DOWNLOAD PDF Fiatallis FD9 Crawler Dozer Service Information Manual FN 75314593

75314593 IReprinted I

WARNING 00 not operate the machine without first reading this Manual

Most job accidents are due to neglect of simple safety rules or precautions and can be avoided by taking appropriate preventive actions. No device or protective system, however well designed, can prevent accidents more effectively than will caution and alertness on the machine. Look for the safety rules in this Manual.

A WARNING - - ' - - - - - - - - - - - - - - - - , On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, scrapers, etc.) be certain Ihe equipment is lowered to the ground before servicing, adjusting andlor repairing. If it is necessary 10 have the hydraulically, mechanically. and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment.

COPYRIGHT BY FIATALUS - Reproduction of text and illustrations or any part thereof is not perm11ted.

FOg crawler dozer Service information manual

Print No. 753'14593 English

.----------------A WARNING - - - -- - ------------y 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, A 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.

A This symbol is your safety alert sign. It MEANS ATTENTIONI BECOME ALERT! YOUR SAFETY IS IN INVOLVED.

Read and heed all safety instructions carrying the signal words WARNING and DANGER. Machine mounted safety signs have been color coded yellow w ith black border and lettering for

A WARNING and red with white border and lettering for DANGER points.

TABLE OF CONT EN TS

TOPICS

SUBGROUP

ILLUSTRATION NU1'1BERS

SAFET Y RULES ... ....... .. . ....... . INIC LAL ENGINE ASSEM.BLY .. .. .... .• .... . ... A

001- 08 7/\

CONVERTER AS SEt-:BLY ....... . . .. . . .. B

001-020

ASSENBL Y .......•.... C

001-058

CONTROL VALVE ASSEMBL y ........... C

059- 0 65

STEERING CLUTCH ASSENBLY . ..... . .. D

001-030

STEERING CLUTC H AND BRAK E FILT ER S. D

031-034

CO NTRO L VALVE ASSEMBLy ....... . ... D

035-045

BRAKE CYLINDER ASSENBLY ..•....... D

046 - 04 8

BEVEL GEAR AND PINION ASSENBLY ... D

049-084

FINAL DRIVE CO MPO NEN TS ASSn1 BLY .. D

085 - 10 3

FINAL DRIVE ......... . . . . . . . . . . . . . D

104-138

UNDERCARRIAGE .......... . .... •.. . .

001-013

TR A NS t>~ IS SION

E

SAFETY RULES GENERAL Study the Operation and Maintenance Inslruction Manual before starting, operating. maintaining, fueling, or servicing machine.

Read and heed an machine-mounted safety signs before starting, operating. maintaining,fueling Of servicing machine.

Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with whit.eborders and lettering for danger points.

Do not allow unauthorized personnel to operate, service Of maintain this machine.

Do not wear rings. wrist watches, jewelry, loose or hanging apparel, such as ties, tom clothing. scarves, unbuttoned, or unzipped jackets thaI can catch on moving parts. Wear proper safety equipment as authorized for the job. Examples: hard hats. safety shoes, heavy gloves, ear protectors, safety glasses or goggles. reflector vests. or respirators. Consult your employer for specific safety equipment requirements, Keep operator's compartment, stepping points, grab rails and handles clean and free from loreign objects, oi[, 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, 00 not jump on or off machine. Keep two hands and one toot, or two feet and one hand, in contact with steps and grab rairs and handles at all times.

Do not use controls or hoses as handholds when climbing on or off machine, Hoses and controls are movable and do not provide a solid support Controls also may be moved inadvertently causing accidental machine or equipment movement.

Never attempt to operate the machine or its tools from any other position than seated in the operator's seat.

Keep head, body, timbs, hands and feet inside operator's compartment at all times to reduce exposure to hazards outside the operator's compartment.

Be careful of slippery conditions on stepping points, hand rails, and on the ground.

Get off machine only when il is (uHy slopped.

START UP

00 not start Of' operate an unsafe machine.

Before working lhe machine, be sure that any unsafe condition has been satisfactorily remedied. Check brakes and sleering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system.

Be sure all protection guards or panels are in place and all safety devices provided are in place and in good operating conditions.

Before starting machine, check, adjust and lock the 0perator's seat for maximum comfort and control of tile machine. Be sure all people in the area are dear of the unit before releasing the parking brake or moving the machine or its attachments. Walk completely around machine before mounting. Sound hom.

Obey flagman, safety signals and signs.

Due to the presence of flammable fluid, never check or fill fuel tanks, storage batteries, or use starter fluid near lighted smoking materials or open flame or sparks.

Starting fluid Is flammable. Follow the recommendations as outlined in the Operation and Maintenance Instruction Manual and as marked on the containers. Store containers in cool, well·ventilated place secure from unauthorized persormet Do not pUncturE! or bum containers. Follow the recommendations of the manufacturer for storage and disposal.

Never use starter fluid near lighted smoking materials or open flame Of sparks due to the presence of flammable fluid.

OPERATING Do not run the engine of this machine in closed area without proper ventilation to remove deadly exhaust gases.

Ro!! Over Protective Structures are required on wheel loaders, dozer tractors, track type loaders, graders and sorapers by local and national requirements, Do not operate this machine without a Roll Over Protective Structure.

Keep operator's compartment clear of loose obiects. 00 not use machine to carry loose objects by means other than attachments designed for such objects.

00 not carry riders unless the machine is equipped for carrying people to reduce persona! exposure to being thrown off.

Observe and know the mechanics of altemate exit routes.

Seat belts are required to be provided with roU over protective structures or roll protection cabs by local and national requirements. Keep the safety bert fastened around you during operation.

For your personal protection, do oot attempt to climb on or off machine while machine is in motion.

Be sure exposed personnel in the area of opemtiorl are cleat of the unit before moving the machine or its attachments. Sound horn. Obey flagman. safety signals and signs.

Never coast the machine down grades and slopes with the transmission in neutral on power shift machines, or clutch disengaged on manually shifted machines.

To reduce ihe danger 01 an uncontroUed machine choose a gear speed before proceeding down grade that will hold machine to proper speed for conditions.

SAFETY RULES

See the Operation and Maintenance Instruction Manual, When counterweights have been provided. do not work machine if they have been removed unless the equivaJent weight has been replaced,. See the Operation and Maintenance Instruction Manual.

During operation always carry ripper in full raised position when nol in use and lower to ground when parked, When operating machine know what clearances will be encountered, overhead doors, wires, pipes, aisles, road· ways; also weight limitations of ground, floors, anc ramps, When roading findouf what conditions are likely 10 be met - clearances, congestion, type of surface, etc. Be aware of fog, smoke or dust elements that obscure visibility.

Cross gullies or ditches at an angle with reduced speed after insuring ground conditions will perm!! a safe traverse.

Always check work area for dangerous features. The fol· lowing are examples of dangerous work areas: slopes, overhangs, timber, demolitions, fire, high walls, dropoffs. backfills, rough terrain, ditches, excavations, heavy traffic, crowded parking, crowded maintenance and closed areas, Use extreme care when in areas such as these, Avoid going over obstacles such as rough terrain, rocks, logs, curbs, ditches. ridges. and railroad tracks whenever possible. When obstructions must be crossed, do so with extreme case at an angle if possible. Reduce speed downshift Ease up to the breakover point - pass the balance point slowly on the obstruction and ease down on the other side. In steep downhill operation. do not allow engine to overspeed. Select proper gear before starting downgrade.

Avoid sidehill travel whenever poSSIble, Drive up and down the slope. Should the machine start Slipping sideways on a grade. turn it immediately downhill.

The grade of slope you should attempt will be limited by such factors as condition of the ground, load being handled. the type of machine. speed of machine and visibility.

There is no substitute for good judgement when working on slopes.

Know the prinCiples 01 cross steering 01 crawler lo aders, Read section in Operation and Maintenance Instruction Manual on cross steering, Avoid operating equipment 100 close to an overhang or highwa!1 either above or below the machine. Be on the lookout for caving edges, falling objects and slides, Beware 01 concealment by brush and undergrowth of Ihese dangers, When pushing over trees. the machine must be equipped with a proper overhead guarding, Never aHow a machine 10 climb up on the root structure particularly while the tree is being felled. Use extreme cafe when pushing over any tree with dead branches, Avoid brushp!les, logs or rocks, Do not drive the machine on10 brush piles, logs, large rocks or other surface irregularities that break traction wtth the ground especially when on slopes or near dro·

Operate at speeds slow enough to insure complete control at all times, Travel slowly over rough ground, on slopes or near dropoffs. in congested areas or on ice or slippery surfaces, When backing, always look to where the machine is to be moved. Be alert to Ihe position of exposed personnel. Do not operate.if exposed personnel enter the immediate work area.

Mainlaina safe distance from other machines. Provide sufficient clearance for ground and visibility conditions, Yietd right-of-way to loaded machines.

Maintain clear vision of all areas of travel or work. Keep cab windows dean and repaired. Carry blade low for maximum viSibility while traveling, Obtain and use fan blast deHectors where tractors are used as pusher tractors in tandem.

When pulling or towing through a cable or chain, do not start suddenly at fun throttle. Take up slack carefully.

Guard against kinking chains or cables. Inspect carefully for flaws before using. Do not pull through a kinked chain or cable due to the high stresses and possibility 01 failure of the kinked area. Always wear heavy gloves when handling chain or cable.

Be sure cables are anchored and the anchor point is strong enough to handle Ihe expected load, Keep exposed personnel ciear of anchor point and cable or chain.

00 not pull or tow unless operators compartments of machines Involved are guarded against potential cable or chain backlash.

Be alert to soft ground conditions close to newly constructed walls. The Ill! material and weight of machine may cause the wall to collapse under the machine.

In darkness. check area of operation carefully before moving in with machine. Use ali lights provided, Do not move into areas of restricted viSibility.

If engine has a tendency to stalilor any reason under load or idie, report this for adjustment to a proper maintenance authority immediately. Do not continue to operate machine until condition has been corrected.

On machines equipped with suction radiator fans, be sure to periodically check alt engine exhaust parts for leaks as exhaust gases are dangerous to the operator. Keep a vent open to outside air at times when operating within a closed cab.

An operator must know the machine's capabilities, When working on sropes or near dropoffs be alert and avoid loose or soft. conditions that could cause sudden tipping or loss of control.

Where noise exposure exceeds 90 dBA for 8 hours, wear authorized ear protective equipement per local and other national requirements that apply.

Do not operate miilchinery in a condition of extreme fatigue or illness. Be especially careful towards the end of the shift.

Do not operate a machine with brakes out of adjustment

II

SAFETY RULES

pofts, Be alert to avoid changes in traclfon conditions thai could cause loss of control. Do not d.rive on ice or frozen ground conditions when working the machine on steep slopes or near dropoffs.

Operating in virgin rough terrain that includes previously mentioned hazards is caned pioneering, Be sure you know how this Is dona. Danger from falling branches and upturning roots is acute in these areas.

MAINTENANCE GENERAL Study the Operation and Maintenanc& Instruction Manual before starting. operating, maintaining, fueling or servicing machine.

Read and heed aU machine mounted safety signs before starting operating., maintaining., fueling or servicing machine.

Do not allow unauthorized person to service or maintain this machine, Do not perform any work on equipment that is not authorized, Follow the Maintenance and Service procedures.

00 not wear rings, wrist watches. jewelry or loose or hanging apparel, such as ties, tom clothing, scarves, unbuttoned or unzipped jackets Ihat can catch on moving parts, Do wear proper safety equipment as authorized for Ihe job. Examples: hard hats, safety shoes, safety glasses or goggles, heavy gloves, reflector vests, ear protectors or respirators. Consult your employer for specific safety equipment requirements.

Do not use controls or hoses as handholds when climbing on or off machine, Hoses and controls are movable and do not provide a soHd support. Controls may also be inadvertenlly moved causing accidental machine or equipment movement Do not jump on or off machine. K.eep two hands and one foot, or two feet and one hand, in contact with steps and grab-rai!s and 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.

K.eep 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 Of grease from shoes before attempting to mount or operate the machine, Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

Keep operator's compartment clear of loose objects.

If movement of an attachment by means of the machine's hydraulic system is required for service or maintenance, do not raise or lower attachments from any position other than when seated in the operator's seat Belere starting machine or moving attachment or too!, make sura to set brakes, sound horn and cal! for an all clear. Raise attachment slowly.

Always block with external support any linkage or part dn machine that requires work under the raised linkage, parts or machine per local and national requirements.

Never aHow anyone to walk under or be near unblocked raised equipment. Avoid working or walking under raised blocked equipment unless you are assured of your safety.

Never place head. body. limbs, fingers. feet or hands Into

SHUTDOWN When stopping operation of the machine for any reason, always retum the transmission or hydrostatic drive control control to neutral and engage the control lock to secure the machine for a safe startup, Set parking brake if so equipped.

Never leave the machine unattended with the engine running, Always before leaving the operator's seat and after making certain all people are clear of the machine, slowly lower attachments or tools flat to the ground in a positive ground support position, Move any multipurpose tool or attachmenl to positive closed position, Return the controls to hold. Place transmission control in neutral and move engine controls to off position, Engage all control locks. sel parking brake, and open and lock the master key switch, Consult Operation and Maintenance Instruction Manual.

Park in a non-operating and non·traffic area or as in· structed, Park on firm level ground if possible. Where not poSSible, position machine at a right angle to the slope. making sure there is no danger of uncontrolled sliding movement. Set the parking brake.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers. flares and waming signals as required. A!so provide advance waming Signals in the traffic lane for approaching traffic.

Keep head, body. limbs, feet. hands and fingers away from blade, boom, bucket, Of ripper when in raised position, Always turn the master switch (key switch jf so equipped) to the off position before cleaning, repairing., or serviCing and when parking machine to forestall unintended unauthorized starting, Never lower attachments or tools from any poSition other than seated in operator's seat Sound the hom. Make sure the area near the attachment is clear. lower the attachment slowly. 00 not use noat poSition to lower hydrauBc equipment.

Always lock up the machine when leaving it unattended.

Return keys to authorized security. Heed all shutdown procedures of ihe Operation and Maintenance Instruction Manual. Always set the parking brake when leaving the machine for any reason.

III

SAFETY RULES

the exposed portion between uncontrolled or unguarded scissor points 0# machine without first providing secure blocking.

Never lubricate, service or adjust a machine with the engine running. except as called for in the Operation and Maintenance Instruction Manual. 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 a ladder or step platform that meets local and national requirements to reach the service point. If such ladders or platiorms are not available, use the machine handho!ds and steps as provided, Perlorm all service or maintenance carefuHy. Shop Of fiejd service platforms and ladders used to main· tain or service machinery should be constructed and maintained according to local or national requirements.

Disconnect batteries and Tag att conlrols, according to local and national requ irements, to warn that work is in progress.

Block the machine and aU attachments that must be raised per local and national reqUirements .

Never check or fill luel tanks, storage batteries or use starter fluid near lighted smoking materials or open flames due 10 the presence of flammable fluid.

Brakes are inoperative when manually released for servicing. Provision must be made to maintain conlrol of the machine by blocking or other means.

Always place the fuel nozzle against the side of the fille r opening before starting and during fuel flow. To reduce the chance of a sIalic electricity spark, keep contact until after fuel flow is shut oft Use only designated towing or pumng 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 a traHer or low boy truck if availab!e. If towing is necessary, provide warning signals as required by ioca! rules and regulations and foUow Operation and Maintenance Instruction Manual recommendations. Load and unload on a level area that gives full s.upport 10 the trailer wheels, Use ramps of adequate strength. low angle and proper height Keep trailer bed dean of clay, oil and aU materials that become slippery. Tie machine down securely to truck or trailer bed and block tracks or wheels as required by the carrier.

Never align holes with fingers or hands - Use the proper aligning 1001: 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 alt heavy parts with a lifting device of proper 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 a open pan. Never use gasoline or solvent or other flammable fluid to clean parts. Use authorized commercial, non-flammable, non· toxic solvents.

