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Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
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Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
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Description
Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
Language : English
Pages : 374
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
SAFETY RULES
– Do not allow unauthorised personnel to operate service or maintain this machine.
– Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.
– Keep operator’s compartment, stepping points, grabrails and handles clear of foreign objects, oil, grease, mud or snow accumulation to minimize the danger of slipping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.
– Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step grab rails and handles at all times.
– Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a solid support. Controls also may be inadvertently moved causing accidental machine or equipment movement. – Never attempt to operate the machine or its tools from any position other than seated in the operator’s seat
. – Keep head, body, limbs, hands and feet inside operator’s compartment at all times to reduce exposure to hazards outside the operator’s compartment.
– Be careful of slippery conditions on stepping points, hand rails, and on the ground. Wear safety boots or shoes that have a high slip resistant sole material.
– Do not leave the machine until it is completely stopped.
– Check the seat safety belt at least twice a year. If there are signs of wear or fraying or other signs of weakness that could lead to failure, replace it.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi FD255 CRAWLER DOZER Service Manual – PDF DOWNLOAD
Introduction................................................................................. 1 Summary...................................................................................... 3 0. Generalities.......................................................................... 4 SAFETY RULES......................................................................... 5 TECHNICAL DATA TABLES................................................................ 14 GENERAL INSTRUCTIONS................................................................. 29 DIAGNOSTIC CHECKS.................................................................... 34 UNITS OF MEASURE..................................................................... 35 CLASSIFICATION OF STANDARD PARTS FOR TORQUE DETERMINATION............................ 35 TIGHTENINGTORQUETABLES............................................................... 36 1. Engine................................................................................ 38 1.1 Trouble Shooting of Major Malfuncions............................................ 39 1.2 Removal of Engine ............................................................... 47 1.3 Disassembly of the Engine on Bench ............................................. 48 1.3.1 Removing Crankshaft Damper Hub............................................. 50 1.3.2 Removing Flywheel.......................................................... 52 1.4 Repair Operations Cylinder Block Checks and Measurements......................... 54 1.4.1 Replacing Cylinder Sleeves................................................. 56 1.4.2 Checking and Adjusting Cylinder Sleeve Protrusion.......................... 58 1.4.3 Timing System.............................................................. 59 1.4.4 Bushings................................................................... 61 1.4.5 Tappets.................................................................... 63 1.4.6 Crankshaft................................................................. 65 1.4.7 Engine Flywheel............................................................ 72 1.4.8 Piston and Connecting Rod Assembly......................................... 72 1.4.9 Timing Gear................................................................ 81 1.4.10 Fitting Injection Pump and Setting Timing ................................ 83 1.4.11 Cylinder Heads Checking Hydraulic Tightness............................... 84 1.4.12 Fitting Cylinder Head..................................................... 91 1.4.13 Lubrication............................................................... 94 1.4.14 Water Pump................................................................ 97 1.4.15 Completing Engine Assembly on the Test Bench ............................. 99 1.4.16 Supercharging.............................................................101 1.4.17 Disassembly ..............................................................103 1.4.18 Inspections...............................................................106 1.4.19 Assembly .................................................................107 1.4.20 Securing the Engine to the Frame .........................................109 1.4.21 Adjustment of Linkage Injection Pump Electric Cut-Off.....................110 1.4.22 Adjustment of Linkage Throttle............................................111 1.5 Specification and Data ..........................................................112 1.5.1 Calibration Data of Injection Pump.........................................115 1.5.2 Fitting Data ..............................................................116 1.6 Tightening Torque ...............................................................122 1.7 Special Tools....................................................................123 2. Transmission .........................................................................124 2.1 General Description .............................................................125 2.2 Trouble Shooting.................................................................130 2.3 Hydraulic Torque Converter.......................................................135 2.3.1 Removal Converter..........................................................137 2.3.2 Disassembly Converter .....................................................139 2.3.3 Checking the Parts.........................................................139 2.3.4 Converter Safety Valve.....................................................143 2.4 Gearbox..........................................................................144 2.4.1 Removal of Transmission Group..............................................144 2.4.2 Disassembly Transmission...................................................147 2.4.3 Clutch Disassembly ........................................................154 2.4.4 Reassembly Transmission....................................................159 2.4.5 Pressure Control Valve Transmission Lubrication Oil .......................163 2.4.6 Exaust Valves .............................................................164 2.4.7 Refitting Transmission.....................................................164 2.5 Transmission Distributor.........................................................165 2.5.1 Removal and Disassembly ...................................................165 2.5.2 Checking the Parts.........................................................169 2.6 Transmission Control ............................................................173 2.6.1 Disassembly Control Lever..................................................173 2.6.2 Control Lever - Operating Diagram..........................................174 2.6.3 Checking the Parts ........................................................176 2.6.4 Safety Deflector...........................................................177 2.7 Hydraulic Pump Converter, Transmission/Converter, Transmission Oil Recovery......178 2.7.1 Disassembly and Revision ..................................................179 2.8 Heat Exchanger Transmission Oil..................................................180 2.9 Drive Shaft Converter-Transmission...............................................181 2.9.1 Dismantling and Revision...................................................181 2.9.2 Reassembly.................................................................181 2.10 Converter-Transmission Oil Filter...............................................183 2.11 Testing the Converter-Transmission Unit on the Mashine ........................185 2.11.1 Gear Selection with Converter in Stall Test...............................185 2.11.2 Checking the Transmission Converter Pressure..............................186 2.11.3 Checking the Transmission - Clutch Pressure...............................186 2.11.4 Lubrication Oil Pressure Check............................................188 2.11.5 Converter Oil Pressure Check..............................................188 2.11.6 Transmission Feed Pressure Check..........................................188 2.12 Specifications and Technical Data ..............................................189 2.13 Tightening Torque...............................................................194 2.14 Tools...........................................................................197 3. Steering Clutches and