All 544 pages of this Fiat-hitachi FD 145 Service Manual PDF (OEM #604.00.506) cover one machine: the FD 145 crawler dozer, from break-in checks to full powertrain teardown. You get factory wiring diagrams tracing everything from the start motor to the hydraulic filter clog sensor, hydraulic schematics for the pump, control valve, and dozer lift cylinders, and page after page of exploded views spanning the transmission, final drives, steering clutches, and undercarriage. Torque tables sorted by resistance class take the guesswork out of every fastener. Keep coolant 3 cm (1 inch) below the filler neck rim; when the hydraulics go soft, check solenoid spool travel against the 3 to 4 cm spec before condemning your pump. A dragging steering clutch won't wait for a dealer callback. Download the bookmarked PDF, search any spec by keyword, and get wrenching.
What's Inside This FiatAllis FD145 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Rules | 3-12 | General Safety, Start-Up, Operating, Shutdown and Maintenance Precautions, Decals |
| Identification, Specifications and Break-In | 13-18 | Engine Type and Serial Numbers, ROPS/Cab Data, Engine, Power Train, Steering and Brake Specifications, Preliminary Instructions and Break-In Period |
| Controls, Instruments and Operating Instructions | 19-34 | Controls and Instrument Panel, Starting the Engine (Incl. Very Low Temperatures, Start-Pilot Button), Engine Operation at Minimum, Shutdown Procedures |
| Machine Operation | 35-43 | Dozing, Road and Ditch Cutting, Piling, Ripping, Towing and Transport, ROPS and Anti-Vandal Protection |
| Cab | 44-48 | ROPS Cab, Doors, Window Panes, Cab Ventilation and Heating |
| Maintenance Schedule | 49-73 | Visual Inspection, Daily and 10-Hour Checks, Every 250 Hours (Fuel Lift-Pump Filter, Engine Oil, Alternator Belt), Every 500 / 1000 / 2000 Hours, Lubrication Points |
| Electrical System and Wiring Diagram (Operator Section) | 74-80 | Fuses, Main Electrical Components, Batteries, Start Motor, Alternator, Wiring Diagram |
| Fluid Capacities, Torques and Lubricants | 81-97 | Cooling System, Fuel Tank, Engine and Transmission Oil Capacities, Standard Torque Specifications, Lubricant Grades and Ambient Temperature Chart |
| Engine Related Components | 98-139 | General Description, Troubleshooting, Tests and Adjustments, Cooling System, Fuel System, Air Cleaner, Engine Mounts, Removal and Installation |
| Transmission | 140-232 | General Description, Troubleshooting, Pressure Tests and Adjustments, Torque Converter, Transmission Disassembly and Assembly, Clutch Packs, Control Valve |
| Final Drives | 233-274 | Outboard Bearing Cap, Final Drive Removal, Disassembly and Assembly, Sprocket, Seals and Bearings, Wear Limits |
| Bevel Gear, Steering and Brakes | 275-373 | Steering Clutches and Brakes, Bevel Gear and Shaft, Adjustment Procedures, Disassembly and Assembly, Brake Bands and Linkage |
| Implement Hydraulics | 374-426 | Hydraulic/Fuel Tank, Hydraulic Pump, Control Valve, Blade and Ripper Cylinders, Pressure Tests, Circuit Diagrams |
| Undercarriage | 427-481 | Track Chain, Track Release and Tension, Track Rollers and Idlers, Carrier Rollers, Sprocket Segments, Track Frame |
| Electrical System (Service Section) | 482-528 | Electrical Wiring and Harnesses, Fuses and Relays, Starting and Charging Circuits, Instruments and Sensors, Troubleshooting |
| Cab (Service Section) | 529-544 | Cab Tilting and Lowering, Seat Assembly, Cab Removal and Installation, Glass and Seals |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| If controls or other hydraulic systems feel spongy have the machine checked for air in the systems. Presence of air in these systems could cause improper control and result in an accident. See the Operation and Maintenance Instruction Manual for corrective procedures. | See the Operation and Maintenance Instruction Manual for corrective procedures. | p. 3 |
| Hydraulic system pressure loss due to sticking spool or weak spring in solenoid valve | 3 to 4 cm (1 1/4 to 1 1/2 in) | p. 71 |
| Hydraulic return filter replacement | item 17 | p. 70 |
| Air cleaner element replacement | item 27 | p. 71 |
| Coolant level from rim of filler neck | 3 cm (1") | p. 70 |
| Max. pressure of safety valve | 37 bar | p. 95 |
| Rating of safety valve | 230 + 5 bar | p. 95 |
| Main relief valve pressure | 190 ± 5 bar | p. 382 |
| Safety valve (adjust valve with shims (5) so that it begins to open at a pressure | 230 ± 5 bar | p. 415 |
| Reflow/safety multiple valve (rate valve with shims (5) so that it begins to open at a pressure | 210 ± 5 bar | p. 416 |
| Cooling System Capacity | 39 Liters | p. 81 |
| Engine Rated Speed | 2100 RPM | p. 14 |
FiatAllis FD145 Common Problems This Manual Covers
Fiat-Hitachi FD 145 hydraulic pressure loss under load, blade drops and cylinders move slowly
Test the main relief valve first and confirm it opens at 190 ± 5 bar, the adjustment spec on page 380. If pressure stays low, remove the solenoid valve block and check the spool for sticking or a collapsed spring; contaminated fluid is the usual cause. Drain the system, replace the return filter, and refill with clean oil.
