT link - 2. Master shoe - 3. Link pin -

C. Master link hinging securing screws (21 to 30 daNm +
1/2 turn) (154.87 to 221.25 ft lb + 1/2 turn) - C1. Shoe and
split link securing screws (21 to 54 daNm + 1/3 turn)
(154.87 to 398.25 ft lb + 1/3 turn).
Copyright ©
5 - 10 UNDERCARRIAGE 1650K
5.4.2 REPLACING A DAMAGED LINK a 8

AND RE-INSTALLATION 7
To replace a damaged link, not adjacent a master link,
it is possible to perform the operation, without remov-
6 11 9 10 8
ing the track chain assembly, proceeding as follows:
5
6
1. Remove shoe (1 fig. 5-13) secured to the link to be 1
replaced (2) and the two adjacent shoes: Spread
the track chain.
4
1
2
3 SM9365
Fig. 5-13
a. Detail of chain joint - 1. Shoe to be removed - 2. Dam-
aged link - 3 and 4. Pins to be removed prior to use the
torch - 5. Bush to be cut - 6, 7 and 8. Links - 9. New master
bushing - 10. New link.
T
2. Pull-out the hinging pins (3 and 4) of the damaged
IN
link, using portable press (A fig. 5-14).
3. Cut with a torch a section of bushing (5) 20 to 30

PR
mm (0.787 to 1.181 in) long.
R
FO
SM9366
Fig. 5-14
T
O
N
D C 9
A B E
SM9367
Fig. 5-15 Pressing out a chain master link (9) using a portable press (G)
A. Hydraulic press - B. Pusher punch - C. Pin puller punch - D. Alignment bushing - E. Pin removal support and linkage.
Copyright ©
1650K UNDERCARRIAGE 5 - 11
6. For the re-installation, use a portable hydraulic

WARNING press complete with the tooling illustrated in figure
5-15.
Wear welder personal protection equipment, such
as mask or dark glasses, helmet, apron, shoes and
7. Install a master bushing (9) on a new link (11) and
heavy gloves, every time arc cutting or welding is
secure it to the track chain.
performed. Always wear dark protective glasses
near welding in progress. NEVER LOOK DIRECTLY
8. Reinstall the second link (6) on the master bush-
AT THE ARC WITHOUT APPROPRIATE EYE PRO-
ing.
TECTION.
9. Install the two master bushing rings (10) on links
4. Remove the damaged link (2). (7 and 8) and complete the operation reinstalling
pins (3 and 4).
5. Remove link (6) and pull-out the section from it
remaining in bushing (5).
T
C
A
IN
B
PR
R
a G 9 11 F
FO
SM9368
T
O
N
6 9 G
b
SM9369
Fig. 5-16
a. Installation phase of the bushing on the first link - b. Installation phase of the second link.
Copyright ©
Re-assembly of a lubricated track chain

Prior to reassembling the components of the track
chain, follow the notices and procedures listed in item
5.4.1.
1. Press the pins using the portable hydraulic press.
2. Press the rubber plug into the pin hole using tool
(A fig. 5-17). Take care in positioning the plug in-
side 8 to 10 mm (0.315 to 0.393 in) from the rim of
the pin. A
SM9370
Fig. 5-17
3. Check the tightness of the seals and the oil filling
into the pins, using tool (B) fig. 5-18.
T
IN
PR
SM9371
Fig. 5-18
R
5.4.3 IDLER
(removal/installation/overhaul)
FO
Removal
1. Split the track chain (see item 5.4.1 TRACK CHAIN

- removal).
T
2. Remove the idler guards.

O
1
3. Remove screws (1 fig.5-19) securing the idler sup-
N
ports. 6 SM9372
4. Separate the idler from yoke (2) fig. 5-20. Fig. 5-19
WARNING
Handle all components with extreme care. Never
place hands and fingers between one piece and
another.
2
5. Remove the idler from the machine using tool (A)
fig. 5-21.
4 5
SM9373
Fig. 5-20
Copyright ©
Re-installation
1. Position the idler on the track frame, using tool (A,
fig. 5-21).
2. Split the same number of adjusting shims (3, A

fig. 5-22) between the inner and outer end plates,
previously removed.
Position the end paltes (4, fig. 5-20) and tighten
the fixing
screw (5, fig. 5-20).
SM9374
WARNING Fig. 5-21

3
Note – If the original quantity of shims is unknown,
T
split them so that clearance (G1) between the end
IN
plate and the guide plate is 1 mm (0.03937 in), on each
side of the idler.
Also, check that the axis of the idler is aligned with the
PR
axis of the bottom rollers.
SM9375
3. Tighten screws (1, fig. 5-19) connecting the yoke Fig. 5-22
to the idler supports.
R
4. Reinstall the idler guards.

C
FO
5. Connect the track chain (see 5.4.1 TRACK CHAIN

- installation) and re-adjust to a correct tension.
6. Refill the idler with oil.

T
O
Overhaul
N
Remove the idler from the machine (see removal).

D150-2R0049
1. Support adequately the idler. Remove plug (6, Fig. 5-23

fig. 5-19) and drain the lube oil.
Then retighten the plug to avoid the entry of dirt

inside the lube duct.
A
2. Remove screw (7, fig. 5-26) locking the idler shaft.
Mark end supports (8, fig. 5-26).
3. Pull-out the ends using tool (C, fig. 5-23). In case

this operation is difficult, use portable press (A,
fig. 5-24), complete with the tooling illustrated in
the figure, to pull-out the supports.
D150-2R0050
Fig. 5-24
Copyright ©
4. Remove the front seals (9, fig. 5-25) and keep the
matching to avoid mixing them, when reassem-
bling. Remove O-Rings (10).
Remove screws (11, fig. 5-27) securing the bush-
ing housings. Remove bushing housings (2, 9
fig. 5-28) assemblies forcing the idler shaft end
(5-28) with a hydraulic press.
5. In case of replacement, press-out the bushing from

the relevant housings, using an adequate punch.
6. Reassemble the components in the same manner SM9378

as described in paragraph 5.4.5 BOTTOM ROLL-
ERS - Overhaul. Fig. 5-25
7. Check the axial play of the idler, using dial gauge

(D) as illustrated in fig. 5-29. The reading value to 7
be obtained is listed in paragraph 5.5.1 SPECIFI-
CATIONS AND DATA - Idler.
Reinstall the front seals, making sure that the metal 8
T
ring faces are free from dents, scratches or traces
of wear.
IN
9
DEGREASE AND CLEAN THE FRONT SEAL SEATS.
PR
ELIMINATE ALL TRACES OF DUST OR IMPRINTS
D150-2R0051
FROM THE SURFACES THEN COVER THEM WITH
A THIN FILM OF OIL, MAKING SURE THAT THE Fig. 5-26
OTHER SURFACES REMAIN DRY.
R
FO
11
WARNING
Never use gasoline, solvents or other flammable
fluids to clean components. Use approved non-
T
toxic and non-flammable commercial solvents.

O
10
N
Reinstall idler supports (8, fig. 5-26) and block the D150-2R0052
idler shaft with screw (7) making sure, before tighten-
ing to torque, that item (9) is properly seated. Fig. 5-27
Reinstall the idler on the machine (see Installation).
2 3
WARNING
D150-2R0053
Fig. 5-28
Copyright ©
WARNING
of adequate capacity.
Make sure that parts are properly slinged and
hooked. Use the lifting eyes provided for this pur-
pose.
Beware of by-standers in the vicinity of the load to
be lifted.
D
D150-2R0054
Fig. 5-29
5.4.4 TRACK CHAIN SUPPORT ROLLERS
(removal/installation/overhaul)
Removal
1. Loosen and split the track chain (see paragraph
5.4.1 TRACK CHAIN - removal). 1
T
IN
2. Remove screws (1, fig. 5-30) securing the roller
support to the track frame.
PR
WARNING D150-2R0054
Lift and handle all heavy parts with lifting devices Fig. 5-30
of adequate capacity.
R
Make sure that parts are properly slinged and

hooked. Use the lifting eyes provided for this pur-
FO
pose.
Beware of by-standers in the vicinity of the load to
be lifted.
1
T
WARNING
O

N

such as glasses, gloves and safety shoes. 2
3. Remove the roller complete with support, as shown

in fig. 5-31. SM9384
If the roller must be disassembled, it is necessary
Fig. 5-31
to separate it from support (2), loosening com-
pletely screws (1) securing it to the track frame.
Re-installation
4. To re-install the rollers, reverse the operation de-
scribed above. Tighten the screws securing the
roller support to the track frame to a torque of
48 daNm (353.9 ft.lb.).
Reassemble the track chain and reset the tension
(see paragraph 5.4.1 TRACK CHAIN - installation).
Copyright ©
Overhaul
Remove the roller from the machine. 5 15
Block the roller in a vice using tool (A, fig. 5-32), and
drain the lube oil.
Loosen completely screws (15) and remove roller sup-
port (2).
Loosen screws (10) and remove cover (5) complete 10
with seal (6).
Remove the screws securing thrust ring (4, fig. 5-33)
2
and remove the ring; pull-out the shaft from the roller
body.
Remove bearing (12) using an appropriate puller. A
Remove seal (13).
Pull-out the second bush from the relevant seat using
an inner puller.
In case of replacement of bushing, press them into
their seats on the roller body.
SM9385
T
Fig. 5-32
IN
WARNING
Install the shaft into the roller body and the thrust
Never use gasoline, solvents or other flammable
ring. If a high wear of the thrust face of the ring toward
fluids to clean components. Use approved non-
PR
the roller is found, reverse the position of the ring.
toxic and non-flammable commercial solvents.
Tighten the screws to the prescribed torque (see
SPECIFICATIONS AND DATA - support rollers).
Install cover (5) complete with O-Ring. Tighten secur-
R
ing screws (10) to the prescribed torque.

Note – Install the front seals. Degrease and clean the Re-install the roller on the support, tighten locking
FO
front seal seats. Eliminate all traces of dust or imprints screws (15).
from the surfaces then cover them with a thin film of
oil, making sure that the other surfaces remain dry. Refill the roller with SAE 40 oil (0.28 kg, 0.617 lb). Re-
install the roller on the machine (see Installation).
T
10
11 12 1
O
6
4 13
N
5 3
8
9 7
14
15
16
2
SM9412A
Fig. 5-33 Support roller components

1. Track support roller - 2. Support - 3. Shaft - 4. Thrust plate - 5. Cover - 6. Seal - 7. Plug - 8. O-Ring - 9. Screw - 10. Screw -
11. Spring washer - 12. Bushing - 13. Seal - 14. O-Ring - 15. Screw 16x1.5x100- 16. Washer.
Copyright ©
5.4.5 TRACK CHAIN BOTTOM ROLLERS

(removal / installation / overhaul)
Removal 2
If the intervention is limited to one or few rollers, to
remove them, it is sufficient to follow the procedure
described here below.
1. Remove screws (1, 2 and 3 fig. 5-34) and remove

the bottom roller inner and outer guards. Salvage
the spacers mounted coaxial with screws (1).
1 D150-2R0056
2. Split the chain

(see 5.4.1 TRACK CHAIN -Removal).
3. Lift the machine using an hydraulic jack (4 fig. 2

5-35) of adequate capacity. Immediately support
the machine using a strong wooden block (5)
capable of supporting its weight (fig. 5-35).
3
T
4. Loosen screws (6) securing the rollers to the track
frame.
IN
1
5. Insert tool (A), remove the screws and remove D150-2R0057
PR
the roller, as illustrated in fig. 5-36.
Fig. 5-34
WARNING
R
Every time groups of the machine must be re-

FO
moved or installed, requiring to be supported by

jacks, make sure that the contacts under the jack 4
and between jack and machine are appropriate for
the load to be supported. Immediately transfer the
load to appropriate supports or stands. Do not
T
work under or near a machine or its components

O
which are supported only by jacks or other lifting

devices, according to current national or local regu-
lations.
N
D150-2R0058
Fig. 5-35
Re-installation
1. Place the roller on tool (A fig. 5-36) and arrange it
on the track frame. Install screws (5) and tighten
to the prescribed torque (see 5.5.4 SPECIFICA-
TIONS AND DATA - bottom rollers).
2. Re-install the roller guards, placing the spacer pre-

viously removed, and lower the machine to the 6
ground.
A
3. Reassemble the track chain and set the correct 5
tension (see 5.4.1 TRACK CHAIN - Installation). D150-2R0059
Fig. 5-36
Copyright ©
Overhaul
Remove the roller from the machine and proceed as 2
described here below.
1. Block the roller in a vice using tool (A fig. 5-37), 1

remove plug (1) and drain the lube oil.
2. Remove roller support retaining plate (2).