When using compressed air tor cleaning parts use safely glasses with side shields or goggles. Limn Ihe pressure to 30 psi according to local or national requirements, Do not run lhe engine of this machine in closed areas without proper ventilation to remove deadly gases.

Do not smoke or permil any open flame cr spark near when refueling, or handling highly flammable materials.

Do not use an open !tame as a light source to look for leaks or lor inspection anywhere on the machine, Be sure aU mechanics tools are in good condition. Do not use tools with mushroomed heads, Always wear safety glasses wilh side shieldS. Move carefully when under, in or near machine or implements. Wear required protective equipment, such as hard hat. safety glasses, safety shoes, ear protectors.

When making equipment checks that require running of the engine, have an operator in the operalor's ~eat a\ all times with the mechaniC in sight Place the transmission in neutral and set the brakes and lock. Keep head, body, limbs, feet. hands and fingers away from blade or ripper when in raised position, Shut off engine and disengage the Power Take,Off tever , if so equipped. before a:tempting adjustments or service, Do not perform any worK on equipment lhat is not authorized. Follow the Maintenance or Service Manua! Procedures.

For field service. move machine to level ground if possi· ble and block machine. If work is absolutely necessary on an incline, block' machine and its attachments 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 heavy gloves when handling chain or cable.

Be sure cables are anchored and the anchor point is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cable or chain.

Do not pull or low unless operator's compartment of machines Involved are properly guarded against accidental cable or chain backlash.

Keep maintenance area clean and dry. Remove water or oil slickS immediately, 00 not pile ony greasy rags - they are a fire hazard.

Store in a closed metal container.

Before starting machine Of moving attachment check and adjust and lock operator's seat Be sure all personnel in the area are clear before starting or moving machine or its attachments. Sound hom.

Rust inhibitors are volatile and flammab!e. Prepare parts in weI! ventilated p!ace. Keep open flame away - do not smoke Store container in a coo! well-ventilated place seIV

SAFETY RULES

cured against unauthorized personnel.

Do not carry toose objects in pockets that might fall unnoticed into open compartments.

Keep clu tches and brakes on machine and attachments such as Power Control Units, winches and masler clutches adjusted according to Operation and Maintenance Instruction Manual of the manufacturer at aH times, Do not adjust machine with engine running except as specified, Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or olher particles are apt to fly or fall.

Wear welder's 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 arc without proper eye protection.

Know your jacking equipment and its capacity, Be sure the Jacking point used on Ihe machine is appropriate for the load to be applied, Be sure the support of the jack at the machine and under the jack is appropriate and stable.

Any equipment up on a lack is dangerous. Transfer load to appropriate blocking as a safety measure before proceeding with service or maintenance work, according to !ocaJ or national reqUirements, Wire rope develops steel silvers. Use authorized protective equipment such as heavy gloves, safety glasses when handling.

Never use makeshift jacks when adjusting track tension.

Follow the Undercarriage Service Manual.

Handle ali parts with extreme care, Keep hands and fingers from between parts. Wear authorized protective equipment such as safety glasses, heavy gloves, safety shoes,

See Ihe Operation and Maintenance Instruction Manual Keep engine exhaust system and exhaust manifolds dear of combustible material. Equip machine with screens and guards when working under conditions of flying combustible material.

Do no! run engine when refueling and use care if engine is hot due to the Increased possibility 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 molion.

Never lubricate a machine with the engine running. Avoid running engine with open unprotected air inlets, If such running is unavoidable for service reasons, place protective screens over all inlet openings before servicing engine,

ELECTRICAL Be sure to connect the booster cables to the proper terminals ( + to +) and (- to -) at both ends. Avoid shorting clamps. FoHow the Operation and Maintenance Instruction Manua! procedure .

Always turn the master switch (key switch if so equipped) to the off position when maintaining or servicing machine.

Battery gas Is highly flammable. Leave battery box open to improve ventilation when charging batteries. Never check battery charge by placing meta! objects across the posts. Keep sparks or open flame away from batteries. Do not smoke near battery to guard against the possibility of an accidental explosion. Check for fuel or battery electrolyte leaks before starting service Of maintenance work. Eliminate leaks before proceeding, Do not charge batteries in a 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 or repair work of any kind.

START UP Do not run the engine 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 bellS. Be especiaHy alert around a pusher fan.

Starting fluid Is ffammable. Foflow the recommendations as outlined in the Operation and Maintenance Instruction Manual and as marked on the containers. Store containers in cool, well-ventilated place secure from unauthorized personnel. Do not puncture or burn containers. roflew the recommendations of the manufacturer for storage and disposal.

HYDRAULIC F!uid escaping under pressure from a verysma!i hole can almost be invisible and can have sufficient force to penetrale the skin. Use a piece of cardboard or wood to search for suspected leaks. Do not use hands. If injured by escaping fiuid, see a doctor at once. Serious infection or reaction can develop i! proper medical treatment is not administered immediately.

Shut off engine and be sure aU pressure in system has been relieved before removing panels, housing covers,

ENGINE Turn radiator cap sfowiy to relieve pressure before removing. Add coolant only with engine stopped or idling if hot

v

SAFETY RULES

and caps. See the Operation and Maintenance Instruction Manual.

When making pressure checks use the correct gage for expected pressure. See the Operation and Maintenance Instruction Manual or Service Manual for guidance.

ATTACHMENTS Keep head, body, limbs. feet, hands and lingers away from blade, bucket or ripper when in raised position. Use authorized blocking as a safety measure before proceeding with service or maintenance per local and national requirements.

If movement of an attachment by means of the machine's

hydraulic system is required for service or maintenance 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 hom and call for an all clear. Raise attachments slowly.

Do not use machine 10 carry loose objects by means other than attachments for carrying such objects. Never use any gas other than dry nitrogen to charge accumula· tors. See Operation and Maintenance Instruction Manual, Keep clutches and brakes on machine and attachments such as power control unrts, winches and master clutches adjusted according to Operation and Maintenance In· struction Manuals of the manufacturer at all times. Do no! adjust machine with engine running except as specified.

FOREWORD This Manual was designed to serve as guidance for correct and sale operation of the machine and its systematic servicing, The continued observance of the instructions provided will ensure best possible performance, operation economy and long life of the machine and will avoid the more common causes of accidents which may occur during

work or maintenance operations, As regards safety in particular read carefully the general rules given on pages! thru V I. The repair procedures for this machine are described in separate service publications available on request frOI'll the F!ATAlUS Organization,

Each machine is supplied with a copy of this manual. The descriptions and illustrations appearing in this manual are not binding, FIATAlUS reserves the right - while retaining Ihe basic features of the model herein described and illustrated - to make at any time, and without necessarily bringing this manual up-to-date, any alteration to units, parts. accessories or their supply, deemed expedient for improvement or for any manufacturing or commercia! reason. For any clarifications ' Head Offices who will pro\lide any information you may need, refer 10 your Dea!er or flATAlUS

MODEL FD9 AOOl

ENGINE REBUILD

ENGINE CHARATERISTICS

TYPE ••.• •• ••• DIRECT INJECTION DIE3EL,4 CYCLE TURBOCtLi\RGED N. CyLINDERS........ (:; BORE . . • • . • • • . • • • •• 104 MM. STROKE •..••.•.••••• 115 MM. D1 SPLACE l'fENT • • • • • • •• 5861 COMPRESSi.ON RATIO... 15,7 : 1 VALVES •••• • •• • •.•.• O.lL I·HTH CAJ¥iSHAFT IN THE ENGINE BLOCK .

A002

RIGHT SIDE VIEW

ON THE RIGHT IIlI,ND SIDE OF TIlE ENGINE YOU SEE THE t<lATERPUMP , THE TURBO CHARGER, TIiE OIL COOLER, THE OIL FILTERS) BETWEEN THE TWO FILTERS) TIm CRANA CASE 'VENTILATION AND THE ENGINE OU COOLER.

A003

LEFT SIDE VIEW

ON THE OTHER SIDE OF THE ENGINE WE SEE THE STARTER MOTOR, TIlE FUEL FUTERS AND THE INJECTION PIJMP. TO THE L01<lER RIGHT .

THE OU FILLER PIPE A,~D THE DIP STICK.

A004

FRONT VIEI4 OF THE ENGINE

THE TENSION OF nm TWO BELTS DRIVING THE FAN ARE MAINTAINED BY A,~ IDLER WITH THRE AD ADJUSTMENT THE TENSION OF TIlE SINGLE BELT FOR THE WATER PUMP AND ALTE&~ATOR IS lillJUSTED BY HOVING ALTERNATOR.

StudY SAFETY RllLES in the front ·of this manu a! thoroughly fo r

MODEL FD9 A004A

ENGINE REBUILD

CONT'D

THE ENGINE FAN IS OF THE PUSHER TYPE. IN CHECKING THE CRANKSHAFT DAMPER MAKE SURE THAT THE LINE lJP MARK GIVEN BY THE FACTORY DOES NOT DE VIATE MORE THAN lOMM AS THIS MIGHT INDICATE THAT THE DAMPER IS NON SERVICEABLE AND NEEDS TO BE REPLACED.

A005

REt-iOVAL OF EXTERNAL COMPONENTS

AFTER PLACING THE ENGINE ON A REPAIR STAND THE COMPONENTS HAY BE IlENOv'ED, START WITH IHE TORSO CHARGER.

A006

REt-lOVAL OF EXTERNAL COHPONENTS

REMOVAL OF THE ALTERNATOR AND TUBING CONNECTING lA'ATERPUMP WITH THE RADIADOR.

A WARNiNG"~"'~~;~"'=~;":::~~~"

ALL HEAVY PARTS WITH A LIFT iNG DE V IC E OF PROPER CAPAC ITY. BE SLiRE !"ARTS I\RE SUPPORTED BY PROPER !iL INCS AND HOOKS. USE U FT INC; EYES IF PRO-

VIDED . WATCH OUT FOR 'EOPLE

A007

IN THE VICINITY.

RENOVAl OF EX"TERNAL COMPONENTS

REMOVE THE INTAKEfYlANIFOLD, THE IN JECTOR TUBES MD THE INJECTOR PUMP TOGETHER

\1'I TH THE INJE CTORS.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

HODEL FD9 A008

ENGINE REBUILD

ENGINE DISASSENBLY

REHOVAL OF THE T'HERHOS'TAT HOUSING TOGETHER tHTH THE TUBING tEAJJING THE WATER TO THE TRAl~SHISSION OIL COOtER. BE TO THE SEALRING ATTACHED TO THE WATERPUMP BY-PASS

A009

ENGINE DISASSEt-'fJ3LY

REMOVING THE WATERPU1'1P.

AOOIO

ENGINE DISASSEMPLY

REMOVING THE WATERPUMP SUPPORT.

AOOll

ENGINE DISASSEHBLY

REHOVE THE ENGINE OIL FE TERS, THE CRANKCASE BREATHER THE EXHAUST HANIFOLD ,'\ND THE VALVE COV1~R. YOU HAY NOTICE THE CYLINDER HEAD IS OF ON E PIECE CONSTRUCTION.

Study SAFETY RULES in the front of this manual thoroughly for the protecticn of machine and safety of pers~!lneL

MODEL FD9 A0012

ENGINE REBUILD

REMOVAL OF THE CYLINDER HEAD

BEFORE REMOVING THE CYLINDER NUTS> THE ROCKER SHAFT HAS TO BE REMOVED.

AOOl3

CYLINDER HEAD GASKET

THE CYUNDER HEAD GASKET CONSISTS OF A STEEL BASE PLATE WITH GASKET MATERIAL BOTH SIDES (LIKE VICTACORE DESIGN) THE WATER AND OIL PASSAGES ARE REINFORCED WITH PLASTIC CO}WOL~DS.THE GASKET IS MARKED "ALTO" AND HAS TWO HOLES TO LOCATE ON THE CYLINDER HEAD DOWEL P I NS.

A0014

DAMPER REMOVAL

LOOSEN THE NUT HOLDING THE DMWER ONTO THE CRANKSHAFT.

A0015

DMWER REMOVAL

WITH THE USE OF A PULLER THE DMWER IS TO BE EXTRACTED FROM THE TAPERED SK4FTEND.

Study SAFETY RULES ill the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9

ENGINE REBUILD

A0016 HUB REMOVAL PULLING THE HUB OFF THE

~HAFT.

WARNING:"~;"~~"'~~;=;~";;" SiR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER THAN A SOI'T IRON OR NON-FERROUS HAMMER.WHEN INSTALLING OR REMOVING SUCH PARTS WEAR SAFETY GLASSES WITH SIDE SHfELDS AND HEAVY GLOVES, ETC., 10 REDUCE THE POS5!SILITY OF INJURY.

Ii.

AOOl7

FLYWHEEL REMOVAL

~~

GO TO THE OTHER SIDE OF THE ENGINE BLOCK Al'W REMOVE THE FLYifHEEL. BEFORE REMOVING THE FLYWHEEL HOUSING. MOUNT THE SLEEVE SHOWN IN THE SLIDE TO AVOID DA}~GE TO THE SEAL. THIS RING HAS TIlE PURPOSE TO RETAIN THE SEAL CONCENTRIC IN THE FLYWHEEL HOUSING Al1llD WITH AN Ex"TERNAL SPIR.A.L CUT CONTRARY TO THE ENGINE TURNING DIRECTION HELPS THE SEALING THROUGH A Pill-PING ACTION.

AOOlB

OIL PAN REMOVAL

ROTATE THE ENGINE IN THE STAND TO REMOVE THE OIL PAl~> PAY SPECIAL ATTENTION TO THE RUBBER SEAL RING BETWEEN THE SU1vlP AND THE DISTRIBUTOR COVER .

AOOl9

OIL Pu}lP REMOVAL

REHOVE THE SINGLE LUBRICATING OIL PUMP FROM THE BLOCK COMPLETE WITH THE TUBING.

Study SAFETY RULES in thl!! trent of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 A0020

ENGINE REBUILD

ENGINE DISASSEMBLY

TAKE THE DISTRIBUTOR GEAR COVER OFF.

A WARNING :"":~::~;=;~:;";;;;TY GLASSES WITH SfCE

SHIELOS WHEN

REMO VING, OVERHAULING,

CLEANING OR TESTING MACHINE FARTS.

Aoon

ENGINE PISTON REMOVAL

ROTATE THE ENGINE 909 AND REMOVE THE CONNECTING ROD CAPSCREVIS, THEN PUSH. THE CONNECTING RODS AND THE PISTONS OUT THROUGH THE TOP.

A0022

ENGI NE C&\NKSHAFT REMOVAL

LOOSEN THE SEVEN t-1AIN BEARING CAPS AND LIFT THE CRANKSHAFT OUT l>1AKING USE OF A CANVAS STRAP AS TO BE SURE NOT TO JvfARK THE· CRANKSHAFT.

A0023

ENGINE CAMSHAFT REMOVAL

TURN THE ENGINE BLOCK UP SIDE DOI-.'N BEFORE PULLING THE CAMSHAFT TO LET THE CAMSHAFT FOLLOWERS FALL DOWN AND OUT OF THE WAY FROM THE CAMS. IN THIS SLIDE YOU CAN SEE THE CAH FOLLOWERS AND THE BORES IN WHICH THEY ARE SITUATED .

Study SAFETY RULES in the front of this manual thoroughly for the protection of mach ine and safety of perSOnnel.

NODEL FD 9

A002 4

ENGINE RE BUILD

ENGINE CAMSHAFT RENOVAL

PULL THE CANS RAFT FROM THE BLOCK MAKING SURE NOT TO DA;\1i\ GE THE BEARINGS I N THE THESE BEARINGS ARE MADE FROM STEEL BACKED WHITE t-iETAL .

A0025

ENGINE CYLINDER SLEEVES

THE CYLINDERS ARE LI NE BORED INTO THE ENG INE BLOCK AND A DRY SLEE V1~ IS PRE SS ED INTO THE BLOCK liTHeR MAY BE BORED TO OVERS IZE UP TO 0 , 8MN P I STON OVE RSI-

AG0 26

ENGINE CYUNDER SLEEVE REl:IOVAL

THE REMOVAL OF THE WORJ)1 ST,EEVES FROM THE BLOCK BORE M.A.Y BE DONE WITH THE APPROPRI ATE DI SCS AND PULLER SET UP AS SHOV,lN IN THIS SLIDE .

