NEW HOLLAND AGRICULTURE D180 Dozer Electrical System User Manual

: June 16, 2024
: NEW HOLLAND AGRICULTURE

Table of Contents

SAFETY RULES
ELECTRICAL SYSTEM
MAIN SWITCH
ENGINE STARTING SWITCH
INSTRUMENT PANEL / MONITOR
Operation
ELECTRICAL DIAGRAM OF INSTRUMENT PANEL/MONITOR
MONITOR SENDERS
DISPLAY
RELAYS – DIODES – DIVERTER BOX GROUP
ELECTRICAL SYSTEM
MAIN CONNECTORS 19 – 21 – 23 WAYS
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NEW HOLLAND AGRICULTURE D180 Dozer Electrical System User Manual

SAFETY RULES

WARNING
When working on the electrical system, always wear safety glasses and remove rings, wrist watches and any metal jewellery.
WARNING
Prior to inspection or repair interventions on electrical components, DISCONNECT GROUND CABLE “A” from the battery negative terminal “B”. DISCONNECT CABLE “D” FROM POSITIVE TERMINAL “D”.

DISCONNECT

TO GROUND

WARNING
NEVER REST METAL OBJECTS on the battery to prevent dangerous short-circuits.
WARNING
FUMES FROM THE BATTERY ELECTROLYTE ARE FLAMMABLE.
Never generate sparks nor bring free flames near the batteries. The emission of fumes is stronger when recharging.
WARNING
BATTERY FUMES ARE DANGEROUS if in contact with the skin or materials.
WARNING
Beware when maintaining the battery.

**WRONG

CORRECT
** Use a flashlight to inspect the level of the battery electrolyte.
Always perform the inspection with engine inoperative.

Do not charge the battery or start the engine with jumper cables if the battery is frozen-up. warm-up the battery to 15 °C (59 °F) otherwise it could explode.

ELECTRICAL SYSTEM

ELECTRICAL DIAGRAM OF PROTECTION TREE Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

FUSES

Fuses are located on the left side of the dashboard for the cab version and inside the front pocket (as indicated in the figure).
Remove the pressure fitted covers on fuse boxes (A) and (B).

The fuses protect:

FUSE BOX A (upper mounted)

= Tractor relay solenoid – Cab relay solenoid – 5 A
= Operator safety proximity sw. – Engine stop electromagnet hold solenoid – Timer elettrostop – 5 A
= Starting relay solenoid – Eng. stop electr. relay solenoid – 5 A
= Buzzer – Monitor – 6W/B solenoid valve – Resistance – Control valve linkage – 5 A
= Steering safety solenoid valve – I.R.C. block supply solenoid valve – 5 A
= Horn – 7.5 A
= Micro controller (PIN 1,2,33,46) – 7.5 A
= Micro controller (PIN 12,13,14,24,39,40,41, 3,52) – 5 A = Cab lights – Lighter – Pot. divider – Radio (optional) – 7.5 A
= Flood lights (side beam) – 7.5 A
= Rear flood lights (side beam) – 7.5 A

FUSE BOX B

(lower mounted)

= Flood lights (front beam) – Switches lamps – 7.5 A
= CR climate control – 20 A
= R-H door windshield motor pump – 7.5 A
= L-H door windshield motor pump – Side windshield washer motor pump – 7.5 A
= Rear windshield wiper motor 1 speed – 7.5 A
= Front and rear windshield motor pump – Front windshield wiper motor 1 speed – 7.5 A
= CR climate control – Compressor solenoid (optional) – 20 A
= Cold starting relay solenoid – Cold start. indicator lamp – 5 A
= Optional – 7.5 A
= Steering s.v. cut-off relay – 5 A

WARNING
Always disconnect the battery grounding cable
prior to cleaning, repairing, connecting or disconnecting any wire of the electrical system, to prevent personal injuries.
Always keep all lights mounted on the machine in working conditions. Replace all burnt-out bulbs as soon as possible.
“LINK” FUSES AND COLD STARTING FUSE

“LINK” fuses are seen when opening the left side engine hood, located on the inner side of the frame beam.
Fuse 1 protects the machine – 50.
Fuse 2 protects the alternator – 80.