A
SM9389
Fig. 5-37
3. Use a screw puller (B fig. 5-38) to pull-out sup-
ports (3) from the roller shaft.
B
T
IN
3
PR
SM9390
Fig. 5-38
R
In the event this operations becomes difficult, use

portable press (B fig. 5-39), equipped with the tooling B
FO
illustrated, to pull-out the supports. Remove the

O-Rings on the roller shaft.
T
O
N
D150-2R0060
Fig. 5-39
4. Remove screws (1, fig. 5-44) securing the bush
housings and pull-out housing assemblies (2, fig. 1 2
5-40) pushing roller shaft (1) using a universal puller
or a stand press. Match the front seals to avoid
mismatching during reassemble.
5. In case of replacement, pull-out bushes (1, fig.

5-41) from the relevant housings (2, fig. 5-41) us-
ing an appropriate punch.
SM9392
Fig. 5-40
Copyright ©
6. Install new bushing into the relevant housings,

operating as follows:
- remove dowels (3 fig. 5-42) from the housing or,

in case of necessity, cut them flat with the face; 1
2
- press the new bushing into the housing so that,
after pressing, lube holes (F) are coaxial with a
maximum run-out of 2.5 mm (0.984 in).
- drill two new holes for dowels (3) as far as pos-

sible from the lube holes. Press the dowels mak- SM9393
ing sure that they don't protrude over the bush-
ing surface. Fig. 5-41
3
7. Install O-Ring (*) (1 fig. 5-43) on bushing housing
(2).Press the first housing, using guide pins (S
fig. 5-43) to facilitate the alignment of the holes of
the housing securing screws.
T
8. Install the roller shaft, press the second bushing
housing assembly and make sure that the shaft
IN
turns freely.
Install and tighten to the prescribed torque screws
(1 fig. 5-44) (see 5.5.4 SPECIFICATIONS AND
PR
DATA - Bottom rollers)
F SM9394
9. Check the axial play of the roller shaft using dial
gauge (A) as illustrated in fig. 5-44. Fig. 5-42
R
Compare the value measured with the data of 5.5.4

SPECIFICATIONS AND DATA - Bottom rollers.
FO
10. Re-install the front seals.
Note – Degrease and clean the front seal seats. S

T
Eliminate all traces of dust or imprints from the 2

surfaces then cover them with a thin film of oil, making 1
O
sure that the other surfaces remain dry.

N
Install supports (3 fig. 5-38) on the shaft, pushing them

fully to win the resistance provided by the front seals SM9395
and hold the pack inserting securing plate (2 fig. 5-37)
into its seat. Fig. 5-43
(*) It is recommended that the O-Rings are always

replaced.
1 A
SM9396
Fig. 5-44
Copyright ©
11. Check the tightness of the front seals.

Connect tool (A fig. 5-45) to the threaded hole of
the lubrication duct. Inject compressed air into the
roller at a pressure of 2 to 3 bar (29 to 43.5 psi). If
the seals are efficient and correctly installed, no
pressure drops must occur for about 15 seconds.
12. Refill the roller and install it on the machine (see

Installation).
A
D150-2R0062
Fig. 5-45
T
IN
PR
R
FO
T
O
N
Copyright ©
5.5.1 IDLER
Type ............. permanently lubricated, equipped with
Bushing housing self-locking securing screws (C1)
metal (long-life) front seals.
...........................M10x1.5 (6.5 daNm) (47.94 ft lb)
Thickness of clearance adjusting shims (S1) between
end plates and idler guide pads: 0.5 mm (0.196 in).
Note – Degrease and clean the front seal seats.
Thickness of clearance adjusting shims (S2) between Eliminate all traces of dust or imprints from the
end idler support pads and track frame pads: 0.5 mm surfaces then cover them with a thin film of oil, making
(0.196 in). sure that the other surfaces remain dry.
5 2 3 1 4 S1 C3
T
C4
IN
PR
8
7
C2
9
R
FO
10 S2
G1
C1
T
O
11
G2
N
12 C5
SM9398
Fig. 5-46 Idler
C1. Bushing housing self-locking securing screws - C2. Guide pad securing screws - C3. End plates self-locking securing
screws - C4. Idler shaft locking screw - C5. Idler support pad securing nuts - G1. = 1 mm. Clearance between end plates and
guide pads G2. = 0.5 to 1 mm. (0.019 to 0.039 in) Clearance between support pads and track frame - S1. Clearance (G1)
adjusting plates - S2 Clearance (G2) adjusting shims - 1. Idler - 2. Bushing housing - 3. Idler shaft - 4. Idler support - 5. Front
seal - 6. Shaft bushes - 7. Lube plug - 8. End plate - 9 and 10. O-Ring - 11. Guide pad - 12. Idler support pads.
Copyright ©
5.5.2 SPROCKETS
Type ...............................................bolted segments
Number of teeth per crown ................................ 28
Sprocket pitch diameter .........790.94 mm (31.140 in) 1
Width of segment .......................... 70 mm (2.756 in)
Wear limit .........................................(see pag 5-30) 2
5.5.3 TRACK CHAINS

SM9399A
Link type ..................................... with master pins
Number of shoes per track chain 42 plus master shoe Fig. 5-47 Section view of sprocket
T
Total shoes per track chain ...................................43
Totale suole per cingolo (vers. LGP) .................... 48 1. Toothed sector - 2. Sector securing screw - 3. Hub.
IN
Number of split master links per track chain ...........2
PR
Width of shoes:
- standard ................................. 500 mm (19.685 in)
Tightening torques
- optional .................................. 550 mm (21.653 in)
- LGP ....................................... 800 mm (31.496 in) Master link C securing screws (21 to 30 daNm)
(154.875 to 221.25 ft lb)
R
Note – Prior to installation, degrease screws (C) and plus a further 1/2 turn tightening.
the treaded seats on master links (1).
FO
Apply LOCTITE 243 on the screw tread and tighten to Shoe securing screws C1 (46 to 54 daNm) (339.25 to
the prescribed torque. Lubricate the other screws (C1) 398.25 ft lb)
with engine oil and tighten to the prescribed torque. plus a further 1/3 turn tightening.
T
O
N
3 C 1 2 C1
SM9364
Fig. 5-48 Master links
C. Master link hinging securing screws - C1. Shoe and split link securing screws - 1. Split master link - 2. Master shoe - 3.
Link pivot pin.
Copyright ©
5.5.4 BOTTOM ROLLERS

Type ........ permanently lubricated, equipped with Tightening torque
Self-locking screws (C1) securing the bush housings
Quantity of bottom rollers per track chain: M10x1.25 .......................... (7.8 daNm) (57.525 ft lb)
- double flange ..................................................... 3
- single flange ....................................................... 4 Screws securing the rollers to the track frame M16x1.5
- single flange (LGP version) ................................ 5 ..................................... (24.5 daNm) (180.687 ft lb)
Single flange Lube plug (6) 3/8 " x 18 NPSF................................

- weight of roller assembly ........ 44.9 kg (99.004 lb) ................. (13 to 17 daNm) (95.875 to 125.375 ft lb)
- diameter of race ....................... 195 mm (7.677 in)
- diameter of outer flange ........... 230 mm (9.055 in)
- quantity of oil (SAE 30/40) ...... 0.200 kg (0.441 lb)
Double flange
- weight of roller assembly ......... 51.4 kg (113.33 lb) Note – Before assembling, degrease and clean the
- diameter of race ....................... 195 mm (7.677 in) front seal seats. Eliminate all traces of dust or imprints
- diameter of outer flange ........... 230 mm (9.055 in) from the surfaces then cover them with a thin film of
- quantity of oil (SAE 30/40) ...... 0.200 kg (0.441 lb) oil, making sure that the other surfaces remain dry.
T
2
IN
PR
4 3
10 9
5
R
FO
T
O
6
N
4 C1
1
C1
D150-2R0083
Fig. 5-49 Bottom roller
C1. Bushing housing self-locking securing screws - 1. Double flange roller body - 2. Single flange roller body - 3. Bushing
housing - 4. Front seal - 5. Shaft bushing - 6. Lube plug - 7. Lube shaft - 8. Support roller - 9 and 10. O-Ring.
Copyright ©
5.5.5 SUPPORT ROLLERS

Type ........ permanently lubricated, equipped with Tightening torque
Self-locking screws (C1) securing the bushing
housings M10x1.25 .................................................
Quantity of rollers per track chain ......................... 2
................ (5.3 to 6.3 daNm) (39.087 to 46.462 ft lb)
- weight of roller assembly ....... 27.45 kg (60.527 lb)
- diameter of race ........................ 165 mm (6.496 in)
Self-locking screws (C2) securing thrust
- diameter of outer flange ........... 200 mm (7.874 in)
washer M12x1.25 ....................................................
- quantity of oil (SAE 30/40) ......... 0.28 kg (0.617 lb)
............... (5.3 to 6.3 daNm) (39.087 to 46.462 ft lb*)
- diameter of shaft ......................... 44 mm (1.732 in)
- specs of material of support roller body according to
Plug (C3) .... 13 to 17 daNm (95.875 to 125.375 ft lb)
standard .............................................. PDQB 4000
- material of body ................................... 35 MB4 - 2
(*) Apply LOCTITE No. 243
Note – Before assembling, degrease and clean the

front seal seats. Eliminate all traces of dust or im-
prints from the surfaces then cover them with a thin
film of oil, making sure that the other surfaces remain
dry.
T
IN
PR
7 8 6 3 4 1 9 11 10 12 2
R
FO
C1
13 14
T
C2 C3
O
N
SM9404A
Fig. 5-50 Support roller
1. Upper roller body - 2. Shaft - 3. Thrust washer - 4. Shaft securing screw - 5. Cover - 6. Cover seal - 7. Cover securing
screw - 8. Flat washer - 9. Bushing - 10. Seal ring - 11. Elastic ring - 12. Collar - 13. Plug - 14. Plug seal.
Copyright ©
5.5.6 TRACK TENSIONER DEVICE

Type .................................................... single spring. S1
Track tension adjustment ……………… .... hydraulic
Pressure relief valve (Vs) setting ............................
........................ 900 to 950 bar (13050 to 13775 psi)
V1 ............... 6.41 to 6.86 daNm (47.273 to 50.592 ft lb)
(Load at which the pressure relief valve must stay
closed)
V2 ............... 6.86 to 7.35 daNm (50.592 to 54.206 ft lb)
(Load at which the pressure relief valve opens,
corresponding to 900 to 950 bar)
Thickness of valve setting shims (S1) .....................
..... 0.1 - 0.2 - 0.5 (mm) (0.0039 - 0.0079 -0.0196 in) SM9386A
Specifications of track tension spring: Fig. 5-51 Pressure relief valve VS
- Spring free length ................... 736 mm (28.976 in)

- Spring pre-loaded length .......................................
(13500 daN) ........................... 600 mm (23.622 in)
T
IN
PR
R
SM9406A
FO
Fig. 5-52 Track tension adjustment valve VR

T
O
600 mm
N
Ø 200 mm
Ø 111 mm
SM9407A
Fig. 5-53 Track chain tensioner
Copyright ©
5.5.7 FRONT CROSS-MEMBER PIVOTS
1 2
3
5
4 (*)
A A1
Side pivot
T
IN
PR
1
Central pivot
R
6 7
FO
B1 B
T
O
N
SM9408A
Fig. 5-54 Front cross-member pivots
1. Front cross-member - 2. Ball joint - 3. Circlip - 4. Seal - 5. Side pivot pin - 6. Phenolic bushing - 7. Central pivot pin.
(*) Before installing seal (4) smear a line of LOCTITE 603 on its seat.
Copyright ©
FRONT CROSS-MEMBER PIVOTS

Min. Max Min. Max
A. Side pivot
- Pin diameter 59.920 to 59.950 mm 2.359 to 2.360 in
- Ball joint inner diameter 60.000 to 60.300 mm 2.362 to 2.374 in
- Clearance 0.050 to 0.380 mm 0.002 to 0.149 in
A1. Side pivot

- Joint seat diameter 89.965 to 90.000 mm 3.542 to 3.543 in
- Joint outer diameter 89.960 to 89.985 mm 3.541 to 3.542 in
0.025 clear. to 0.040 interf. 0.001 clean to 0.002 in
B. Central pivot
- Ball joint inner diameter(*) 60.450 to 60.550 mm 2.380 to 2.383 in
T
IN
B1. Central pivot
- Bush seat diameter 75.000 to 75.046 mm 2.952 to 2.954 in
- Phenolic bushing outer diameter (*) 75.206 to 75.256 mm 2.961 to 2.963 in
PR
- Interference 0.160 to 0.256 mm 0.006 to 0.010 in
(*) Dimension referred to prior press fitting into seat.