AO() 2

ENGINE CYLINDER

THE DRY SLEEVES ARE SENI FINISHED ON THE INSIDE DI AMETER AND NEED TO BE BORED AND HONED AFTER THEY HAVE BEEN PRESSED IN THEIR BORE ; THE OUTER DIAME TE R I S AVAILAB LE IN 0 >ZOl·tH OVERSIZE JUST IN CASE THE ORIGI NAL BLOCK BO RE IS DANAGED .

Study SAF ETY RULES in the front of this manual thoroughly for t he protection

machine and safety

MODEL 1"])9

A0028

ENGINE REBUILD

VIEW OF CYLINDER SUmVE

IN THIS SLIDE THE INSIDE OF A NEw SLEEVE IS VISIBLE AND j.JE NOTICE THE ROUGH APPEARANCE.

AO029

ENGINE CYLINDER SLEEVE I NSTALLATION

BEFORE INSTALLING THE SLEEVE OIL THE OUTER CI.RC C:1FE RENCE t.JTTH ENGINE OIL AND MA1(E SURE THE MOUNTING FORCE FOR THE FIRST lOOtt,J>} IS NOT' Bl1.:LOW 1500KG. TH IS FORCE SHOtJLD BE BETw'EEN 3600 -6 500KG. FOR THE RE ST THE WAY DOI·lN. mIEN THESE FIGURS CANNOT BE ATTAINED> RENOVE THE SLEEVE AND REBORE THE BLOCK TO THE NEXT OVERSIZE.

A0030

ENGI NE PISTONS

CAST TN A SPECIAl THE PISTONS ALLlJfHNIUH AlLOY AND 01A.CHINED WITH GREAT , IN THE CENTER OF THE PISTON HEf\D THERE IS A MEXI CAN HAT TYPE C01'mUSTION CHAl'fBE R. THE CONNECTING RODS ARE DROP FORGED ,'iND THEY HAVE A RIFLE DRIlL TO CONi/EY 011, TO THE TOP BEARING.

A0031

ENGINE PISTONS

THE PISTONS ARE SELECTED BY \\'EI GHT AND DIf4.ENSION. THEY ARE AVAILABLE IN OVERSIZES OF 0,1-0, 2-0,4-0,6 AND O,8MM. THEIR \·tEIGHT SHOULD BE HELD VJITHIN 10 GRlu1MS AND10..ATERIAL HAY BE REMOVED FROM THE BOTTO~l OF THE SKIRT.

StudY SAFETY RULES in tne front of this manual thoroughly tor the protection of machine and saft'ty of personnel.

HODEL FD9 A0032

ENGINE REBUILD

CONNECTING ROD BEARINGS

IN CASE THE CONNECTING ROD BIG END BEARING HALVES ARE TO BE CHANGED .MAKE SURE THEIR ENDS LINE UP WI TH THE PLAIN OF THE CAP HOUNT ING AREA.

A0033

CONNt~CnN G

ROD INSPECTION

THE ALIGNNENT OF THE CONNECTING ROD HAY BE CHECKED \\fITH THE INSTRUNENT HERE ILLUSTRATED. THE PISTON PIN BORE HAS BEEN FITTED WITH AN EXPANDABLE PIN AND THE BIG END 1:1.1\5 BEEN FITTED ONTO THE STANDARD PIN. tHTH THE USE OF A "V" BLOCK SQUARE AGAINST THE VERTICAL PLANE EVENTUAL DEFOR~I\TION COULD BE DETECTED WITH A FEELER GAUGE. THE GAP .MAY NOT BE MORE THAN O,O.5HM.

A0034

CONNECTING ROD REPLACENENT

IN CASE OF CONNECTING ROD REPLACEMENT, f.fAKE SURE THE WEIGHT OF THE NEW CONNECTI NG ROD IS WITHIN 40 GRAf.IMS. THE NEW CONNECTING ROD NUST BE NUFfBERED ON THE ROD AND THE CAP AS TO THE CYLINDER IT WILL BE FI TTED. THE CAPSCREWS ON ALL RODS ARE TO BE RENEI.JED EVERY TIJ>1E AN ENGINE IS nOV-TN FOR A GENERAL OVT::RHAUL.

A0035

PISTON RING ASSEMBLY

THE PISTON RINGS ARE TO BE PLACED ON THE PISTON WITH THE IR GAPS 1809 APil.RT AND NO GAP SHOUW BE IN LI NE WITH THE PIN HOLE . THE PISTONS COf.l:E IN THE FOLT~m.JING o\rERSIZES : 0, 1-0,2-0 ,4-0,6

- 0 , 8~1M,

Study SAFETY RULES in the front of this manu,,! tho roug.hly for the protection of machine and safety of personnel.

}IDDEL FD9 A0036

ENGINE REBUILD

CR.A.l>JKSHAFT INSPECTION

MAKE SURE THE SEATS ARE TIGHT IN THE HEAD AND IF THEY NEED TO BE REPLACED, LOCK THEM I-HTH THE PUNCH.

A0037

C~~NKSHAFT

INSPECTION

THE CRANKSHAFT HAS TO BE E~4MENED ACCURATELY BY uLTRA SONIC OR MAGNA FLUX TESTING. !>1EASURE THE MAIN AND CONNECTING ROD JOURNALS AND REMOVE EVENTUAL SNALL INPERFECTIONS WITH EMERY CLOTH. ~~EN THE DIMENSION ARE BELOW THE MINIMUM INDICATED, THE SHAFT HAS TO BE GROlJND TO THE FIRST AVAILABLE UNDERSIZE.

A0038

CR.A.~KSHAFT

INSPECTION

THE OVALIZATION OF THE JOURNALS SHOULD NOT SURPASS O.OSMM.

Ii,. WARNING~"":~:=;;=;~;;=;=;=TY GLASSES WITH S IO£ SHIELDS WHEN REMOVING, OVERHAULING. C\..EANING OR TESTING MAO-lINE PARTS.

A0039

CRANKSHAFT INSPECTION

WITH A DIAL INDICATOR AND "Vi! BLOCKS THE CRANKSHAFT IS TO BE CHECKED FOR STRAIGHTNESS ,NO MORE THEN ,OS!>lH IS ALLOWED ON THE CENTER M1\IN JOURNALS.

°

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 A0040

ENGINE REBUILD

REMOVAL OF CAMSHAFT BEARINGS

UNSCREW THE BEARING FASTENING SCREWS AND WITH THE PULLER SHOWN ~ EXTRACT THE BUSHING FROM THE BORE.

A0041

CMfSHAFT BEARINGS

THE NEW BUSHINGS NEED TO BE REMlED AFTER THEY HAVE BEEN PRESSED IN THEIR BORES.

A WARNlNG:"'~;"~;"~~;;;~";~'" STR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER THAN A SOFT

IRON OR NON -fERROUS HAMMER.WHEN

INSTALL-

ING OR REMOVING SUCH "ARTS WEAR SAFETY GLASSES WITH SlOE SHiElDS AND HEAVY GLOVES, EiC" TO REDUCE THEPOSSISlllTY Of IN1URY.

A0042

CAMSHA.FT INSPECTION

CHECK THE CAHSHAFT FOR IMPERFECTIONS AND STR.UGRTl\TESS; MAKE SURE THE CAM SURFACES ARE NOT SCORED.

A0043

CMlSHAFT INSPECTION

CHECK THE SHAFT IN "V" BLOCKS TO SEE THAT IT IS NOT BENT MAXIMUM DEVIATION IS 0, Uft1.•

in the front of this manual thoroughly for ~he protection of machine and safety

MODEL FD9 A0044

ENGINE REBUILD

CRANKSHAFT ASSEMBLY

MAKE SURE THAT THE CRAt"lKSliAFT RUNS FREE AFTER ASSE,'ffiLY.

A0045

CRANKSHAFT ASSEMBLY

PLACE A DIAL INDICATOR ON THE FRONT OF THE SHAFT TO CHECK THE AXIAL PLAY \,'H ICH SHOLtD BE 0, REPLACE THE HALF MOON THRUST PLATES ,\-iHEN TE GAP IS TOO WIDE.

A0046

EN GINE PISTON i\SSEl'mI,Y

FOR PISTON ASSEMBLY MAKE USE OF A RING CONPRESSOR AS SHOWN.

A0047

ENGINE PISTON ASSEr-mLY

MAKE SURE THAT AFTER THE PISTONS ARE MOUNTED, THE HEIGHT ABOVE THE BLOCK WHEN IN T.D.C. IS WITHIN ,460 -O, 79 01'I,'L

Study SAFETY RULES in the front of this manual thoroughly for the protectlc.n of machine and safety of personnel.

HODEL FD9 A0048

ENGINE REBUILD

FLYwtIEEL HOUSING

THE SEALING BETi",TEEN FLYWHEEL HOUSING AND THE BLOCK IS l'IADE BY k~ "O"RING .

A0049

REAR CRANKSHAFT SEAL

THE SEALING OF THE CRk~KSHAFT AT THE FLYHHEEL END IS l'IADE BY AN OIL SEAL RING AND A STEEL RING \\,ITH PLASTIC COATING ON THE INSIDE WITH A HELICS CURv~ IN COUNTER ROTATION TO THE CRANKSHAFT ROTATION .

MAKE SURE NOT TO DAl'~GE THE SEAL RING IN THE FLYWHEEL HOUSING WHEN PLACING THE RING IN PLACE .

A0050

FLYI.JHEEL HOUSING CAPSCREWS

THE CAPSCREWS HAVE TO BE TORQt~D TO THE CORRECT VALUE AS GIVE IN THE l'IANUAL .

A0051

VALVE REMOVAL

fO REHOVE AND INSPECT THE VALVES, RENOVE THEM BY COMPRE SSING THE SPRINGS WITH THE TOOL ILLUSTRATED AND REMOVE THE HALF MOON KEYS .

Study SAFETY RULES in the front of this manual thoroughly fo r the protection of machi ne and safetY of ~rsonne l.

MODEL FD9 A0052

ENGINE REBUILD

VALVE INSPECTI ON

I NSPECT THE VALVES FOR SCORE MARKS ON THE STEM k~D BURNS OR CRACKS OF THE SEALING SURFACES, REGRIND THE VAL'liES AND SEATS IF POSSIBLE. GRIND THE VAL'ilES LI GHTLY I N THE SEATS TO THE GIVEN SEAT WIDTlLCHECK THE VALVE SPRINGS FOR IMPERFECTIONS AND TEST THEM ON THEIR CONPRESSED FORCE.

A0053

VALVE GUIDES

THE VALVE GUIDES ARE PRESSED INTO THE CYLINDER HEAD AND NEED A SPECIAL PUNCH FOR REMOVAL. CHECK THE GUIDES FOR SCORING MARKS AND INTERNAL BORE SIZE.

A0054

VALVE

ASSEMBLY

FORCING THE GUIDES BACK INTO THE HEAD, ONE DOES NOT HAVE TO MEASURE THEIR DEPTH SINCE THEY HAVE A CIRCLII' ON THEIR OUTER CIRCUMFERENCE \>.'HICH LOCKS IN A GROOVE IN THE HEAD.

A0055

VALVE GUIDE ASSEMBLY

AFTER THE GUIDE HAS BEEN PL~ IN PLACE THE INNER BORE HAS TO BE REAMED TO SIZE.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine atl() safety of personnel.

MODEL FDg

AO(}56

ENGINE REBUILD

INJE CTOR TUBES

TO REPLACE THE INJECTOR TUBES. THREADS HAVE TO BE CUT INTO THE INNEH. DIAl:1ETER AND AN EXTRACTOR TO BE USED TO Pur;L THEH OUT OF CYLINDER HEAD .

A0 057

INJEC TOR TUBE AS SEHBLY

\vl:!EN A NE\¥ INJECTOR TUBE IS TO BE PLACED THE PUNCH SHOWN NUS T BE USED TO PLACE THE SLEEVE IN ITS BORE . AN OLD INJECTOR HOLDER l'lAY ALSO BE USED, JUST NAKE SURE NOT TO Dk'1J\GE THE SLEEVf': .

A0058

INJECTOR TUBE ASSEMBLY

SEAL THE BOTTOl:l SEATING OF THE TUBE

BY SwAGING AND CLEAN THE INJ ECTOR TAPERlm SEAT SURFACE WITH SEAT CUTTER SHO~'N. THE INJECTOR HUST EXTEND AT LEAST 1 TO 1 , SHH FROM THE BEAD SURFACE .

A0059

VALVE ASSEMBLY

CHECK THE POSITION OF THE VALVES IN CONJ UNCTI ON tHTH THE CYLINDER HEAD Sll RFACE . THIS N.UST BE .7:::.

0, 1}1}1.

A

.:';t..~===:$:tZ'.===='t#.~

... WARNING·

ALWAVS WEAR SAFEiY GLASSES WITH SIDE SHiELDS WHEN REMOVING, OVERHAULING, CI.EAN ING OR TI:: ST ING MACH INE PARTS • •

Study SAFETY RULES in the front of this manual thoroughiy fOf the protection of machine and safety of personnel.

MODEL FD9 A0060

ENGINE REBUILD

WATER PUMP DISASSE}1BLY

THE ~.JATER Pill1P IS OF THE CENTRIFUGAL TYPE . WITH AN EXTRACTOR. THE FAN FLAi.'\GE IS TO BE PULLED OFF THE SHAFT.

A0061

WATER PL~ DISASSE}1BLY

REMOVE THE COVER ON THE OTHER SIDE AND USE AN EXTRACTOR TO PUtT. THE H1PELLER OFF THE SHAFT> THEN LOOSEN THE BEARING LOCK SCRE\v AND KNOCK THE BEARING AND SHAFT OUT OF THE HOUSING.

A0062

WATER PUNP INSPECTION

REMOVE THE SEAL FROM THE HOUSING AND CHBCK THE SPRING AND SEAL ASSE}1BLY FOR SCORE MARKS AND DAMAGE TO THE RUBBER BOOT .

A0063

WATER PUMP

EXPLODED VIEW OF THE WATERPUMP ,FROM LEFT TO RIGHT THE PULLEY FLANGE . AND PULLEY , THE SHAFT AND BEARING ASSEMBLY ) THE Pill1P HOUS INC; H1PELLER Ac\JD THE BACK COVElL

Study SAFETY RULES in the front of this manual thoroughly for tht! protection of machine and safe ty of personnel.

HODEL FD9 A0064

ENGIN!'2 REBUILD

WATER PUMP ASSHfBLY

WHEN REBUILDING THE PUMP CHECK THE SPACE BETWEEN THE IHPELLER AND THE HOUSING SINCE THIS ESTABLISHES THE PRELOAD ON THE ROTARY SEAL ARRANCEMENT . (l-1,25MM)

A0065

COOLING SYSTE1"1 SCHEMATIC

THE ENGINE COOLING SYSTEH IS OF THE PRESSURIZED WATER CIRCULATING TYPE, ACTIVATED BY A CENTRIFUGAL PUt-1P AND REGULATED BY A THERHOSTAT WITH BY-PASS LINE. THE CENTRIFUGAL PUMP IS DRIVEN

BY A SINGLE BELT TOGETHER WITH THE ALTERNATOR AND THE WATER IS FORCED INTO THE BLOCK AND THROUGH THE OIL COOLERS.

A0065A

CONTID

UNTIL AN OPERATING TEHPERATURE OF 809 THE THER1"1OSTAT REt-tAINS CLOSED AND THE WATER CIRCULATES IN THE BLOCK Al'iD COOLERS ONLY THROUGH THE BY-PASS LINE.

A0066

ENGINE OIL PUHP

THE LUBRIFICATION . SYSTEt-i IS SUPPLIED

BY A SINGLE GEAR TYPE PUi'1P DRIVEN BY THE FRONT GEAR TRAIN, THE ONLY PRESSURE REGULt\TION VALVE IS M01.;'NTED ON THE PIJMP BODY.