Brakes..........................................................198 3.1 General Description .............................................................199 3.2 Troubleshooting of Major Malfunctions............................................205 3.3 Central Reduction Bevel Gear Set.................................................210 3.3.1 Disassembly................................................................210 3.3.2 Assembly...................................................................212 3.3.3 Setting of the Bevel Gear Set..............................................215 3.4 Steeing Clutches and Brakes......................................................218 3.4.1 Removal of Brake Bands.....................................................218 3.4.2 Disassembly................................................................219 3.4.3 Inspection of Steering Clutch Packs........................................221 3.4.4 Assembly of Steering Clutches..............................................223 3.4.5 Installation of Steering Clutch............................................225 3.5 Brake Cylinder...................................................................227 3.6 Steering Clutch and Brakes Control Hydraulic Pump................................228 3.6.1 Inspection of Components...................................................228 3.7 Steering Clutch and System Oil Filters...........................................229 3.8 Steering Clutchers and Brakes Control Valve .....................................230 3.8.1 Disassembly................................................................230 3.8.2 Inspection of Components...................................................232 3.9 Brakes Control Valve.............................................................233 3.9.1 Disssembly ................................................................233 3.9.2 Inspection of Components...................................................235 3.10 Control Pilot Valve.............................................................236 3.10.1 Disassembly of Pilot Valve ...............................................236 3.10.2 Inspection of Components..................................................238 3.11 Tests...........................................................................239 3.11.1 Checking the Pressures of the Steering Clutches - Brakes Control Valve....239 3.11.2 Adjustment of Brake Pedal.................................................241 3.11.3 Check of the Brakes System Pressures......................................242 3.12 Specification and Data .........................................................244 3.13 Tightening Torques..............................................................253 3.14 Special Tools...................................................................254 4. Final Drives and Sprockets............................................................255 4.1 Description .....................................................................257 4.2 Removal..........................................................................258 4.3 Disassembly .....................................................................260 4.4 Inspection of Sprocket...........................................................263 4.5 Assembly.........................................................................263 4.6 Installation.....................................................................265 4.7 Specifications and Data..........................................................268 4.8 Tightening Torques...............................................................269 4.9 Special Tools....................................................................270 5. Undercarriage ........................................................................272 5.1 General Description .............................................................273 5.2 Troubleshooting of Major Malfunction.............................................274 5.3 Truck Chains.....................................................................275 5.3.1 Disassembly................................................................275 5.3.2 Inspection of Undercarriage Components.....................................277 5.3.3 Replacement of a Damaged Link..............................................277 5.4 Track Release and Adjuster Mechanism.............................................278 5.4.1 Disassembly................................................................278 5.4.2 Setting of Hydraulic Adjuster Cylinder Relief Valve........................280 5.4.3 Inspection and Adjustment of Track Chain Tension ..........................281 5.5 Track Idler Wheels...............................................................283 5.5.1 Removal....................................................................283 5.5.2 Overhaul...................................................................283 5.5.3 Installation and Adjustment................................................286 5.6 Track Rollers....................................................................286 5.6.1 Removal....................................................................286 5.6.2 Overhaul...................................................................286 5.7 Track Carrier Rollers............................................................290 5.7.1 Disassembly................................................................290 5.8 Lubrication of Rollers and Idler Wheels..........................................292 5.9 Track Frames.....................................................................292 5.9.1 Inspection of Track Frames.................................................294 5.9.2 Adjustment of Track Frames.................................................295 5.9.3 Track Frame Pivot..........................................................296 5.10 Front Suspension................................................................297 5.11 Specifications and Data.........................................................299 5.12 Tightening Torques..............................................................303 5.13 Special Tools...................................................................305 6. Hydraulic System for Bulldozer Equipment .............................................307 6.1 Description and Operating of Hydraulic System....................................308 6.1.1 Hydraulic Blade Tilting....................................................311 6.1.2 Rapid Release Valve........................................................311 6.2 Trouble Shooting.................................................................312 6.3 Hydraulic Oil Tank and Oil Filter ...............................................314 6.3.1 Filters....................................................................314 6.3.2 Removal of the Tank........................................................314 6.4 Hydraulic Pump ..................................................................316 6.4.1 Uncoupling.................................................................316 6.4.2 Overhaul of the Control Pump...............................................317 6.4.3 Pump Overhaul..............................................................318 6.4.4 Reassembly ................................................................319 6.4.5 Flow Testing...............................................................319 6.5 Distributor......................................................................320 6.5.1 Removal....................................................................320 6.5.2 Disassembly and Overhaul...................................................320 6.5.3 Reassembly.................................................................325 6.5.4 Hydraulic Bench Test of Distributor........................................326 6.5.5 Checking and Setting the Main Safety Valve on the Machine..................328 6.6 Arch and Blade of the Angledozer.................................................329 6.7 Blade Raising and Lowering Control Cylinders.....................................329 6.8 Rapid Release Valves.............................................................331 6.9 Angledozer with Blade Tilt Cylinder (Hydraulic Tilt).............................332 6.9.1 Angledozer Blade Tilt Cylinder (Hydraulic Tilt)............................332 6.10 Arms and Blade of the Bulldozer.................................................334 6.10.1 Bulldozer Blade Tilt Control Cylinder.....................................334 6.11 Ripper..........................................................................337 6.12 Techical Data...................................................................339 6.13 Tightening Torques..............................................................343 6.14 Special Equipment...............................................................344 7. Electrical System.....................................................................346 Safety Rules.........................................................................347
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