————& FIATALLIS FL7 FD7 Service manual GENERAL ENGINE RELATED COMPONENTS. UNDERCARRIAGE Form 604.06.191AVOID ACCIDENTS. Most accidents, whether they occur in industry, onthe farm, at home or on the highway, are caused by the falure of some indlviual to follow simple anc fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and doing something about before the ‘acidont occurs Regardiess of the care used in he design and constructon of any ype of ‘equipment tare are conditions that cannot be completely safeguarded against without Intereing wih reasonable accessbity and efcent operation, ‘Acar operators the bet insuranes against an accident. ‘Te complete obserace of one sol le woud prevent many thousand sous ines each ye. “Tat ‘Never attempt to clean, oil or adjust a machine while itis in motion. WARNING (On machines having hydraulically, mechanicaly, andor cable contoled equip- ‘ment (such as shovels, loaders, dozer, scrapers, et) be certain the equipment Is lowered tothe ground before servicing, gusting andlor repang. itis necessary to have the nyraucaly, mechanically, andor cable contol equipment partly o uly raised to gain access to certain tems, be sure the equipment is suably supported by ‘means otner than the hydraulic i cylinders, cable andlor mechanical devices used for controling the equipment. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ofits constituents are known to the State of Califomia to cause cancer, birth defects, and cther reproductive harm, COPYRIGHT BY FIATALLIS . Allright reserved. Reproduction of tox and iustations ‘in whole or in par, i sey prohibited.ya Dy a-_ > -_ FiATALEEs FL7 FD7 Service manual 1- GENERAL 2- ENGINE RELATED COMPONENTS 10 - UNDERCARRIAGE Form 604.06.191 - English Awasnine STUDY THE OPERATION AND MAINTENANCE INSTRUCTION MANUAL THROUGH BEFORE STARTING, OPERATING, MAINTAINING, FUELING OR SERVICING THIS MACHINE. ‘The Operation and Maintenance Instruction Manual provides the instructions and procedures for starting, operating, maintaining, fueling, shutdown and servicing that are necessary for properly conducting the Procedures for overhaul of the related components outlined in this Service Manual, ‘This symbol is your safety alert sign. It MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS IN IN- VOLVED. Read and heed all safety instructions carrying the signal words WARNING and DANGER. a a Machine mounted safety signs have been color coded yellow with black border and lettering for WARNING and red with white border and lettering for DANGER points. IMPORTANT The information in this manual was current at the time of publication. Itis ourpolicy to constantly improve ‘our product and to make available additional optional items. These changes may affect procedures outli- ned in this manual. If variances are observed, verify the information through your Dealer. NOTE ‘Additional. publications pertaining to this model an to all other FIATALLIS products are available through FIATALLIS deelers. Publications are generally available in several languages. Refer to Service Publications index for all such publications; this index is available from FIATALLIS.SAFETY RULES GENERAL ‘Study the Operation and Maintenance Instruction Mi ‘nual before starting, operating, maintaining, fueling, or ‘servicing machine. Read and heed ali machine-mounted safety signs be- fore starting, operating, maintaining, fueling or servi- cing machine. ‘Machine-mounted sgfety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger points. Do not allow unauthorized personnel to service or maintain this machine. Do not perform any work on ‘equipment that is not authorized. Follow the Mainte- nance and Service procedures. Study the Operation ‘and Maintenance Instruction Manual before starting, ‘operating, maintaining, fueling or servicing this ma- chine. ‘Always wear safety glasses with side shields. Do not wear rings, wrist watches, jewelry, or loose or hanging apparel, such as ties, torn clothing, scarves, tunbuttoned or unzipped jackets that can catch on mo- ving parts. Wear proper safety equipment as authori- zed for the job. Examples: hard hats, safety shoes, heavy gloves, ear protectors, safety glasses or goggles, reflector vest, or respirators. Consult your employer for specific safety equipment requirements. Do not use controls or hoses as handholds when clim- bbing on or off machine. Hoses and controls are mova- ‘ble and do not provide a solid support. Controls may also bainadvertently moved causing accidental machi- ‘ne oF equipment movement. Do not jump on or off machine. Keep two hands and ‘one foot, or two feet and one hand, in contact with steps and grab-rails ahd handles at all times. Machine should not be serviced with anyone in the ‘operator's seat unless they are qualified to operate the machine and are assisting in the servicing. Keep operator's compartment, stepping points, grab- rails and handles clean 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. Never attempt to operate the machine or its tools from ‘any other position than seated in the operator's seat. Keep operator's compartment clear of loose objects. Hf movement of an attachment by means of the machi ine’s hydraulic system is required for service or mi tenance, do not raise or lower attachments from any position other than when seated in the operator's seat. Before starting machine or moving attachment or tool, ‘make sure to set brakes, sound horn and call for an all clear. Raise attachment slowly. ‘Always block with external support any linkage, parts, ‘or machine according to local or national requirements. Never allow anyone to walk under or be near unblo- cked raised equipment. Avoid working or walking un- der raised blocked equipment unless you are assured of your safety. Never place: head, body, limbs, fingers, feet or hands into an exposed portion between uncontrolled or un- ‘guarded scissor points of machine without first provi ding secure blocking. Never lubricate, service or adjust a machine with the engine running, except as called for in the Operation and Maintenance {nstruction Manuals. Do not wear loose clothing or jewelry near moving parts. ‘When servicing or maintenance requires access to areas that cannot be reached from the ground, use 2 ladder or step platform that meets local or national re- ‘Quirements to reach the service point. If such ladders ( platform are not available, use the machine hand- holds and steps as provided. Perform all service or maintenance carefully. : Shop or field service platform and ladders used to maintain or service machinery should be constructed ‘and maintened: according to local or national requi- ements. Never check or fill fuel tanks, storage batteries or use starter fluid near lighted smoking materials or open fa- ‘me due to the presence of flammable fluid Brakes are inoperative when manually released tor servicing. Provision must be made to maintain control of the machine by blocking or other means. ‘Always place the fuel nozzle against the side of the filler opening before starting and during fuel flow..To reduce the change of a static electricity spark, keep Contact until after fuel flow is shut off Use only designated towing or pulling attachment points. Use care in making attachment. Be sure pins and locks as provided are secure before pulling. Stay clear of drawbars, cables or chains under load. ‘To move a disabled machine, use @ trailer or low boy truck if available. If towing is necessary, provide war- ‘ing signals as required by local rules and regulations ‘and follow operation and maintenance instruction ma- ‘nual recommendations. Load and unload on a level ‘area that gives full support to the trailer wheels. Use ramps of adequate strength, low angle and proper height. Keep trailer bed clean of clay, ol and all ma- terials that become slippery. Tie machine down secu- rely to truck or trailer bed and block tracks (or wheels) ‘as required by the carrer. Never align holes with fingers or hands. Use the proper aligning tool Remove sharp edges and burrs from reworked parts. Use only grounded auxiliary power source for heaters, ‘chargers. pumps and similar equipment to reduce the hazards of electrical shock. Lift and handle all heavy parts with a lifting device of ‘propre capacity. Be sure parts are supported by proper slings and hooks. Use lifting eyes if provided. Watch ‘out for people in the vicinity. Never place’ gasoline or diesel fuel in an open pan. Never use gasoline or solvent or other flammable fluid to clean parts. Use authorized commercial, non-flam-SAFETY RULES mabe, non-toxic solvents. When using compressed air for cleaning parts use safety glasses with side shields or goggles. Limit the pressure to 2 bar {30 psi} according to local or na- tional requirements. Do nat smoke or permit any open flame or spark near when refueling, oF handling highly flammable mate- als, Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine Be sure all mechanic's tools are in good condition. DO NOT use tools with mushroomed heads. Always wear safety lasses with side shields, Move carefully when under, in or near machine or im= plements. Wear required protective equipment, such a hard hat, safety glasses, safety shoes, ear protec- tors. When making equipment checks that require of the “engine, have an operator in the operator seat at all times with the mechanic in sight. Place the tran- mission in neutral and set the brakes and lock. Keep hands and clothing away from moving parts. Shut off ‘engine and disengage the Power Take-Off Lever be: fore attemting adjuustments or service Never use the bucket as a man lift, The articulation point between frames will nt clear a Person. Stay clear when engine is running. Support, Using device provided when servicing. Return support to carry position and secure before moving machine after servicing. See Operation and Maintenance In. struction Manual For feld service, move machine to level ground if possiole and block machine. If work is absolutely ne- Ccessary on an incline, block machine and its attach- iments securely. Move the machine to level ground as soon as possible. Guard against kinking chains or cables. Do not lift-or pull through a kinked chain or cable. Always wear hea- vy gloves when handling chain or cable. Be sure cables are anchored and the anchor point is. Strong enough to handle the expected load. Keep ex: posed personnel clear of anchor point and cable or ‘chain DO NOT PULL OR TOW UNLESS OPERATOR'S, COMPARTMENTS OF MACHINES INVOLVED ARE PROPERLY GUARDED against accidental cable or ‘chain backlash, Keep maintenance area CLEAN and DRY. Remove ‘water or oil slicks immediately. DO NOT pile oily, greasy rags ~ they are a fire hazard. Store in a closed metal container. Before starting machine or moving attachment check {and adjust and lock operator's seat. Be sure all per- sonnel in the area are clear before starting or moving mactine and any of sts attachments. Sound horn Rust inhibitors are volatile and flammable. Prepare partsin well-ventilated place. Keep open flame away = DO NOT SMOKE. Store container in a cool well-ven- tilated place secured against unauthorized personnel, Do not carry loose objects in pockets that might fall ‘unnoticed into open compartments. Keep clutches and braces on machine and attach- ‘ments such as Power Control Units, winches and ma ster clutches adjusted according to Operation and. Maintenance instruction Manuals of the manufac- turer at al times. DO NCT adjust machine with engine running except ad specified, ‘Wear proper protective equipment such as safety gog les or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly ofall. ‘Wear welder’s protective equipment such as dark s3- fety glasses, helmets, protective clothing, gloves and safety shoes when welding. Wear dark safety glasses ‘near welding. 