RULES in the front of this manual thoroughly for the protection of machine and

MODEL FD9 A0067

ENGINE REBUILD

VIEW OF OIL PUMP

IF WORN THE P1J}1P SH01.ILD BE REPLACED.

A0068

OIL PRESSURE REGULATOR

THE PRESSURE REGULATION VALVE IS SET TO OPEN AT 6,6 BAR.

A0069

OIL PUMP ASSE}ffiLY

IS M01JNTED WITH TWO CAPSCREWS TO THE FRONT MAIN BEARING CAP.

T~ PU~

A0070

ENGINE L1JBRICATION SCHEMATIC

SCHE}~TIC OF THE LUBRICATION CIRCUIT. THE CIRCULATION IS ACHIEVED THROUGH A SINGLE GEAR PUMP TAKING THE OIL FROM A DEEP DRAWN SDPW AND DELIVERING IT INTO THE MAIN OIL GALERY BY THE WAY OF THE FILTERS AND THE COOLER.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

HODEL FD9 A0071

ENGINE REBUILD

ENGINE LUBRICA'flON SGHEHATIG

SCHEt-lATIG OF THE OIT" CIRCUIT IN THE FRONT DISTRIBUTING COVER. THE OIL IS DIVERTED FRON THE t-lA.IN OIL GALLERY TO LUBRICATE THE TURBO CHARGER /U\jD THE FRONT GEAR TRAIN.

A0072

ENGINE PISTON ASSEMBLY

THE PISTON HEADS ARE r.lARKED TO INDICATE THE DIRECTION OF MOUNTING (VERSUS THE CMiSHAFT).

THE ASSEMBLY UNE USES STANDARD PISTONS BUT IN THE FIELD THEY MIGHT HAVE BEEN REPI,ACED WITH OVERSIZE PISTONS.

A0073

CYLINDER HEAD ASSE~!BLY

NAKE SURE THE CYLINDER HEAD BOLTS ARE TIGHTENED IN THE PROPER SEQUENCE.

A0074

ROCKER SHAFT ASSEMBLY

MOUNT THE ROCKERSHAFT AND TORQL'E THE CAPSCREWS TO 2,3 KG/M.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of perSOnnel.

MODEL FD9 A0075

ENGINE REBUILD

VALve ADJUST~~NT

CHECK THE VALVE GAP COLD. INTAKE -O,25Mr1 EXHAUST -035Mr1.

A0076

FUEL INJECTORS

THE INJ ECTORS COULD BE OF FOUR DIFFERENT MANUFACTURES DUE TO THE LARGE VOUTHE OF ENGINES BUILT; FIAT-BOSCU-CAV OR OMAP. THE SETTING IS 230 KG/CM2. THE WORKING PRINCIPLE IS SI~LE,THE FUEL CO~RESSED BY THE PU~ PLUNGERS IS DIRECTED THROUGH HIGH PRESSURE

A0076A

CONTtD

TUBING IN A CHAHBER UNDER THE NEEDLE AND ~~EN THE PRESSURE ATTAINS A VALUE HIGHER THEN THE SPRING SETTING, THE NEEDLE CO~lES. FROM ITS Al'JD THE FUEL IS INJECTED VIOLENTLY OUT OF THE THREE HOLES AND WELL ATOMIZED .

A0077

CROSS SECTION OF THE TURBO CHARGER

THE TURBO CHARGER MOUNTED ON THE }1)9 IS A GARRETT AIR RESEARCH TO-4. THE UNIT CONSIST OF ONE SHAFT ON ONE srDE THE TURBINE WHEEL DRIVEN BY THE HOT EXHAUST GASES AND ON THE OTHER SIDE

Study SAFETY RULES in thefrorit of this manual thoroughly for the protection of machine and safety ot personnel

~10DEL

ADonA

FD9

ENGINE REB UILD

CONTID

THE IMPELLER \,JHEEL WITH THE PUMP HOUSING. THE CENTE R HOUSI NG CONTAINS F13LL FLOATING BEARINGS LUBRICATED BY THE ENGINE OIL AND SEALS ASSURE THAT NO OIL CAN ENTER THE HOT TURlHNE AREA OR 'lHE AI R INTAKE CmIPRESSOR HOUSING.

A0077B

CONI'D

THE TURBO NO MAINTENAl;;CE BUT SONE DIS CI PLINE PJ~GARDING ENGINE OPERATION 14ILL HAVE TO BE OBSER\'ED : -ACCUl:lA.TE OIL CHANGE AND FILTER l':lAINIENAl\JCE. -AIR CLEANER RENEI4AL IO AVOID OVERSPEEDING THE TURBO SHAFT. - STOP PI NG THE EN GINE ONLY AFTE R A 3MIN.IDLE PERIOD.

===========2 •• =====

A WARNING· L 1FT AND HANDLE ALL HEAVY

PARTS WlTH A LIFTING DEVICE OF PROPER CAPACITY. SE SURE PARTS ARE SUPPORTED 8v PROPER SLINGS AND HOOKS. USE L fFT!NG EYES IF PROV ID ED . WATCH our FOR PEOPlE {N THE VI C Hi lTY.

A00 78

EXPI,ODED VIE;'; OF THE TURBO CHARGER

TIlE PREVIOUS MENTIONED DISCIPLINE IN THE~1P,INTENANCE AND THE OPERATION OF ENGINES WITH TURBO CHARGERS I S TO BE STRICTLY ADHERED TO. BUILD UP OF CARBON IN THE BEARING HOUSING AND BEHIND THE ROTARY SE ALING ARRANGEMENTS COUIJ) REDUCE THE RUNNING CLEARANCE OF

MODEL FD9 A0078A

ENGINE REBUILD

CONT'D

THE SHAFT AND CAUSE OVERHEATING. WORKING THE TURBO WITH TOO HIGH INTAKE VACUUN WILL SPEED UP THE SHAFT ROTATION AND SPEEDS IN EXCESS OF 130000 R.P.N.• WILL DESINTEGRATE THE IMPELLER '\.JHEEL.

A0079

TURBO CHARGER INSPECTION

THE VERIFICATION OF THE R~DIAL AND AXIAL PLAY OF THE SHAFT IS VERY IMPORTANT,TOO LI TTLE PLAY WILL SEEZE THE SHAFT AT HIGH . OPERATING TEHPERATURES. THE CONNECTIONS ON THE SUCTION SIDE OF THE TURBO COMPRESSOR ~:fIJST BE TIGHT AS DIRT I.JILL DAMAGE THE IMPELLER WHEEL .

A0080

SCHEMATIC OF THE FUEL SYSTEM

THE FILTERING OF INCOMING FUEL IS TWO FOLD. FIRST THE SEDIHENT BOWl, IN THE SUCTION LINE OF THE TRANSFER PUMP) THEN A PRHiARY FILTER ELEMENT ON THE OUTPUT SIDE OF THE TRANSFER PUMP. THE PRlHARY FILTER ELEMENT IS OF PAPER CONSTRUCTION .

ADOSI

OVER FUEL SOLENOID

IN THIS SLIDE WE SEE THE SOLENOID ATTACHED TO THE FUEL PUMP. THIS SOLENOID OPERATES THE OVER rUEL DEVICE IN THE GO\~RNOR FOR COLD STARTING .

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

f.10DEL FD9 A0082

ENGINE REBUILD

VIEW OF FUEL INJECTION PLTfA,F

THE INJECTION PUtvlP IS AN INLINE UNIT TYPE ROBERT' BOSCH PES 6A 90B AND IS HOUNTED AT 289 B.LD.C.THE PUf.1P IDENTIfICATION l'lEANS: ) LINE pm1P; FLANGE HOUNTED; ( OF PLUNGERS; NOHINAL DUlENSIONS HEIGHT AND DIAlvlliTER; INDIDIHENSION IN TENTH OF HODIFICATION TO THE STANDARD CATES DESIGN.

A0083

FUEL INJECTION PUt-II'

THE INJECTION PUNt' IS \.JITH A VA.RIABLE SPEED GOVERNOR 1,41TH CENTRIFUGAL v;rEIGHTS. ON THE TOP OF THE GOVERNOR HOUSING liE SEE THE LDA DEVICE . THIS CONTROLS THE RACK STOP TO AVOID HAXIMUH RACK TRAVEL

A0083A

CONT'n

\.JHEN THE ENGINE RP~l IS Lm\' Al"iD SUBSEQUENTLY THERE IS LO\-J AIR INTAKE PRESSURE FROM THE TURBO.

ALLOWING FULL RACK TRAVEL DURING ACCELER.i \TION THAT \·mULD PRODUCE BLACK SNOKE.

A WARNING ~"'=;~;=~;"';;=;";:;;TY GLASSES WITH SlOE SHIELDS WHEN REMOVING , OVERHAULING, CLEANING OR TESTING MACHINE PARTS.

;\0084

FUEL INJECTION PUMP TIMING

ON THE FLYHHE EL HE FIND TWO l<LA,RKINGS PMS FOR TOP DEAD CENTER AND I NTEZ FOR ~1mlENT OF INJECTION.TIm INIE Z SIGN IS 289 BEFORE TOP DEAD CENTER. TO TUlE THE pmiP, PLACE THE FIRST CYLINDER IN END OF COMPRESSION STROKE REVERSE CRANKSHAFT ROTATION AND TURN IN THE CORRECT SENSE OF ROTATION UNTIL THE INTEZ MARK LINES UP ON THE FLYWHEEL HOUSING HOLE.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FJ)':J

A008S

EN(;lNJ;; 1{t;l:SUILD

FUEL PUMP MOUNTING

THE PUMP FLANGE MOUNTING HAS SLOTTED HOLES AND THE DRIVE COUPLING HAS A DOUBLE SPLINE SO THERE IS NO FALSE THnNG POSSIBLE BETWEEN THE PUMP AND DISTRIBUTION DRlVE , SMALL INCREMENTS ARE POSSIBLE THROUGH THE SLOTS.

A0086

FUEL PtJMP TIMING GEAR

THE TIMI NG GEAR IS KEPT IN PLACE

BY A CIRCLlP.

AOOS?

INJECTION PUMP TIMING TEST

INJECTION PUMP TIMING TEST USING THE HIGH PRESSURE PUMP.A SPECIAL SAFETY VALVE IS PLACED IN THE RETURN LINE FROM THE PUHP GALLERY (30KG/CM2).

REMOVE THE HIGH PRESSURE LINE TO THE FIRST INJECTOR AND OPERATE THE HIGH PRESSURE PUMP CONNECTED TO THE INPUT OF

AOOS?A

CONT'D

THE GALLERY AND OBSERi,'E WHEN THE FUEL WILL COME THROUGH THE DELlVERY VALVE. TURN THE CRru~KSHAFT IN THE CLOCKWISE DIRECTION UNTIL THE FLOW STOPS OUT OF THE FIRST INJECTOR LINE CONNECTION. AT THIS MOplENT THE FLYWHEEL l'tARK INIEZ SHOULD CORRESPOND WITH THE HOUSING HARK.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 BOOI

TORQUE CONVERTER REBUILD

DISASSEHBLY

CLAMP BRACKET 75295475 ONTO CONVERTER SHAFT RUB AND POSTION HOOK 75295551 ON THE BRACKET REMOVE RETAINING CAP SCREWS AND REMOVE HOUSING COMPLETE WITH TORQUE CONVERTER.

B002

TORQUE CONVERTER CROSS SECTION

NOTE INTERNAL OIL FLOW OF TORQUE CONVERTER P:PUMP, S:STATOR, T:TURBINE.

A WARNING~.""'~:;;'"':~~"~;:~~ ;"'Atl HEAVY PARiS WITH A L ffTtNG DEVICE OF PROPER CAPACliV. BE SURE PARTS ARE SUPPORTED BY PROPER SL ING5 A:-;O HOOKS . USE L 1FT iNC EYES IF PROV!DED. W,\1C H OUT FOR PEOPLE IN TIlE VICINITY.

B003

VIEW OF TORQUE CONVERTER HOUSING

PLACE THE CONVERTER UNIT COMPLETE WITH HOUSING ON REVOLVING STAND 75290086 OBSERVE COMPONENTS FROM RIGHT TO LEFT HYDRAL'LIC EQUIPMENT CHARGING Pill1P, STEERING CLUTCH-BRAKE AND CONVERTER HOUSING SCAVENGE FUM?, TRANSMISSION TORQUE CONVERTER PUMP> PUMP OUTLET LINE FILTER , PtJ'MP SUCTION LINE FILTER.

8004

CLAMP

INSTALL CLAMP 75296030 AS SHOWN AND REMOVE RETAINING PLATE CAPSCREHS.

Study SAFETY RULES in the front of thi. manual thorOIJ<;hly for the p rotection of machine and lafety of peuonne ••

HODEL FD9 BOOS

CONVERTER REBUILD

REMOVE CONVERTER

TRANSMISSION CONNECTING SHAFT FLANGE AND O-RING.

B006

PILOT HUB REMOVAL

LOOSEN CAPSCREWS AND RENOVE PILOT HUB. THEN REMOVE FRONT BEARING RETAINING PLATE.

WARNlNG~~~7;~"=~~~~=~;~~'" ALL liEAVY PARTS WITli A L!FY)NG DEVICE OF PROPER CAPACITY. BE SURE PARTS ARE SUPPORTED BV PROPER SLINGS AND HOOKS. USE LIFTING EYES IF PROVIDED . WA TCH .our FOR PEOPLE IN THE VICINITY.

A

B007

CON\?ERTER REMOVAL ~HTII LIFT CHAIN

PLACE CONVERTER UNIT i.JITH FRONT E~1) OF SHAFT FACING UPWARD REtvl0VE REAR BEARING CARRIER CAPSCRE~.JS. REMOVE PUMP DRIVEN GEAR RETAINING CAPSCREWS AND SLIDE GEAR OUT OF l.JAY. USING LIFT CHAIN 75291517 AND nvo CAPS CREWS REMOVE CONVERTER UNIT FROM HOUSING.

BOOS

CONVERTER

PARCIALLY REMOVED FROH HOUSING . OBSERVE AT RIGHT PUMP DRIVEN GEAR REMOVED .

Study SAFETY RULES in the front of th is manual thorcH.lghly for the protection of machine and safety of personnel.

MODEL FD9 13009

TORQUE CONVERTER REBUILD

DISASSEMBLY

USING PULLER SCREt\1S 75295473, SEPERATE TURBINE ASSEMBLY FROM CONVERTER HOUSING.

BOOIO

VIEW OF INTERNAL COMPONENTS OF CONVERTER

NOTE THAT IMPELLER AND STATOR HAVE BEEN SEPERATED FROM TURBINE A~l) HOUSING.

Boon

DISASSEMBLY

REHo\iE SNAP RING AND THEN USING AN ALLEN WRENCH REMOVE STATOR RETAINING SCREHS.

BOOIZ

INTERNAL COMPONENTS

VIEW OF STATOR, IMPELLER AND BEARING CARRIER.

Study SAF ETY RULES in the f,ont of this manual thoroughly for the protection of machine and safety of personnel.

MODEL fD9 BOOD

TORQUE CONVERTER REBUILD

CONVERTER SHA,FT

VIE'I.J Of CONVERTER SHAFT WITH BEARING AND SEALING RING.

B0014

INTERNAL COMPONENTS

IJIE\v OF CONvl~RTER liN IT COHPONENTS.

It,. WARNING ~.,.,=~;,:~; ..;;;;"';;;; TV GLA S SE S WITH SlOE SHIELDS WHEN REMOVING, OVERHAUL lNG, CLEANING OR TESTING MACH INE

B0015

PARTS.

G0NVERTEH, ASS EHBLY

PLACE UIPELLER ONTO BEARING CARRIER .

OBSERVE POSITION OF OIL INLET AND OUTL ET HOLES WHICH INDICATE CORRECT ASSEHBLY OF STATOR.