MACHINE SERVICES “LINK” FUSE (50 Amp)
WIRES
777 AL + batteries
772 To diverter box

ALTERNATOR “LINK” FUSE (80 Amp) WIRES
777 AL + batteries
773 To alternator

COLD STARTER FUSE MEGA FUSE (150 Amp) Optional WIRES
777 AL + batteries
780 To cold starter relay

MAIN SWITCH

LOCATION – Inside the left panel, under the cab .
**D180 POWER STEERING

D180 STEERING CLUTCH

**

ENGINE STARTING SWITCH

LOCATION – Right console in the cab.

WIRES
Red position “B”
Yellow/Red position “G1”
Brown/Green position “ACC”
Grey/Red position “M”
Light blue/Yell position “ ST”

BACK-UP ALARM

WIRES
163 To electronic controller
000 To ground
LOCATION – Left side of machine under the fuel reservoir.

STARTER MOTOR

Brand: DELCO – REMY
Type: 42 MT-7.8 kW (10.5 Hp)
LOCATION: on engine.

INSTRUMENT PANEL / MONITOR

The monitor is seen in the cab, in front of the operator’s seat and is made of a panel on which no repair intervention are possible, including a circuit board and L.E.D.s.

D180 POWER STEERING

Turn the electrical system main switch indicated into “ON”, for the cab or ROPS structure version.
Turn the starter motor switch in the cab into the first step e .

D180 STEERING CLUTCH

Operation

When activated, the instrument performs a short test for 1 second switching all LEDs, segments of the display and buzzer ON; then the display (ref. S) indicates the engine hours.
The indicator lights and instruments indicate the state of the machine. Once the engine is started, pointer (R) shows the engine r.p.m., with 100 rpm increments.
To return visualising the engine hours, it is necessary to switch off and re- power the system using the key; the hours stay ON until the engine is cut-off.
In the event of any malfunction, this is signalled by the relevant LED indicators, identified by the appropriate “ISO standard” symbols, and, for part of them, a sound alarm during 3 seconds is associated; in case the malfunction persists, the alarm warns the operator with one minute cycles, lasting one second.
The engine work hours are recorded only when the engine speed exceeds 500 rpm.
The instrument receives data from an outer control unit, through serial line RX for the indication of the speed selected and eventual error codes.
These codes are indicated on the 5-digit numerical display (S).

REF. DESCRIPTION| ALARM| SIGNAL| 2 WAY CONN.| 8 WAY CONN.
---|---|---|---|---
A| Red LED, engine air cleaner| NO| IN (-)| 2|
B| Red LED, hydraulic oil filter| NO| IN (-)| 1|
C| Red LED, transmission oil pressure| YES| IN (-)| 8|
D| Red LED, Engine oil pressure| YES| IN (-)| 2
E| Red LED, general alarm| YES| activated by ind.| C, D, L, M, N, O, P
F| Green LED, front work lights| NO| IN (+ 24V)| 3|
G| Green LED, rear work lights| NO| IN (+ 24V)| 7
H| Green LED, head lights + instr. light.| NO| IN (+ 24V)| 12|
L| Red LED, engine coolant temperature| YES| IN (-)| 10
M| Red LED, transmission oil temperature| YES| IN (-)| 9
N| Red LED, battery| YES| IN (-)| 4
O| Red LED, brakes failure| YES| IN (-)| 4
P| Red LED, fuel reserve| NO| IN (-)| 11
Q| Engine coolant temperature indicator at 10 lcd| YES| IN (var. -)| 1
R| Engine rpm analogical display at 24 lcd| –| IN (+ 24V)| 6
S| 5 digit display for No. speeds and “engine hours”| NO| IN (-) (NPN -NO)| | 3 (RX)
T| Fuel level indicator at 10 lcd| YES| IN (var. -)| | 5
BUZZER OUTPUT| –| OUT (-)| | 8
POWER INLET “positive”| –| IN (+ 24V)| 6|
GROUND INPUT (GND)| –| IN (-)| 7|

Then connectors are male, one 8-way and one 12-way.
The corresponding connectors for the harness are of a female type, 12-way and 8-way, both with female contacts.

ELECTRICAL DIAGRAM OF INSTRUMENT PANEL/MONITOR

MONITOR SENDERS

Location on engine

Air cleaner clogging sensor.
Engine coolant max. temperature switch.
Engine rpm sensor.
Engine oil low pressure sensor.
Alternator.

