Fiatallis FD20 Crawler Dozer Service Manual PDF

This workshop service manual covers the FiatAllis FD20 Crawler Dozer. It provides detailed information on machine systems, service specifications, adjustment procedures, troubleshooting, component removal and installation, overhaul procedures, and repair instructions.

The manual is intended for qualified service personnel and technicians. It includes technical data, torque specifications, service tools, hydraulic testing procedures, and step-by-step instructions for servicing major machine components.

Service and Repair Coverage

The manual covers the engine-related components, including removal and installation of the engine-converter assembly, engine sump, fuel supply, turbocharging, cooling system, service tools, torque specifications, and technical data.

The torque converter and transmission sections provide procedures for removal, disassembly, overhaul, assembly, installation, clutch servicing, clutch pack dimension checks, drive shaft service, adjustments, specifications, and torque data.

The torque converter and transmission hydraulic system section explains system operation and covers hydraulic pumps, scavenger pumps, oil filters, transmission valve blocks, valve adjustment, hydraulic bench tests, clutch apply circuits, pressure checks, remote control adjustment, troubleshooting, and on-machine torque converter testing.

The steering and braking systems are covered in detail, including bevel gear, steering clutches, brakes, hydraulic control systems, pumps, valve blocks, brake control valves, power cylinders, linkage adjustment, troubleshooting, and service specifications.

The final drives and sprockets section includes removal, disassembly, inspection, assembly, installation, specifications, torque loadings, and special tools.

The undercarriage section covers track chains, track adjusters, idler wheels, track rollers, carrier rollers, track frames, front suspension, lubrication procedures, component inspection, adjustment, repair, and replacement.

The dozer equipment section provides detailed information on the hydraulic control system, oil tank and filters, hydraulic control pump, main control valve, angledozer frame and blade, hydraulic cylinders, quick-drop valves, bulldozer push beams and blade, single-lever control, ripper, hydraulic system troubleshooting, specifications, and special-purpose tools.

This FiatAllis FD20 service manual is a useful reference for maintenance, diagnostics, adjustment, overhaul, and repair of the crawler dozer and its major mechanical and hydraulic systems.

CONTENTS

GENERAL
1.1 Principal data
1.2 Notes for spare parts
1.3 Capacities
1.4 General instructions
1.5 Troubleshooting
1.6 Measurement units

ENGINE RELATED COMPONENTS
2.1 Removing (installing) of the engine-converter assembly
2.2 Engine sump
2.3 Fuel supply
2.4 Turbocharging
2.5 Cooling
2.6 Service tools
2.7 Torque specification
2.8 Specifications and data
3 - TORQUE CONVERTER
CONTENTS
3.1 CONVERTER REMOVAL, FD 20 CRAWLER TRACTOR
3.2 CONVERTER REMOVAL, FL 20 CRAWLER LOADER
3.3 DISASSEMBLY
3.4 ASSEMBLY
3.5 INSTALLATION
3.6 SPECIFICATION AND DATA
3.7 SERVICE TOOLS
4 - TRANSMISSION
CONTENTS
4.1 TRANSMISSION REMOVAL, FD 20 CRAWLER TRACTOR
4.2 TRANSMISSION REMOVAL, FL 20 CRAWLER LOADER
4.3 TRANSMISSION DISASSEMBLY
4.3.1 Clutch disassembly
4.3.2 Clutch overhaul
4.3.3 Clutch assembly
4.3.4 Clutch pack assembly dimensions check
4.4 TRANSMISSION ASSEMBLY
4.5 TRANSMISSION INSTALLATION
4.6 TRANSMISSION DRIVE SHAFT
4.6.1 Disassembly and overhaul
4.6.2 Assembly
4.7 SPECIFICATION AND DATA
4.8 TORQUE DATA
4.9 SERVICE TOOLS

TORQUE CONVERTER/TRANSMISSION HYDRAULIC SYSTEM
CONTENTS
5.1 OPERATION
5.2 HYDRAULIC PUMP (TORQUE CONVERTER, CONVERTER/TRANSMISSION, TRANSMISSION SCAVENGER)
5.2.1 Overhaul
5.2.2 Output test
5.3 TORQUE CONVERTER SCAVENGER PUMP
5.4 TORQUE CONVERTER/TRANSMISSION OIL FILTERS
5.5 TRANSMISSION VALVE BLOCK
5.5.1 Removal and disassembly
5.5.2 Overhaul
5.5.3 Assembly
5.5.4 Transmission valve block bench test
5.6 VALVE ADJUSTMENT
5.6.1 Torque converter safety valve
5.6.2 Torque converter pressure regulator valve
5.6.3 Transmission lubricating oil pressure relief valve
5.7 ON-BENCH TRANSMISSION HYDRAULIC TESTS
5.7.1 Lubricating oil pressure check
5.7.2 Clutch apply circuit check
5.7.3 Apply clutch slip check
5.8 TRANSMISSION REMOTE CONTROL ADJUSTMENT
5.9 TROUBLE SHOOTING
5.9.1 Troubles, causes and remedies
5.9.2 On-machine torque converter tests
5.9.2.1 Stall test
5.9.2.2 Transmission-converter pressure test
5.10 SPECIFICATION AND DATA
5.11 TORQUE DATA
5.12 SERVICE TOOLS
STEERING CLUTCHES