B0016

CONv'ERTER ASSEHBLY

PL\CE BEARING C/iRRIER IN AND SEAT USIN G RUBBER lLt;}l}lER . POSTION STATOR ON BEARING CARRIER \11TH OIL INLET AND OUTLET HOLES ALIGNED.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine arn::l safety of personnel.

MODEL FD9 130017

TORQUE CONVERTER REBUILD

STATOR INSTALLATION

TIGHTEN CAPSCREW ~

••

TO SPECIFIED OF 2.0 KGM.

#*.~=====:~a

•••

~

A WARNING· USE PROPER TOOLS TO BRING

HOLES INTO ALIGNMENT. 'DO NOT USE F INGERS OR HANDS , "

130013

STATOR SNAP RING

INSTALL STATOR SNAP RING , THEN PLACE TURBINE ONTO CONVERTER SHAFT.

130019

TURBINE/IMPELLER INSTALLATION

INSTALL TURBINE WITH IMPELLER IN CONVERTER HOUSING.

B0020

IMPELLER COVER - REASSEMBLY FINISHED

TIGHTEN CAPSCREWS TO SPECIFIED OF 2,3 KGM. THIS COMPLETES REASSEMBLY OF THE CONVERTER.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

TORQUE CONVERTER

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

CROSS SECTION OF TRANSMISSION

Study SAFETY RULES in the front of this manual thoroughly

machine and

of personnel.

NODEL FD9

COOl

TRANSMISSION REBUILD

TRh'JSMISSION

THE FD9 TR.tiliSHISSION IS A SUfPU COUNTERSHAFT DESIGN 3::<3 FrILL POWER SHU'T 'i.;rmCH PERNITS SMOOTH SPEED liND DIRECTION C!:lA'1GES EVEN AT FULL ENGINE RPM.

C002

TRANSHISSION REMOVAL

REMOVE THE 6 CAPSCREWS '(.;rHICH FIX TRANSNISSION TO FINAL DRIVE HOUSING. REMOVE TRh'JSMISSION USING A CHAIN A!'ID PLACE IN REVOLVING STAND.

C003

REAR VIEW OF ' TBJu'ISMISSION

SLIDE SHOWS. LOW SPEED CLUTCH PACK COVER; OUTPUT SHAFT A!,,\D P. T.O SHAFT.

C004

VALVE REMOVAL

LOOSEN CAPSCREWS AND CAREFULLY REMOVE VALVE ,NAINTAIN VALVE IN UPRIGHT POSITION TO AVOID DANAGE TO TUBE AND 0 RING .

Study SAFETY RULES in the front of this manual thoroughly for t he protection of machine and safety of. personnel.

HODEL FD9 C005

TRAt'lSMISSlON REBUILD

DISASSEHBLY

REMO\~ LUBE OIL MANIFOLD COVER. AT THE RIGHT NOTE OIL PASSAGES TO VALVE .

C006

FRONT VIEW OF LUBRICATION MANIFOLD

FROM RIGHT TO LEFT, I "'REVERSE ACTUATING PRESSURE AND BELOW REVERSE LUBE, AND 2ND GEAR CLUTCH LUBE.

C006 A

CONT f D

A=FORWARD CLUTCH PACK LUBE> BELm..J SLIDE SHOWS LUBE OIL PRESSURE RELIEF VALVE, AT FAR LEFT LUBE AND PRESSURE TUBES FOP. 1ST AND 3RD SPEED CLUTCH PACKS.

C007

CROSS SECTION OF LUBE PRESSVRE RELIEF VALVE.

SLIDE SHOWS ITE1'1 22=VALVE CLIP AND 25= VALVE SPRING.

Study S/\FETY RUL;::S in the front or thiS manu,,! thoroughly for the protectkm

MODEL PD9 C008

TRANSMISSION REBUILD

LUBE PRESSURE RELIEF VALVE

FREE LENGTH OF VAL\TE SPRING IS 95.0 NN AND WHEN LOADED WITH 4,35 TO 4.81 KG SPRING LENTH SHOULD BE 46.0 MM,

G009

VALVE SPOOL REMOVAL

AFTER REr.lOVING COVERS REMOv'E VALv'E SPOOLS FOR FOm.,'ARD AND 2ND GEAR CLUTCH PACKS ,DO NOT ROTATE SPOOLS 14HILE REMOVING BECAUSE THIS COULD DAMAGE O-RINGS AND TEFLON SEALING RINGS.

COlO

FRONT VIEW OF TRANSl'llSSION AFTER COVER RENOVAL

SLIDE SHOWS AT TOP 2ND SPEED CLUTCH PACK, BHOt.,' .FOR~vARD CLUTCH PACK AND TO THE

RIGHT PRESSURE AND LUBE TUBES FOR REVERSE.

COlI

TRANSMISSION COVER

SLIDE SHOIvS CLUTCH PACK LUBE AND PRESSURE TUBES, WITH SPEED f0.\NGE TRH1NER VALVES.

Study SAFETY RULES in the front of this manua!thorQughly for the protection of machine and safe1.y of personnel.

MODEL FD9 COllA

T~~SMISSION

REBUILD

CON'T

FRONT VIEW OF SPEED RlL~GE TRIJ:vflvLER VALVES .

C012

FORWARD CLUTCH PACK DISASSEMBLY

REHOVE OLEO BOWL AND CLUTCH PACK LUBE AND PRESSURE HIBES, THEN REMOVE CLUTCH PACK RETAINING NUT.

C013

VIEW OF FORWARD CLUTCH PACK

FORI']ARD CLUTCH PACK HAS 8 FRICTION Drscs k'\iD 7 STEEL DISCS, CLUTCH PACK ALSO

INCLUDES PISTON, AND END PLATE .

COlA

RETUR.~

SPRINGS. DRUM

LOW SPEED CLUTCH

AFTER REMOVING COVER REJ:v10VE VALVE SPOOL.

Study

the front or this manual thoroughly

machine ilnd

of personnel.

HODEL PD9

C015

TRANSMISSION REBUUD

Lm.] SPEED CLUTCH PACK

LOOSEN CAPSCREWS AND REHOVE COVER,.

OBSERVE LOW AND 3RD SPEED CLUTCH PRESSURE TUBES ORIFICES BELOW CLUTCH PACK. REHOVE RETAINING NUT AND l)1SASSEMBLE CLUTCH PACK.

C016

VI EW OF LOW SPE ED CLUTCH PACK

LOW SPEED CLUTCH PACK HAS 7 FRICTION DISCS AND 6 STEEL DISCS.

con

LOW SPEED CLUTCH PACK DRUtl REMOVAl.

AFTER REHOVING DISCS , REt'lOvE DRUM TOGETHER WITH SUPPORT AND GEAR .

C018

FORWARD A"JD LOW SPEED CLUTCH SHAFT REHOVAL .

REHOVE FORWARD AND LOW SPEED CLUTCH SHAFT THROUGH REAR OF TR,,\'NSHISSION HOUSING .

Study SAFETY RULES in the front of this Inanu;lI thoroughly for the protection of mnchine and safety oi~~

!>10DEL FD9 co 19

TRANSMI S$1ON REBUILD

GEAR REHOVAL

USING OPENING ON RIGHT SIDE OF TRANSHISS10N HOUSING REMO\'E 2ND> SPEED 3RD SPEED AND REVERSE DRrVEN GEARS.

c020

FORi.JARD CLUTCH PACK DRUH REHOVAL

USING NEEDLE NOSE PL I ERS REHOVE RETAINING RING.

C021

CON'T

SEPERATE LOW SPEED CLUTCH PACK DRIVE GEAR, THEN REMOVE FORWARD CLUTCH PACK DfUJM.

WARNING· iT ! S UNSAFE TO HR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER TKAN A SOFT IRON OR NON-FERROUS HAMMER.WHEN iNSTAllING OR REMOV ING SUCH FARTS WE/lit SAFETY GLASSES W!TH S!DE SH!ELDS AND HEAVY GLOVES, ETC., TO REDUCE THE POSSIBILiTY OF INJURY.

C022

SPECIAL TOOL

USING TOOL COMPRESS 3RD SPEED CLUTCH PACK TO PERMIT REi-iOVAL OF CLUTCH PACK ASSEMBLY TOGETHER WITH GEARS .

ETY RULES in the front of thi. manwoi

machHl0 ;:me:! safG:Y of personnel.

MODEL FD9

C023

TRANSMISSION REBUILD

VIEW OF 2ND SPEED CLUTCH PACK

2ND SPEED CLUTCH PACK HAS 7 FRICTION DISCS AND 6 STEEL DISCS.

C024

2ND AND 3RD SPEED CLUTCH SHAFT RENOVAL

REMOVE SHAFT FROM TRANSMISSION HOUSING

BY TAPPING WITH PI.ASTIe HAMMER.

C025

2ND SPEED SHAFT SNAP RING RENOVAL

USING NEEDLE NOSE PLIERS REMOVE SNAP RING TO PERMIT REi-l0VAL OF 2ND SPEED CLUTCH DRUN.

C026

2ND SPEED CLUTCH PACK DRUM RENOVAL

REMmiE 2ND SPEED CLUTCH DRlJM, THEN REMOVE DRIVEN GEAR TO PERMIT REl'iOVAL OF 3RD SPEED CLUTCH PACK .

StudV' SAP ETY RU LES in the front of this manual thoroughly for the protection of machine and safety of personnel.

NODEL F09

C027

TRANSMISSION REBUILD

3RO SPEED CLtJTCH PACK RENOVAt

PLACE TRANS?'HSSlON IN HORIZONTAL POSTlON AND REt<10'vl~ 3RI) SPEED CLUTCH PACK ,

C0 28

GL\R RE NOVAL

REMOVE SUPPORT TO PEWIT REHOVAL OF I MPUT DR IVE

C029

OUT PUT SHAFT REHOVAL

OUTPUT SHAFT BEARING ~. = .=w~~· == ····· = ~=

A WARNING· L I FT AND HANDLE: ALL HEAVY PA RTS W ITH A L IFTING DEViCE OF PROPER CAPA-

CI TY. BE SURE PARTS ARE SU PPO RTE D BY PR OPER SL INGS A:-lO HOOKS. U SE LlFTING EYES I F P ROViDED. WATCH OUT FOR PEOPLE IN THE V ICINITY.

REVERSE CLUTCH SHAFT REHOVAL AFTER CONPRESSING REVERSE CLUTCH PACK T.AP SHAFT FROH WITH TOOL HOUSIN G WITH PLAST IC HANNER .

St udy SAFETY RULES in the front of thi, mBnual thoroughly for the

HODEL FD9 C031

TRANSt-'lISSlON REBUIlD

REVERSE CLUTCH PACK REMOVAL

REt-fOVE REVERSE CLUTCH PACK THROUGH OPENING ON REAR SIDE OF HOUSING. REt-lOVE PIO DRIVe GEAR THROUGH OPENING ON RIGHT SIDE OF HOUSING.

C032

REVERSE CLUTCH

THE REVERSE CLUTCH PACK HAS 7 FRICTION DISCS AND 6 STEEL DISCS.

C033

CLUTCH DISC INSPECTION

PLACE DISCS ON FLAT SURFACE AND MEASURE WARPAGE WITH A FEELER GAGE, MAXIMUM I>JARP AGE PERHITTED IS 0> 40 i'ffv1.

C034

FRICTION DISC INSPECTION

MEASURE THICKNESS OF FICTION DISCS WITH A MICROMETER. THICKNESS f.'fAY VARY BETWEEN 3,15 MM AND 3,25 f.'1t1, f.'HNIHDN FICTION DISC THICKNESS IS 2,60 ~~.

Study SAFETY RULES in the front of this manu a! thoroughly for the protection of machine and safety of personnel.

HODEL FD9 C035

TRA.~SHISSION

REBUILD

CLUTCH PACK END PLATE

PINS ON 3RD SPEED CLUTCH END PLATE ARE SHORTER THAN THOSE FOR FORHARD, REVERSE, LOW AND 2ND SPEED CLUTCH PACKS.

C036

VIEW OF 2ND SPEED CLUTCH PACK COMPONENTS.

SLIDE SHOWS STATIONARY PISTON, SLIDING PISTON AND END PLATE.

C037

VIEW OF FORWARD, REVERSE k'JD LOW SPEED CLUTCH PACK ACTUATING COHPONENTS

SLIDE SHOWS STATIONARY PISTON> SLIDING PISTON AND END PLATE .

C038

VIEW OF 3RD SPEED CLUTCH GEAR AND PISTON

SLIDE SHOWS 3RD SPEED CLUTCH PACK DRPlEN GEAR AND ACTUATING PISTON.

Study SAFETY RULES in the

safety of personnel.

MODEL FD9 C039

TRANS!'H SSION REBUIIJ)

VI£l.,1 OF CLUTCH PACK I i\'NER DRUM

OBSERVE DIFFERENCE IN HEIGHT OF INNER DRU}!):; OF FORWARD, 3RD > LOW, 2ND SPEED AND REVERSE .

C040

REVERSE CLUTCH PACK ASSEJfBLY

TO ASSEMBLE REVERSE CLUTCH PACK, INSTALL FRONT BEARI NG ON Slli\FT THEN PLACE DRTVE GEAR ONTO SHAFT -AND THRUST RING WITH CHAMFER FACINC UP.

COif}

ASSEMBLY

ASSEHBLE REVERSE CLUTCH PACK AS SHOvJN IN SLIDE.

C04 2

REVE RSE CLUTCH PACK SHAFT REI40 VAL

ASSEIvllLING Cm1PONENTS COt>lP RES S CLUTCH PACK WITH TOOL N9 75295002, .s.."l\JD RE1>lO VE SHAFT TO PERt>lI T I NSTALLAT ION OF CLUTCH PACK IN TR.ANSNISSION HOUSING.

Study SAr ETY RU LES In the fron t or this mantlal thoroughly

protection of ffiachinit and safety of

NODEL FD9 CO£;3

TRilliSMISS ION REBUILD

REVERSE CLUTCH PACK INSTALLATION IN HOUSING

PLACE REVERSE CLUTCH PACK IN HOUSING THROUGH OPENING FOR LOW SPEED CLUTCH PACK, AND THEN INSTALL REVERSE CLUTCH PACK SHAFT.

C044

REVERSE CLUTCH PACK INSTALLATION

TIGHTEN RETAINING NUT TO 85 KGM &'JD LOCK IN PLACE WITH PUNCH. THEN REt-fOVE TOOL USED TO COl>fPRESS CLL~CH PACK.

C045

REVERSE CLUTCH SHAFT CO\~R INSTALLATION

INSTALL REVERSE CLUTCH SHAFT TIGHTEN CAPSCREWS.

C046

COv~R

AND

OUTPUT SHAFT INSTALLATION

INSTALL OUTPUT SHAFT TOGETHER WITH FRONT BEARING AND DRIVEN GEAR. LOCK IN PLACE WITH SNAP RING.

Study

ml!'1ual thoroughly

the protection

of personnel.

HODEL FD9 C047

TRANSl'HSSION REBUILD

VIEW OF 3RD SPEED CUJTCH SHAFT

OBSERVE ASSEHBLY OF DI SCS ON CLUTCH PACK SHAFT.

C048

VIEW OF 2ND AND 3RD SPEED CLUTCH PACK ASSEMBLY

TO I NS'I'ALL TH IS ASSEHBLY IN TRANSHIS SI ON HOUSING IT IS NECESSARY TO SEPARATE 2ND SPEED AND 3RD SPEE D CLUTCH PACK.

C049

3RD SPEED CLUTCH PACK I NSTALLATION

USING TOOL N9 75295004 COMPRESS 3RD SPEED CLUTCH PACK AND INSTALL I N TRAN StvlISS I ON THROUGH OPENING ON RIGHT smE OF HOUSING. PLEA SE, SE E T HE S LIDE NR C02 2

coso

2ND SPEED CL UTCH PACK I NSTALLATION

POSTION 2ND SPEED CLUTCH PACK AND I NSTALL SHAFT TAPPING viI IH PLAS TIC HAf1f.'iER.