00 NOT LOOK AT ARC WITHOUT PRO- PER EYE PROTECTION. ‘Know your jacking equirment and its capacity. Be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support for the jack at the machine anc under the jack is appropriate land stable. Any equipment up on a jack is dangerous Transfer load to appropriate blocking as a safety measure before proceeding with service or mainte: nance work according to local or national require ments. Wire rope develops ster! slivers. Use authorized pro- tective equipment such as heavy gloves, safety glasses, when handling Handle all parts with extreme care. Keep hands and fingers from between parts. Wear authorized protec- tive equipment such as safety glasses, heavy gloves, safety shoes. Inspect your seat belt at least twice a year for signs of fraying, wear. or other weakness that could lead to failure. ‘Where itis necessary to use diesel fuel as a lubricant ‘make sure all smoking material and open flames are extinguished or that no sparks are near. Place all parts in a closed container cf clear diesel fuel for use as needed. To minimize dangers offre and explosion, itis recom. ‘mended that before any welding is done on a fuel tank the tank be completely drained of fuel, fuel lines di sconnected and the ends closed to protect them, and the tank be steam cleaned, ll traces of fuel must be removed before welding is started. Flood the tank with carbon dioxide (CO,) before and during welding. Caps. ‘must be removed and vents and other openings lett ‘open during welding, . Diy ice (solid carbon dioxide) is extremely cold and, will freeze flesh on contact. Use care to prevent con- tact with skin, eyes, or cther parts of the body to avoid personal injury ‘When work is required under or between components, block with an external support capable of holding the ‘components in place according to local or national requirements,SAFETY RULES ‘START UP ‘Do not run the éngine of this machine in closed areas without proper ventilation to remove deadly exhaust gases: Do not place head, body, limbs, feet, fingers, or hands near @ rotating fan or belts. Be especially alert around 3 pusher fan. STARTING FLUID IS FLAMMABLE. Follow the recom mendations as outlined in the Operation and Maint. ance Instruction Manual and as marked on the con- tainers. Store containers in cool, well-ventilated place ‘Secure from unauthorized personnel. 00 NOT PUNC: TURE OR BURN CONTAINERS. Follw the recommen dation of the manufacturer for storage and disposal ENGINE Turn radiator cap slowly to relieve pressure before re moving. Add coolant only with engine stoppedior idling if hot. See Operation and Maintenance Instruction Manual Do not run engine when refueling and use care it en- gine is hot due to the incresed possiblity of a fire if fuel is spilled. Never attempt to check or adjust fan belts when engine is running, Do not adjust engine fuel pump when the machine is in motion, Never lubricate @ machine with the engine running, ‘Avoid running engine with open unprotected air inlets I such running in unavoidable for service reasons, pla- ceprotective screen over all inlet openings before se vicing engine ELECTRICAL Be sure to connect the booster cables to the proper terminals (+ to +) and (= to ~) at both ends. Avoid shorting clamps. Follow the Operation and Mainte- nance Instruction Manual procedure. Always turn the master switch (key switch i 0 equip- ped to the of postion when maintaining or servicing machine. BATTERY GAS IS HIGHLY FLAMMABLE. Leave bet- tery box open to improve ventaiion when charging batteries. Never check charge by placing metal objects a6r0ss the posts Keep sparks or open flame away from batteries. Do not smoke near battery to guard against the possiblity of an accidental explosion Check for fuel or battery electrolyte leaks before star ting service or maintenance work. Eliminate leaks be- fore proceeding Do not charge batteries ina closed area, Provide proper ventilation to guard against an accidental explosion from an accumulation of explosive gases given off in the charging process. Disconnect batteries before working on electrical system oF repair work of any Kind HYDRAULIC Fluid escaping under pressure from a very small hole ‘can almost be invisible and'can have sufficient force m1 to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE HANDS. If injured by escaping fluid, see a doctor at ‘once. Serious infection or reaction can develop if pro- per medical treatment is not administered immediately. Shutt off engine and be sure all pressure in system has been relieved before removing panels, housing, co- vers. and caps. See Operation and Maintenance In: struction Manual ‘When making pressure checks use the correct gage for expected pressure. See Operation’ and Maint ‘nance Instruction Manual or Service Manual for Gui dance. ATTACHMENTS Keep head, bod!, limbs, feet, hands and fingers away from blade, bucket or ripper when in raised position Use authorized blocking as 3 safety measure before proceeding with service or maintenance according to local or national requirements, If movernent of an attachment by means of the ma chine’s hydraulic system is required for service or ma- intenance do not raise’or lower attachments from any position other than when seated in the operator's seat Before starting machine or moving attachments or tools, make sure to set brakes, sound horn and call for {an all clear. Raise attachment slowly. Do not use machine to carry loose’objects by means. other. than attachments for carrying such objects, Never use any gas other than dry nitrogen to charge ‘accumulators. See Operation and Maintenance In struction Manual. Keep clutches and brakes on machine and attech ments as power control units, whiched and master clutches adjusted according to Operaltion and Main: ‘tenance Instruction Manuals of the manufacturer at all times. DO NOT adjust machine with engine rinning except as specified TIRES (APPLICABLE'MACHINES) Be sure tires are properly inflated to the manufacturer's ‘specified pressure. Inspect for damage periodically. Stand to one side when changing inflation of tires. ‘Check tires only when the machine is empty and tires, {are cool to avoid overinflation. Do.not use reworced ‘wheel parts. Improper welding, heating or brazing ‘weakens them and can cause failure. . Never cur or weld on the rim of an inflated tire. Infate. 2 spare tire only enough to keep rim parts in place ~ a {ally inflated tire might fly apart when its non installed fon a machine. Use care if you must transport (haul) 3 fully inflated ire. ‘When servicing tires block the machine in front and back of all wheels. After jacking up, place blocking under machine to protect from falling according 0 local or national requirements, Defiate tires before removing objects from the tread. Never inflate tires with flammable gases. Explosion {and personal injury could result.FL7 FD7 14 12 13 14 15 16 7 18 19 2. 24 22 23 24 25 GENERAL MAIN DATA NOTES FOR SPARE FILLUPS ROLLOVER PROTECTION STRUCTURE (ROPS) GENERAL INSTRUCTIONS ‘TROUBLESHOOTING MEASUREMENT UNITS. STANDARD PART CLASSIFICATION TO DETERMINE TORQUE DATA. FIAT STANDARD TORQUE CHARTS ENGINE RELATED COMPONENTS REMOVING ENGINE - CONVERTER - TRANSMISSION UNIT ENGINE OVERHAUL INSTALLING ENGINE - CONVERTER - TRANSMISSION UNIT Tests ENGINE TEST STAND SPECIFICATIONS 22 23 23 23 263D7/FL7 GENERAL, 1-3 1. GENERAL 1.1 MAIN DATA IDENTIFICATION AND TYPE FD7 model = technical identification of frame... sss + + + + +2602,200.00.1 ~ type of Fiat engine... . 8065.04.095 FLT model = technical identification of frame... sss + + + + +2602,100.00.1 = type of Fiat engine . . . . 8065.04.095 DIMENSTONS AND WEIGHT Dimensions . . . . . see fig. 1-1 and 1-2. Weight of unit (with fuel and operator): FD? 2. 2 ee ee + + + 8105.kg (17868 1b) FLT... se es + + + 8960 kg (19753 1b) ENGINE cycle... ++... . + Diesel, aspirated Strokes... es 4 Fuel injection... . . direct No. of cylinders... . 6 Bore... + ++ +. + + 103 mm (4.05 in) Stroke... . 2... - 110 mm,(4.33 in) Total displacement . . .5499 om (335.6cu.in) Compression ratio . . . wed No. of main bearings . . 5 Direction of crankshaft rotation (as seen from fan side). clockwise Max. power speed... 2250 rpm Max. torque speed... 1600 rpm Weight (without fluids) about... ss =. = 535. ke(1179 1b) Contrarotating weights vibration damper housed in the oil pan. Timing system: ohv (two per cylinder) with camshaft in the block. Valve clearanc -intake opens . . . . 3° before T.D.c. closes. . . . 23° after B.D.C. wexhaust opens. . . 48°30" before B.D.c. closes... 6° after T.D.c. operating valve clearance: - intake... 2. . . 0.25 mm (0.0098in exhaust ©... . . 0.35 mm (0,013 in HOUR METER Electronic, controlled by the engine oil pressure switch. The hour meter is automatically start- ed when the engine oil reaches pressure. FUEL SYSTEM Air cleaning: dry filter with pre- cleaner and two renevable paper ele- ments provided with transmitter for clogging warning light on instrument panel. Oil-bath filter optionally available. Fuel cleaning: renewable filter. Fiat injection unit (BOSCH licence) with four in-line pumping elements, with speed regulator (for all operat ing speeds) and automatic advance variator. + PES 6A 80B-L4/219 1-5-3-6-2-4 Type. ee Injection order. . Injector calibration pressure. . + 225-235bar (3200- 3342 psi)07-FL7 _ Mshydrautte 78 Angledozer =A Fig. 1-1 - Main dimensions of dozer FD7. | | - Main dimensions of loader FLT. Fig. 1-2¥07/FLT GENERAL 1-5 LUBRICATION 707 model Forced-feed type, with gear pump pro- Speed ise [ane [ora vided with pressure relief valve; Forward PB 3.54] 6.14 | 10.50 - engine rpm-to-oil pump rpm pb pore fSeea meee ratio. aoto-t packwara ¥PE 4.17] Tas [11.87 kh ph 2isa| 414g | 7.37 Total oil filtering on the delivery ‘through a filter with renewable paper FLT model element. Speed Tat [nd] Sed kph 3.53] 6.12 | 10.38 ‘orward COOLING sYSTEN Forward Koh 3.53] 6.22 [10.38 Water pressure type with centrifuagal backward FPP aire} 7212 | 11269 blade pump and thermosta! mph 2138 | 4.42 | 7:26 ~ engine rpm-to-water pump rpm ratio... e+ + + + + Isto-1.83 Water cooling: radiator with 5 rows of pipes and a 7-blade fan. ‘TRANSMISSION CLARK-HRS-18301-1 converter-gearbox unit. Hydraulic monostage torque converter, 12.2" diameter,with rubber diaphragm. = convertion ratio at stall 2.85 to-1 0i1 cooling through heat exchanger con— nected to, the engine cooling system. A two-joint shaft connected by a stiff element transmits motion between gearbox and bevel gear set. Total power-shift countershaft gearbox, with hydraulic control, : Three forward and three reverse speeds (5 multi-plate clutch engagements) controlled by one single control lever located in the left side of the operator. Safety devices: = No electric engine starting when the locking lever is in "Unlocked" posi tion; ~ Gear lever neutral locking lever hinders the driver getting off if ‘the lever is not in "Locked" position. Converter-gearbox hydraulic control fed by a gear pump. 0i1 cleaning: two full-flow filters, one mesh type on the suction, the other one, paper, on the delivery. POWER TAKE-OFF Provision is made for the application of a power take-off cardan shaft. Motion is taken from the gearbox and through a rear aperture on the trans- mission casing. Power take-off shaft speed: 1154 rpm Shaft rotation (as seen from rear of machine): clockwise. ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of @achine and safety of personnelGENERAL, Fig. 1-3. Transmission layout - FD7 and FLT models. BEVEL GEAR SET central reduction with helical bevel gears and added bevel ring gear: = reduction ratio (1/47) oe ee ee A oton 44273 STEERING CLUTCHES Hydraulically actuated — multiple-plate side clutches in oil bath: = aty. of friction plates for each clutch... 12. 110 Controls + FD7 - two levers located in the central part of instrument panel. FL7 - two independent pedals that,in the second part of their travel, ope- rate the brakes. ED7-FL7 BRAKES Band brakes in oil bath, acting on outside drums of steering clutches, both mechanically operated by a single pedal (FL7)and two pedals (FD7). +340mm (13.38in) + 60mm (2.36in) = dram diameter... ~ band width... . Parking A locking lever keeps the brakes applied. STEERING CLUTCHES HYDRAULIC TEM Fed by a Plessey A42X hydraulic gear pump. ‘Study SAFETY RULES in the front of thie manual thoroughly for the protection of machine and safety of¥D7-FL7 Nominal pump delivery at max. rotation speed... eee 39 liters/min (10.3 U.Segals) O51 cleaning Full-flow filter with magnetic plug on pump suction. Renewable paper element on oil return line to the transmission casing; a safety valve ensures lubrication in case of cartridge clogging. Hydraulic distributor with two distri- butor rods directly controlled by the steering clutches pedal (FL7) and two levers located in the central part of instrument panel (FD7). FINAL DRIVES Straight toothed side reduction: = reduction ratio ( 11/68). . .1-to-6.18 SPROCKET: One-piece crown gear: ~No. of teeth... 2. ...... 27 = Pitch diameter . 693 um (27.28 in) ~ width of toothing. 54-Sémm(2.12-2.2in) UNDERCARRIAGE Rigid boxed track frames connected front and rear to the machine frane: = No.of shoes (per track) se 8 ~ shoe width: SPDT 2 ee eee + 450 mm (1747 tn) © FLT. 2... + 360 mm (14,17 in) ~ Ground contact area PO? ee pious ad 18,045 cm?(2797 sq.in) 14,436 cm2(2237 sq.in) GENERAL = Specific pressure on ground: © D7... s+ + + 0442 bar (6.09 psi) / FLT... + + 0,59 bar (8.56 psi) = No. of track rollers (per track) 5 = No. of carrier rollers (per track) see ee ee spring track release mechanism with hydraulic track chain tension adjust- ment: ~ pressure relief valve setting ., 950-1000 (13,779-14,504 psi) Lube-free track idlers; track rollers nd carrier rollers with metal long Life front seals. SUSPENSION (FD7) Front suspension : oscillating beam which ends rest on track frames. Rear suspension: two shafts located in front of sprockets and secured to the rear transmission housing. SUSPENSION (FL7) Front suspension: rigid cross beam resting on the track frames. Rear suspension: rigid cross beam se— cured to the rear transmission casing and resting on the track franes. EQUIPMENT Hydraulic system fed by a gear pump: = nominal delivery at max. engine rpm (2250 rpm): 128 liters/min (33.8 U.S.gals) type C8axP 2. type TA 22-90/380. + 96 liters/min + 91.2 liters/min Full-flow oil filter with renewable metal filter element and magnetic plug ‘on pump suction; paper element on oil return line. Study SAFETY AULES in the front of this manual thoroughly for the protection of machine and safely of personnel108 GENERAL FD7_EQUIPMENT Max-system operating pressure + 150 bar(2133__ psi) Basic machine two double-acting cylinders for blade raise and lower. ‘ = bore x stroke . 80%760 - mm (3+12x29.9 in) BLADE VERSIONS Angledozer manually adjustable upper struts or one hydraulic tilt cylinder (optional) to replace left upper strut. = bore x stroke 90x10 om (3-54x4.33 in) S-way blade (all-hydraulic) one tilt double-acting cylinder + 105x96 oni (4413x378 in) two angle double-acting cylinders 90x383 om (3.54x15.08 in) - bore x stroke = bore x stroke seseeee Bulldozer one tilt double-acting cylinder 125x62 om (4,92x2 44 in) = borexstroke . Three-spool hydraulic one-piece control valve including : = pressure relief valve = two multiple make-up and overload valves = flow reducing valve = two make-up valves = two check valves. FD7-FL7 FL7_Equipment Max. system operating pressure... . . . 188bar (2204psi) A three-spool hydraulic control valve controls: = bucket retract and dump, lift arms raise, lower and float (single con- trol lever); - ripper raise and lower (optionally). The control valve is provided with: ~ pressure relief valve; multiple back-flow and sefety valve on bucket retract circuit; multiple back-flow and ssfety valve on bucket dump circuit; = safety valve on Jift arm circuit 5 ~ back-flow valve on arms lover circuits ~ three non return valves, one for each circuit. ‘Two double-acting cylinders for lift arm raise and lower: = bore x stroke 110x703 mm (4.33x27.67 in) ‘Two double-acting cylinders for bucket rotation: = bore x stroke 100x590 mm (3.94x23423, in) Adjustable lift arm stroke stop device. Automatic bucket leveler mounted on the R.H. rotation cylinder. Double-acting cylinder for ripper (optional on both models FD7/FL7).: = bore x stroke 110x250mm (4.33x9.84in) Study SAFETY RULES In the front of this manual thoroughly for the protection of machine and safety of personnel,¥D7/FL7 GENERAL 19 ELECTRIC SYSTEN 1.2 NOTES FOR SPARES. Voltage... -........ 24Volt To ensure perfect machine operation, ‘Two in-series batteries (12 V each) with nominal discharge capacity in 24 hours Coe ee eta, Ar Three-phase self-rectifying alternator with built-in voltage regulator: = type ee ee + DELCO-REMY, = nominal rating... . . 454 DELCO-REMY starter moto! s type ee ee ee SMT nominal ratings... 2. 1 4 kW Headlamps with rubber mountings, 115mm (4,52in) diameter. NOTE + Service operatiénson electrical system components are described in ma- nual, 604.06 .381+ Instruments Warning lights + = gearbox oil low pressure 3 ~ air cleaner clogging 3 = fuel low pressure 5 = faulty battery recharge system, Gauges = water temperature ; = engine oil pressure 5 = gearbox of] temperature ; = gearbox oil pressure 5 = electronic hour meters only original parts should be used for replacements. When ordering spares, specify: ~ chassis No. and types = engine No. and types = catalog part No. of the part re- quested. When equipment parts are ordered (buck- et and ripper) also indicate type and number of the equipment. For machine identification data see the “operation and Maintenance Manual". 1.3 FILL-UPS, See the “Operation and Maintenance Manual". Study SAFETY RULES in the front of this manual thoroughly for the orotection of machina and eafahu ah naw1-10 GENERAL ¥D7-FL7 1.4 ROLLOVER PROTECTION STRUCTURE (ROPS) Squaré box section anchored to the rear fenders. For removal proceed as follows + = disconnect the electrical terminals to the rear work lights 5 = remove the ROPS retaining screws and by means of lifting chain and hoist remove the dtructure as shown in fig.i-4. Upon installation tighten the screws to 29 daNim (213.8 ft 1b) torque. San ay oe 1.5 GENERAL INSTRUCTIONS INSTALLING FLOATING RING SEALS Thoroughly inspect metal rings M en— suring that their sealing surfaces are free from score marks, dents or signs of wear due to misalignment or flatness errors. Both metal rings M with rubber seals G should be renewed even if only one is found to be defectives Do not pair new and worn metal rings together, nor used rings of different pairs. To install seals proceed as follows: = remove all sharp corners and burrs and thoroughly clean rubber seal housings; - thoroughly clean the rubber seals; Fig. 1-4 - Rops structure removal, Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel#D7-FL7 = couple each metal ring M to the associat- ed rubber seal G as shown in a, pushing as indicated by the arrows; = ensure that each metal ring is correctly seated. Dimension I (detail b) should be equal all round; - place each seal assembly in position by manually pressing the rubber seal as shown in detail ¢; = before pairing the seal essemblies (see detail d) clean sealing surfaces F using a lint-free cloth and smear a light film of thin oil on the contact surfaces. INSTALLING ROTARY SHAFT SEALS To install rotary shaft seals proceed as follows: = prior to installation soak the seals for at least half an hour in the same oi] as that in which they will operate; = thoroughly clean the shaft and ensure that the contact surface is free from damage; GENERAL Att - turn sealing lip towards the flui of the thrower lip type, turn the grooves so that during shaft rotation the fluid is thrown back; ~ smear the sealing lip with a thin film of lubricant (oil is better than grease) - install the seal into the housing by pressing or using a flat ended punch; on no accounts use a hanmer; = avoid entry of the seal into the recess in a tilted position. after installation ensure that the seal is pressed fully home; - to prevent sealing lip damage during installation, use some sort of protec— tion between seal and shaft. INSTALLING NGS Lubricate O-rings before installation and do not twist them when installing, other— wise leakage will result. REMOVING/INSTALLING FACE SEALING RINGS To remove proceed as follows = press one end of the ring into its seat (see a); = hold ring in position and insert a scriber point beneath the other end to separate the interlocking ends as shown (a); To install proceed as follows = press one end of the seal into the seat (b); = hold in position and lift the free end (b) to lock the two ends together (ce). Study SAFETY RULES in tha fant af this oem1012 GENERAL ¥D7-FL7 ADVICE FOR DISASSEMBLY AND REASSEMBLY OF Materials such as aluminium, rubber, units fibers, sintered bronze and binding agents are particularly sensitive to The following general information is aimed at helping disassembly and reassembly of units. Read it attentively and bear it in mind when carrying out the work. Certain heat exchangers and radiators have aluminium fins. To clean both inside and outside of these parts we recommend the use of solvents that After disconnecting the electric system do not react with aluminium. ‘thoroughly clean the parts to be disassem— bled, if possible with a jet of steam. all high-concentration caustic con- pounds. CLEANING DISASSEMBLY Many repair or service shops use caustic compounds to remove traces of grease, dirt, paint and remains