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T
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PIVOT SHAFT
Min. Max Min. Max
C. PIVOT SHAFT
- Shaft diameter 119.946 to 120.000 mm 4.722 to 4.724 in
- Phenolic bushing inner diameter 110 H6
C1. PIVOT SHAFT

- Bushing outer diameter 14.280 to 114.330 mm 0.562 to 4.501 in
- Bushing seat diameter on track frame 114 H8
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2
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C1
SM9409A
Fig. 5-55 Pivot Shaft hinging
1. PIVOT SHAFT - 2. Phenolic bushing - 3. Track frame body.
Copyright ©
CROSS-MEMBER SUPPORT
Min. Max Min. Max
D. Cross-member pivot support

- Bushing inner diameter 60.200 to 60.270 mm 2.370 to 2.373 in
D1. Cross-member pivot support

- Bushing outer diameter 71.970 to 72.000 mm 2.833 to 2.834 in
- Support inner diameter 71.895 to 71.941 mm 2.830 to 2.832 in
- Interference 0.029 to 0.105 mm 0.001 to 0.004 in
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2
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PR 1
D1 D 3
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SM9410
Fig. 5-56 Cross-member support
1. Bushing - 2. Cross-member support - 3. Track frame body.
Copyright ©
5.5.8 WEAR LIMITS
Measuring procedure Nominal dimension Wear limit

mm (in) mm (in) (*)
Pitch
704 (27.716 in) -
4XP
4XP
Link
TRACK
(height) LINK 106 (4.173 in) 97 (3.819 in)
HEIGHT
Top support
roller 195 (7.677 in) 177 (6.968 in)
(diameter)
T
ROLLER DIA.
IN
Bottom
165 (6.496 in) 151 (5.944 in)
PR
roller
(diameter)
ROLLER DIA.
S H O E S U R FA C E
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Bushing
(diameter) 60 (2.362) 57 (2.244 in)
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SHOE BUSCHING
D I S TA N C E
T
Idler
76 (2.992 in) 66 (2.598 in)
(width)
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Idler
(height) 18 (0.708 in) 23 (0.905 in)
CENTER FLANGE HEIGHT
GROUSER HEIGHT
Grousers
(height) 55 (2.165 in) -
Sprocket
(root) 20 (**) (0.787 in)
(*) The wear limit indicated corresponds, generally, to the thickness of the hardened layer at 100 % wear.
(**) The wear limit can change considerably in relation to the real working conditions (6 mm available).
Copyright ©
SECTION 6
DOZER EQUIPMENT HYDRAULIC SYSTEM

TABLE OF CONTENTS
6.1 GENERAL DESCRIPTION ....................................................................................... 6-1

6.1.1 Operation of hydraulic circuit ............................................................................... 6-1
6.1.2 Dozer equipment hydraulic system diagram ......................................................... 6-3
6.2 TESTS ..................................................................................................................... 6-7

6.2.1 Use of flow-meter ................................................................................................ 6-7
6.2.2 Delivery test in the single circuits ........................................................................ 6-7
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6.3 REPAIR PROCEDURES ........................................................................................... 6-8
IN
6.3.1 Hydraulic oil tank (removal/installation) ................................................................ 6-8
6.3.2 Equipment hydraulic pump ................................................................................... 6-10
6.3.3 Hydraulic control valve (removal/disassembly/ overhaul) ..................................... 6-11
PR
6.3.4 Installation of blade .............................................................................................. 6-12
6.4 SPECIFICATIONS AND DATA ................................................................................... 6-13

6.4.1 Hydraulic control valve ........................................................................................ 6-13
R
6.4.2 Power hydraulic pump .......................................................................................... 6-14

6.4.3 Pilot valve power valve block ............................................................................... 6-15
FO
6.4.4 Blade lifting cylinder joint ..................................................................................... 6-16

6.4.5 Blade lifting control cylinder (Angledozer version) ................................................ 6-17
6.4.6 Blade lifting control cylinder (Bulldozer version) ................................................... 6-18
6.4.7 Blade tilt cylinder (PAT version) ............................................................................ 6-19
6.4.8 Blade tilt cylinder (Bulldozer version) ................................................................... 6-20
T
6.4.9 Blade angle cylinder (PAT version for LT and XLT) ............................................... 6-21
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6.4.10 Blade angle cylinder (PAT version for LGP) .......................................................... 6-22
6.4.11 Ripper RP12F cylinder ......................................................................................... 6-23
N
6.4.12 Ripper RP10F cylinder ......................................................................................... 6-24

6.4.13 Push beams and blade rods ................................................................................ 6-25
6.4.14 C-frame and rods ................................................................................................. 6-26
6.4.15 Ripper (LT, XLT version) ....................................................................................... 6-27
6.4.16 Ripper (LGP version) ........................................................................................... 6-28
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1650K DOZER EQUIPMENT HYDRAULIC SYSTEM 6-1
6.1.1 OPERATION OF THE HYDRAULIC the following valves are installed on the control valve.
CIRCUIT The circuit is equipped with a Load Sensing system.
A connection between power pump and control valve
The 1650K dozer can be equipped with a Bulldozer or allows the control valve to forward a signal to the pump
an Angledozer. regulating the oil flow depending upon the real require-
The equipment hydraulic circuit is equipped with a ments of the actuators, changing the displacement of
variable displacement piston power pump (P) mounted the pump up to maximum delivery at maximum speed
on the torque converter sucking oil from tank (S) (150 lt/min, 39.6 gpm).
through metal mesh filter (Fa). The steering circuit and Also, the circuit regulates the flow in accordance with
the equipment circuit are separate, but have in com- a priority logic to the steering that prevails over the
mon the same power (piston) pump and the same equipment circuit when both are used.
control valve. Thus, the two circuits use the same oil,
but operate at different pressures.
QUICK DROP VALVES
The operating pressures of the single circuits are:
- equipment circuit 190 ± 5 bar (2755.7 ± 72 psi); Quick drop valves (V) are included in the bottom of
- steering circuit 350 ± 5 bar (5076.3 ± 72 psi). the blade lift cylinders operate during the lowering
The pump powers the steering circuit through a sec- phase of the blade to accelerate the movement.
tion of the control valve dedicated to the steering. When the operator pushes the blade control pilot valve,
T
Pilot valve (Mr) controlling the ripper can move into the oil flowing-out the lower chamber of the cylinder,
three positions corresponding to: raise, neutral and under the effect of the blade weight and the oil under
IN
lowering. pressure flowing into the upper chamber of the cylin-
Pilot valve (Ma) controlling the blade can move into ders, pushes the ball actuating the plunger that un-
PR
four positions corresponding to: raise, neutral, lower- covers the oil delivery port of the valve to the cylinder
ing and float as well as the blade Tilt rightward or upper chamber, thus speeding-up the lowering of the
leftward. blade.
Two safety levers, located on the right and left side of When the operator pushes the blade control lever
the operator's seat block electrically (when raised) by slightly forward, the condition occurs when the blade
R
a proximity sensor, the power to the control pilot drops under its own weight instead being pushed by
valves, preventing accidental movements of the pilot oil under pressure. The ball is blocked in its seat and
FO
valve. When the machine is standing and the safety the oil does not flow from one end of the cylinder to
lever is lowered, it allows the machine to operate. the other.
When indicator light (4) located on the Monitor in the The stroke-end valves are located in the blade con-
cab is ON, it signals that the cartridge of return filter trol cylinders. They are made of ducts inside the pis-
T
(Fr) is clogged and that it must be promptly replaced. ton, where the seats and a plunger are located. the
Oil sucked by pump (P) power control valve (D) plunger closes the passage when the oil pressure
O
powering block (Va) reaching pilot valves (Ma and Mr) blocks it against the relevant seat. It stays closed
through steering pilot block (Vp) providing the hydraulic until the piston ends its stroke. The plunger is removed
N
piloting of the control valve spools (Pilot valve powering from the relevant seat by the contact of the plunger
pressure 31.5 to 35.0 bar, 457 to 507 psi). rod against the end of the cylinder. Oil flows from one
The movement of any control valve spool occurs end of the cylinder to the other, limiting the stroke of
through the check valves of the actuator circuit used. the cylinder. These valves are needed, in view of the
The pressure established in the delivery circuit is pro- blade tilt action. Thus it is possible that the piston of
portional to the effort required and it is limited by pres- one blade control cylinder is at stroke-end whereas
sure relief valve (5) set at 190 bar (2755.7 psi). Also the other still needs to travel further.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
Copyright ©
6-2 DOZER EQUIPMENT HYDRAULIC SYSTEM 1650K
BLADE HYDRAULIC TILT

The tilt control is obtained by moving the lever side-
ways. The rightward movement of the lever determines
a rightward tilting of the blade (clockwise); in the same
manner, the leftward movement of the lever tilts the
blade leftward (anticlockwise).
The Tilt control has a reduced flow for a finer control
of the blade tilting.
POSITIONS OF THE BLADE CONTROL LEVER

The lever controls the raising, lowering and tilting of
the blade. F
To raise or lower the blade, move the lever respec-
tively backward into position D or forward into posi-
tion H.
The stopping of the blade in a defined position is ob-
H
tained, under both circumstances, by releasing the
T
lever that returns automatically in neutral N.
IN
To make the blade floating, meaning resting on the
ground under the effect of its weight only, move the
lever full stroke forward, into position F where it stays A B
PR
kept by a detent.
The floating condition is terminated when the lever is
returned into neutral N.
D
When moving the lever leftward into position A or right- SM9474
ward into position B the side inclination of the blade
R
(Tilt) is obtained. The lever must be held until the de-

Fig. 6-1 Blade control lever position plate
FO
sired position is reached.

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POSITIONS OF THE RIPPER CONTROL LEVER

(Optional)
- With lever forward P = ripper lowering.
- With lever backward R = ripper raising.
- Lever in N = neutral
SM9475
Fig. 6-2 Ripper control lever position plate
Copyright ©
6.1.2 DOZER EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

P. Variable displacement piston power pump (150 lt/min, 39.6 gpm at 2000 rpm)
D. Piloted system control valve
S. Hydraulic oil tank
Va. Pilot valves power block
Fa. Tank oil suction filter
Fr. Filter on oil return line to tank
Ls. Load-Sensing signal
V. Quick drop valves
Connecting ports
- Control valve - Cylinders Delivery
A1. Ripper cylinder lowering Q = 120 lt/min (31.6 gpm)
B1. Ripper cylinder raising Q = 150 lt/min (39.6 gpm)
A2. Action on tilt cylinder with rightward blade lifting Q = 50 lt/min (13.2 gpm)
B2. Action on tilt cylinder with leftward blade lifting Q = 70 lt/min (18.5 gpm)
A3. Blade control cylinder lowering Q = 150 lt/min (39.6 gpm)
B3. Blade control cylinder raising Q = 150 lt/min (39.6 gpm)
A4. Action on angle cylinder with blade leftward angling Q = 150 lt/min (39.6 gpm)
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B4. Action on angle cylinder with blade rightward angling Q = 150 lt/min (39.6 gpm)
IN
- Blade control pilot valve - Control valve (piloting)
Blade lowering 1Î a3
PR
Floating 5Î x
Blade tilt 2Î b2
Blade raising 3Î b3
Blade tilt 4Î a2
R
- Ripper control pilot blade - Control valve (piloting)

FO
Raising 1 Î b1
Lowering 2 Î a1
T
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6-5
EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
BLADE
V V
MANIPULATOR
(RIPPER) M RIPPER TILT
1 soll. ANGLE
76068326
HYDRAULIC
T Mr MOTOR
P
76072083
2 abb. A1 S B1
Ma
P
2 5 float
1 abb.
T
25 bar (362.6 psi)
D
b5 b2 b1
3 soll.
877109
877109
877109
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
b4 L2 x b3 γ1
230 bar (60.8 gpm)
230 bar (60.8 gpm)

230 bar (60.8 gpm)
230 bar (60.8 gpm)

MANIPULATOR 76074729
(FRONT IMPL.)
76074300 Vp
396467
396467
76069635 25 6
396467
230 bar (60.8 gpm)
230 bar (60.3 gpm)

230 bar (60.8 gpm)
230 bar (60.8 gpm)
0 (5656.5 psi 0 )
STEERING
+72
BLOCK ELECTROVALVE 8
396467
ANGLE
7
321141
321141
TL.
396467
396467
396467
396467
MT
390 bar+5
L1
30±2 bar a 15 lt/min.(435+29 a 3.9 gpm)

L R1
190/360 bar (2755/5221.3 psi)

1
IN
23 22 2 T
5 bar (72 psi)
X
26
5 bar (72 psi)
898999
21
719176
719176
723199
723216
719176
(580.1 psi)
A
3
40 bar
938489
19
0.7 L/min.
PR
B P
C D
S P
560952
24 24
18 LS
MP
R
Q = 70 lt/min (18.5 gpm)
Q = 50 lt/min (13.2 gpm)
Q = 150 lt/min (39.6 gpm)