StudY SAf ETY HU LES in the front of this manu al thorQugL'}f for the protection of machine and

MODEL FD9 C051

TRANSMISSION REBUILD

2ND SPEED CLUTCH PACK ASSEMBU

2ND SPEED CLUTCH S!:h\FT NUT TO 85 KGM AND LOCK IN PLACE A PUNCH.

C052

VIE\v OF LOW AND FORWARD SPEED CLUTCH PACK ASSEMBLY

TO INSTALL THIS ASSEMBLY IN TRANSMISSION HOUSING IT IS NECESSARY TO SEPARATE LOH SPEED AND FORHARD CLUTCH PACKS.

C053

LOW AND FORWARD CLUTCH PACK ASSEMBLY

OBSERVE CORRECT POSTIONING OF CLUTCH PACK SHAFT.

C054

LOH AND FORWARD CLUTCH PACK SHAFT ASSEMBLY

SLOWLY INSTALL SHAFT INTO HOUSING AND AT THE THm PLACE DRIVEN GEARS ONTO SHAFT.

SAFETY RULES in the front of this manual HVlrn""n

pcr$Qrm~!.

MODEL FD9 C055

TRAl\lSNISSION REBUILD

LOW AND FORWARD CLUTCH PACK ASSEr.illLY

TIGHTEN LOW SPEED CLUTCH RETAINING NUT TO 20 KGM.

C056

SHAFT NUT

TIGHTEN FORWARD CLUTCH PACK RETAINING NUT TO 85 KGr.l At'lfJ WITH PUNCH NOW GO BACK AND TIGHTEN LOW SPEED CLUTCH PACK RETAINING NUT TO SPECIFIED OF 85 KGf.! AND LOCK WITH PUNCH.

COS7

FORWARD CLUTCH PACK ASSEtffiLY

INSTALL PRESSURE AND LUBE TUBES FOR Lo\1' Al"JD 3RD SPEED CLUTCH PACKS . LOCK TUBES IN POSTION BY INSTALLING FORWARD CLUTCH PACK BO~~.

coss

FRONT COVER ASSE~ffiLY

INSTALL TRAl~SMISSION FRONT COVER USING TWO GUIDE PINS N9 75291525. ~=~=~==.:~=~=e=:.=:

A WARNING· LI FT AND HANDLE ALL HEAVY PARTS W!TH A LIFTING DEVICE OF PROPER CApACITY. SE SURE PARTS ARE SUPPORTED BY PROPER SL INGS AND HOOKS. USE LIFTING EYES IF PROVIDED. WATCH OUT FOR PEOPLE IN THE VICINITY.

Study SAFETY RULES in the front of this mallual thorou:!n!y fot the protection

MODEL FD9

C059

VAL\~

TR.t\NSMISSION REBUILD

ASSEMBLY

USE CARE "mILE INSTAUING VALVE TO AVOID DAMAGE TO O-RINGS.

coso

CONTROL VALVE ASSEMELY

THE VALVE BLOCK HOUSES THREE SPOOLS 1.1HICH CONTROL TRANSMISSION CLUTCHES. THE VAL\~ COVER HOUSES THE SHIFT LEVERS AND CAMS, THE DIRECTIONAL SHIFT LEVER HAS THREE POSTIONS: A=FORWARD. F=NEUTRAL AND I=REVERSE.

C061

CONTROLE VALVE ASSENBLY

SPEED SELECTION LEV'ER ALSO HAS THREE POSTIONS. SPEED, 2~ZND SPEED AND 3=3RD SPEED.

C062

CROSS SECTION OF CONTROL VALVE

Study SAFETY RULES in the front of this manual thoroughly fo r the protection of machine and safety ot personotl.

MODEL FD9

TRANSMISSION CONTROL VALVE

C063

LONGITUDINAL CROSS SECTION OF CONTROL VALVE

C064

VIEW OF CONTROL VALVE DISASSEMBLIED

C065

VIEW OF HODlJLATING VALVE FOR DIRECTIONAL CLUTCH PACKS

SLIDE SHOWS REVERSE CLUTCH PACK f'10DULATING VALVE DISASSEMBLIED.

Study SAfETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 0001

FINAL DRIVE

FINAL DRIVE HOUSING

SLIDE SHOWS STEERING CLUTCH CONTROL VALVE, BRAKE CYLINDERS AND CLUTCH RETURN FILTER COVER.

0002

FRONT VIEW OF FINAL DRIVE HOUSING

OBSERVE AT THE RIGHT STEERING CLUTCH PUMP SUCTION FILTER.

0003

FINAL DRIVE COVER REMOVAL

REMOVE STEERING CLUTCH AND BEVEL GEAR COMPARTI}lliNT COVERS.

A WARNING: "' ~;"'7;"~~;;;;";~"

STR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER. THAN A SOfT IR.ON OR NON-fERROUS HAIi!MEILWHEN !NSTALLING OR REMOVING SUCH PARTS WEAR SAfETY GLASSES WITH SIDE SHIELDS AND HEAVY GLOVES, ETC •• TO REDUCE THE POSS IS IL IiY Of INJURY.

D004

STEERING CLUTCH TUBES

REMOVE STEERING CLUTCH PRESSURE AND LlJBRICATION TUBES.

Study SAFETY RULES in tlie front of this manu a! thoroughly for the protection of machine and safety of porsonnel.

MODEL FD9

FINAL DRIVE

D005

CROSS SECTION OF BR.AKE ASSE~LY

D006

BRAKE BAND RETU!L'J SPRINGS

HOOK SERVICE LEVER TO RELEASE LOAD ON RETURN SPRINGS.

D007

BRAKE LINKAGE REN:OVAL

REMOVE BRAKE CONTROL LINKAGE SUPPORT AFTER REMOVING RETAINING CAPSCRE'i\fS.

D008

BRAKE DRUM: AND Btu'JD

THE BRAKE BAND IS A FULL v/RAP AROUND TYPE AND C.t.N ONLY BE REMOVED AFTER REMOVING CLUTCH PACK FRO~'l HOUSING.

Study SAFETY RULES in the front of this manual thoroughly

the protection

AODEL FDS! D009

FINAL DRIVE

CROSS SECTION OF STEERING CLUTCH

TOTAL STEERING CLUTCH PACK THICKNESS SHOULD BE 70/71, 5MJ1.

DOlO

CLUTCH PACK REMOVAL

REHOVE ALL BUT TWO DRUM SELF- LOCKING CAPSCREWS.

DOlI

CLUTCH PACK REMOVAL

ATTACH LIFT CHAIN N9 517 TO CLUTCH DRill-I. REMOv'E REMAINING CAPSCREWS AND LIFT CLUTCH PACK WITH BRAKE BAND FROM HOUSING.

D012

STEERING CLUTCH PACK DRIVE HUB

DRIVE HUB IS FIXED TO BEVEL GEAR SHAFT

BY ONE LOCK PLATE AND SNAP RING.

----------------------------------------.--Study SAFETY. RULES in the 'ront of this manual thoroughly for the protection of machine and sof,ty of personnel.

MODEL FD9 DOl3

FINAL DRIVE

DRIVE HUB RETAINING CAPSCREW REMOVAL

PLACE LOCKPLATE N9 75291579 AND PULLER N9 75291578 AS SHOWN AND REMOVE PISTON GUIDE RETAINING CAPSCREW.

D014

STEERING CLUTCH PISTON GUIDE

REMOVE GUIDE AND PISTON AS SHOWN IN SLIDE. PISTON CAN ALSO BE REMOVED

BY INJECTING AIR INTO CLUTCH PACK OIL DUCT.

D015

CLUTCH PACK PISTON REMOVAL

REMOVE CLUTCH PACK PISTON AND GUIDE, OBSERVE PIN IN DRIVE HUR FOR PISTON GUIDE.

WARNING:=~~=~~=~~~=;~=;~= STR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER THAN A SOFT IRON OR NON-FERROUS HAMMER.WHEN INSTALLING OR REMOVING SUCH PARTS WEAR SAFETY GLASSES WITH SIDE SHIELDS AND HEAVY GLOVES, ETC., TO REDUCE THE POSSIBILITY OF INJURY.

A

D016

STEERING CLUTCH DRIVE HUB REMOVAL

REMOVE DRIVE HUB USING TOOLS N9 75291579 AND 75291578 AS SHOWN IN SLIDE.

---------

Study SAFETY RULES in the front of this ma~ual thoroughly for the protection of machine and safety of personnel.

MODEL FD9

D017

FINAL DRIVE

STEERING CLUTCH PACK DISASSEMBLY

AFTER TIGHTENING TOOL N9 75295415 IN A VISE AS SHOWN, PLACE CLUTCH PACK ONTO PLATE AND INSERT STUDS AND COMPRESS CLUTCH PACK.

D018

STEERING CLUTCH PACK DISASSEMBLY

BEND BACK LOCK PLATES AND RE~OVE CAPSCREVJS.

0019

TOOL REMOVAL

SLOWLY LOOSEN NUT AS SHOWN TO RELEASE PRESSURE ON CLUTCH PACK SPRINGS.

DOLO

CLUTCH PACK DISASSEMBLY

REMOVE CLUTCH PRESSURE PLATE, THEN REMOVE STEEL DISCS AND FRICTION DISCS.

Stt.;dy SAFETY RULES in the front of this manual thoroughly for the prater-lion of machine and safety of personnel.

MODEL FD9 n021

FINAL DRIVE

DRIVE DISC DRUM

AFTER REMOVING DISCS, REMOVE DRIVE DISC DRUM AND INNER AND OUTER SPRINGS.

D022

STEERING CLUTCH PACK SPRINGS

SLIDE SHOWS STUD PLATE, SPRING THRUST WASHERS, SPACER, INNER AND OUTER SPRI NGS.

D023

CLUTCH PACK FRICTION DISC WEAR

DISC THICKNESS SHOULD BE BETWEEN 4,20 AND 4,SOMM. ~AXIMUM WEAR LIMIT IS 3,20 MM.

D024

VIEW OF STEERING CLUTCH PACK

SLIDE SHOWS CORRECT ASSE~mLY SEQUENCE.

Study SAFETY RULES in the fro nt of this mi'tnual thoroughly for the protect ion of machine and SiJ fety of personnel.

MODEL FD9 D025

FINAL DRIVE

STEERING CLUTCH PACK ASSEMBLY

CLAMP BOTTOM PLATE OF TOOL N9 75295415 IN A VISE, POSITION STUD PLATE AND THREAD STUD INTO STUD PLATE, PLACE THRUST WASHERS, SPACERS, INNER SPRINGS AND OUTER SPRINGS ONTO STUDS.

D026

STEERING CLUTCH PACK ASSEMBLY

SLIDE DRIVE PLATE DRUM OVER THE STUDS UNTIL CONTACT WITH OUTER SPF.ING IS ESTABLISHED. BEFORE ASSEMBLY OF DISCS CHECK THEM FOR WEAR. DIFFERENCE IN THICKNES OF DISCS SHOULD NOT BE MORE THAN 0,05MM.

D02?

CLUTCH PACK THICKNES

AFTER ASSEMBLY OF CLUTCH PACK PLACE PRESSURE PLATE INTO POSTION. CLUTCH PACK THICKNESS MUST BE 70,0 TO 71,0 MM WHEN LOAD WITH 300 TO 400 KG AS SHOWN IN SLIDE.

D028

CLUTCH PACK THICKNESS

IF CORRECT THICKNESS IS NOT OBTAINED, STEEL DISCS SHOULD BE ADDED TO PRESSURE PLATE SIDE OF CLUTCH PACK.

------------------------------

Study SAI-'ETY RULES in the front of this manual thoroughly tor the protection of machine and saiety of persoiloel.

HODEL FD9 D029

FINAL DRIVE

STEERING CLUTCH PACK ASSEMBLY

INSTALL CLUTCH PACK DRUM USING CARE TO ALIGN FRICTION DISC TEETH.POSTION TOOL N9 75291535 SLEEVE AND FULLY TIGHTEN TIE BOLT.

D030 STEERING CLUTCH PACK ASSEMBLY SUBSTITUTE TOOL STUDS WITH ORIGINAL CLUTCH PACK CAPSCREWS, APPLY TORQUE OF 12 MKGF, THEN LOCK CAPSCREWS TN PLACE.

STEERING CLUTCH AND B~AKE FILTERS

DOll

PUMP INLET FILTER

THE STEERING PUHP INLET FILTER IS A FULL FLOW METALLIC ELEMENT WITH A HAGNETIC ROD.

D032

CROSS SECTION OF PUMP INLET FILTER

INLET FILTER SHOULD BE CLEANED EVERY 300 HOURS.

PU~P

A WARNING·

ALWAYS WEAR SAFETY GLASSES SHIELDS WHEN REMOVING, OVERHAULING. CLEANING OR TESTING MACHINE PARTS. WITH SIDE

----------Study S/,i-ETY RULES -i-n t'1e front of this m<lflual thoroughly for the protection of machine and ,afcty of p,"rwnnel.

MODEL FD9 D033

FINAL DRIVE

BEVEL GEAR SUMP RETURN FILTER

RETURN FILTER PAPER ELEMENT SHOULD BE CHANGED EVERY 600 HOURS.

D034

CROSS SECTION OF RETURN FILTER

RETURN FILTER WITH REPLACEABLE PAPER ELEMENT INCORPORATES A BY-PASS VALVE (19) WHICH PERMITS THE CIRCULATION OF OIL IN THE EVENT OF FILTER RESTRICTION.

D035

FRONT VIEW OF CONTROL VALVE

SLIDE SHOWS 30 AND 31 - CONTROL VALVE LEVERS, 33 - RELIEF VALVE PLUG, 36 STEERING CHECK VALVE PLUGS AND 37 STEERING AND BRAKE CHECK VALVE PULG.

D036

REAR VIEW OF CONTROL VALVE

SLIDE SHOWS STEERING CLUTCH PRESSURE CHECK POINTS. PD = RIGHT SIDE AND PS= LEFT SIDE.

._----_..

._---_._------

Study SAf' ETY RU LES in the front of this manual thoroughly for the protection of 012chine and safety of personnel.

MODEL FD9 D037

LI~

'~ , J-U

~

FINAL DRIVE

CROSS SECTION OF STEERING/BRAKE CONTROL VALVE

SLIDE SHOWS 7 - SERVO VALVE SPOOL, 9PRESSURE RELIEF VALVE, IS-SERVO VALVE PLUNGER, I6-FLOW CONTROL VALVE LOWER PLUG.

D033

CONTROL VALVE WITH FRONT COVER REMOVED

SLIDE SHOWS R-FRONT COVER OIL ORI FICE WHICH DRAINS DIRECTLY IN FINAL Dx IVE HOUSING, 9-SAFETY VALVE.

D039

CROSS SECTION OF CONTROL VALVE

SLIDE SHOWS S-PISTON, lO-CONTROLVALVE; SPOOL, AND 9-CONTROL VALVE PRESSURE REGULATING VALVE. FOR CORRET ADJUSTMENT OF THIS VALVE, CONSULT SERVICE SPECIFICATIONS HANUAL.

D040

STEER/BRAKE CONTROL VALVE

SLIDE SHOWS I8-PISTON RETURN SPRING, 8-PISTON, M-CLUTCH PRESSURE REGULATING CARTRIAC'E.

:Study SAFETY RULES in the front ~f-;-his m~nual thoroughly for the protection of milchine and safety of per,;()nnel.

MODEL FD9

FINAL DRIVE

D04l CROSS SECTION OF CHECK VALVE SLIDE SHOPS lO-BRAKE AND CLUTCH OIL FLOW CHECK VALVE BALL, ll-STEERING CLUTCH CIRCUIT CHECK VALVE BALL.

D042

CHECK VALVES

SLIDE SHOWS lO~12 - LEFT AND RIGHT BRAKE CIRCUIT CHECK VALVES, 11STEERING CHECK VALVE. USE CARE DURING ASSEMBLY TO NOT MIX CHECK VALVES BECAUSE OF THE CALIBRATED ORIFICES.