of gaskets etc. Such compounds are extremely useful and effective if employed correctly, but may cause con- siderable damage to certain materials. When operating on the engine or on other units removed from the machine always use stands. Place small items in containers. Be careful not to da~ mage the machined surfaces of compo nents and rest them on shelves or on wood blocks. ‘Study SAFETY RULES In the Wont of this manual thoroughly for the protection of machine and safety of personnelane GENERAL, When dismantling alike components, such as valves, valve lifters etc., place ‘then in suitable containers to avoid incorrect reassembly. ASSEMBLY Carefully clean all parts to be refitted as described in the manual. We recommend the use of the special tools illustrated. Whenever possible, drive in bushings to their correct position using a press. If it is necessary to use a hammer to install the bushing, employ a suitable punch to prevent any damage. Lubricate ball bearings before assembly and bushings prior to installing their pins. Lubricate the sealing lip on all seals before installing (see section 1.4). Wherever possible, use new seals. Cylinder head gaskets should always be new. Use screws with the dimensions and cha~ racteristics indicated, making reference to part numbers in the Spare Parts Ca- talog. Where indicated, use safety washers, cot- ter pins, locking wire etc. Respect specified torque loadings as in- dicated in the appropriate section of ‘this manual, using a suitable torque wrench. Self-locking nuts should be replaced every time a disassembly operation is carried out, so as to guarantee a con— stantly good seal. 1.6 TROUBLESHOOTING GENERAL For a quick troubleshooting abide by the following rules: a) Acquaintance with the machine. It is impossible to look for causes and find a solution without a tho- rough knowledge of the machine. Therefore we recommend to study the descriptions given in the manuals about composition and operation of the various units. b) Check up with the operator. Many troubles originate from incorrect use or poor maintenance. Check with the operator whether the machine has already suffered from similar trouble and whether repairs were carried out with suitable equipment and original spares. Also check the machine en- vironmental and operating conditions and see how the routine service is carried out. c) Operating the machine. ‘The best way for monitoring machine condition is to test it under effect ive working conditions. on that oc- casion check: ~- that instruments function properly; - that the machine performs as spe- cified; ~ that there are no smells or signs of overheating; = if anomalous noises are detected, identify their origin and the op- erating conditions under which they occur. Shudy SAFETY RULES in the front of this manuel thoroughly for the protection of quchine and safety of personnel114 GENERAL D7-FL7 4) Machine inspection. After the test indicated in c) stop the machine and visually check it. also check for any leaks, loose bolts, break- ages or distortions etc. e) Diagnosis. once the fault has been identified, make ‘a list of the possible causes with the aid of the suggestions given in the ap- propriate section of the manual and identify the correct one by means of practical tests, starting with the most likely causes and the easier tests. 1.7 MEASUREMENT UNITS ‘The measurement units used in this manual are those adopted by the In- ternational system (I.S.), replacing ‘the MKS system used previously. Force: decanewton (daN) replaces kilogram (kg) 2 Pressure: bar replaces kg/cm decanewton x meter (datin) replaces kg.m Torqu Apply the following table to convert measurement units: multiply by __|to obtain Force ke 0.9807 | dan Pressure| kg/om” 0.9807 bar torque | kg.m 0.9807 | dann NOTE - For everyday use, the following equivalences mgy be considered valid: kg=dan kg/cm kg.m=daN.m ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safely of personnelFDT-FLT GENERAL, 1-15 1.8 STANDARD PART CLASSIFICATION TO DETERMINE TORQUE DATA IMPORTANT given the should be the part. Part may only When a specific torque isnot FIAT STANDARD TORQUE CHART used after fully indentifying be fully identified by the eight-digit code number, as follows: BH/HE EE eae I ~ Standard part code Always represented by figure 1. Such a number indicates that the part can be produced in various versions which differ in material and coating. acb-c~d-e - Standard part basic number It always consists in five figures to identify the part in its dimensional characteristics. f - Material code number This number represents the material provided for a specific part. 1.9 FIAT STANDARD TORQUE CHARTS When a specific fastener torque is not given, the following charts may be used: IMPORTANT - Fasteners with nominal diameter up to 24 mm to be lubricated with engine oil, major diameter fasteners with tal, low. - Torques for cadmium plated faste— ners are valid also for not coated parts. Nominal torque tolerance is + 5% REO, R100, R120 strength classes are to be considered as follows: 10.9 replaces R100 crews 12.9 replaces Riz0{ DO1t and screw 10 replaces R 80] | 12 replaces R100 Coating abrevistion meaning: : cor = Cadniun plated es aeoning is indicated in the tabte Sosr Seneca! low. ZNT = 2ine plated g ~ Coating code number This number represents the coating pro- vided for a specific part. Material Strength class and type. —oof_—somaterial core FIAT UNI DIN SAE BSI BNA ° R 40 4D - 45 - 48 1 A 42 1 R50 58 - 65 3 P 56 2 R 80 a 5 T 80 3 R 300 200 10K 8 v 100 4 ortone | ottone | messing | Brass | Brass Laiton 5 Allusinio| Alluminio | Alusiniun | aluminium [Aluminium | Aluminius + 6 Rane Rane Kupfer | copper | Copper- | Cuivre 7 open to other metallic material ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and1416 GENERAL ¥D7-FL7 NUTS TORQUE CHART - Unit of measure datin(Ibs Ft) iaacter nd Sererght class: 10. (0) rength clase wath of trea serene — fe . sonar seme | jue type [stand | imme | Nr! Next 13 (96) f= = = = 1,4 (40) nex i,28 | 3.2 (23) - [#26 cas) | *3,9 (29) fes,2 (23) [3,5 (26) mio x 2,25 : - [8,2 (38) | #8,2 (60) |e6.2 (48) | - moxiss | 6,5 (48) | 7,2 (53) [#8 (37) | #7,7 (57) fee (4a) [7 (52) maz x 1,25 : 13, (96) | *8,7 (64) | #24,5(207) [es0,2¢78) | - mi2xa,75 | 12 (#1) = |¥8,2 (60) | *32,9(05) foo,e (72) ]x2 (88) Maa x 1,5 7 19,5(244)| #13 (96) | +21,6(259) fess (210) | ma x2 38 (233) - | +az,8¢92) | #20 (247) fexa,ecaon [29 (240) mis x 2,8 | 30 (221) | 23,5(273)] #13 (96) | #26,e(298) fox6 (328) [30 (222) mie x 2 : 23 (170) | °12,8(92) | °26,8(298) fore (aae) | - mas xi,8 | 45 (352) | 34,5(254)] #19 (240) | #39 (236) fo23,8(273)]45 (352) mas x 2,5 = 32 (236) | °17,9(229)| #36,5(268) eae (262) | - w2o x 2,8 | 60 (442) | 46 (339) | #23,8(275) | #52,7(381) [228 (224) [oo (42) w20 x 2,5 : 44,8(328)| °21,5(258)| °50 (369) fea? (299) | - x22 x 3,8 | 80 (590) | 62 (487) | o32 (236) = = 80 (590) n22 x 2,5 = 61 (480) | °28,s(217)| = - - M24 x 2 100 (737) | 78 (575). | ¢37 (275) | *8s,8(633) Joas (332) |100(737) n2a x3 = 76 (560) }°33 (243) | 84 (629) [oan (302) | - N27 x 2 95 (700) 7 : = = 95 (700) M30 x 2 130 (958) - : - - 130(959) mss x 2 370 (1254) : : : : 360(1180) . 436 x5 220 (2622) = = : : 220(1622) * mt (Zine olated) © Got (Cadniun plated)o7-FL7 GENERAL 1-17 BOLT AND SCREW TORQUE CHART Dianeter and Strongit_class:_ 10.8 Strengit_clase: 12.9 wigth of treae | atandord self Tecking standard] eel F Tooting a Tocking = mt a cor or fost dove (s/s) | date ts/ee) dot (2/2) date (6/00) ae Feieyee)_ | abe #7") abe (0/9) Bes FeO") Mex a 13 6S) ~ : : ratzye) | s.6(0.37/0.25) 10(0.<00.3) we nae SHI2, 8/8) TET 7 TREES) | $.506,8/10)] S60ESTH) : zo.6.28)__| 26(0.47/0.313 22(0.5/0.37) | 26(0.65/0.44| 260.6543) 79U6/iz -SU8/12.5) aeeeeinans - s2(0.70/0.50) - 48(0.70/0.50 - - . eae) | 708.5/0,8) eaMms) | 7 and | aeeIANs) BIO x 155 T ceto.ssio.as) | s(0.61/0.41) - sores(0.as) | s2p.se(0.s8]s7(0.80.57) TMs ST Mr? x 1526 - 102(0.80/0.81) = 24 (0.07082) | - Maa maare | Ban) [at 5712,5) 7 1e,1(20,8/14) | 12(6707,8) | 1526707,8) : (0.760458) | ea(0.72/0.50) 4% (6.80/0:55)| e(1.02/0.68|960.02/0.68) 22(26,5/18) 1e126.5/38) wan - 162(1.04/0.7) r22t1.04/0.70)| - mane Ta) 18 (22h8) ~ ne,200e/6.5) | 18 (0720) | as0720) s2z(0.90/0.62) | 0(0.86/0.58) 119(0.90/0.8)] 400,190.78) 151.18076) mene BOC SOT] 35 (aries) | ETAT] (aires) | 35 (worms) |e (60.5) : zzi(110/0.76)_ | 243(2.140.76)_| 194(0.22/0.82) | r991s.22/0.82)| ave.s7 aoe) [est smb00) mene ~ ~ Biases) | 2B.) | _ rno(1.12/0.76) | 183 (1.10/07) me xis Tay | BRERA | 3 35,8120) | 0 (5.8/0) | eaesraes) | s2ems/=05) : ssa(i.sejo.sr) } s5(1.21/0.86) | 26s(2.30/0.00) | 2ae(229/0.94)| 3540 eu..20)| 3063.20) BRAT | 35st STE) ee - - zaalr.zojo.ee) | atawzojo.sey| - mo e105 WE | SCP) 0059, 5/26.5) | BRS7R 5) POST) 2 exatns0/1.00) | 679(1.50 0.80 | 3690.35/1.00 7.61.35) s02.061.37) ESTE Meo x 2S - - s(1,37/1.73) = - = Ca a) WET RET [=e APD) Ley ‘$90(2.65/210) | 664(1.67/1.10) | 487(1.73/1.16) = 56402. 32/1 58) 7002.%4/222)| SSTEES) eed = : 15(0.53/1.04 - ~ Mane ooraressy | ToT sre8.8) | e5tes.8/22) | eBeTROT | reaTaTS roars) | an0.r5/.16)_ | 12t1.79/.2) ep. /asa Joes) ans = — 0 (aeY 7 ~ ~ 48(0.81/1.20) S TOE TETET TOS TSTERT hor x 2 rater.) - : ee 160 (05) BOTT) MSO x? roze(2.40/1.60) - - 7 fansssve23} 196 (68765) 5 BOTSTES) MSS x2 1491(2.67/1.7) - - 7 festrvase 7 0 (7447) 20 {STHEE) mse x S 3702.80 : - 7 | rswtoavassy] 7 (*/ )Wininun thread Length in a ‘specified for cast iron wi 255 Wa? tensile strength=( /™*)Kirimue Uhread length in a specified for steel with S10 W/an® tensile strength-(9/ )Winisun tread length in inches, specified for cast iran with 537,008 psi tensile strength /6°)Wininun tread length in inches. sneciFied foe eras) vith annED7-FL? ENGINE RELATED COMPONENTS 2. ENGINE RELATED COMPONENTS NOTE - Data, characteristics and instruc- tions for repair given in this manual refer exclusively to installation of the 8065 .04,095 engine on FD7 and FL? models. other engine parts are dealt with in the Service Manual ~ Engine 8065, print No. 73121213. A wasnine This symbol is your safety alert sign. It means ATTENTION! BECOME ALERT! YOUR ‘SAFETY INVOLVED. Read and heed all safety instruction car- rying the signal words WARNING and DAN. GER. Awannne Use linkage safety support provided whenever itis necessary to put linkage in the raised posi tion for any reason. Implement must be empty when using safety supports. Remove support and secure immediately after use for opera- tion and transporting according to the Opera. tion and Maintenance Instruction Manual. Oo not substitute any other device for these sup. ports. Lock up linkage with an external sup port capable of holding up the linkage when ‘work is required under the linkage, according, 10 local or national requirements. A wannine _ Handle all parts with extreme care. Keep hhands and fingers from between parts. Wear authorized protective equipment such as sa- fety glasses, heavy gloves, safety shoes. Fig. 2-1 - Removal-installation of engine by means of lift hook 75297417. Study SAFETY RULES in the Wont of this manual thoroughly for the protection of machine and safely of personnel2x2 