Q = 150 lt/min
877109
Q = 120 lt/min (31.7 gpm)
877109
877109
877109
TR PS PM T B5 A5 B4 A4 a4 L1 B3 A3 B2 A2 B1 A1 MLS
Q = 150 lt/min
Q = 150 lt/min
Q = 150 lt/min (39.6 gpm)
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
φ 2.0
φ 0.8
(39.6 gpm)
(39.6 gpm)
24
TILT
(39.6 gpm)
RIPPER
Q = 150 lt/min
5
BLADE
Q = 150 lt/min (39.6 gpm)
(39.6 gpm) 24 20 10
a5 a3 a2 a1
R
76073165
FO
BLOCK CHECK POINT
P1
14
15
16
T
Va
35 bar
(507.6 psi)
45 bar
O M A G X T1 R T2
(652.7 psi)
N
17 20÷21
P2 T PR LOAD bar
SENSING (290 to 305 psi)
VALVE"S"
PRESS 11
CUT-OFF
"D"
350bar
(5076.3 psi)
12
COSTANT
POWER
"LR" 58KW
EQUIPMENT PUMP
2.20 bar @
OIL - TANK (31.9 psi) 2000rpm
(78 HP)
9
4
2.5 bar (36.6 psi)
75 (Qmax=75C /REV.)
3 13
76072082
3
CC/REV
5 (Qmin=15C /REV.)
0.2 bar (2.9 psi) Fv P

OLIO
S M1
HI-TECH 46
KSM0002
Fa
KSM0002
Fig. 6-3 Dozer equipment hydraulic system diagram
1. Blade spool - 2. Tilt spool - 3. Ripper spool - 4. Hydraulic oil filter clogging indicator - 5. Load sensing relief valve (190 ± 5 bar/350 ± 5 bar) - 6. Blade spool safety valves (230 ± 5 bar) - 7. Tilt spool safety valves (230 ± 5 bar) - 8. Ripper spool safety valves (230 ± 5 bar)
- 9. By-pass valve - 10. Unloading valve (30 bar, 10 lt/min) - 11. Load sensing signal regulating valve - 12. Cut-off signal valve - 13. Constant power control valve - 14. Accumulators 0.75 lt - 15. Flow reduction valve - 16. Power block pressure relief valve 45 bar -
17. Power block solenoid valve - 18. Reduction valve - 19. Distribution valve - 20. LS line decompression valve (it stabilises LTS signal) (0.7 lt/min) - 21. Main pressure relief valve - 22. Piloting valve - 23. Selector valve - 24. Pressure compensators - 25. Angle control
spool safety valve (230 ± 5 bar) - 26. Angle control spool - D. Equipment/steering control valve - M. Steering hydraulic motor (see SECTION 4 Steering) - P. Variable displacement piston power pump 58 kW/2000 rpm - Ma. Blade control pilot valve - Mr. ripper control
pilot valve - Va. Pilot valves powering valve - Vp. Steering piloting valve.
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6.2 TESTS
6.2.1 USE OF FLOW-METER TABLE OF REFERENCE PERFORMANCES

The use of flow-meter 75298406 facilitates the identi-
fication of troubles in the system. In order to prevent ENGINE RPM PRESCRIBED VALUES
possible counter-pressures, the return pipe from the
flow-meter must have a diameter slightly larger that Low idle 850 to 1050 rpm
the inlet pipe. The return pipe is connected to the tank
filler neck: remove the strainer and insert the pipe High idle 2260 to 2360 rpm
into the tank to a depth ensuring that it is well sub-
Transmission stall 1930 to 2070 rpm
merged.
The pipe connected to the tank has the tendency to Equipment stall 2210 to 2350 rpm
"jump-out" during the test; thus it must be firmly se-
cured in its position. When applying a pressure actu- Total stall 1825 to 2025 rpm
ating the instrument loading valve, this tendency could
increase, but within the limits of controllability. Prior
to starting the tests, make sure that the pipes used PRESSURES PRESCRIBED VALUES
are of a high-pressure type capable of standing a mini-
mum pressure of 210 bar (3045.8 psi). Equipment (Max.) 190 bar
T
(2755.7 psi)
IN
Equip. control valve piloting 28 to 32 bar
(Pick-up Pr) (406.1 to 536.6 psi)
6.2.2 DELIVERY TEST IN THE SINGLE
PR
Pump pilot valve in neutral 33 to 37 bar
CIRCUITS (Pick-up P2) (406.1 to 536.6 psi)
Plug the delivery pipes to the blade and tilt control
Pump pilot valve in float 33 to 37 bar
cylinders, so that they can be loaded. Since the cylin-
(Pick-up P2) (406.1 to 536.6 psi)
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ders are equipped with stroke-end valves on the pis-

tons, it is not possible to obtain the load required ac- Steering 350 bar
FO
tuating the cylinders to stroke-end. On the contrary, (5076.3 psi)

the ripper circuit can be tested actuating to stroke-
end in the two directions. Brake control 18 to 22 bar
(261 to 319 psi)
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DANGER Transmission 16.5 to 17.5 bar

(239.3 to 253.8 psi)
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Fluid under pressure - Always rest the hydraulic

equipment on to the ground. Cut-off the engine,
N
actuate the control levers a few times without load,

then loosen and retighten the tank cap before loos-
ening the connections of the system.
WARNING
NEVER USE HANDS to find leakages under pres-
sure. Spill of fluid under pressure can be strong
enough to penetrate the skin. Start the engine and
wait that the hydraulic oil warms-up, then acceler-
ate the engine to maximum speed.
Copyright ©
6.3.1 HYDRAULIC OIL TANK

(removal/installation) ON
Removal
Turn the main switch "OFF" to disconnect the electri- OFF
cal system and place a sign "DO NOT OPERATE" on
the switch, as indicated.
WARNING
To minimize the danger of fires and explosions it
is recommended, prior to performing any weld-
DSM 0130
ing on the fuel tank, to drain completely the fuel,
disconnect the pipes and protect their ends and Fig. 6-4 Electrical system main switch
clean the tank inside. All traces of fuel must be
eliminated prior to starting welding. Also flood the
T
tank with carbon dioxide (CO2) before and during
the welding.
IN
While wending, all covers and plugs must be re-
moved and all other openings must be kept free
to ensure ventilation.
PR
Then, proceed as follows:
R
– tilt the cab;

– drain the hydraulic oil from the tank using a con-
FO
tainer of a capacity of at least 70 litres (18.5 gal.)

loosening the appropriate plug (T) and magnetic rod
(Z) located under the tank.
– disconnect the oil delivery and return pipes to the
T
equipment control valve;

O
Z
N
T D150-2R0100
Fig. 6-5 Hydraulic oil tank
Copyright ©
– disconnect the terminal from oil filter clogging sig-

nal sender (5, fig. 6-6) for equipment hydraulic cir- C2
cuit; 2
– remove the two upper screws (C) securing the oil 3
tank to the fuel tank; 3
– remove the four lower screws (C1) securing the tank
Fr
to the frame;
– remove the tank with an adequate lifting device.
5
6
DANGER 4
chains.
Fa
3
T
1
IN
7 C1
C 2
C2
PR
DSM 0131
Fig. 6-6 Hydraulic oil tank and filters
1. Hydraulic oil tank - 2. Filter covers - 3. O-Ring - 4. Oil

R
filler cap - 5. Oil return filter clogging sensor - C. Tank

upper securing screws (M14x2x30) - C1. Tank lower
FO
securing screws (M14x2x35) - C2. Cover securing

screws - Fa - Suction filter - Fr - 6. Breather - 7. Draining
plug.
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FILTERS Return filter (Fr) must be replaced periodically every

500 hours, to prevent that a clogged filter prevents
The cleaning of the oil of the equipment hydraulic
the filtration of the oil.
system is ensured by two separate full-flow filters lo-
cated inside the hydraulic oil tank and precisely:
– filter (Fa, fig. 6-6) located on the pump suction and
DANGER
metal element filter;
– filter (Fr) located on the pump return, equipped with Never use gasoline, solvent or other flammable
a paper-filtering element, with a filter by-pass valve fluid to clean parts. Use exclusively qualified, non-
cutting-off the filter in case of clogging and sender flammable, non-toxic approved commercial sol-
(5) for the indicator located on the dashboard. vents.
Both filters are accessible by removing covers (2) lo-

cated on the tank, removing the relevant securing
screws (C2).
Re-installation of filters and tank
Filter (Fa) is cleaned using an appropriate solvent at
each hydraulic oil change (every 2000 hours) and is To re-install the filters and hydraulic oil tank reverse
replaced when needed only. the removal procedures.
Copyright ©
6 - 10 DOZER EQUIPMENT HYDRAULIC SYSTEM 1650K
6.3.2 EQUIPMENT HYDRAULIC PUMP Only after disconnecting all the pipes, proceed with
the removal of the pump from the torque converter.
Removal Lift the pump as required using cables and remove
Proceed as follows: screws (8) securing the pump. Then remove the pump
- drain the oil from equipment tank (S) as described from torque converter cover (3).
in item 6.3.1;
- start the engine and run it for a few seconds to
drain pump (P) suction pipe (1);
WARNING
- tilt the cab/operator's compartment;
- disconnect suction pipe (1) from pump P loosening Avoid kinking chains and steel cables.
retaining screws C1; Always wear protective gloves when handling ca-
- disconnect pipes (2) removing screws C2 on half- bles and chains.
flanges (5);
- disconnect draining pipes and LS signal (6 - 7) from Make sure that lifting cables are secured to points
the pump side; strong enough to handle the load.
- disconnect the diagnostic pipe and the "DSD" pres- Keep all bystanders away from the securing point,
sure blocking from flange (9) on the pump. cables or chains.
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2 6
4
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C2
5
7
T
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P
8 C1
D150-2R0101
Fig. 6-7 Equipment hydraulic and pipes
P. Equipment hydraulic pump - S. Tank - 1. Suction pump from tank - 2. Delivery pipe to control valve - 3. Torque converter -
4. Control valve - 5. Half flanges - 6. Draining pipes - 7. LS signal pipe - 8. Pump securing screws - 9. Delivery flange -
C1. Screw TE M12x100 - C2. Screw TE M12x1.75x40.
Copyright ©
1650K DOZER EQUIPMENT HYDRAULIC SYSTEM 6 - 11
6.3.3 HYDRAULIC CONTROL VALVE

(removal/disassembly/overhaul)
The control valve is located under the cab and to re-
move it, it is necessary to tilt the cab, as described in
the OPERATION A AND MAINTENANCE MANUAL.
Removal of the control valve
WARNING
Fluid under pressure. Always rest the hydraulic
equipment on to the ground. Cut-off the engine,
actuate the control levers a few times without load,
then loosen and retighten the tank cap before loos-
ening the connections of the system.
Label and disconnect the hydraulic pipes, remove

screws (C1) securing the control valve to the support
on the machine, sling appropriately with a cable and
lift it with a hoist to remove it.
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IN
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Disassembly and overhaul
C1
Drain completely the residual oil form the tank and
place it on a workbench, then proceed with a com-
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plete disassembly.
Remove the control valve securing screws and re-
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move the single spools.

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D150-2R0102
Fig. 6-8 Hydraulic control valve
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6.3.4 INSTALLATION OF BLADE
D
E
H
T
G1
F B
IN
PR
G D150-2R0103
Fig. 6-9
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A. Push-beam front pivot - B. and C. Cross rods pivots - D. Blade control cylinder rods pivot - E. Blade central linkage
pivots - F. Tilt cylinder rear pivot or side rod - G. Push-beam rear pivot - G1 = 67 to 82 da Nm (494 to 604.6 ft.lb.) - H. Tilt
FO
cylinder or side rod securing nuts (49 to 53 daNm, 361.3 to 390.8 ft.lb.).
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PREPARATION
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Before re-installing any component of the blade, elimi- Install the blade cross rods. Install the pins, levers
N
nate all protective coatings, paint or scales from the and locking plates.
mounting or mating faces. Remove all pugs from Move the machine forward between the push-arms
mounting holes and re-do each hole with a tap. aligning them with the ball joints.
Remove the pin cover and grease the ball joint. Install
the shims on the cover, then lubricate the screws be-
INSTALLATION fore installing them.
Install the pins and locking plates of the blade lifting
Install a joint (G) to each track frame, tightening the cylinders.
relevant securing screws. Install the hoses and the tilt cylinder guards (if any).
Clean accurately the pin ball and the ball seat on the Grease accurately all the linkages.
push-beams and pin covers. Smear grease freely on
the ball joints and their seats in the joint.
Position the blade and block it firmly.
Position each push beam on the blade and install the
lower pins.
Copyright ©
6.4.1 HYDRAULIC CONTROL VALVE
Single, 5-spool control valve made by REXROTH