6 - BEVEL GEAR
CONTENTS
6.1 REMOVAL
6.2 INSTALLATION
6.3 ADJUSTMENT
6.4 SPECIFICATION AND DATA
6.5 TORQUE DATA
6.6 SERVICE TOOLS

CONTENTS
7.1 REMOVAL
7.2 DISASSEMBLY
7.3 CHECKING STEERING CLUTCH PACKS
7.4 ASSEMBLY
7.5 INSTALLATION
7.6 DATA
7.7 TORQUE LOADINGS
7.8 SPECIAL TOOLS

BRAKES
CONTENTS
8.1 DISASSEMBLY
8.2 INSPECTION
8.3 ASSEMBLY
8.3.1 Adjustment
8.4 DATA
8.5 TORQUE LOADINGS
8.6 SPECIAL TOOLS

STEERING CLUTCH AND BRAKE HYDRAULIC SYSTEM
CONTENTS
9.1 OPERATION
9.2 HYDRAULIC PUMP
9.2.1 Output test
9.3 OIL FILTERS
9.4 VALVE BLOCK
9.4.1 Bench test
9.5 BRAKE CONTROL VALVE
9.6 HYDRAULIC BRAKE PUSHROD CONTROL CYLINDERS
9.7 BRAKE POWER CYLINDERS
9.8 LINKAGE ADJUSTMENT
9.9 TROUBLE SHOOTING
9.10 DATA
9.11 TORQUE LOADINGS
9.12 SPECIAL TOOLS

10. FINAL DRIVES AND SPROCKETS
10.1 REMOVAL
10.2 DISASSEMBLY
10.3 INSPECTION OF SPROCKETS
10.4 ASSEMBLY
10.5 INSTALLATION
10.6 DATA
10.7 TORQUE LOADINGS
10.8 SPECIAL TOOLS

11. UNDERCARRIAGE
11.1 TRACK CHAINS
11.1.1 Track chain removal and installation.
11.1.2 Track chain disassembly and assembly
11.1.3 Inspection of track components
11.1.4 Replacement of a damaged track link
11.2 TRACK RELEASE AND ADJUSTER MECHANISM
11.2.1 Setting of hydraulic adjuster cylinder relief valve
11.2.2 Checking and adjusting track chain tension
11.3 TRACK IDLER WHEELS
11.3.1 Removal
11.3.2 Servicing (Early wheels)
11.3.3 Servicing (Late wheels)
11.3.4 Installation and adjustment
11.4 TRACK ROLLERS
11.4.1 Removal
11.4.2 Servicing (Early rollers)
11.4.3 Servicing (Late rollers)
11.5 TRACK CARRIER ROLLERS
11.6 LUBRICATION OF TRACK ROLLERS, CARRIER ROLLERS AND IDLER WHEELS
11.7 TRACK FRAMES
11.7.1 Track frame checks
11.7.2 Track frame adjustments
11.7.3 Track frame pivots
11.8 FRONT SUSPENSION
11.9 SPECIFICATIONS
11.10 TORQUE DATA
11.11 SPECIAL PURPOSE TOOLS

12. DOZER EQUIPMENT
12.1 HYDRAULIC CONTROL SYSTEM DESCRIPTION AND OPERATION
12.2 HYDRAULIC CONTROL SYSTEM OIL TANK AND FILTER
12.2.1 Filters
12.2.2 Tank removal
12.3 HYDRAULIC CONTROL PUMP
12.3.1 Removal
12.3.2 Pump drive servicing
12.3.3 Pump servicing
12.3.4 Installation
12.3.5 Pump flow rate test
12.4 MAIN CONTROL VALVE
12.4.1 Removal
12.4.2 Disassembly and servicing
12.4.3 Assembly
12.4.4 Main control valve fluid tests on bench
12.4.5 Pressure relief valve setting check and adjustment on machine
12.5 ANGLEDOZER FRAME AND BLADE
12.5.1 Blade raise/lower control cylinders
12.5.2 Quick-drop valves
12.5.3 Hydraulic tilt blade
12.5.4 Hydraulic tilt cylinders
12.5.5 Check valve
12.6 BULLDOZER PUSH BEAMS AND BLADE
12.6.1 Blade tilt cylinder
12.6.2 Flow reduction valves
12.7 SINGLE LEVER CONTROL
12.8 RIPPER
12.9 DOZER BLADE EQUIPMENT HYDRAULIC SYSTEM TROUBLE SHOOTING
12.10 SPECIFICATIONS
12.11 TORQUE DATA
12.12 SPECIAL PURPOSE TOOLS

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