ENGINE RELATED COMPONENTS 7-FLT 2.1 REMOVING ENGINE-CONVERTER- TRANSMISSION UNIT Fig.2-4 Engine-transmission unit re~ sting on support 75297150. Fig. 2-2 - Renoving radiator grill. ~ disconnect battery earth lead; ~ disconnect intake manifold-to-air cleaner duct; = remove top cowling with air cleaner, = Remove engine side panels, lower pre-cleaner and exhaust muffler; wards and rear platform; b us = drain coolant through bottom tap. Remove radiator cap te ease the op- eration; = remove radiator grill capscrews and withdraw grill using a hoist as shown in fig. 22; = remove fan grill; = disconnect water hose from radiator and withdraw radiator as shown in fig.2-3 5 = drain the oil from the converter- gearbox unit and from the equipment fluid reservoir; ~ tilt driver's seat and close fuel tap; = remove pins from steering clutches ig. 263 = Removing radiator. ead : es and brake linkages; Siudy SAFETY RULES In the front of this manual thoroughly for the protection of machine and safety of personnelD7-FLT = disconnect accelerator and decelera~ tors = remove front footboard with pedal gear; = disconnect all tubes connecting engine— converter-gearbox unit to fixed part of machine; = disconnect all wires and tubes connect ing instrument panel to engine-convert— ers = disconnect transmission coupling; ~ prepare lift-hook 75297417 and tension with the hoist; ~ free gearbox-to-frame mounting brack— ets and rubber blocks; A wasnine Be sure cables are anchored and the anchor ppoint is strong enough to handle the expected load. Keep exposed personnel clear of anchor ppoint and cables or chain. Awaanins Guard against kinking chain or cables. Always wear heavy gloves when handling chain or cable. = lift out engine-converter-gearbox unit as shown in fig.2-1. 2.2 ENGINE OVERHAUL Remove converter-gearbox unit from en- gine following the instructions given in the Service Manual - Sections 3 and 4 - Print No. 604,06. 380+ ENGINE RELATED COMPONENTS 203 Mount engine on revolving stand and adhere to what described in the Ser— vice Manual - Engine 8065 - Print No. 73121213. 2.3 INSTALLING ENGINE-CONVERTER- TRANSMISSION UNIT To install engine-converter-gearbox unit proceed as described in the ser- vice Manual ~ Sections 3 and 4 - Print No. 604.06.380. Prepare lift chain 75297231, lift en- gine-converter-gearbox unit and place on the machine reversing the removal operations. 2.4 TESTS 2.4.1 Engine compression test A wannine Donotrun the engine ofthis machine inclosed ‘areas without proper ventilation to remove deadly exhaust gases. A wannine ‘Warn all people who may be servicing or wor- king around machine before starting engin Awesnne keep clothing far from moving parts and be ‘careful to prevent hand injuries. In case of poor engine performance, besides checking the injection system, also check compression of each cylinder. ‘Study SAFETY RULES in the front of this manual thorouahly for the wratertinn af ow224 ENGINE RELATED COMPONENTS Fig.2-5.Checking cylinder compression with compression tester 75291310 and dummy injector 75292634. To this purpose use test equipment 7529- 1310 as shown in fig.2-5 and perform the operation as follows: = thoroughly remove all dirt, oil and diesel oil from engine outside; - bring engine to normal operating tem- perature, then switch it off; ~ remove the injectors from the four cylinders; = install dummy injector 75292634 in place of the injector of the cylinder under test and ensure tightness by fit- ting a copper washer on the bottom of the injection holder; = connect the instrument to the dummy injector by means of the special flex- ible pipes = keep injection pump in "STOP" position and take the measurenents by cranking the thermal engine by means of the starter motor. D7-FL7 Under normal operating cenditions the compression measured with an oil tem perature in the pan of 40-60 deg C at sea level atmospheric pressure (760mm mercury) should exceed 2€ bar (355psi). Minimum permissible compression of g worn engine should be 2272 bar (313 28 psi). Bear in mind that an altitude of 100 meters above sea level entails a 1% decrease of the atmospheric pressure. Maximum permissible deviation of the compression among cylinders is 3 bar (42.6 psi). Compression anomalies may be originat- ed by defective operation of the fol- lowing parts: valves and seats, pis— tons and rings, cylinder sleeves and cylinder head gasket. NOTE - Test results do net have an absolute significance, as the test is mainly aimed at checking the uniform- ity of compression in the various cylinders. Fig.2-6 - O{1 temperature check by means of digital dip gauge 75294318. Bice SaEERy BINES i tes faa At This amnal Tharnunhiy nv the nratantion af machine and safely of personnelCOMPONENT. 2-5 Figs 2-8 ~ Centralized diagnostic system (optional). Pressure check points + ~ transmission lubrication = reverse transmission = forvaré transmission. Fig. 2-7 - Injection pump timing by means of digital reading tester 75297258. 2.5 ENGINE TEST STAND SPECIFICATIONS Test conditions + ~ Relative humidity 70u15%. = Engine at bench without fan, air = Fuel specific weight 830410 g/1t filter, muffler. = Atmospheric pressure 735-745 om = Fuel injection advance 25°+1° BTDG (28,9-29.3 in) of mercury. on cylinder No.1 in compression phases = Temperature 17-23°C (62-74°F). Power with engine broken | Tive needed to Throttle control mngine [12 - K# GP) ae lever position RPM for total | for coral | fuel {sccons) of 2 hrs. | of 50 brs. Maximum (under load) 2250 - 6352(84.47)| 48 min Maximum (max torque) 1600 - 51,4(68.9)) 60,5 min Maximum (ne load) 2390 max s : s Minimum (no load) 800-850 - - - Study SAFETY RULES in the font of this manual thoroughly for the nrntactian af marhinFL7 FD7 10. 10.1 to. 10.12 10.13 102 10.21 10.2.2 103 104 105 106 107 107.1 10.7.2 107.3 108 1084 1082 1083 108.4 109 10.10 10.11 UNDERCARRIAGE TRACK CHAINS Removal and installation Disassembly and assembly Overhaul TRACK RELEASE MECHANISM Hydraulic cylinder pressure relief valve calibration ‘Track chain tension inspection and adjustment TRACK IDLERS TRACK ROLLERS CARRIER ROLLERS LUBRICATION ‘TRACK FRAMES (FL.7) Removal Installation Checking track frames parallelism TRACK FRAMES (FD 7) Removal Installation Front suspension Rear suspension ‘SPECIFICATION AND DATA TIGHTENING TORQUES SERVICE TOOLS. 103 108 103 10-4 108 10-40 10-11 10-12 10-43 10.417 10418 10-19 10-19 10-20 1020 10-21 1021 10-22 10.22 10-28 10-24 10-28 10-29™D7-FLT UNDERCARRIAGE 103 10. UNDERCARRIAGE 10.1 TRACK CHAINS Note - For troubleshooting of the undercarriage see “Undercarriage Guide” print No. 731 15607. 10.1.1 TRACK CHAIN REMOVAL AND INSTALLATION A warn When disassembling track chains, anchor the two fend links and stretch out slowly the chain, using a hoist. Make sure that the area is thoroughly clear of ‘personnel and foreign objects. For removal proceed as follows: ~ remove the two shoes adjacent to the master pin and loosen each track chain, as described in section 10.2.2 to facitate the subsequent removal operation; withdraw roll pin (2, ig. 10-1) situated on the outside of each track chain. ~ withdraw the master pin from the inside using maul and punch or, if necessary, hydraulic ram 75295015 with hand pump 75295017, connecting pipes 78295018 and tools illustrated in detail b, fig. 101. Note - Pin (S, fig. 10-1) should never be removed from master pin (4). Poll pin (2) should always be located on the outer side of track chain For installation proceed as follows: = ingert thrust rings (8, fig. 10-1) in their seats on the ‘coupling inks; ————— a warning —__ Use proper tools to bring hotes into alignment. DO NOT USE FINGERS OR HANDS. A warn ‘Take the necessary precautions 1 protect eyes and body from metal particles which are apt to fly when instaling the master pin — instal master pin (4, fg. 10-1) with fed pin 5 from the Inside of the track chain, and drive it ino its seat with maul and punch; — finally install roll pin 2 and shoes. 10.1.2 TRACK CHAIN DISASSEMBLY AND REAS- SEMBLY BD wrtiens. Handle ail parts with extreme care. Keep hands and fingsts from between parts. Weer authorized Protective equipment such as safety giesses, heavy glowee, safety shoes. ‘To disamsemble and reessemble the track chains use the ouble-acting hydraulic ram and associated tool kit ‘shown infig. 10-2, which allow a pin, bushing and link to bbe disassembled or assembled at the same time, with considerable time saving. Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safely of personnel10-4 UNDERCARRIAGE FD7-FLT Fig. 10-1. Removing the master pin using the hydraulle ram. ‘2. Section through the master pin, Pn removal F. Hydraulic ram 75295015 - G. Forcing pin 75295690 - M. Pict pn 78208628 - Frame 75294948 - P. Forcing pin 75287210 - Ri ‘Thrust plate 75205754 "1. Master bushing -2. Ral pin” 3. Thrust ngs 4 Master pin -§- Fix pin. 10.1.3 TRACK CHAIN OVERHAUL ‘Track pin and bushing rotation ‘The ierent service conditions under which tracked ‘machines are used cause link pin and bushing surfaces to wear unevenly at both the pintbushing and bushing! ‘Sprocket teeth interface, In most cases, where the machines are used to perform @ ‘repetitive work cycle, wear is limited to a certain part of To extend the lie of both pins and bushings, itis possible to rotate them through 180°, bearing in mind the ‘ol: lowing: Study SAFETY RULES In the front of this manual thoroughly for the protection of machine and safely of personnel\ UNDERCARRIAGE ‘Se. Operate righthand ram. Brackst (A) moves towards anvi removes busheg and pin trom nghtchand ink (0) and returs ne y Gy ‘Sy. Operate lat-hand ram. Bracket (A) moves towards anv, re- ‘ves and busting om Tethand in (8) an rts wih 105 My, Pace ks (0 an) over brakes (8) ad pin an busing ay v My. O Brackets (B) move simutaneovsy to wars ona and pero easser)) neers operation. Chock ‘Spacing usng gauge Fig. 10-2. Disassembly (operations &, - S;-S;) and assembly (operations M, Ma ~ Ms) of track chain using double ram fixed nyerauic press. ‘A. Disassembly brackets - B. Assembly brackets - D. Righthand links - 1- Anil - . Lefthand links -T. Spacer - U, Link spacing Inspection gauge.108 UNDERCARRIAGE rau FD7-FL7 . Fig. 10.3. Track pin and bushing retation. Note Tho ilustratcn represents a left-hand ink ad the arrow points the erection of machine forward Wavel ‘8. Pins and bushings before rotation -b. Pins and bushings rotated trough 180°, ~ disassemble one track pin and locate position of wom, ‘areas on both bushings and pins with respect to length; = detal a, fig. 10-3 shows a typical instance of wear; — reassemble bushings and pins rotating them through 180° 60 that wom areas are on opposite sides to pre- vious assembly positions on links (detail b, fig. 10-3); ‘This operation may be worthwhile whenever the following conditions exist ~ avaliablity of a workshop equipped with a fixed type ress to keep repair times to a minimum; ~ amount of wear detected is within prescribed limits; = other track parts are in good working order. (On completion of track chain reassembly, assess pin-to- bushing clearance by measuring average pitch (P, fig. 10-4) a8 follows: BA wosnne Handle all