D043

TOP VIEW OF CONTROL VALVE

HERE WE CAN SEE BRAKE CHECK VALVE.

D044

CONTROL VALVE LEVER REMOVAL

AFTER REMOVING CAPSCREW AND WASHER, REMOVE LOCATING PINS USING A PULLER BOLT M4xO, 7Iv1M.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety 'of personnel.

MODEL FD9 D045

FINAL DRIVE

CONTROL VALVE LEVERS AND CAMS

IF BUSHINGS ARE TO BE REPLACED, DRIVE THEM OUT WITH A SUITABLE PUNCH FROM THE OUTSIDE IN. OBSERVE SERVICE SPECI FICATIONS MANUAL FOR CORRECT POSITIONING OF NEW BUSHINGS.

D046

CROSS SECTION OF BRAKE SERVO CYLINDER

D047

BRAKE SERVO CYLINDER

ARROWS SHOW HIGH PRESSURE OIL INLET AND OIL OUTLET TO RETURN LINE. ~.

==================~

f1:f,> WJUmING· ALWAYS WEAR SAFE TY GLA 5 SF S WITH SIDE ' SHIELDS WHEN REMOVING, OVERHAULING, CLEANING OR TESTING MACHINE PARTS.

D048

BRAKE SERVO CYLINDER COMPONENTS

BRAKE CYLINDER HOUSING, BRAKE SERVO PISTON, VALVE SPOOL, SEALS, COVERS AND SNAP RINGS.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safp.ty of personnel.

MODEL FD9 D049

FINAL DRIVE

BEVEL GEAR SET

BEVEL GEAR AND PINION ARE A MATCHED SET AND NUMBERED FOR IDENTIFICATION.

DOSO

CROSS SECTION OF BEVEL GEAR SET

OBSERVE IN SLIDE 51 -PINION ADJUSTMENT SHIMS, SC- BEVEL GEAR ADJUSTMENT SHIMS AND L-NOMINAL DISTANCE BETWEEN PINION HEAD AND BEVEL GEAR SHAFT WHICH IS 18,0 MM.

DOS1

REVEL GEAR REMOVAL

REMOVE REVEL GEAR SHAFT BEARING CARRIER CAPSCREWS.

Study SAFETY RULES in tha front of this manual thoroughly for tbe protection of machin" and safety of personnel.

MODEL FD9 D052

FINAL DRIVE

BEVEL GEAR DISASSEMBLY

PARCIALLY REMOVE RIGHT BEARING CARRIER USING PULLER SCREW N9 75291585, AVOID MIXING BEARING CARRIER SHIMS, SLIDE BEVEL GEAR TO THE RIGHT TO PERMIT PINION REt--:OVAL.

-

.-

D053

PINION SUPPORT COVER R~MOVAL

REMOVE COVER CAPSCREWS USING TWO PULLER SCREW 75291585. REMOVE COVER AND SHIMS.

1/

D054

PINION REMOVAL

SLIDE PINION DEARING SUPPORT WITH PINION FORWARD AND REMOVE .

•

• D055

PINION DISASSEMBLY

SECURE PINION SUPPORT IN FIXTURE 75283213 AS SHOWN AND BEND BACK RETAINING NUT LOCK.

Study SAFl:TY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

HODEL FD9 D056

FINAL DRIVE

PINION RETAINING NUT REMOVAL

REHOVE PINION ~ETAINING NUT USING N9 75293210 AS SHOWN.

WP~NCH

D057

PINION REMOVAL

~-

-

USING A HYDRAULIC PRESS, P.EMOVE PINION WITH BEARING FROM SUPPORT.

D058

VIEW OF PINION

PINION, DOUBLE TAPER ROLLER BEARING AND PINION SUPPORT.

D059

PINION

THE PINION IS IDENTIFIED WITH TWO NUHBERS ETCHED ON THE HEAD, ONE Nill'lBER IS TO IDENTIFY THE PAIR AND THE OTHER Illf'ICATES THE VARIATION IN ASSEMBLY DISTANCES.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - _._ ------Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and oafety of. personnel.

MODEL FD9 D060

FINAL DRIVE

PINION BEARING

THE DOUBLE TAPER PINION BEARINGS ARE MARKED TO AVOID MIXING CUP AND CONE AS SHOWN IN SLIDE.

D061

PINION BEARING

VIEW OF PINION BEARING AFTER ASSEMBLY .

D062

PINION ASSEMBLY

AFTER HEATING BEARING TO 1209C PRESS ONTO PINION SHAFT, HAND TIGHTEN NUT ON PINION SHAFT AND THEN PRESS PINION INTO SUPPORT.

D063

TORQUE

SECURE PINION SUPPORT WITH HOLDER 7583213 AND PLACE IN A VISE. TORQUE NUT USING WRENCH 75293210 TO 100 KGM.

WARNING· I TIS UNSAFE ·TO S TR IKE HARDENED STEEL PARTS W I TH ANYTHING OTHER THAN A SOFT IRON OR NON-FERrOUS HAMMEf{'WHEI~ INSTALLING OR REMOVING SUCH PARTS WEAR SAFETY GLASSES WITH S IDE SHIELDS AND HEAVY GLOVES, ETC., TO REDUCE THE POSSIBILITY OF INJURY.

Study SAFE J Y RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 D064

FINAL DRIVE

PINION NEEDLE BEARING SEAL

IN CASE SUBSTITUTION OF THIS BEARING IS NECESSARY INSTALL NEW SEAL AND STAKE IN PLACE.

D065

BEVEL GEAR ASSEMBLY

PLACE BEVEL GEAR IN HOLDER 75291221 AND TIGHTEN CAPS CREWS TO 18 KGM.

D066

BEVEL GEAR IDENTIFICATION

SLIDE SHOWS BEVEL GEAR IDENTIFICATION NUMBER,PINION WILL ALSO HAVE SAME NUMBER.

D067

BEVEL GEAR ASSEMBLY

AFTER ASSEMBLY OF BEVEL GEAR ON SHAFT, PLACE IN FINAL DRIVE HOUSING AS SHOWN.

Stud,! SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of. personnel.

HODEL FD9 FINAL DRIVE D068

CROSS SECTION OF BEVEL GEAR ASSEMBLY

SLIDE SHOWS C3 - LEFT BEARING CARRIER RETAINING CAPSCREWS, SC - SHIM PACK THICKNESS FOR RIGHT BEARING PRELOAD.

D069

BEVEL GEAR SHAFT BEARINGS

POSITION BEVEL GEAR IN FINAL DRIVE HOUSING. LUBRICATE BEARINGS WITH SPECIFIED OIL AND INSTALL LEFT BEARING CARRIER WITH LUBRICATION ORIFICE AT THE TOP, TIGHTEN LEFT BEARING CARRIER WITH FOUR CAPSCREWS 909 APART TO 6KGM.

D070

BEVEL GEAR SHAFT BEARINGS

INSTALL RIGHT BEARINGS CARRIER WITHOUT SHIllS. TIGHTEN TWO CAPSCREv]S POSITIONED l~GC? APAP.T AT INTERVAL OF 0.100 KG m~TIL R.EACHINC 0.500 KG. AND AT THE SAlYlE TU.I£ ROTATE BEVEL GEAR SHAFT TO SEAT BEARINGS.

D071

SHIM PACK THICKNESS

USING A FEELER GAUGE MEAURE GAP BETWEEN HOUSING AND RIGHT BEARING CARRIER AT TWO POSTIONS 1809 APART.

Study SI\F ETY RULES in t')e front of this manual thoroughly for the protectivn of machine and safety 0 f personnel.

MODEL FD9 D072

FINAL DRIVE

SHIM PACK THICKNESS

AVERAGE OF THESE TWO MEASUREMENTS WILL BE THE THICKNESS OF THE RIGHT BEARING CARRIER SHIM PACK. EXAMPLE: SC ==4,05 + 4,15 = 4,10MM 2

D073

SHIM INSTALLATION

REMOVE CAPSCREW AND INSTALL SHIM PACK eSC) BETWEEN RIGHT BEARING CARRIER AND HOUSING, TIGHTEN THE FOUR CAPSCREWS TO 6 KGM.

DO 74

BEVEL GEAR ROLLING TORQUE

INSTALL CAPSCREW IN END OF BEVEL GEAR SHAFT AND CHECK ROLLING TORQUE WHICH SHOULD BE 0,3 TO 0,4 KGM AS SHOWN IN SLIDE. IF THIS VALVE IS NOT OBTAINED, ADJUST BEARING PRELOAD AGAIN.

D075

PINION ASSEMBLY

SLIDE SHOWS L - DISTANCE BETWEEN PINION AND BEVEL GEAR SHAFT, N = BEVEL GEAR AND PINION IDENTIFICATION NUMBER, Q = VARIATION IN ASSENBLY DISTANCE, SC = RIGHT BEARING CARRIER SHIM PACK, Sl = PINION SHIM PACK WHICH SHOULD BE 3,0 MM INICIALLY.

Study SAFETY RULES in the tront of this manual thoroughly tor the protection of machine and safety of personnel.

MODEL FD9

D076

FINAL DRIVE

PINION

ASSE~BLY

PLACE PINION IN HOUSINC TTSINC TWO GUIDE PINS 75291586, INSTALL SHU' PfCK BETWEEN PINION SUPPORT AND HOUSING. INICIAL SHIM PACK THICKNESS SHOULD BE 3,0 t~~.

D077

PINION ASSEMBLY

INSTALL FOUR CAPSCREWS AND TORQUE TO 24 KGM.

D078

CROSS SECTION OF PINION

SLIDE SHOWS L=DISTANCE BEn·1EEN PINION AND SHAFT WHICH IS 18,0 MH, Sl=PINION SHIM PACK WHICH IS INICIALLY 3,0 }1M THICK.

00 79

PINION POSTIONING

EEASURE DISTANCE BETWEEN PINION P.ND BEVEL CEAR SHAT<'T USINr- GAUGE 75291529 AND FEELER GAUGE, AS SHm-JN. EXAt"PLE: L=13, SO MM..

---_._-----------

Study SAFETY RULES in the front of this ffi.3nual thorough IV for the protection of mach ine and safety cf personnel.

MODEL FD9 D080

FINAL DRIVE

SHIM PACK THICKNESS CALCULATION

THE THEORETICAL THICKNESS OF SHIM PACK (SP) WHICH IS INSTALLED BETWEEN HOUSING AND PINION. EXAMPLE: SP=Sl-(L-18) : Q. 18 = NOMINAL DISTANCE BETWEEN PINION AND BEVEL GEAR SHAFT. EXAMPLE: SP =3-(18,8 - 18)+0=2,2MM.

D081

Sp = SI-( L-lS)t Q

sp=3 -( 18,8 -IS) + 0=2,2 mm

PINION MARKING

IN THE EQUATION EXPLAINED EARLIER Q= VARIATION IN ASSEMBLY DISTANCE. THIS PARTICULAR PINION THE VARIATION WAS O,HOWEVER THIS - DIMENSION- MAY VARY + OR -

D082

PINION SHIM PACK THICKNESS

INSTALL SHIMS BETWEEN PINION SUPPORT AND FINAL DRIVE HOUSING TORQUE CAPSCREWS TO 24,0 KGM

D083

BEVEL GEAR BACKLASH

ENGAGE CRANK 75293322 TO ROTATE PINION DURING BACKLASH CHECK AS SHOWN. USING A DIAL GAGE MEASURE BACKLASH IN FOUR POSITIONS 1209 APART AND AVERAGE THESE MEASUREMENTS.

..J11 rW i..

.'

Study SAFETY RULES in the "front of this manual thorouyhly for the protection of machine and safety of persof1nel •

MODEL FD9 D084

FINAL DRIVE

BEVEL GEAR BACKLASH

THE SPECIFIED BACKLASH BETWEEN BEVEL GEAR AND PINION TEETH IS O,24MM, TO O,28MM, TO OBTAIN THIS VALVE CONSIDER FIXED RATIO OF 1: 1. 35 FOR BEVEL GEAR SHIFT. IN THIS EXAMPLE, THE BEVEL GEAR SHIFT WILL BE THE SAME AS THE SHIM PACK THICKNESS WHICH IS TO BE INSERTED IN THE

D084A

CON'T

LEFT BEARING CARRIER. EXAMPLE: Ss=(G-O,25)x1,35 THE SHIM PACK THICKNESS TO BE INSERTED IN THE RIGHT BEA~ING CARRIER WILL BE SD=SC-Ss. EXAMPLE: AVERAGE BACKLASH FOUND AFTER FOUR MEASUREMENTS - G=1.81MM INICIAL SHIM PACK THICKNESS INSTALLED

D084B

CON'T

IN RIGHT BEARING CARRIER - SC=4,10MM, LEFT BEARING CARRIER SHIM PACK THICKNESS Ss=(G-O,24)x1,35=1.81-0,24 x 1.35=1,57x 1.35 =2,11MM LEFT BEARING CARRIER SHIM PACK THICKNESS SD=SC-Ss=4,10-2,11=1,99MM ROUND OFF RIGHT SHIM PACK THICKNESS TO 2,10MM AND LEFT SHIM PACK THICKNESS TO

DOiJ4C

CON'T

2,OOMM. AFTER INSTALLING SHIM PACKS AND TIGHTENING BEARING CARRIER CAPSCREWS RECHECK BACKLASH.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 DOSS

FINAL DRIVE

CROSS SECTION OF STEERING CLUTCH

SLIDE SHOWS STEERING CLUTCH ACTUATING PISTON.

DOS6

STEERING CLUTCH DRIVE HUB

SLIDE SHOWS PRESSURE AND LUBRICATION GROOVES.

DOS7

STEERING CLUTCH DRIVE HUB ASSEMBLY

WHEN INSTALLING DRIVE HUB, OBSERVE POSITIONING MARKS ON BEVEL GEAR SHAFT AND DRIVE HUB.

DOSS

STEERING CLUTCH DRIVE HUB INSTALLATION

COMPRESS FIRST STEEL SEAL RING WITH TOOL 75293321.

Study SAFETY RULES in the front of this manual thoroughly for the protection of. machine and safety of personnel.

MODEL FD9 D089

FINAL DRIVE

DRIVE HUB INSTALLATION

INSTALL DRIVE HUB AS SHOWN USING CARE NOT TO DA~AGE SEAL RINGS.

D090

STEERING CLUTCH ACTUATING PISTON

INSTALL ACTUATING PISTON IN DRIVE HUB THEN INSTALL PISTON GUIDE, OBSERVE CORRECT POSITIONING OF GUIDE PIN.

D091

STEERING CLUTCH PISTON GUIDE

WHEN INSTALLING PISTON GUIDE OBSERVE CORRECT POSITIONING OF LUB AND PFESSURE ORIFICES.

D092

STEERING CLUTCH ACTUATING PISTON

DURING INSTALLATION OF ACTUATING PISTON USE CARE TO AVOID CUTTING 0 RING.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of per~onnel.

MODEL FD9 D093

FINAL DRIVE

STEERING CLUTCH ACTUATION

SLIDE SHOWS STEERING CLUTCH ACTUATING COMPONENTS.

D094

STEERING CLUTCH PISTON GUIDE

INSTALL RETAINING CAPSCREW AND TORQUE TO 60,0 KGM.

D09S

LOCK PLATE

SLIDE SHOWS CAPSCREW LOCK PLATE INSTALLED.

A WARNING~==~~\~:~;=;~:==~:;~TY GLASSES WITH SIDE SHIELDS WHEN REMOVING, OVERHAUL lNG, CLEANING OR TESTING MACHINE PARTS.

D096

STEERING CLUTCH PACK INSTALLATION

PLACE CLUTCH PACK WITH BRAKE BAND IN COMPARTMENT AND TORQUE CAPSCREWS TO 7,OKGH.

Study SAFETY RULES in t\)<.: front of this fnanual thoroughly for the protection of rnachine and s~felY of ~~~nnel.

MODEL FD9 D097

FINAL DRIVE

BRAKE ASSEMBLY

INSTALL BRAKE BAND LINKAGE AND TORQUE CAPSCREW TO 6KGM.