Location on oil – fuel reservoirs
Fuel level sensor.
Hydraulic oil filter clogging sensor.
Brakes – clutches low oil pressure sensor (set at 11.5 bar) (166.79 psi).
Transmission oil low pressure sensor (set at 11.5 bar) (166.79 psi).
Transmission oil temperature sensor (119 °C – 246 °F).

AIR CLEANER CLOGGING SENSOR WIRES

663 To monitor
000 To ground
Setting: (closing of contact) 62 mbar (0.899 psi) ± 8 °C – (46.4 °F).
LOCATION – Left front side of machine, over the air cleaner.
Installation notes
The depression switch must be tightened manually, without using tools.

**ENGINE COOLANT MAX. TEMPERATURE SWITCH

WIRES
552 to monitor
000 To ground
Thread: M16 x 1.5
Setting: 100° ± 3 °C (212 ± 37.4 °F)
Wrench: 22 mm (0.866 in)
Torque wrench:** 2.5 daNm (18.44 lbf.ft)
LOCATION – Right front side of machine, on engine.

ENGINE RPM

Thread: 3/4 – 16 UNF
Wrench: 29 mm (1.142 in)
Torque wrench: 1.9 ÷ 2.5 daNm (14.01 ÷ 18.44 lbf.ft)
LOCATION – On engine flywheel housing
**ENGINE OIL LOW PRESSURE SENSOR

WIRES
503 To monitor
000 To ground
Thread: M10 x 1 taper
Setting: 1.2 ÷ 0.8 bar
Wrench: 27 mm
Torque wrench:** 3.5 daNm
The sensor is normally closed, it opens when the pressure drops or reaches the setting value.

ALTERNATOR

BRAND: DELCO – REMY 70 Amp
Power voltage: 24 VOLT
LOCATION – on engine
FUEL LEVEL SENSOR

WIRES
555 To monitor
557 To monitor
000 To ground
Thread: M10 x 1 taper
Setting: 1.2 to 0.8 bar (17.4 to 11.6 psi)
Wrench: 27 mm (1.063 in)
Torque wrench: 3.5 daNm (25.8 lbf.ft)
LOCATION – Rear side of machine over the fuel reservoir
HYDRAULIC OIL FILTER CLOGGING SENSOR

WIRES
580 To monitor
000 To ground
Thread: M18 x 1,5
Setting: 2 ÷ 2.2 bar (29 ÷ 31.91 psi)
Wrench: 22 mm (0.866 in)
LOCATION – On hydraulic oil reservoir.
BRAKES AND STEERING CLUTCHES OIL LOW PRESSURE SENSOR

WIRES
611 To monitor
000 To ground
Thread: M10 x 1 taper
Setting: 12.5 ÷ 11 bar (181.30 ÷ 159.54 psi)
Wrench: 27 mm (1.063 in)
Torque wrench: 3.5 daNm (25.84 lbf.ft) The sensor is normally closed, it opens when the pressure drops or reaches the setting value.
TRANSMISSION OIL LOW PRESSURE SENSOR

WIRES
581 To monitor
000 To ground
Thread: M10 x 1 taper
Setting: 12.5 ÷ 11 bar
Wrench: 27 mm (1.063 in)
Torque wrench: 3.5 daNm (3.5 lbf.ft)
The sensor is normally closed, it opens when the pressure drops or reaches the setting value.
TRANSMISSION OIL MAX TEMPERATURE SWITCH

WIRES
559 To monitor
000 To ground
Thread: M16 x 1.5
Setting: 119° ± 3 °C (246 ÷ 37.4 °F)
Wrench: 22 mm (0.87 in)
Torque wrench: 2.5 daNm (18.44 lbf.ft)

DISPLAY

The display indicates three functions:
A) – Digital hourmeter, indicating the total hours work and is automatically actuated when the engine operates.
B) – Speed engaged
C) – Troubleshooting the transmission operation

DIAGNOSIS ON DISPLAY
The display has 5 digit fields providing the following messages.

A – Work hour indication
B – Speed engaged indication + failure code

Work hourmeter indication
The engine hours are indicated when the instrument panel is switched ON, for about one second, when the instrument undergoes a general test. To return visualising the engine hours, cut-off and re-power with the starter key.
The hours stay On until the engine is cut-off.

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

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.