parts with extreme care. Keep hands and fingers from between parts. Wear authorized Protecive equipment such as salety glasses, heavy gloves, safety shoes. ~ ‘stretch track chain inserting pin X in a sprocket space width, then reverse machine until pin Xi in position ‘shown in fig. 10-4;Fig. 10-4. Measuring average link pitch (P) or pin-to-bushing working clearance. |. Length over 4 inks -P. Pach = Ye -X. Track tensioning pin = measure length L and divide by No. of links included in ‘section used to determine lenght of average pitch P. Compare value obtained with values indicated in fig 10-32, During overhaul, assess pin and bushing wear directly (Gee section 108). Track link replacement ‘Any damaged track link not immediately adjacent to cou- pling link can be renewed without disassembling the track ‘chain by proceeding as follows: = remove shoes (1, fig. 10-5) adjacent to link to be re- placed 2; = withdraw damaged link pins (8 and 4) using ram and tools as decribed in section 10.1.1; Fig. 10-5, Replacing a damaged link. ‘2 Assembly of trust rings (10) and track link connection « 1. Shoes tbe removed - 2. Damaged ink 3 and 4. Link pins to be removed betore using oxyhyarogon lame ~ 8, Bushing tobe cut= 68,7 and 8 Links ~&. New coupling nk bushing » 10. Couping Tink bushing tvust ange - 1. New brik BA worn ‘Take the necessary precautions to protect eyes ‘and body from metal particles which are apt to fly when instaling the master pin A wornine When disassembling track chains, anchor the two fend links and stretch out slowiy the chain, using a hoist. Make sure that the area is thoroughly clear of personnel and foreign objects, = using an_oxyhydrogen flame, cut off a section of bushing (6, fig. 105) 20-30 mm long (0.74-1.25 in); ‘Study SAFETY RULES in the front of this manual thorouahlv for the aratectinn nf manhina ana arian”108 UNDERCARRIAGE B wornins . ¥D7-FL7, A warn ‘Wear welders protective equipment such as dark - safety glasses, helmets, protective clothing, gloves and safety shoes when welding. Wear dark safety glasses near welding. DO NOT, LOOK AT THE ‘ARC WITHOUT PROPER EYE PROTECTION. = remove damaged link (2, fig. 10-5): withdraw link 6 and take out remaining part of bushing 5 — assemble a link bushing 9 over new link 11 and fasten 1 track chain; = reassemble second fink 6 onto link bushing: reinstall two thrust rings 10 on links 7 and 8 and reas- semble pins 3 and 4, 10.2 TRACK RELEASE MECHANISM ‘To remove the track release mechanism from the track cartiage proceed as follows: A vance Fluid’ under pressure. Always lower hydraulic ‘equipment to ground. Shut off engine, move control levers to each position several times and loosen ‘and retightén hydraulic tank filer cap to relieve trapped pressure belore loosening hydraulic con- nections. release track chain tension by slackening grease drain plug (Vr, fig. 106) by some tus; = disconnect and extend track chain as described in sec- tion 10.1.1; = remove carrier roller assy; = take off track release spring guard: move track idler forward until rod is clear of hydraulic cylinder chamber; ‘When disassembling track chains, anchor the two ‘end links and stretch out slowly the chain, using a hoist. Make sure thatthe area is thoroughly clear of Personnel and foreign objects. ~ remove screw (Cz, fig. 10-7) and plate 8 retaining nut % = tighten nut 7 by some tums further compressing tre spring 10 relieve load from cylinder support dowels; ~ remove support capscrews (C, fig. 10-6) and withdraw track release mechanism as shown in fig. 10-6 To disassemble piston (4, fi. 10-6) proceed as follows: A worn ‘Aways wear safety glasses with side shigid when metal of other particles are apt to fly or fall remove hydraulic regulation valve and admit compress {4 air into the cylinder to bring piston to start of stroke; = remove cover with rod seal; = withdraw piston 2 using universal puller 75292909 as ‘Shown in fig. 10-8. Recoil spring disassembly and reassembly require use of too! 75295567 (A) and hydraulic ram 75300853 as shown infia, 10-10; Fig. 10-6. Removing/nstalling track release mechanism. ©. Support mounting capscrews - Vr. Drain plug and hydraulic ‘adjustment valve “Ve. Pressure rele! valve. ‘indy SAFETY WINFS in the Font of this manual thorouahiv for the orotection of machine and safety of personnel¥D7-FLT LELere? UNDERCARRIAGE 109 “ff Fig. 10-7. Track release mechanism. cov) sx: Nu (7 sr =e Br gare eae Serb 2 Sia natn tyoatle uide rings 3 A owveen Track release: spring is assembled into machine ‘with high compressive load. Follow procedures re- ‘commended in the Undercarriage Service Manual ‘when assembling or disassembling this part. — tighton threaded element 75295724 (E) on end of ram piston rod B, position adapter 752905588 (G) for spring cup 2 and operate ram to relieve nut 3 from the load of spring 1; = remove nut and gradually reduce load on ram until spring is fll released; use the same equipment to reassemble spring: posh lion pilot pin 75283209 (P) and operate ram unt ‘spring reaches installed length of L = 457 mm (18 in), remove pit pin 75293209 (P), tighten nut 3, capscrew (Cx, fig. 10-7) and withdraw ram. dodevell 4505) ‘acjustment valve - Vs. Pressure rele va 1. Rod seal- 2. Rod ‘Bunger= 5: Spring 6: Spring rst plate 7. Spring retaining mut 8: os nt retaining plate Fig. 108. Disassombling track tonsion pleton using univer- ‘sal puller 75252009. Vr. Regulating valve - Ve. Presaure relief valve - 1. Cyincer ‘over with rod sou = 2. Piston Note - Smear rod end thread with anticorosion protective il prior to tightaning nut (7, fg. 10-7. Study SAFETY RULES in the front of this manual thoroug! hly for the protection of machine end safely of personnel10-40 UNDERCARRIAGE, ¥7-FL7 = when reinstaling track release mechanism (fig. 10-6) ‘on a new track frame it is necessary to tighten suppor ‘capscrews (C, fig. 10-6), ream dowel holes on frame to 17.973-18.000 mm (0.7075-0.7086 in) using pilot ‘bushing 75292761 for preliminary driling with 18 mm ‘helical dri, and pilot bushing 75292762 for subsequent reaming with reamer 75281869. Finally, ress fit dowels, 10.2.1 HYDRAULIC CYLINDER PRESSURE RELIEF VALVE CALIBRATION B wrsnne Never use gasoline or solvent or other flammable fluid to clean parts. Use authorized commer ‘ron flammable, non-toxic solvents. Fig. 108, Disascomblingaasembling tack tension piston |. Piston soction- 1, Piston - 2. Cli - 3, Sea - 4. Piston ring, When redissembling track release mechanism, bear in babe lparriran peer eleehraeece oclaenooelal = Position seal parts on piston as indicated in fig. 10-9; Reassomble the valve proceeding as follows: ~ carefully lubricate piston and cylinder with grease; rk | ® ul B) ® L a Fig. 10-10, Disassemblinglassombling track reco apring ung hyralc ram 75900559. 1, eens (asso) or 0 (ascembly) of sping End of assembly or sta of reassert ‘A. Track tool sping fomover 750a6067~B Hysaute fam 76900860, Treadad ting PABSTaN Adapt Yeaa0688- LS mm (0 Lang of staled sping “PPt pn Psab0208 = 1! Tack col sping!" 2Sonng cups. Spans mt ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safely Of personnelFD7-FL7 A wannins Handle all parts with extreme care. Keep hands ‘and fingers from between parts. Wear authorized protective equipment such as safety glasses, heavy gloves, safety shoes, — clamp tester 75291873 (A, fig. 10-11) in a vice, screw in valve Vs interposing relevant O-ring; ~ fil well P win gasoline or alcohol: = operate toque wrench B bearing in mind that the valve shoul remain closed, and therefore the level of, liquid in the well P should not change for a torque rea- ding of-7 to 7.5 daNm. (51.6 to 5.3 f Ib). The valve should open and the well should drain at a torque of 8 to 85 daNn (59 to 627 ft Ib), equivalent to a valve setting of 950 to 1000 bar (13,779 - 14,504 psi); = change shim thickness (S;) to obtain the prescribed setting: ~ reinstall valve packing it with pumpable lthium-calcium ‘mineral grease, resistant to water, high loads and tem- peratures with N.LG.12 consistency (e.g. Grassofiat G9), 10.2.2 TRACK CHAIN TENSION INSPECTION’ AND ADJUSTMENT ‘Track chain tension should be adjusted according to na- ture of ground on which the machine is used; normal track chain tencion te adequate for dry, etony or rocky ‘round, whereas track chain camber should be increased when working on muddy ground, wet clay, or wherever UNDERCARRIAGE so11 ‘sand, gravel, snow orice are present. Proceed as follows: = prise track chain applying sufficient load to take up both slack and play of both sides; = using a suitable straight edge, measure resulting cam- bor (F, fig. 10-12). which, under normal tension condi- ‘tons, should be 30-40 mm (1.18-1.57 in); = 10 increase track chain tensior, pump grease into track tension cylinder through reguating valve (Vr, fig. 10 12); 10 this purpose use pumpable lithium-calcium ‘mineral grease, resistant to water, high loads and ‘temperatures with N.L.G..2 consistency (e.g. Grasso- fiat G9); 0 reduce track chain tension, back off regulating valve (Vr, fig. 10-12) and drain some of the grease from the ‘oyiinder; if possible back the machine a few yards or insert a wood plank between sprocket teeth and track chain B owen Fluid under pressure. Do not loosen track tension by Unscrewing overioad relief valve. Do not remove the lube fiting located on top of the ball check assembly. Follow procedures recommended in the Undercarriage Service Manual Note - Before adjusting a new or overhauled track re- lease mechanism, bleed as follows: Fig. 10-11. Track release hydraulle oyinder reiet valve (Vs) adjustment and cross-section. [A Tester 75291673 -B. Torque wrench - Cy. Valve cover Gasoline or alcohol well- Sy. Valve adjusting shins -T. Pressure setting faite 2980-1000 bar (13.798 = 14504 pal) 1. Pubber cap "2, Stoel washers ~ 8. Disc springs (BAUER tpe) - 4 anc 6. Plunger and "valve bal 6. ubber cup (1) eapocrow. ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel10-412 UNDERCARRIAGE Fig. 10-12, Checking track tension, FF. = 90-40 mm (1.18-1.57 in) camber under normal tension - Vr. Regulating valve. = partially undo regulating valve (Vr, fig. 10-12); = pump grease through valve Vr until lubricant issues {rom valve thread; tighten valve and proceed with adjustment. 