Max. operating pressure: 190/350 bar (2755.7/5076.3 psi).
Oil temperature - 20 through 80 ° C (- 4 through 176 ° F).
Hydraulic oil recommended: Case Hydraulic Excavator
Fluid-MS 1230 (ISO VG46)
Power ports
SPOOL
}
A1 - B1 Cylinder STEERING
A2 - B2 power ports
ANGLE
A3 - B3 a = Lowering
A4 - B4 b = Raising 25 25
A5 - B5 Hydraulic motor BLADE
T
power ports 3 6
6
IN
TILT
2 7
Piloting of spools 7 RIPPER
T 1
5
PR
8 8
}
a1 - b 1 = MSL
a2 - b 2 = a= lowering piloting 10 20 21
a3 - b 3 = b= raising piloting
a4 - b 4 = T
SPOOL
R
a5 - b 5 = Steering STEERING
FO
ANGLE
BLADE
T
TILT
O
RIPPER
N
Steering hydraulic motor safety

valves setting 380 ± 5 bar P
DSM 0134
(5511.4 ± 72 psi)
Fig. 6-10 Hydraulic motor and connections (Ref. D hydraulic system
diagram)
P. From power pump - T. To hydraulic oil tank - 5. LS pressure cutting dual stage
valve (190 ± 5 bar / 350 ± 5 bar, 2755.7 ± 72 psi/5076.3 ± 72 psi) - 6. Blade spool
safety valves (setting 230 ± 5 bar, 3335.9 ± 72 psi) - 7. Tilt spool safety valve
(setting 230 ± 5 bar, 3335.9 ± 72 psi) - 8. Ripper spool safety valve (setting 230 ±
5 bar, 3335.9 ± 72 psi) - 10. Unloading valve 30 bar (435 psi), 10 lt/min(2.6 gpm) -
20. LS line decompression valve - 21. Equipment circuit main pressure relief
valve - 25. Angle spool safety valves (setting 230 ± 5 bar, 3335.9 ± 72 psi).
Copyright ©
6.4.2 POWER HYDRAULIC PUMP
M X
R S DSM 0135
Fig. 6-11 Hydraulic pump
T
S. Suction from tank - M. Pressure pick-up - X. To control valve - A. Control valve powering - R. To power block.
IN CONTROL VALVE
PR
TO PILOTING
POWERING
BLOCK
M A G X T1 R T2
R
76072082
FO
20 to 21 bar
LOAD
(290 to 305 psi)
SENSING
VALVE "S"
PRESS
350 bar 11
T
CUT-OFF
"D" (5076.3 psi)
COSTANT
POWER LR
O
58 KW @
2000rpm
(78 Hp) 12
N
13
(Qmax=75c /rev)
3
75
TORQUE CC/REV
(Qmin=15c /rev)
3
CONVERTER P
S M1 A11V075
DSM 0136
Brand ................................................................................................................................................. REXROTH

Variable displacement piston type ........................................................................................................A11VO75
Total nominal delivery at 2000 rpm .................................................................................... 150 lt/min (39.6 gpm)
Copyright ©
6.4.3 PILOT VALVE POWER VALVE 14

BLOCK
(Ref. Va hydraulic diagram)
It is installed on the transmission. To reach it, tilt the
110 PRECARICA
cab.
15 13 bar (188.5 psi)
P1 1/4'G
35 bar 101 Va
(507.6 psi)
45
bar
(652.7 psi)
17
16 P2 1/4'G T 1/4'G PR 1/4'G
T
IN
PR
DSM 0137
Va. Power valve block - 14. Accumulator 0.75 lt (0.2 gal.) -

R
15. Flow reduction valve - 16. Power block pressure relief

valve 45 bar (652.7 psi) - 17. Power block solenoid valve.
FO
T
O
L0.75
N
P2 PR
P1
T
D150-2R0104
Fig. 6-14 Pilot valves power valve block
Ports on power valve block

P1. Pressure pick-up - P2. From pump - T. To tank - PR.
From pilot valves.
Copyright ©
6.4.4 BLADE LIFTING CYLINDER JOINT
D B C A
T
IN
PR
F SM9455
R
Fig. 6-15 Section view of blade lifting cylinder joint

FO
A. Diameter of joint inner bushing .................................................. 79.895 to 79.941 mm (3.145 to 3.147 in)
Outer diameter inner bushing .................................................... 79.970 to 80.000 mm (3.148 to 3.150 in)
Mounting interference ................................................................ 0.029 to 0.105 mm (0.0001 to 0.0041 in)
T
B. Diameter of joint inner bushing .................................................. 119.921 to 119.867 mm (4.721 to 4.719 in)
O
Outer diameter inner bushing .................................................... 120.090 to 120.120 mm (4.728 to 4.729 in)
N
C. Inner diameter inner bushing ..................................................... 70.200 to 70.270 mm (2.764 to 2.766 in)
Outer diameter of pin in correspondence with inner bushing ...... 69.970 to 70.000 mm (2.755 to 2.756 in)
Play .......................................................................................... 0.200 to 0.300 mm (0.0079 to 0.0118 in)
D. Inner diameter outer bushing ..................................................... 105.300 to 105.350 mm (4.146 to 4.148 in)
Outer diameter of pin in correspondence with inner bushing ...... 104.960 to 105.000 mm (4.132 to 4.134 in)
Play .......................................................................................... 0.300 to 0.390 mm (0.0118 to 0.0153 in)
E. Inner diameter cylinder pin (seated) .......................................... 40.050 to 40.112 mm (1.577 to 1.579 in)
Outer diameter cylinder joint pin ................................................ 39.975 to 40.000 mm (1.574 to 1.575 in)
Play .......................................................................................... 0.050 to 0.137 mm (0.0019 to 0.0054 in)
F. Tightening torque of joint plate securing screws ....................... 18 daNm (132.7 ft.lb.)
Copyright ©
6.4.5 BLADE LIFTING CONTROL CYLINDER (Angledozer version)
18
3 7 6 8 10 13 14 15 17
1 2 5 11 16
B
A
9
C1
4 C2
12 C
19
T
IN
PR
D150-2R0105
R
Fig. 6-16 Section view of blade cylinder

FO
A. Rod nominal diameter ........................................... 50 mm (1.97 in) 1. Rod

B. Piston nominal diameter ....................................... 90 mm (3.54 in) 2. Circlip
T
C. Cylinder rod strike .............................................. 826 mm (32.5 in) 3. Ball joint

C1. Front sleeve tightening torque ................................ 73.5 ± 5 daNm
O
4. Front sleeve
(542 ± 36.9 ft.lb.) 5. Seal
C2. Piston securing nut tightening torque ............... 65.7 to 72.6 daNm
N
6. Securing plate
(484.4 to 535.3 ft.lb.) 7. O-Ring
8. Rod seal
9. Buffer ring
10. Back-up ring
11. O-Ring
12. Rod guide ring
13. Cylinder sleeve assembly
14. Piston
15. Piston seal
16. Piston guide ring
17. Nut
18. Grease fitting
19. Unloading valve (quick drop)
Copyright ©
6.4.6 BLADE LIFTING CONTROL CYLINDER (Bulldozer version)
6 7 8 10 11 13 14 15 19
5
C
4 3 12
1 2
T
IN
PR
19
D150-2R0106
R
Fig. 6-17 Section view of blade lifting cylinder

FO
T
O
A. Rod nominal diameter ........................................... 45 mm (1.77 in) 1. Circlip

B. Piston nominal diameter ....................................... 80 mm (3.15 in) 2. Ball joint
N
C. Cylinder rod strike .......................................... 1185 mm (46.65 in) 3. O-Ring

– Front sleeve (6) tightening torque ......................... (80 to 88 daNm, 4. Seals
589.8 to 648.8 ft.lb.) 5. Rod
– Piston (14) securing nut tightening torque .................. (31.5 daNm, 6. Front sleeve
232.2 ft.lb.) 7. Ring
– Dowel (15) tightening torque ............................... (1.75 to 2 daNm, 8. Seal
12.9 to 14.7 ft.lb.)
10. Cylinder sleeve
11. Piston
13. Seals
14. Nut
15. Dowel
19. Unloading valve (quick drop)
Copyright ©
6.4.7 BLADE TILT CYLINDER (PAT version)
1 2 3 4 5 6 7 8 9 10 11 12 13
B
A
C
14 15 16 17
T
IN
PR
D150-2R0107
R
Fig. 6-18 Section view of blade tilt cylinder

FO
T
O
A. Rod nominal diameter ......................................... 63 mm (2.48 in) 1. Rod

B. Piston nominal diameter ................................... 125 mm (4.92 in) 2. Circlip
N
C. Cylinder rod strike ............................................ 135 mm (5.31 in) 3. Ball joint

– Front sleeve (4) tightening torque ............... 74 daNm (545.6 ft.lb.) 4. Front sleeve
– Piston (13) securing nut tightening torque ........... 177 ± 10 daNm 5. Securing plate
(1305 ± 73.7 ft.lb.) 6. O-Ring
7. Back-up ring
8. O-Ring
9. Cylinder sleeve ass.ly
10. Piston
11. Piston seal
12. Rod guide ring
13. Cylinder locking nut
14. Seal
15. Rod seal
16. Buffer ring
17. Rod guide ring
Copyright ©
6.4.8 BLADE TILT CYLINDER (Bulldozer version)
3 4 5 9-10 8 2 1 12 13 15-16
A
B
C
T
IN
PR
R
D150-2R0108
FO
A. Rod nominal diameter ........................................... 63 mm (2.48 in)

T
1. Cylinder sleeve assembly

B. Piston nominal diameter ..................................... 125 mm (4.90 in) 2. Rod assembly
O
C. Cylinder rod strike .............................................. 140 mm (5.51 in) 3. Screw securing sleeve
– Sleeve (3) securing screws tightening torque .................. 79 daNm 4. Front sleeve
N
(582.5 ft.lb.) 5. Seal assembly kit

– Piston (12) tightening torque ......................................... 210 daNm 8. Guide ring
(1548.3 ft.lb.) 9. O-Ring
– Screw (15) tightening torque .......................................... 1.6 daNm 10. Retaining ring
(11.8 ft.lb.)
11. Screw TCEM10x40
12. Piston
13. Piston seal kit
15. Screw
16. Steel ball
Copyright ©
6.4.9 BLADE ANGLE CYLINDER (PAT version for LT and XLT)
15 1 2 3 4 5 6 7 8 9 10 11 12
B
C
14 13
16 21 17 18 19 20
T
IN
PR
R
D150-2R0109
FO
1. Securing plate
A. Rod nominal diameter ........................................... 50 mm (1.97 in) 2. O-Ring
T
B. Piston nominal diameter ..................................... 100 mm (3.94 in) 3. Back-up ring

O
C. Cylinder rod strike ............................................ 509 mm (20.04 in) 4. O-Ring

– Front sleeve (5) tightening torque ................ 74 daNm (545.6 ft.lb.) 5. Front sleeve
N
– Piston nut M42x2 (10) tightening torque .............. 177 ± 10 daNm 6. Cylinder sleeve assembly
(1305 ± 73.7 ft.lb.) 7. Piston
8. Piston seal
10. Piston locking nut
11. Circlip
12. Brake bushing
13. Brake locking ring
14. Stop ring
15. Ball joint
16. Circlip
17. Seal
18. Rod seal
19. Buffer ring
20. Rod guide ring
21. Rod
Copyright ©
6.4.10 BLADE ANGLE CYLINDER (PAT version for LGP)
7 8 9 10 11 12
15 1 2 3 4 5 6
B
C
14 13
16 21 17 18 19 20
T
IN
PR
R
D150-2R0110

FO
A. Rod nominal diameter ........................................... 55 mm (2.16 in) 1. Securing plate

T
B. Piston nominal diameter ..................................... 110 mm (4.33 in) 2. O-Ring

C. Cylinder rod strike ............................................ 509 mm (20.04 in) 3. Back-up ring
O
– Front sleeve (5) tightening torque ................. 74 daNm (545.6 ft.lb.) 4. O-Ring
– Piston nut M42x2 (10) tightening torque ............... 177 ± 10 daNm 5. Front sleeve
N
(1305 ± 73.7 ft.lb.) 6. Cylinder sleeve assembly

7. Piston
8. Piston seal
10. Piston locking nut
11. Circlip
12. Brake bushing
13. Brake locking ring
14. Stop ring
15. Ball joint
16. Circlip
17. Seal
18. Rod seal
19. Buffer ring
20. Rod guide ring
21. Rod
Copyright ©
6.4.11 RIPPER RP12F CYLINDER
7
8
20 5
19
18
4
3
1
6
17
2
T
1
IN
16
15
PR
11
10
9
R
12
FO
14
13
D150-2R0111
Fig. 6-22 Ripper cylinder

T
O
Brand ...................................................................................... RECO 1. Bush

Model ..................................................................................... RP12F 2. Cylinder
N
Nominal diameter of rod ............................................ 70 mm (2.76 in) 3. Nut

Nominal diameter of piston ...................................... 125 mm (4.92 in) 4. Piston
Cylinder rod strike ................................................. 380 mm (14.96 in) 6. Seal
7. Seal
8. Seal
9. Seal
10. Seal
11. Seal
12. Cover
13. Screw 20x70
14. Washer
15. Rod
16. Bushing
17. Grease fitting
18. Screw
19. Washer
20. Steel pipe
Copyright ©
6.4.12 RIPPER RP10F CYLINDER
7
8
3
20 5
19 16
18
1
8
17
T
2
IN
1
1
PR
15
11
10
9
R
12
FO
14
13
DSM 0141
T
Fig. 6-23 Ripper cylinder