-

..

D098

STEERING CLUTCH TUBES

INSTALL CLUTCH PACK ACTUATING PRESSURE TUBE IN BEARING CARRIER.

D099

STEERING CLUTCH TUBES

LOCK TUBESIN PLACE WITH SEMI LOCKRINGS

DOIOO

STEERING CLUTCH TUBES

INSTALL CLUTCH PACK LUBRICATION TUBES USING CARE TO AVOID CUTTING 0 RINGS.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

HODEL FD9 DOIOI

FINAL DRIVE

COVER ASSEMBLY

BEFORE INSTALLING COVERS APPLY SEALANT AND TORQUE CAPSCREW TO 6,0 KGM.

DOI02

TRANSMISSION ASSEMBLY

REINSTALL TRANSMISSION AFTER APPLYING SEALANT TO MATING SURFACE. TORQUE CAPSCREWS TO 6,0 KGM.

DOI03

BRAKE BAND ADJUSTMENT

TORQUE ADJUSTING CAPSCREW TO 3,0 KGM AND THEN BACK OUT TWO TURNS.

D0104

FINAL DRIVE

VIEW OF FINAL DRIVE ASSEMBLY AND SPROCKET.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and satety ot personnel.

MODEL FD9 D105

FINAL DRIVE

CROSS SECTION OF FINAL DRIVE

OBSERVE COMPONENTS OF FINAL DRIVE.

D106

FINAL DRIVE DISASSEMBLY

AFTER REMOVING SPROCKET, LOOSEN CAPSCREWS AND SEPERATE FINAL DRIVE HOUSING FROM CENTER HOUSING.

D107

FINAL DRIVE DISASSEMBLY

ATTACH FINAL DRIVE HOUSING TO ROTATING STAND 75290090 USING FOUR CAPSCREWS.

D108

DISASSEMBLY

USING A PUNCH UNLOCK SPROCKET SHAFT INNER BEARING NUT.

Study SAfETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 D109

FINAL DRIVE

DISASSEHBL Y

SECURE SHAFT DRIVE GEAR WITH TOOL N9 75293318 AND REMOVE SPROCKET SHAFT INNER BEARING RETAINING NUT.

D110

SPROCKET SHAFT REMOVAL

ROTATE HOUSING TO HORIZONTAL POSITION AND REMOVE SPROCKET SHAFT FLANGE CAPSCREWS.

DIll

SPROCKET SHAFT REMOVAL

USING CHAIN LIFT SPROCKET SHAFT FROM HOUSING.

WARNING=~=~~;;=:~~=~:~~~;= ALL HEAVY PARTS WITH A LIFTING DEVICE OF PROPER CAPACITY. BE SURE PARTS ARE SUPPORTED BY PROPER SL INGS AND HOOKS. USE LIFT ING EYES IF PROVIDED. WATCH OUT FOR PEOPLE IN THE VICINITY.

A

Dl12

OUTER BEARING FLANGE REMOVAL

REMOVE OUTER BEARING FLANGE RETAINING CAPSCREWS.

Study SAFETY RULES in the front of this manual thoroughly for the pro,ection of iTlilchine and :;atp.ty

at persorulei:-

MODEL FD9 Dl13

FINAL DRIVE

BEARING FLANGE REMOVAL

AFTER REMOVING CAPSCREWS REMOVE OUTER BEARING FROM HOUSING.

, Dl14

SPROCKET SHAFT INNER BEARING

TO REMOVE SPROCKET SHAFT INNER BEARING, FIRST REMOVE BEARING COVER LOCK PLATE.

DllS

BEARING COVER REMOVAL

AFTER REMOVING LOCK PLATE, REMOVE BEARING COVER USING A SUITABLE LEVER .

Dl16

SPROCKET SHAFT INNER BEARINT

SLIDE SHOWS SPROCKET SHAFT INNER BEARING, BEARING COVER AND LOCK PLATE.

-----------:--------------:-------------

St'Jdy SAFETY f-lULES ill th(~ fron-~- oi this manual thorou~hly for the protection of rna(;hine anJ 5'lfety of p{:rsonn~1.

MODEL FD9 Dl17

FINAL DRIVE

SPROCKET SHAFT OUTER BEARING

AFTER REMOVING THE THREE SPROCKET SHAFT PLUGS, REMOVE OUTER BEARING USING A PUNCH AS SHOWN.

Dl18

INTERMEDIATE PINION REMOVAL

USING A CHAIN OR CABLE REMOVE INTERMEDIATE PINION . ===================

A WARNING· L 1FT AND HANDLE ALL HEAVY PARTS WITH A LIFTING DEVICE OF PROPER CAPACITY. BE SURE PARTS ARE SUPPORTED BY PROPER SLINGS AND HOOKS. USE LIFTING EYES IF PROVIDED. WATCH OUT FOR PEOPLE IN THE VICINITY.

Dl19

SIDE VIEW OF FINAL DRIVE HOUSING

OBSERVE CENTER HOUSING AFTER REMOVING INTERMEDIATE PINION.

•

D120

DRIVE PINION REMOVAL

TO REMOVE DRIVE PINION ITS NECESSARY TO REMOVE STEERING CLUTCH HUB. SECURE STEERING CLUTCH HUB WITH FIXTURE N9 75291579 AND REMOVE RETAINING NUT.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 D121

FINAL DRIVE

STEERING CLUTCH HUB REMOVAL

AFTER REMOVING PINION SHAFT NUT, REMOVE $TEERING CLUTCH HUB WITH EXTRACTOR N9 75291578.

D122

DRIVE PINION REMOVAL

AFTER REMOVING STEERING CLUTCH HUB, REMOVE DRIVE PINION.

D123

BEARING REMOVAL

TO REMOVE DRIVE PINION AND INTERMEDIATE PINION INNER BEARINGS REMOVE LOCK PLATE.

D124

SPROCKET SHAFT SEAL INSTALLATION

INSTALL SEAL BETWEEN SPROCKET SHAFT AND OUTER BEARING RETAINING FLANGE USING CARE TO AVOID DAMAGE TO SEAL.

Study SAF ETY RL LES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 D125

FINAL DRIVE

SPROCKET SHAFT OUTER BEARING

SLIDE SHOWS BEARING IDENTIFICATION NUMBERS. THESE BEARINGS ARE A MATCHED SET AND CANNOT BE MIXED.

D126

OUTER BEARING ASSEMBLY

AFTER INSTALLING BEARING RETAINING FLANGE, PLACE SPACER AND OUTER BEARING ONTO SPROCKET SHAFT.

D127

FINAL DRIVE GEAR TRAIN

SLIDE SHOWS FINAL DRIVE GEAR TRAIN AS POSITIOND IN HOUSING.

D128

FINAL DRIVE ASSEMBLY

WITH HOUSING ATTACHED TO ROTATING STAND 75290090 PLACE SPROCKET SHAFT DRIVE GEAR IN HOUSING.

I ,f ~11f :

,

i

J

Study SAFETY RULES in t'1e front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 D129

FINAL DRIVE

SPROCKET SHAFT ASSEMBLY

WITH LIFT CHAIN INSTALL SPROCKET SHAFT USING CARE TO LINEUP SHAFT SPLINES WITH DRIVE GEAR.

Dl30

FINAL DRIVE ASSEMBLY

ROTATE HOUSING TO VERTICAL POSITION AND INSTALL SPROCKET SHAFT INNER BEARING SPACER.

D131

SPROCKET SHAFT INNER BEARING

PREHEAT SPROCKET SHAFT INNER BEARING TO 1209C AND INSTALL ON SHAFT.

D132

SPROCKET BEARING RETAINING NUT

TORQUE INNER BEARING RETAINING NUT TO 95,0 KGM AND LOCK WITH A PUNCH AS SHOWN.

A WI\RNING=.==~;=~;=~~;:;~=;~= STR IKE HARDENED STEEL PARTS WITH ANYTHING OTHER THAN A SOFT IRON OR NON-FERROUS HAMMER.WHEN INSTALLING OR REMOVING SUCH PARTS WEAR SAFETY GLASSES WITH SIDE SHIELDS AND HEAVY GLOVES, ETC., TO REDUCE THE POSSIBILITY OF INJURY.

Study SAFETY RULES in tht! front of this m3nual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 Di33

FINAL DRIVE

OUTER BEARING RETAINING FLANGE

TORQUE OUTER BEARING RETAINING FLANGE CAPSCREWS TO 10,0 KGM AS SHOWN.

D134

BOTTOM COVER ASSEMBLY

APPLY SEALANT ON BOTTOM COVER AND INSTALL. TORQUE CAPSCREW TO 6,0 KGM AS SHOWN.

D135

STEERING HUB ASSEMBLY

DURING ASSEMBLY OF STEERING CLUTCH HUB OBSERVE MARKS ON DRIVE PINION SHAFT AND STEERING HUB. THESE MARKS INDICATE CORRECT SPLINE ENGAGEMENT.

D136

STEERING HUB RETAINING NUT

SECURE STEERING CLUTCH HUB WITH FIXTURE N9 75291579 AND TORQUE RETAINING NUT TO 106,0 KGM AS SHOWN.

WARrJING:=7;;=7;~~~;:;;=;;= STR IKE HARDENED STEEL PARTS WITH ANYTI! ING OTHER THAN A SOFT IROI~ OR NON-FERROUS HAMMER.WHEN INSTALLING OR REMOVING SUCH PARTS WEAR SAFETY GlASSES WITH SIDE SHIELDS AND HEAVY GlOVES ETC., TO REDUCE THE POSSIBILITY OF IN;URY.'

A

----. _--------------------------------------------------------------------Study SAFETY RULES in the front of this manual thoroughly for the protection of machine ?nd $afety of personnel.

MODEL FD9 D137

FINAL DRIVE

INTERMEDIATE PINION

INSTALL INTERMEDIATE PINION IN CENTER AS SHOWN.

~OUSING

===================

A WARNING· LIFT AND HANDLE ALL HEAVY PARTS WITH A LIFTING DEVICE OF PROPER CAPACITY. BE SURE PARTS ARE ~UPPORTED BY PROPER SLINGS AND HOOKS. USE LIFTING EYES IF PROVIDED. WATCH OUT FOR PEOPLE IN THE VIC INITY.

D138

FINAL DRIVE ASSEMBLY-

USING LIFT HOOK 75295408 REINSTALL FINAL DRIVE AFTER APPLING SEALANT ON MATING SURFACE, TORQUE CAPSCREWS TO 16,5 KGM.

UNDERCARRIAGE E001

ROLLER GUARDS

TRACK FRAMES ARE OFTEN EQUIPPED WITH TRACK ALIGNMENT GUARDS, THE GUARDS PERFORM TWO FUNCTIONS: 1.PREVENT MATERIAL FROM LODGING BETWEEN THE ROLLERS AND THE TRACK CHAIN AND BETWEEN THE TRACK CHAIN AND THE SPROCKET.

E001

CON'T

2. THEY ACT TO AL I GN THE TRACK CHAIN IF THE TRACK CHAIN TENSION IS TOO LOOSE.

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Study SAl' ETY RULES in ,hlc) front of this manual thoroughly for the protection of machinf' and safety o·f personnel.

MODEL FD9 E002

UNDERCARRIAGE

TRACK CHAIN COMPONENTS

TRACK CHAIN CONSISTS OF BUSHINGS PINS AND LINKS. THESE FORM A CONTINUOUS CHAIN. NOTE THAT THE LINK HAS A BUSHING AND A PIN FIRMLY ATTACHED. THE OPPOSITE LINK WOULD HAVE THE CORRESPONDING PIN ABD BUSHING ATTACHED TO IT.

E003

TRACK PITCH

TRACK PITCH IS THE DISTANCE BETWEEN ADJACENT PINS. THIS CAN BE ~illASURED FROM ON EDGE OF ONE PIN TO THE SAlill EDGE OF AN ADJACENT PIN. OFTEN THIS MEASUREMENT IS MADE OVER A NU}ffiER OF PINS TO OBTAIN A MORE ACCURATE INDICATION OF THE TRUE PITCH.

E004

SPROCKET

THE SPROCKET DRIVES THE CHAIN. THE SPROCKET TEETH MATE WITH THE CHAIN'S BUSHING TO DRIVE THE CHAIN.

E005

•

SPROCKET PITCH

THE PITCH OF A SPROCKET IS THE DISTANCE BETWEEN THE CENTER POINTS OF TWO ADJACENT BUSHINGS AS THEY REST IN THE SPROCKET. IDEALLY, THE PITCH OF THE SPROCKET AND THE PITCH OF THE TRACK WILL BE THE SAXE. THIS WILL ALLOW THE BUSHINGS TO MATE PROPERLY IN THE SPPDCKET TEETH.

Study SAF ETY RU LES in the front of this manual thoroughly for the protection of machine and safety of personnel.

MODEL FD9 E006

UNDERCARRIAGE

TRACK FRAME·

THE TRACK FRAME SUPPORTS THE ROLLERS, IDLER AND MACHINE. EACH MACHINE HAS TWO TRACK FRAMES WHICH MAY OSCILLATE.

E007

DISASSEMBLED ROLLER

THE TRACK ROLLERS AND CARRIER ROLLERS AS WELL AS THE IDLER ARE EQUIPPED WITH BUSHINGS. THE ROLLERS AND IDLERS CAN BE REBUILT BY INSTALLING NEW BUSHINGS AND SEALS. REFER TO THE PROPER SHOP MANUAL FOR THE PROPER REBUILD TECHNIQUE.

EOOS

DOUBLE AND SINGLE FLANGE ROLLERS

BOTTOM ROLLERS, ALSO CALLED TRACK ROLLERS, COME IN TWO STYLES, DOUBLE AND SIN~LE FLANGE. THE DOUBLE FLANGE ROLLER KEEPS THE TPACK CHAIN IN BETTER ALIGNMENT, WHILE THE SINGLE FLANGE DOES NOT INTERFERE WITH THE IDLER OR SPROCKET. IN SOME MACHINES THE SPROCKET AND IDLER COULD ACTUALLY CONTACT THE CENTER FLANGE OF THE END ROLLERS ,CAUSING DAMA~E.

E009

TRACK ROLLERS

TWO TYPES: TOP (CARRIER)ROLLERS SUPPORT THE CHAIN AND BOTTOM ROLLERS SUPPORT THE MACHINE.

Study SAFETY RULES in t'1e front of this manuiii thoroughly for the protection of machine and safety of personnel.

MODEL FD9 E010

UNDERCARRIAGE

IDLER SHIMS

THE ~DLER IS THE PRINCIPLE GUIDING MEMBER IN THE UNDERCARRIAGE SYSTEM, THE PROPER ALIGNl"ENT AND POSITIONING OF THE IDLER WILL AFFECT NOT ONLY THE WEAR OF THE IDLER, BUT ALSO OTHER COMPONENTS.

E011

IDLER

THE TRACK CHAIN ROLLS AROUND AN IDLER AT THE FRONT OF THE TRACTOR TO RETURN THE CHAIN TO THE SPROCKET.

E012

TRACK RELEASE

THE TRACK RELEASE SPRING EXERTS TREMENDOUS FORCE. BEFORE SERVICING ANY TRACK RELEASE SPRING. OBSERVE CAREFULLY THE INSTRUCTIONS IN THE APPROPRIATE UNDERCARRIAGE SHOP MANUAL FOR THAT MACHINE, USE EXTREME CARE IN DEALING WITH THIS COMPONENT.

E013

TRACK RELEASE

EACH TRACK FRAME IS EQUIPPED WITH A TRACK RELEASE MECHANISM. THE TRACK RELEASE FUNCTIONS TO ABSORB SHOCK AS THE CRAWLER TRACTOR NEGOTIATES ROUGH TERRAIN. IF THE TRACK RELEASE MECHANISM SHOULD MALFUNCTION THE TRACTOR WOULD BE SUBJECT TO SEVERE SHOCKS.

Study SAFETY HULES in the front of this manual thoroughly for the protection of machine and safety of personl1el.

Farm 753'14593

English