10.3 TRACK IDLERS To remove each track idler i is sufficient to: = uncouple track chain as described in section 10.1.1; — remove, screws (Cy, fig. 10-13) and end brackets and adjusting shims (Sy, fig. 10-17); — remove screws (Cs, ig: 10-13) and separate yoke trom idler brackets; A wasn ‘Guard against kinking chains or cables. Always ‘wear heavy gloves when handling chain or cable. ~ remove track idler assembly using scissor hook 75291426 (fig. 10-14). Disassemble track idler as folows: = remove capsorews (Cz, fig. 10-17), mark postion of lend brackets 2 and withdraw using puller 75295565 as ‘shown in fig. 10-18; ~ remove floating ring seals (12, fig. 10-17) and keep together to avoid incorrect reassembiy; ~ remove O-rings (13, fig. 10-17); — remove capscrews (C;) and, using a press, withdraw a bushing cartier § acting on idler shaft end as shown in fig. 10-16; — withdraw the other bushing carrier using the press and ‘working on the same idler shaft; ~ using a press and a suitabie punch, drive out bushings (10,9, 10-17) from carriers. Reassemble track idler as follows: press fit new bushings on carers and a bushing car- ‘ier assy on track idler considering what said in section 10.4 for the same components of track rollers; Install idler shant (8, fg. 10-17), press Mm the second Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safely of personnel¥D7-FL7 Fig. 10-14. Removing track idler using sclssor hook ‘Tea 028. bushing carrier assy and make sure the shaft rotates freely; ~ instal O-nngs 13 on shart; = put floating ring seals 12 in their seats taking the M37 Fig. 10-18, Removing track idler bracket using puller ‘TSD05s65. UNDERCARRIAGE 10-13 necessary precautions, Note - Inspect the working suraces of shoes (7, fi. 10-17) and shoes (8) in particular. If they show ‘excessive wear, the shoes should be replaced. Check, aftere installation on track frames, that coplanar tole: ance between shoes (7 & 8) be within 0:3 and 1.5 mm (0.0118 and 0.059 in, = anve idler brackets (2, fig. 10-17) on the shatt pushing them fully home to overcome floating ring seal resis- tance. Secure with capscrews C2 Reinstall track idler using scissor hook 75291426 as ‘shown in fig, 10-14. ‘Secure yoke to idler brackets (2, fig. 10-19) by means of ‘screws C3. ‘Assemble guide plates (1, fig. 10-7) dividing shims S, so that the track idler centerine is in alignment with track roller centerine, and clearance G, between guide plates (1, fig. 10-17) and track frame wear strips is 0.5-1 mm (0.018-0.039 in) Lubricate track idler with correct grade of ot 10.4 TRACK ROLLERS Each track tame assembly incorporates five track roles: three doublesange and two single lange. not all rors are to be removed, proceed as follows: ~ fully slacken track chain in question; B warns Guard against kinking chains or cables. Always wear heavy gloves when handling chain or cable. J Fig. 10:16, Withdrawing bushing cartier using a fixed type press. 2. Bushing carer - 8. Shaft.10-44 UNDERCARRIAGE FDT-FL? Fig. 10:17. Section through track lr. . Bushing carer cepscrews - Gx Saf capecrow - Cx Guide plate caperows - Gy, V = 05-1 mm (0.019.000 i) clearance os rs wes: sia "Gy, V = 02°15 im (20720.059 ) Searence btwoon tr ees an took ame Sy. "Sade plates "2 ier bethats- 8. Track Wet “4, Butung dowel pns-8- Bushing carers 6, Lube ply 7 end 8. = raise machine and apply required supports; “To remove suppors (1, fi 10-18), clamp ech roller in ~ remove guards, outer and inner track frame guide and _—_a vice using tool 75291417 and proceed as fellows: ‘withdraw roller assembly using lft hook 75295729 (ig 1048). = drain ol through plug (6, fg. 10-19): = remove retaining plate (3); = use puller 75295488 as shown in fig. 10-20; = wmndraw support (1, fig. 10-20); = remove floating ring seals from support and from roller, keeping them together so as to avoid incorrect reas- sornbly. Repeat operation on the other support. To renew bushing proceed as follows: withdraw O-ring (1, fig. 10-21); = remove capscrews Cy and withdraw a bushing carrier assembly acting on roller shaft end with a universal puller as shown in fig. 10-22; — withdraw the other bushing cartier folowing the same procedure: using a press and @ suitable driver remove bushings (6, fig. 10-21) from their carters, Press fit new bushings in carters as follows: = withdraw dowel pins (1, fig. 10-23) from cariers (8) or, | required cut them flush withthe carrier; Fig. 10-18. Removingfinstaling a roller using too! 75295729, . a. ‘Study SAFETY RULES in the front of this manual thorouahiv for the rotection of machine and safety of personnelFD7-FL7 UNDERCARRIAGE 10-15 Fig. 10-18. Overhauling a track rote. ‘Clamping a track roller in a vico using tool 75291417 & -b. Exploded view of rl ac ler» Cx Bushing cartier toler capscrew - 2. Bu- Shing carer = 3: Shaft retaining Koy ~4- Plozing ring Seal - 8. Bushing “6. Libe plug ° 7. ole: shaft 8. Support 8, 10. O-rings [A Role clamo 75291417 - 1. Roter suppor. WARNING Never use gasoline or solvent or other flammable fd to clean parts. Use autho rized commercial, non-flammable, non-tox- te solvents. ig ing awal 3, Ba = thoroughly clean bushing outer surtave and cartier ange roler~ a Busting camer -§ Busing dowel prs bore: SS Snst bushing = 7. Rotor suppor = 8 Lube pag a . My Rotor = apply a thin fm of oll on bushing: ap ae, Og = press new bushings in carters positioning them so ‘hat, after installation, lubrication holes (4) are in align- ‘ment (max. misalignment 2.5 mm - 0.10 in); ‘Study SAFETY RULES in the front of this manual thorouahiv or the Aroteatian Af machina ana eofanr nt nacsnnoah1046 UNDERCARRIAGE D7-FL7 = carry out two new holes for dowel pins (1), located as far as possible rom lube grooves, as shown in fig. 10- 23; — press fit the dowel pins taking care that they do not protrude from bushing surface; Reassemble track rollers as follows: = clean bushing cartier outer surface and roller inner surface, and apply “Molkote G Sorav Rapid”: install frst bushing carrier using a press as shown in figure 10-24 ani using pilot pins 75291825 (S) to facilitate retaining screw hole alignment. ~ assemble rier shaft, press home second bushing car- fier assy and make sure the shaft rotates freely: ~ install O-rings (1, fig. 10-21) on roler shaft; — locate floating ring seals 2 in their seats taking the necessary precautions: ~ install support 7 on shaft pushing them fully home to ‘overcome resistance of floating ring seals and insert Fetaining xey (8, fg. 11-19) in its seat. Apply the correct grade of ol to the roller (See the Ope- ration and Maintenance Instruction Marval) Fig. 1023, Sizes of dowel pin holes in track roller and idler ‘wheel bushing earriors. 70 mm; © = 55 mm; c= t4 mm d = 11,5 mm tm: F = 5,80 t0 3.92 1. Bushing retalnment dowels - 2. Bushing - 8. Busing amie “s Lubreston ontoos. Shir SAFETY AULES in the front of this manual thoroughly for the protection of machine end safety of personnel,¥D7-FL7 UNDERCARRIAGE 10-17 10.5 CARRIER ROLLERS Remove capscrews (Cy, fig. 10-27) and withdraw roller with support 6. ‘Afier removal, clamp each roller in a vice using too! 75291417 as shown in fig. 10-28 and disassemble as follows: remove fiting (10, fig. 10-27); = remove capscrews (Cy, fig. 10-27), take off cover 9 and thrust plate 8; — withdraw roller shaft assy with bushings (7); = remove floating ring seals 3 keeping them together to ‘avoid incorrect reassembly; BA wasn Handle all parts with extreme care. Keep hands and fingers from between parts. Wear authorized Protective equipment such as safety glasses, heavy gloves, safely shoes. Fig. 10-26. Overhauling a carrer roller. lamp 75291417 - ¢. Cover capscrow - Cx. Roller 1 Cover» 2. Poller stpport = 3. Lbeeation fing = & Ot tovel pies, ff ~ remove roller shalt (2, fg. 10-27) with O-ring carier 4 from support 6 by removing retaining nut Ca; ~ in case of replacement, withdraw bushings 7 from rer ‘sing universal intemal puller. (On reassembly, bear in mind the folowing ~ thoroughly clean bushing outer surface and roller bore; Bi wanne Never use gaseline or solvent or other flammable fluid to cloan parts. Use authorized commercial, ‘ron-flammable, now-toxic solvents. = apply a thin film of oll on bushing (7, fig. 10-27) and. ‘ress bushing in the roller using a suitable driver: = degrease floating ring seal seats and install seals tak- ing the necessary precautions; PPESPPPP Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of nerannnal10-18 ‘Note - In case of replacement of the roller shaft (2, fig 10-27),bear in mind that the spare comes with seal car- tier 4, = install rollr shaft (2, fig. 10-27) with seal carrier ring, ‘Bushing it fuly home to overcome resistance of floating fing seals 3; = check thrust plate 8 before instalation; if contact face is, badly wom, renew thrust pia, Nota - In case of replacement of seal cartier ring (4, fig. 10-27), withdraw ring from roller shaft and install a ‘Rew one bearing in mind the following: = clean roller shaft outer surface (2, fig. 10-27) and seal camer ring bore, then apply “LOCTITE RE- TAINING COMPOUND"; ] (uaa) Fig. 1.28. Seal carter ng installation. X= 1201-5 1249 em (48 = 4.01.) monsion 2 be obtained ah ‘of camer tng (2) on shat). UNDERCARRIAGE D7-FL7 10.6 LUBRICATION (On completion of overhaul, refil rollers and track idler with the prescribed type of oil (ee the “Instruction and Maintenance Manual”) as follows: place the assembly in @ horizontal position, that is the ‘same position as when installed on the machine; ~ back off lubrication plug (A, fc. 10-29); fully tighten lubrication fiting B and pump prescribed ol! until the fluid issuing ftom the slots is free from air bubbies; = Quickly unscrew the fiting and reinstall the plug. Note - For cartier roller lubrication inject oll through fitting (C. fig. 10-29) until it issues from level plug (4, fig. 10-28) A wasnine Do not work under or near unblocked or unsup- Ported linkage, parts or machine. — press fit seal carrer ring as shown in fig. 10-28. Fig. 10-29, Reflling rollers end track kdler through fing (8) ‘and hand pump. [A Track roller and track idle lubrication plugs - C. Carr roller Tubveation fing. ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safely of personnelFD7-FL7 10.7 TRACK FRAMES (FL7) 10.7.1 REMOVAL ‘To remove each track frame proceed as follows: A wornne UNDERCARRIAGE 10-19 — withdraw the master pin and extend track chain as de- ccibed in section 10.1.1; A wasnna When disassembiing track chains, anchor trie two ‘end links and stretch out slowly the chain, using a hoist. Make sure that the area is thoroughly clear af Personnel and foreign objects. Guard against kinking chains or cables. Always wear heavy gloves when handing chain or cable. ~ take off track release spring guard; = remove track carrer roller with support; Fig. 10-30, Removing a track frame assembly (FL 7). . Capscrews securing frame to beam (1) - > Capscrews securing frame to beam (2) ~ 1. Front suspension beam - 2. Rear ‘suspension boar ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel40:20 BA worn ‘Be sure cables are anchored and the anchor point ig strong enough to handle the expected load. ‘Keep exposed personne! clear of anchor point and ‘cables or chain, — remove capscrews (C;, fig. 10-30) securing frame 10 equalizing beam; = remove capscrews (C2) securing track frame to rear suspension beam; A wasnina UNDERCARRIAGE Litt and haridie all heavy parts witha lifting device ‘of proper capacity. Be sure parts are supported by proper slings and hooks. Use liting eyes if pro- vided. Watch out for people inthe vicinity ¥O7-FL7 = raise machine as shown in fig. 10-30. It necessary, ‘support rear transmission casing with stands or wood. blocks: — move track frame assembly forward as shown in fig 10-30. 10.7.2 INSTALLATION Install each track trame reversing the removal procedure. ‘After installation check parallelism as described below. 