O
1. Bush
Brand ..................................................................................... RECO 2. Cylinder
N
Model .................................................................................... RP10F 3. Nut

Nominal diameter of rod ........................................... 60 mm (2.36 in) 4. Piston
Nominal diameter of piston ..................................... 120 mm (4.72 in) 6. Seal
Cylinder rod strike .................................................. 320 mm (15.6 in) 7. Seal
8. Seal
9. Seal
10. Seal
11. Seal
12. Cover
13. Screw 20x70
14. Washer
15. Rod
16. Bushing
17. Grease fitting
18. Screw
19. Washer
20. Steel pipe
Copyright ©
6.4.13 PUSH BEAMS AND BLADE RODS
C H
A
G1
D
T
F
IN
B
PR
G
SM9477A
Fig. 6-24 Bulldozer equipment pivot points

R
A. Outer diameter push beam front joint ........................................ 49.961 to 50.000 mm (1.967 to 1.968 in)
FO
Inner diameter ball joints ........................................................... 50.180 to 50.242 mm (1.975 to 1.978 in)
Play .......................................................................................... 0.180 to 0.281 mm (0.0071 to 0.0110 in)
B. Outer diameter rod rear pin and tilt cylinder ............................... 59.954 to 60.000 mm (2.360 to 2.362 in)
Inner diameter pin bushing ........................................................ 60.210 to 60.280 mm (2.370 to 2.373 in)
T
Play .......................................................................................... 0.210 to 0.326 mm (0.0083 to 0.0128 in)

O
C. Diameter bush seat on rod and tilt cylinder ............................... 71.895 to 71.941 mm (2.831 to 2.832 in)
N
Outer diameter bushing ............................................................. 71.970 to 72.000 mm (2.833 to 2.835 in)

D. Outer diameter cross rod main pin and blade ............................ 49.961 to 50.000 mm (1.967 to 1.968 in)
Inner diameter bushing .............................................................. 50.190 to 50.270 mm (1.976 to 1.979 in)
Play .......................................................................................... 0.190 to 0.309 mm (0.0075 to 0.0121 in)
E. Inner diameter cross link main pin and blade ............................ 49.961 to 50.000 mm (1.967 to 1.968 in)
Outer diameter bushing ............................................................. 50.190 to 50.270 mm (1.976 to 1.979 in)
F. Outer diameter cross link front pin ............................................ 49.961 to 50.000 mm (1.967 to 1.968 in)
Inner diameter ball joint ............................................................. 50.190 to 50.270 mm (1.976 to 1.979 in)
Play .......................................................................................... 0.190 to 0.309 mm (0.0075 to 0.0121 in)
G. Outer diameter push beam joint pin ........................................... 109.780 to 110.000 mm (4.322 to 4.331 in)
Inner diameter push beam rear pin bushing (seated) ................. 110.180 to 110.400 mm (4.338 to 4.346 in)
Play .......................................................................................... 0.180 to 0.620 mm (0.0071 to 0.0244 in)
Copyright ©
6.4.14 C-FRAME AND RODS
A C-D-E-F G H SM9460
T
Fig. 6-25 Incernieramenti attrezzo angledozer
IN
A. Outer diameter C-frame joint pin ................................................ 109.780 to 110.000 mm (4.322 to 4.331 in)
PR
Inner diameter C-frame rear pin bushing (seated) ...................... 110.180 to 110.400 mm (4.338 to 4.346 in)
Play .......................................................................................... 0.180 to 0.620 mm (0.0071 to 0.0244 in)
B. Inner diameter blade pin seat .................................................... 45.130 to 45.290 mm (1.777 to 1.783 in)
R
Outer diameter pin .................................................................... 44.840 to 45.000 mm (1.765 to 1.772 in)

Play .......................................................................................... 0.130 to 0.450 mm (0.0051 to 0.0177 in)
FO
C. Diameter small seat in rod pin flange ........................................ 52.300 to 52.490 mm (2.059 to 2.066 in)
Play .......................................................................................... 0.300 to 0.680 mm (0.0118 to 0.0267 in)
T
D. Diameter small seat in rod pin flange ........................................ 68.300 to 68.490 mm (2.689 to 2.696 in)
O

Play .......................................................................................... 0.300 to 0.680 mm (0.0118 to 0.0267 in)
N
E. Outer diameter ball joint ............................................................ 79.810 to 80.000 mm (3.142 to 3.149 in)
Inner diameter rod pin seat ........................................................ 80.220 to 80.390 mm (3.158 to 3.165 in)
Play .......................................................................................... 0.220 to 0.580 mm (0.0087 to 0.0228 in)
F. Outer diameter pin seat ............................................................. 89.954 to 90.000 mm (3.541 to 3.543 in)
Inner diameter rod pin seat ........................................................ 90.000 to 90.140 mm (3.543 to 3.549 in)
Play .......................................................................................... 0.000 to 0.186 mm (0.0000 to 0.0073 in)
G. Diameter upper rod pin seat in lower rod ................................... 35.120 to 35.280 mm (1.383 to 1.389 in)
Outer diameter upper rod pin ..................................................... 34.840 to 35.000 mm (1.372 to 1.378 in)
Play .......................................................................................... 0.120 to 0.440 mm (0.0047 to 0.0173 in)
H. Inner diameter ball seat for pin .................................................. 35.120 to 35.280 mm (1.383 to 1.389 in)
Play .......................................................................................... 0.120 to 0.440 mm (0.0047 to 0.0173 in)
Copyright ©
6.4.15 RIPPER (LT, XLT version)
A
B
T
IN
PR
R
FO
C
26°
1412
T
O
D150-2R0112
Fig. 6-26
N
Model ....................................................................................................................................................... RP12F

Type ................................................................................... Parallelogram, actuated by a double stroke cylinder,
equipped with 3 semi-curved shanks with interchangeable tips
A. Work depth (with shoes sunk) .......................................................................................... 495 mm (19.49 in)

B. Maximum work depth ..................................................................................................... 1800 mm (70.87 in)
C. Maximum ground clearance of teeth (with shoes sunk) .................................................... 460 mm (18.11 in)
- Maximum break-up force (standing) ......................................................................... 10350 daN (372283 lbf)

- Maximum penetration force (standing) ....................................................................... 7120 daN (256102 lbf)
- Tightening torque of screws securing the support to transmission housing .................... 83 daNm (612 ft.lb.)
Copyright ©
6.4.16 RIPPER (LGP version)
A
B
T
IN
PR
R
FO
C
26°
T
1412
O
D150-2R0112
N
Fig. 6-27
Model ....................................................................................................................................................... RP10F

Type ................................................................................... Parallelogram, actuated by a double stroke cylinder,
equipped with 3 semi-curved shanks with interchangeable tips
A. Work depth (with shoes sunk) ............................................................................................... 356 mm (14 in)

B. Maximum work depth .......................................................................................................... 1700 mm (67 in)
C. Maximum ground clearance of teeth (with shoes sunk) ...................................................... 474 mm (18.7 in)
- Maximum break-up force (standing) ......................................................................... 10270 daN (369406 lbf)

- Maximum penetration force (standing) ....................................................................... 7700 daN (276964 lbf)
- Tightening torque of screws securing the support to transmission housing .................... 83 daNm (612 ft.lb.)
Copyright ©
SECTION 7
ELECTRICAL SYSTEM
TABLE OF CONTENTS
SAFETY RULES ....................................................................................................... 7-1
7.1 ELECTRICAL DIAGRAM OF PROTECTION TREE .................................................. 7-2

7.1.1 Fuses .................................................................................................................. 7-3
7.1.2 Fuse "links" and cold starting .............................................................................. 7-4
7.1.3 Main switch ......................................................................................................... 7-5
7.1.4 Engine starter switch ........................................................................................... 7-5
7.1.5 Back-up alarm ..................................................................................................... 7-6
T
7.1.6 Starter motor ....................................................................................................... 7-6
IN
7.2 ANGLE CONTROL ................................................................................................... 7-7
PR
7.3 INSTRUMENT PANEL/MONITOR ............................................................................. 7-8
7.3.1 Electric diagram of instrument/monitor panel ....................................................... 7-10
7.4 MONITOR SENDERS ............................................................................................... 7-11

R
7.5 DISPLAY .................................................................................................................. 7-15

FO
7.5.1 Diagnosis on display ............................................................................................ 7-15
7.6 BUZZER ................................................................................................................... 7-19
7.7 RELAY - DIODES - DIVERTER BOX GROUP .......................................................... 7-20

T
O
7.8 MAIN CONNECTORS 19 - 21 - 23 WAYS ................................................................. 7-23

N
Copyright ©
T
IN
PR
R
FO
T
O
N
Copyright ©
1650K ELECTRICAL SYSTEM 7-1
SAFETY RULES
WARNING: When working on the electrical sys-

tem, always wear protective glasses and remove
rings, wristwatches and other metal jewels.
DISCONNECT
WARNING: Prior to proceeding with inspection
operations or the repair of electric components
DISCONNECT THE GROUNDING CABLE “A”
A C
from negative terminal “B” of the battery.
B
DISCONNECT CABLE “C” FROM POSITIVE
T
TERMINAL “D”. D
IN
BATTERY 12V x 2
PR
GROUND
WARNING: NEVER PLACE METAL OBJECTS

R
on the battery.
FO
T
SM9500
O
WARNING: ELLECTROLYTE FUMES OF THE BATTERIES ARE FLAMMABLE.

Do not get sparks or free flames near a battery. When re-charging the emission of gases is greater.
N
WARNING: THE GAS FROM BATTERIES IS DANGEROUS when contacting the skin or materials.
WARNING: Beware when maintaining a battery.
SM9538
CORRECT
Use a torch to check the level of the electrolyte of the battery. Always
SM9539
perform the check with the engine inoperative. Do not charge the
battery nor start the engine with jumper cables when the battery is
WRONG frozen. Warm-up to 15 °C (59 °F) or the battery could explode.
7.1 ELECTRICAL DIAGRAM OF PROTECTION TREE
7-2
FUSE 50A FUSE 150A (D180)

FUSE 200A (D150) STARTER MOTOR
GRID HEATER
FUSE 80A
ALTERNATOR
F7A - 7.5A
PIN 1,2,33,46
TRACTOR RELAY F8A - 5A
KEY SWITCH PIN 12,13,14,24,39,41,43,52
F10A - 7.5A
EMPTY
F3A - 5A F11A - 7.5A
STARTING RELAY SOLENOID REAR FLOOD LIGHTS (SIDE BEAM)
N
ENG. STOP ELECTR. RELAY SOLENOID F1B - 7.5A
FLOOD LIGHTS (FRONT BEAM)
F2A - 5A O
OPERATOR SAFETY PROXIMITY SW. SWITCHES LAMPS
F2B - 20A
FUEL SHUTOFF SOLENOID VALVE T CR CLIMATE CONTROL
THERMAL SWITCH CAB RELAY
EXCESS FUEL SOLEN. VALVE
F5A - 5A
STEERING SAFETY SOLEN. VALVE F3B - 7.5A
FO
R-H DOOR WINDSHIELD MOTOR PUMP
I.R.C. BLOCK SUPPLY SOLEN. VALVE F4B - 7.5A
ENG. STOP ELECTR. PULL SOLENOID
R L-H DOOR WINDSHIELD MOTOR PUMP
FWD/REV. DIRECTION GEARSHIFT
SIDE WINDSHIELD WASHER MOTOR PUMP
HOLDING SOLEN.
STARTER MOTOR CONTROL
ELECTRICAL SYSTEM
F11B - 5A
EMPTY F5B - 7.5A
REAR WINDSHIELD WIPER MOTOR I SPEED
F4A - 5A
BUZZER F6B - 7.5A
PR
FRONT AND REAR WINDSHIELD MOTOR PUMP
MONITOR
FRONT WINDSHIELD WIPER MOTOR I SPEED
F6A - 7.5A
6W/B SOLENOID VALVE HORN
IN
RESISTANCE
CONTROL VALVE LINKAGE F9A - 7.5A

CAB LIGHTS
T
F10B - 7.5A
OPTIONAL LIGHTER
F1A - 5A POT. DIVIDER
TRACTOR RELAY SOLENOID
RADIO - OPTIONAL
CAB RELAY SOLENOID
F8B - 5A F7B - 20A

COLD STARTING RELAY SOLENOID CR CLIMATE CONTROL
1650K
1650-2M031
COLD START. INDICATOR LAMP
Copyright ©
Copyright ©
7.1.1 FUSES
They protect the electrical system from damages caused
by over loaded circuits. Replace the fuses when the ele-
ment is cut-off. If the fuse of a specific electric circuit
burns frequently, check the circuit and fix it, as required. A
Remove the covers pressed-in on fuse holders A and
B in the cab.
B
WARNING
Always replace the fuses with others of the same
type and capacity. Otherwise the electrical system
can be damaged.
1650-2M030
on CAB on ROPS
WARNING
Fig. 7-1
If it necessary to replace the fuses frequently, there
could be an electrical fault.
Please contact the Dealer.
T
The fuses protect:
Box A
IN
FUSE HOLDER A
(top mounted)
PR
1 = Tractor relay solenoid - Cab relay solenoid -
5 Amp
2 = Operator safety proximity sw. - Fuel shutoff
solenoid valve - Thermal switch - Excess fuel
solen. valve - 5 Amp
R
3 = Starting relay solenoid - Eng. stop electr. relay

solenoid - 5 Amp
4 = Buzzer - Monitor - 6W/B solenoid valve - Resi- Box B
FO
stance - Control valve linkage - 5 Amp