TABLE 1

Failed component| Failure code
Left proportional solenoid valve coil| 001
Right proportional solenoid valve coil| 002
Forward “F” speed solenoid| 004
Rear “R” speed solenoid| 008
1st speed solenoid| 016
3rd speed solenoid| 032
Left steering lever solenoid| 064
Right steering lever solenoid| 128
T ABLE 2

Failed component| LHprop. sol. valve coil| RHprop. sol. valve coil| For. “F”speed solen.| Rev. “R”speed solen.| 1st speed solen.| 3rd speed solen.| LHsteer. lever solen.| RHsteer. lever solen.
Left prop. solenoid valve coil| 001| 003| 005| 009| 017| 033| 065| 129
Right prop. solenoid valve coil| | 002| 006| 010| 018| 034| 066| 130
Forward “F” speed solenoid| | | 004| 012| 020| 036| 068| 132
Reverse “R” speed solenoid| | | | 008| 024| 040| 072| 136
1st speed solenoid| | | | | 016| 048| 080| 144
3rd speed solenoid| | | | | | 032| 096| 160
Left steering lever solenoid| | | | | | | 064| 192
Right steering lever solenoid| | | | | | | | 128

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.
Reverse “R” speed solenoid trouble code : = 008 +
1st speed solenoid trouble code : = 016
– – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –
Trouble code for both : = 024

BUZZER

LOCATION – Inside the cab, behind the instrument panel

RELAYS – DIODES – DIVERTER BOX GROUP

The group is seen opening the left rear panel of the machine, near the batteries.

Diodes box
Relay 24 Volt – 50 Amp
Relay 24 Volt – 10/20 Amp
Diverter box
Power relay 90 Amp
19 way connector
Batteries 12 Volt x 2
Cold starting relay
Fuse
Time elettro stop
Timer
Timer wire assembly.

Diode boxes
B. Steering safety solenoid valve
D. Cut-off/cold starting
L. Operator safety indicators
Relay 24 Volt – 50 Amp
A. Cab services
F. Machine services
O. Air conditioner 50 Amp (opt.)
Relay 24 Volt – 10/20 Amp
C. Steering solenoid valve (only D180)
M. Steering solenoid valve (only D180)
G. Operator’s safety
H. Starter safety
N. Air conditioner relay 10/20 Amp (opt.)

ELECTRICAL SYSTEM

DIODE BOXES (REF. B – D – L)
- For the wires and the connections of the components, please refer to the principle electrical diagram.
RELAY 24 VOLT – 50 Amp (REF. A – F – O)
RELAY 24 VOLT – 10/20 Amp (REF. C – M – G – H – N)
The relay is a magnetically activated mechanical switch.
Pins 86 and 85 are used to activate the relay.
Pins 30 to 87a form a N/C (normally closed) switch.
Pins 30 to 87 form a N/O (normally open) switch.
DIVERTER BOX
POWER RELAY (ENGINE STARTING)

MAIN CONNECTORS 19 – 21 – 23 WAYS

MACHINE – CAB INTERFACE OF 19 WAY CONNECTOR

CONTACT NUMBER| CABE WIRE SECTION| ROUTING| WIRE NUMBER| MACHINE WIRE COLOUR| WIRE SECTION
---|---|---|---|---|---
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
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
11| –| NOT USED| –| –| –
12| 2.5| SERVICES UNDER ACC| 864| H-R| 2.5
13| –| NOT USED| –| –| –
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| –| NOT USED| –| –| –
18| 2.5| POWER. OF SERVICES NOT UNDER KEY| 772| R| 2.5
19| 1| COLD STARTING RELAY| 860| A/R|

MACHINE – CAB INTERFACE OF 21 WAY CONNECTOR

CONTACT NUMBER| CABE WIRE SECTION| ROUTING| WIRE NUMBER| MACHINE WIRE COLOUR| WIRE SECTION
---|---|---|---|---|---
A| 1| 4WEG SOLENOID VALVE| 597| C| 1
B| 2.5| (III SPEED) ELECTRIC FAN| 706| B| 2.5
C| 1| CONDITIONER THERMOSTAT| 824| M| 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| SCREEN| 1

MACHINE – CAB INTERFACE OF 23 WAY CONNECTOR

CONTACT NUMBER| CABE WIRE SECTION| ROUTING| WIRE NUMBER| MACHINE WIRE COLOUR| WIRE SECTION
---|---|---|---|---|---
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
X| –| NOT USED| –| –| –