10.7.3 CHECKING TRACK FRAMES PARALLELISM ‘The track frames must be perpendicular to the machined ‘surface ofthe rear transmission housing and parallel with- in + 4 mm (0.15 in, ‘Maximum misalignment between sprocket centerline with respect to each track frame center ine is 2 mm (0.07 in} fig. 10-31), ==) i Y — aay — Fig. 10-81, Parailoliem of track frames (FL 7). ‘Mote - Maximus dferencs betwoon (X) and (is mm (0.15 in) 'S = 2mm (007 in} max, difrence between center nes. ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel¥D7-FL7 UNDERCARRIAGE 1021 10.8 TRACK FRAMES (FD7) 10.8.1 REMOVAL Disconnect from machine the dozer blade complete with pusher frame or C-trame, then proceed to remove the track frames as follows: Awasnine ‘When cisassembing track chains, anchor the two fend links and slowly stretch out the chain, using hoist. Make sure thatthe area is thoroughly clear ‘of personnel and foreign objects, ~ pus out ine track coupling master pin and stretch out the track on ground as described in para 10.1.1; ~ take off the track release spring guard; = remove the carrer roller and its support; ~ back off capscrews (Cz, fig. 10-82) retaining support @ = Separate cap (7) from final drive housing; ~ lift the machine sufficiently high to permit removal of ‘rack frames and support adequately on stands or ‘wooden blocks; Fig. 10-32. FD 7 track frames frent and rear mountings. 2 Front frame mounting - . Detalto show clearance acjustment beeen guise plates (3) and oss plate (4) Cx. Cross plete (3) ‘Sapserews - Cy. Bracket 2) capscrows = Cx. Rar suspension shaft support capscrews ~ Cy. Cap (7) capectews- Hy {2519 im) cearance between cross plato (8) and gue plate - Sy and 5. Shima "1. Pron! cuspension oscitatng bear 2. Boar bracket” 5: Gude plates 4. Cross plate 8. Cross pla support 8. Rear suspension shalt 7. Cap, final ve housing 0 suspension Shatt-@. Snat ower support cover ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel10:22 Note - The machine must be lied level or frst at rear tend and then at front end without inclining it transversal- Wy. Should this not be possible owing to lack of adequate hoisting equipment or cranes, frst disconnect cross plate (4, ig. 11-32) to prevent damages. — Shift forward the track frame assembly as shown in fig. 1133. Fig. 1-88, Removal of one FD 7 track frame. UNDERCARRIAGE, ¥D7-FL7 108.2 INSTALLATION Install each track frame reversing the remove res and considering the following: procedu- ~ atter installation check frames parallelism (see para 10.73); ~ adjust clearance between quide plates (3, fig. 10-32) and cross plate (4). Correct clearance should be 0.5 mm (0.019 in) on each side (Hy and Ha dotallb, fig. 10-32) changing shims (S, and S,) as re: ‘uired, 10.8.3. FRONT SUSPENSION ‘The front suspension consists of an oscillating beam (5, fig. 11-34) pivoted at machine frame center and resting at its ends on track frames. ‘Should the need arise, replace the bushings (4, fig. 11- 34) found to be worn: pull out of their seats in beam (5) taking care not to damage the seats ‘Study SAFETY RULES in the front of this manual thoroughly Yor the protection of machine and safety of personnel™D7-FLT UNDERCARRIAGE 10:23 Fig. 1094. FO 7 front suspension. ‘2. Osoilating beam pivot section - 1. Pivot - 2. Beam support - 3. Pivot seal - 4. Bushings - 5. Oscillating beam - 6. Oscilaing beam bracket -7- Shook pad bushing - 8. Shock ped 10.8.4 REAR SUSPENSION “Two rear suspension shafts located infront of sprockets, Before mounting cover 3 on track frame, clean the ma- attached to the rear transmission housing and tothe final ting surfaces and apply a sealing compound among the rives. folowing types: OMNI - FIT - 150 H or VIT type C; or If required, replace bushings 4 and 5, fig. 10-35, RHODORSIL CAF 1, or LOCTITE PLASTIC GASKET. ‘withdrawing them from the seat on track frame. OO] ¢ “ual | WA Fig. 10-95. FD 7 rear suspension. (Trust pate (2) capscrew -1. Rear suspension shat - 2. Trust late - 3. Suspension shaft cuter suppor cap - 4 and §. Bushings. Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of nerannnel1024 UNDERCARRIAGE ¥D7-FL7 10.9 SPECIFICATION AND DATA Chain Fig. 10-36. Undercarriage components - Prflls, dimensions and wear limits. foweee [AD ® ) > [ee]. LF] 6 [amnion] + Monit ml — [ws | a [ewsar] vere | a | a | caus | 008 reece 160 | neon Z| sho | ar frecrspseace| sae | ose fron] sar fanaa ome a relm>«*|- els i«|=|-|e 6 MBBS Bie iailelcaies (7 Suggeie ature, Lely eoresponding Wo te hcknes of he hetdened ee. Siudy SAFETY RULES In the front of this manual thoroughly Tor the protection of machine and safety of personnel,¥D7-FLT UNDERCARRIAGE 10.25 ‘Specification and data (continued) TRACK CHAINS Type link, with strengthening cross-- ‘member and labyrinth seal ‘Composition of each chain: =No. of shoes (per track) a 38 ‘= No, of right-hand inks (marked D) a7 No, off-hand links (marked S) sr =No. of master links, No. of track rollers (per track). ‘No. of track carter rollers (per track) rend 8 . nz | m0 a Croc ew cance hos (a | sect | see Sate pment oon mz | omer | guped a a a al eee eee oa weaue | Ueeie ees . sons’ | sueao eres eee eer a eee eee aera eel eee a | atsone | Sera Pin-to-bushing clearance 0.120-0.570 0.004-0.022 ucxenise asian ‘Type... eee . ‘single spring pele : aaa a emerar coe a - mmeen | treme a cosa | sovenen eee eed rare] | eaeaae Valve adjustment shim thickness (S,, fig. 10-11) . wee . 01-02-05 1.004-0.008-0, - Shdy SAFETY RULES im the “ont of this manus’ thoroughly for the protection of machine and safety of versonnel10.26 UNDERCARRIAGE ¥D7-FL7 ‘Specification and data (conmnued) Recoil spring longth (8, fig. 10-79: Tc free . 552 2055 ~ under load of 6599-7287 daN (14,821 - 16,381 Ib). 457 1799 — under load of 9171-10739 (20,616 - 24,141 Ib), a2 1622 ‘TRACK IDLERS Bushing carer 0.0. (6, fg. 10-17)... - s0.145-80.180 | 3.470-9.472 Carrier housing diameter in idler. 188,000-88.035 | 3.464-9.465 Intertorence tt. 0.110-0.180 | 0.004-0.007 Idler shaf 9 0.D. at bushings '49.975-50,000 | 1.967-1.968 ‘Bushing LD. 10 (ater press ft in housing) 501300-50.590 | 1.984-1.980 Running clearance oses0ses | 0015-0022 Bushing 10 0.0. s7970-se.c00 | 2282-2288 Bushing carrier § 1D. 5791357959 | 22902282 Bushing interference fit 0.011-0.087 | 0.0004-0.0034 (Guide plateto-track frame wear stips adjusting shim S; thickness, os oe ‘TRACK ROLLERS ‘Bushing carier housing diameter on roller e0.000-se.005 | 3.643.465 Bushing carier 0: (4, fig. 10-21) sasassass0 | 34709472 Interference fit 61100.100 | 0.004-0.007 Shaft 11 diameter at bushings 49.975-50.000 | 1.967-1.968 ‘Bushing 6 1.0. (after instalation) 50,900-80.593 | 1.964-1.980 ~bushing-to-shaft clearance .......... . osesoses | 0.015-0.022 Bushing 6 0.0. s7.970-58.000 | 2282-2280 Bushing catior 4 10. : s7913s7959 | 22002282 Bushing interference ft 0.011-0.087 | 0.00040.0034 ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnelFD7-FL7 UNDERCARRIAGE 10.27 ‘Specification and data (continued) ‘TRACK CARRIER ROLLERS: a = Type sealed for He ication, matched steel "ng seal ong te) No.of ales per tack . 1 Bushing LD. (7,9. 1027 Installed, not reamed 40.095-40.160 | 1876«.581 Saf dametor 2 at bushings | se76-40000 | 15704574 Bushingto-sha clearance 0es-0205 | 0.000.008 using housing clameter on oer +. vice] aps0049900 | 1.964.986 Bushing 70. : soooo-soces | 1.960.900 Busting terrence ft ooe0.0125 | 0.002004 FRONT SUSPENSION (FD7) Prt (9 10:94) camer . v. | 40901-so000 | 1967+.968 Bushings 4 10 o o soszo-soeoo | 1.906:.996 Bushingo-phot cesrnce : (| 04200729 | o0t6-0020 Bushing (4) seat ameter on beam (5) cocoons | 2oez20e Bushing 4) 00. e020060200 | 22702374 Bushing itererence ft o1s+0200 | 00060011 REAR SUSPENSION (FD7) Rear suspension shat (1 to. 1096) ameter... reossso000 | 3409.40 Bushings (4 and 5) 10. : eo2ioe0200 | 9.1579:101 Bushings (4 and 6) seat ameter on Yack rame esc00-sss | a7oa7ae Bushings 4 and 8)00. esc00-0s125 | a74ea74s Bushing nterterence oas.0125 | 0001-0005 Study SAFETY RULES in the front of this manual thoroughly for the protection of machina aad anfaty Af navenanal1028 UNDERCARRIAGE _ w7-FL7 10.10 TIGHTENING TORQUES Torque load Doser iption coed ‘anim () fb C) TRACK CHAINS Nuts, shoe retaining screws. one-18 =o 221 UNF-28 TRACK RELEASE MECHANISM Reatining sraw, spring nut (Cao. 10-7) M10x125 7 516 Capscrew, hydraulic adjustment cylinder support (Gfig. 10) Miex15 2s 104 Seltlocking screws, hydraulic adjustment cylinder cover (C1, fig. 10-7) i M10x125 7 516 Valve, hydraulic acjustment Vr Mrex1s 8 96 Valve, hycrauic adustment cylinder pressure ret Ve Miexi5 7 125 TRACK IDLER Capscrew, idler support to track release mechanism fork (Cay fig, 10-3) M12%1.25 17 26 Seltlocking sorews, guide plate to iler support (x fg. 10-13) M2125 4 108 Ccapserews, idler shaft (Cy fig. 10-19) M10x125, 6s 48 Capserews, bushing carer housing (Cy, fg. 10-17). M 8x125 35 2 Lubrication plug (6, fg. 10-17) Miex1s 8 29 TRACK ROLLERS. Ccapscrews, role supports to track frame (Ca, fg. 10-21). | M 14x15 19 140 Capscrews, bushing carier housing Cy : M 8x25 35 26 Lbrcaton plug 8 Miex15 8 59 “CARRIER ROLLERS Ccapserow, roler cover (Cy, fig. 1027) M ex125 3s 2 Seltlocking sorew, trust ring C2 M 8x125 2 2 Nut roller shat sorew C Mirani 19 140 Capserew, roller support Cx Maxis. 2 147 TRACK FRAMES CCapserews, front and rear suspension beams (Gy and C2, fig, 10-90) (FL 7) Miex15 2 au Ccapserews, oscillating beam bracket (Ca fg. 10-30) (FD 7) || M 18x15 2 236 Capscrews, cross pate (Cr, fig. 10-32) (FD 7) 12x 125 81 Capserews, guide plates (Ca fig. 10-22) =D 7) Mi2K1.25 a1 () Lubreate wit engine ‘Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnelFD7-FL7 UNDERCARRIAGE 1049 10.11 SERVICE TOOLS ‘The service tools referred to inthis manual are listed below. Comply withthe instructions and safety procedures described in the text when using these tools. ‘Requests for further information and orders should be addressed to: FIATALLIS EUROPE S.p.A. ASSISTENZA CENTRALE ‘Sviluppo Strutture Assistenzial Viale Torino, 2 110040 STUPINIGI (Torino) - ITALIA Part No. Description 175295015 Hydraulic ram (fig. 10-1) 75295017 Hand pump for ram 75295015 75295018 ‘Connection pipes for ram 75295015 Equipment for removal of track chain master pin {to be used with ram 75295015/17/18, see fig. 10-1) 75204048 — Frame N 75295630 — Forcing pin G 75298628, — Pilot pin 75297210 — Forcing pin P 75295754 —Thnust plate R 75292481 — Fixed press (ig. 10-2) 75292909 Puller (ig. 10-8) Equipment for disassembly/reassembly of track recoil spring (fig. 10-10) reo00sss | — thera ram 75295867 ney Teese, | — Threaded iting 7sze0sss | — Ataoter G 75293209 — Pilot pin P Equipment for installation of idler support on new track trame (bin instalation) 75292761 — First ting pitt busting yeauare2 — Reamer pot bushing 7s201s69 | — Reamer qeasi873 Teeter for tack release hydraulic cyincer rele valve (A. £9. 10-11) 75291426 Scissor hook for track idler removalnstaiation (ig, 10-14) 75298585 Serew puller (9, 1015) 75296488 oo! for track roller removalnstaliation (A. fig. 10-18) 75291817 iam tor rack roller (A, fig, 10-19) and (A, ig. 10-26) 75291427 Fler suppor puller (, fg. 10-20) 75201525 Guide pins for bushing cartier instalation (S, tg, 10-24) ‘Study SAFETY RULES in the front of this mannal tharanahiy for the