5 = Steering safety solenoid valve - I.R.C. block
supply solenoid valve - FWD/REV. direction
gearshift holding solen. - 5 Amp
6 = Horn - 7.5 Amp
T
7 = Micro controller (PIN 1,2,33,46) - 7.5 Amp

8 = Micro controller (PIN 12,13,14,24,39,40,41,
O
43,52) - 5 Amp
9 = Cab lights - Lighter - Pot. divider - Radio
N
(optional) - 7.5 Amp SM9502

10 = Empty - 7.5 Amp
11 = Rear flood lights (side beam) - 7.5 Amp Fig. 7-2
FUSE BOX B
(lower mounted)
1 = Flood lights (front beam) - Switches lamps -
7.5 Amp
2 = CR climate control - 20 Amp
3 = R-H door windshield motor pump - 7.5 Amp
4 = L-H door windshield motor pump - Side WARNING
windshield washer motor pump - 7.5 Amp Always disconnect the grounding cable prior to
5 = Rear windshield wiper motor 1 speed - 7.5 Amp cleaning, repairing, connecting or disconnecting
6 = Front and rear windshield motor pump - Front
windshield wiper motor 1 speed - 7.5 Amp any cable of the electrical system to prevent pos-
7 = CR climate control - 20 Amp sible damages or injuries.
8 = Cold starting relay solenoid - Cold start. Always keep efficient all the lights equipping the
indicator lamp - 5 Amp machine. Replace any bulb as soon as it burns-
10 = Optional - 7.5 Amp out.
11 = Empty - 5 Amp
Copyright ©
7-4 ELECTRICAL SYSTEM 1650K
7.1.2 FUSE "LINKS" AND COLD

STARTING
The "LINK" fuses are visible when opening the left
side engine hood and are located on the inner side of
the frame beam.
The 50 Amp fuse 1 protects the machine.
D150-2R0093
The 80 Amp fuse 2 protects the alternator.
Fig. 7-3
MACHINE SERVICES "LINK" FUSES (50 Amp)
WIRES
777 ALT + batteries
772 To diverter box
D150-2R0094
Fig. 7-4
ALTERNATOR "LINK" FUSE (80 Amp)
T
WIRES
777 ALT + batteries 1
IN
773 To alternator 2PR
R
FO
D150-2R0096
Fig. 7-5 LINK fuses

T
1
O
N
DSM 0144
Fig. 7-6
1. Mega fuse
COLD STARTING MEGA FUSE (200 Amp)
WIRES
777 ALT + batteries
780 To cold starter relay
SM9504
Fig. 7-7
Copyright ©
7.1.3 MAIN SWITCH

LOCATION - Left inner panel under the cab.
ON
OFF
DSM 0130
T
Battery To ground
IN
PR
SM9508
Fig. 7-8
R
7.1.4 ENGINE STARTER SWITCH

LOCATION - Cab right console.
FO
R A-G G-R
T
O
N
H-R M-V
SM9505
Fig. 7-9
LOCATION
WIRES
Red position “B”
Yellow/Red position “G1”
Brown/Green position “ACC”
Grey/Red position “M”
SM9506
Light blue/Yellow position “ST”
Fig. 7-10
Copyright ©
7.1.5 BACK-UP ALARM
WIRE
163 To electronic controller

000 To ground
LOCATION - Left rear side of machine, under fuel tank.
POS + 163
_ 000
NEG
T
IN
SM9509
PR
Fig. 7-11
7.1.6 STARTER MOTOR

R
Brand: DELCO - REMY

FO
Type: 28 MT 6.8 kW
LOCATION - On engine.
To batteries
T
To starter motor power

relay 90 Amp
O
N
D150-2R0097
Fig. 7-12
Copyright ©
7.2 ANGLE CONTROL

LOCATION - Inside right side of cab.
Blade
control
lever
2
1
T
D150-2R0123
IN
Fig. 7-15 Blade control pilot valve
ROSSO
BLACK
GRIGIO
GREY
NERO
BLUE
BLU
1. Leftward blade angle movement (button 1) -

RED
PR
2. Rightward blade angle movement (button 2).
AB AB
When actuating buttons (1 and 2) located on the pilot
valve, the solenoid valves moving the control valve
R
spool dedicated to the angle operation is electrically

energised with the subsequent movement of the blade.
FO
A B A B
T
991 A-4
O LR
LR
DSM 0152
N
Fig. 7-13
black grey
2
DSM 0154
Fig. 7-16 Equipment control valve

red blue DSM 0153
1. Solenoid valve wire - 2. Equipment control valve (angle
Fig. 7-14 Wiring diagram control spool).
Copyright ©
7.3 INSTRUMENT PANEL/MONITOR
The monitor is installed in the cab in front of the op-

Moving of
erator's seat and it includes a panel on which no re- motion ON
pairs are possible, formed by a printed circuit board
with LEDs.
OFF
- Actuate the main switch: indicated as ON for the

cab or the ROPS version.
- Turn the key of the engine starter switch in the cab
onto the first notch.
DMS 0130
Fig. 7-17
T
Operation Any malfunction is signalled by the appropriate LED
IN
indicator identified by the relevant "ISO standard"
When energised, the instrument performs a short 1- symbols and some of them are associated to a sound
second test lighting all LEDs, the segments of the signal lasting 3 seconds. If the malfunction persists,
PR
display and sounding the buzzer, then, the display the alarm warns the operator with one-minute cycles
(ref. S) shows the engine hours. lasting 1 second.
The indicators and instruments indicate the state of The engine hours are counted only when the engine
the machine. When the engine is started, the pointer exceeds 500 rpm.
R
display (R) indicates the engine rpm with increments The instruments receive the data from an external con-
of 100 rpm. troller through an RX serial line indicating the number
FO
To read the engine hours again, it is necessary to of the speed engaged and possible error codes.
switch OFF e to re-energise the panel using the key; These codes are shown by the 5-digit numerical dis-
the hours stay ON until the engine is cut-off. play (S).
T
O
Q.TY 2 SCREWS 6MA SECURING THE SUPPORT
L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12

N
CONNECTOR SIDE REAR VIEW
PIN. 1 PIN. 2
1 2
n/min
DL1 DL2
S1 0 x 1000 3 S2
8-WAY CONN. 12-WAY CONN.
S3 S4
KSM0006 SM9512
Fig. 7-18
Copyright ©
REF. DESCRIPTION ALARM SIGNAL 12 CON. 8 CON.

L3 Red LED engine air cleaner NO IN (-) 2
L4 Red LED hydraulic oil filter NO IN (-) 1
L5 Red LED Transm. oil pressure YES IN (-) 8
L2 Red LED engine oil pressure YES IN (-) 2
L9 Red LED general alarm YES actuated by indic. C, D, L, M, N, O, P
L10 Green LED front work lights NO IN (+24V) 3
L11 Green LED rear work lights NO IN (+24V) 7
L12 Green LED headlights + instr. light NO IN (+24V) 12
DL2 Red LED engine coolant temp. YES IN (-) 10
L6 Red LED transm. oil temperat. YES IN (-) 9
L1 Red LED battery YES IN (-) 4
L8 Red LED brakes malfunction YES IN (-) 4
DL1 Red LED fuel reserve NO IN (-) 11
S2 Engine coolant temp. gauge YES IN (var. -) 1
S4 Rev. counter – IN (+24V) 6
S3 5-digit display for speed and "eng. h) NO IN (-) (NPN-NO) 3 (RX)
T
S1 Fuel level indicator instrument YES IN (var. -) 5
BUZZER OUTLET – OUT (-) 8
IN
POWER INLET "positive" – IN (+24V) 6
GROUND INLET (GND) – IN (-) 7
PR
The connectors are male type, one 8-way and one 12-way.
The opposite cable connectors are female type with 12-way and 8-way, both with female contacts.
R
FO
T
O
N
Copyright ©
7 - 10 ELECTRICAL SYSTEM 1650K
7.3.1 ELECTRIC DIAGRAM OF INSTRUMENT/MONITOR PANEL
T
IN
PR
R
FO
T
O
N
8-12 way rear PIN. 1 PIN. 2

connectors
8-WAY CONN. 12-WAY CONN.

KSM0005
Fig. 7-19
Copyright ©
1650K ELECTRICAL SYSTEM 7 - 11
7.4 MONITOR SENDERS
– Location on the engine
1. Air cleaner clogging sensor.

1
2. Engine coolant max. temperature switch and 2
sensor.
3. Engine rpm sensor. 4
4. Engine oil low pressure sensor
(Setting 1 ± 0.2 bar, 14.5 ± 2.9 psi).
5. Alternator.
– Location on oil - fuel tanks

5
6. Fuel level and reserve indicator sensor. 3 1850-2R0124
7. Hydraulic oil filter clogging sensor.
8. Brakes - clutches oil low pressure sensor Fig. 7-20
T
(Setting 11.5 bar, 166.8 psi).
IN
9. Transmission oil low pressure sensor Hydraulic
(Setting 11.5 bar, 166.8 psi). oil tank
10. Transmission oil high temperature sensor
PR
(119 °C, 246 °F).
6
R
FO
7
T
Fuel tank
D150-2R0124
O
Fig. 7-21
N
9
Torque converter
10
1850-2R0126
Fig. 7-22
Copyright ©
1. AIR CLEANER CLOGGING INDICATOR

663 000
WIRE
663 To monitor
000 To ground
Setting: (closing contact) 62 mbar (0.899 psi) ± 8 °C
(46.4 °F).
LOCATION - Left side of machine, on the air cleaner.
Installation note.
The depression switch must be tightened manually,
SM9517
without using any tool.
Fig. 7-23
2. ENGINE COOLANT MAX. TEMPERATURE

SWITCH 552 528
T
WIRE
IN
552 To monitor (sensor)
528 Indicator light
PR
Thread: M16 x 1.5
Setting: 107 °C (224.6 °F)
Wrench: 22 mm (0.866 in)
Tightening torque: 2.5 daNm (18.4 ft.lb.)
R
LOCATION - Right side of machine, on engine.

FO
DSM 0147
T
Fig. 7-24
O
3. ENGINE RPM SENSOR

N
Electronic
Thread: 3/4 - 16 UNF controller
Tightening torque: daNm 1.9 to 2.5 daNm
(14 to 18.4 ft.lb.)
LOCATION - On engine flywheel housing.
DSM 0148
Fig. 7-25
Copyright ©
4. ENGINE OIL LOW PRESSURE SENSOR
WIRE
503 To monitor
000 To ground
Thread: M10 x 1 tapered
Setting: 1 ± 0.2 bar (14.5 ± 2.9 psi)
The sensor is normally closed. It opens when the
pressure decreases below or reaches the setting value.
SM9520
Fig. 7-26
5. ALTERNATOR
T
BRAND: DELCO - REMY 70 Amp
IN
Voltage: 24 Volt
To 80 Amp
LOCATION - On engine fuse link
Batteries
PR
773
R
FO
637
Grounding
cable
T
O
SM9521
N
Fig. 7-27
6. FUEL LEVEL SENSOR
WIRE
555 To monitor
557 To monitor
000 To ground
LOCATION - Rear side of machine, top of the fuel

tank.
SM9522
Fig. 7-28
Copyright ©
7. HYDRAULIC OIL FILTER CLOGGING SENSOR

580
WIRE
580 To monitor
Thread: M18 x 1.5
Setting: 2 to 2.2 bar (29 to 31.9 psi)
LOCATION - On hydraulic oil tank.
DSM 0149
Fig. 7-29
8. STEERING BRAKE AND CLUTCHES LOW OIL

PRESSURE SENSOR
T
WIRE
IN
611 To monitor
000 To ground
PR
Setting: 11 to 12.5 bar
(159.5 to 181.3 psi)
R

FO

pressure decreases below or reaches the setting value.
SM9524
T
Fig. 7-30
O
9. TRANSMISSION OIL LOW PRESSURE

SENSOR
N
WIRE
581 To monitor
000 To ground
Setting: 11 to 12.5 bar
(159.5 to 181.3 psi)
pressure decreases below or reaches the setting
value.
SM9525
Fig. 7-31
Copyright ©
10. TRANSMISSION OIL MAX. TEMPERATURE

SEN 559
WIRE
559 To monitor
Thread: M16 x 1.5
Setting: 119 ± 3 °C
(246.2 ± 37.4 °F)
Tightenign torque: 2.5 daNm (18.4 ft.lb.)
SM9526
Fig. 7-32
T
IN
PR
R
FO
T
O
N
Copyright ©
7.5 DISPLAY
The display shows three functions:

A) - Digital hourmeter indicating the total work hours
automatically activated when the engine is opera-
tive.
A
B) - Speed selected
1
n/min
1000
3
0
C) - Diagnosis of the correct operation of the

transmission
DISPLAY
KSM0007
Fig. 7-33
T
7.5.1 DIAGNOSIS ON DISPLAY
IN
1st 2nd 3rd 4th 5th digit
The display has 5 text fields to signal following mes-
sages.
PR
Fig. 7-34
R
FO
A - Work hourmeter signal

or
B - Gear engaged + failure code
T
O
Work hourmeter signal

N
The engine hours are signalled by the lighting for about

1 second when the instrument board carries out the
general test. To re-visualise the engine hours, it is
necessary to switch off and switch on again with the
starter key.
The engine hours stay ON as far as the engine is
inoperative.
Copyright ©
Speed engaged signal + failure code

The first digit indicates the speed engaged (ex. 1st
speed).
The second indicates (in case of failure) letter E.
→
→
1st 2nd (digit) SM9528
Fig. 7-35
The 3rd and 4th digits identify the failure code (ex. failure
code No. 024).
When the components failed is one only, the codes
listed in TABLE 1 appear.
For each failure code, identify the corresponding
→
→
→
component listed.
3rd 4th 5th (digit) SM9528
Fig. 7-36
T
IN
TABLE 1
Failed component Failure code
PR
Forward "F" speed solenoid 004
Rear "R" speed solenoid 008
1st speed solenoid 016
R
rd
3 speed solenoid 032
FO
TABLE 2
T
For. Rev. 1st 3rd

O
"F" "R" speed speed

Failed component
speed speed solen. solen.
N
solen. solen.
Forward "F" speed solenoid 004 012 020 036
Reverse "R" speed solenoid 008 024 040
st
1 speed solenoid 016 048
3rd speed solenoid 032
Copyright ©
Example of identification of a trouble co example, code 024 indicates that two parts are in trou-
ble. On the top, the column identifies, in correspond-
When the failed components are two, the display ence with the "1 st speed " solenoid (first failed com-
shows a trouble code listed in TABLE 2,(given by the ponent).
addition of two single codes listed in TABLE 1). As an
TABLE 2
For. "F" Rever. "R" 1st speed 3rd speed
Failed component speed solen. speed solen. solen. solen.
Forward "F" speed solenoid 004 012 020 036

Reverse "R" speed solenoid" 008 024 040
1st speed solenoid 016 048
3rd speed solenoid 032
Reverse "R" speed

solenoid trouble code
T
Trouble code on display
IN
1st speed solenoid trouble code
PR
Whereas, on the left, it identifies the reverse speed "R" the crossing of the two components determines the trouble
code, given by the addition of the two.
R
Reverse "R" speed solenoid trouble code = 008 +

FO
1st speed solenoid trouble code = 016

Trouble code for both = 024
T
O
N
Copyright ©
7.6 BUZZER
1 2
n/min
0 1000 3
KSM0008
LOCATION - Inside the cab, behind the instrument panel.
T
SM9529
IN
Fig. 7-37
PR
R
FO
T
O
N
Copyright ©
7.7 RELAY - DIODES - DIVERTER BOX GROUP
The group is seen by opening the left rear panel of the

machine.
1
2 3 5
2
4
T
6
IN
PR
D150-2R0085
Fig. 7-38
1. Diode box - 2. Relay 24 Volt - 50 Amp - 3. Relay 24 Volt -

R
10/20 Amp - 4. Diverter box - 5. Power relay 90 Amp -

6. Battery compartment cable.
FO
T
O
N
A C F H
887 860 864 868
B D G
997 163 506
D150-2R0086
Fig. 7-39
1 - Diode box 2 - Relay 24 Volt - 50 Amp 3 - Relay 24 Volt - 10/20 Amp

B. Steering safety sol. valve A. Cab services G. Operator's safety
C. Electric cut-off/Cold starter F. Machine services H. Starting safety
D. Prox. sensors
Copyright ©
1. DIODE BOX (Ref. B - C - D)
- For the wiring diagram and connection of compo-

nents, please refer to the principle wiring diagram.
SM9532
Fig. 7-40
T
2. RELAY 24 Volt - 50 Amp (Ref. A - F - I)
IN
PR
R
FO
SM9533
Fig. 7-41
T
O
3. RELAY 24 Volt - 10/20 Amp (Ref. G - H)

N
Nominal current Wiring diagram
SM9534
Fig. 7-42
Copyright ©
4. DIVERTER BOX
OUTPUT INPUT
T
IN
PR
SM9535
Fig. 7-43
R
FO
5. POWER RELAY (ENGINE STARTING)

T
O
N
SM9536
Fig. 7-44
Copyright ©
7.8 MAIN CONNECTORS 19 - 21 - 23 WAYS
YELLOW BLUE SM9537
Fig. 7-45
MACHINE - CAB INTERFACE OF 19 WAY CONNECTOR

CABE MACHINE
T
CONTACT WIRE ROUTING WIRE WIRE WIRE
NUMBER SECTION NUMBER COLOUR SECTION
IN
1 1 FROM FUSE 11 SWITCH ACC 801 H-L 1
2 1 CUT-OFF DIODE 15 904 S-G 1
3 1 FROM FUSE 17 SWITCH 907 L-B 1
4 1 TO FUSE 24 FOR EV 542 A-V 1
PR
5 1 FROM ALTERNATOR I 637 S 1
6 1 FROM DIODES CONNECTING PROXIM. OPERAT. SAFETY 164 L-N 1
7 - NOT USED - - -
8 2.5 CONDITIONER RELAY 87 809 G-N 2.5
9 - NOT USED - - -
10 2.5 KEY STARTER SWITCH POWER 724 R 2.5
R
11 - NOT USED - - -
12 2.5 SERVICES UNDER ACC 864 H-R 2.5
13 - NOT USED - - -
FO
14 2.5 CONDITIONER RELAY 30 803 A 2.5

15 1 BRAKE SAFETY SOLENOID VALVE 543 Z-B 1
16 2.5 CAB SERVICES FROM RELAY 73 887 R-N 2.5
17 1 6 W / BLADE - - -
18 2.5 POWER. OF SERVICES NOT UNDER KEY 772 R 2.5
19 1 COLD STARTING RELAY 860 A/R 1
T
O

N
CABE MACHINE
A 1 4WEG SOLENOID VALVE 597 - 1
B 2.5 (III SPEED) ELECTRIC FAN 706 B 2.5
C 1 CONDITIONER THERMOSTAT 824 C 1
D 2.5 (II SPEED) ELECTRIC FAN 709 M 2.5
E 2.5 GROUNDING FOR CAB 000 N 2.5
F - NOT USED - - -
G 2.5 (I SPEED) ELECTRIC FAN 745 L 2.5
H 1 ENGINE RPM SENSOR + 536 G 1
J 1 ENGINE OUT RPM SENSOR 537 N 1
K 1 DOOR WINDOW WASHERS ELECTRIC PUMP 885 G-V 1
L 1 FRONT/REAR WINDOW WASHERS ELECTRIC PUMP 886 C-B 1
M 1 FROM R.H. PROX. SW. TO DISCONN. DIODE 156 B 1
N 1 TRANSM. F/R SV - GND 009 V-N 1
P 1.5 F INPUT TRANSM. SV 549 A-G 1
R 1 R INPUT TRANSM. SV 548 A-N 1
S 1 FROM L.H. PROX. SW. TO DISCONN. DIODE 157 G-N 1
T 1 1ST/ 3RD TRANSM. SV - GND 008 C/B 1
U 1 1ST/ 3RD TRANSM SV INPUT 1ST 546 B/R 1
V 1 1ST/ 3RD TRANSM SV INPUT 3RD 547 V/B 1
W - NOT USED - - -
X 1 SCREENED CABLE GROUND SLEEVE 011 ÉCRAN 1
Copyright ©

CABE MACHINE
A 1 FROM BRAKE PEDAL VALVE PRESS. SWITCH TO CONTROLLER 166 C-L 1
B 1 AIR CLEANER CLOGGING 663 B-N 1
C 1 FROM ACC TO BRAKE PEDAL VALVE PRESS. SWITCH (+) 143 M-N 1
D 1 COOLANT HUGH TEMP. INDIC. 528 V-B 1
E - NOT USED - - -
F 1 COOLANT TEMP. SENSOR (TEMP. GAUGE) 552 V 1
G - NOT USED - - -
H 1 TRANSM. OIL LOW PRESS. IND. 581 C-N 1
J - NOT USED - - -
K 1 TRANSM. OIL HUGH TEMP. INDIC. 559 S-N 1
L 1.5 HORN + (1ST WIREE) 119 L-N 1
M 1.5 HORN GROUND (2ND WIREE) 000 N 1
N - NOT USED - - -
O 1 LH PRESS. TRANSDUCER (+) 503 H 1
P 1 ELECTR. CUT-OFF (HOLD COIL) 903 S-G 1
Q 1 BRAKES OIL LOW PRESS. IND. 611 H-N 1
R - NOT USED - - -
S 1 BACK-UP ALARM 163 A-B 1
T - NOT USED - - -
U 1 EQUIPM. OIL FILTER CLOGGING INDIC. 580 M-B 1
V 1 FUEL RESERVE INDICATOR 555 Z-N 1
W 1 FUEL LEVEL SENSOR 557 Z 1
T
X - NOT USED - - -
IN
PR
COLOUR CODE
A LIGHT BLUE
R
B WHITE
FO
C ORANGE
G YELLOW
H GREY
T
L BLUE
O
M BROWN
N BLACK
N
R RED
S PINK
V GREEN
Z PURPLE
Copyright ©
T
IN
PR
R
FO
T
O
N

Case 1650k Tier 2

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THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents, whether they occur in industry, on the

Prior to engaging in any maintenance, adjustment

or repair operation on machines having

FINAL DRIVES SECT. 3

BRAKES AND STEERING SECT. 4

SAFETY RULES ...................................................................................................................................... I - VIII

IDENTIFICATION DATA ............................................................................................................................ 0-1

TABLE OF FLUIDS USED ....................................................................................................................... 0-2

POSSIBLE ARRANGEMENTS OF THE 1650K ....................................................................................... 0-3

STABILITY ............................................................................................................................................... 0-3

EQUIPMENT MANOEUVRE TIMES ........................................................................................................ 0-20

LEAKAGES ............................................................................................................................................. 0-21

GENERAL INSTRUCTIONS ..................................................................................................................... 0-22

TROUBLE SHOOTING ............................................................................................................................. 0-28

UNITS OF MEASURE ............................................................................................................................. 0-29

TABLE OF TIGHTENING TORQUES ........................................................................................................ 0-31

climbing on or off machine. Hoses and controls are

- Do not leave the machine until it is completely stopped.

- Check the seat safety belt at least twice a year. If there

- Roll Over Protective Structures are required on loaders,

- DO NOT CARRY RIDERS ON MACHINE - DO NOT PULL UNLESS OPERATOR's COMPART-

- Do not operate machine with brakes out of adjustment.

- Operate the machine at speeds slow enough to ensure

- Maintain a safe distance from other machines. Provide

- Explore the working area to identify potential risks such

factors such as condition of the ground, load being

that cannot be reached from the ground, use a ladder or

unbuttoned or unzipped jackets that can catch on mov-

constructed and maintained in accordance with local

- Do not use controls or hoses as hand holds when

movable and do not provide a solid support. Also,

hazard. Store in closed metal container.

- Before starting machine, check, adjust and lock the

secure against unauthorised personnel.

- The load lifted by jacks is always dangerous: it is neces- ELECTRICAL SYSTEM

- Fluid escaping under pressure from a very small hole

ENGINE can be almost invisible and can have sufficient force to

penetrate the skin. Use a piece of cardboard or wood to

Serious infection or reaction can develop if proper med-

- Do not adjust engine fuel pump when machine is mov-

- Do not lubricate the machine with engine running.

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

SAFETY RULES FOR SEALS

VITON SEALS (fluoroelastomer)

TEST FOR THE DISCRIMINATION OF RUBBER (BUNA N) MATERIALS

NITRILIC/BUNA N RUBBER VITON"

1650K GENERALITIES 0-1

A. Engine data plate

1. Engine serial number

C.I.D./L CPL Engine Serial No.

Low idle RPM

Firing Order Timing-TDC

C. Marking and serial number

On the right side of the transmission housing it is

1650K LT PAT-T2 PS ★HHA01651Sxxxxxxxx★

1650K LT BD-T2 PS ★HHA01651Sxxxxxxxx★

1650K XLT PAT-T2 PS ★HHA1651STxxxxxxxx★

1650K LGP PAT-T2 PS ★HHA1651SPxxxxxxxx★

QUANTITY Fluids and lubrificants VISCOSITY Outdoor temperatures International

Agriflú Mixture of water and antifreeze at