Manual Section: Implement Hydraulics p. 380Recurring hydraulic contamination with metallic powder in the oil even after filter changes
Remove the pilot filter element and inspect the mesh under good light; a widened or torn net dumps unfiltered oil straight into the circuit. Replace it along with the hydraulic return filter, item 17 on page 70, every 500 hours. If you find metallic powder, pull the cylinders and inspect piston rods and tubes for scoring.
Manual Section: Implement Hydraulics p. 70Crawler track keeps going loose, grease drains back out of the adjust cylinder valve
Measure track sag between the idler and carrier roller; the spec on page 433 calls for 30 to 40 mm. If the track keeps loosening, remove the adjust cylinder cartridge valve and check it for a loose fit or damaged seat, then replace it and repack the cylinder with fresh grease before resetting sag.
Manual Section: Undercarriage p. 433LOW COOLANT warning keeps coming back, expansion tank needs topping up every shift
Fill the cooling system to 3 cm (1 inch) below the filler neck rim, the level given on page 70. Total capacity is 39 liters, listed on page 81, so track how much you add; losing more than a liter per shift means a leak. Pressure-test the expansion tank plug and inspect hose clamps and the radiator core.
Manual Section: Fluid Capacities p. 81Machine creeps in neutral, gear lever hard to move, transmission oil runs hot
Check converter and transmission oil level and condition first, then work through the troubleshooting procedures starting, which cover creeping, low power, and stiff lever movement. If teardown is needed, torque the transmission shaft lock nuts to 92 to 95.5 daNm on reassembly, the spec listed on page 221.
Manual Section: TransmissionFrequently Asked Questions
What are the torque specs for FIAT-HITACHI FD 145 engine bolts?
The torque specifications for engine bolts vary by component. For example, the rear mount center capscrew (M24x2x80) should be tightened to 41-45 daNm, while the front/rear mount capscrew (M15x1.5x50) requires 32.4-35.7 daNm. p. 95
How to reset the hydraulic pressure on FIAT-HITACHI FD 145 bulldozer?
To adjust the main relief valve pressure, apply a pressure gauge to the distributor's pressure intake. If the pressure is not the prescribed 190 ± 5 bar, screw the adjustment screw until the correct pressure is reached, then tighten the counternut and check again. p. 380
What do error codes on FIAT-HITACHI FD 145 display mean?
The Electronic Data Monitor (E.D.M.) displays various fault indicators. For instance, indicator 'a' signifies insufficient gearbox oil level, 'b' indicates insufficient motor oil level, and 'c' points to insufficient motor coolant level. Other indicators cover battery reloading system faults, high motor coolant temperature, and clogged filters. p. 113
How to reset the maintenance timer on FIAT-HITACHI FD 145?
The FIAT-HITACHI FD 145 is equipped with an hourmeter that totalizes the hours and fractions of operation, starting when the engine is turned on. The manual does not describe a procedure to reset a maintenance timer. p. 25
What is the engine oil capacity for the FIAT-HITACHI FD 145?
The engine oil capacity for the FIAT-HITACHI FD 145 is 12.5 liters for initial fill and 14 liters for refill. The recommended lubricant is AMBRA SUPER, meeting MIL-L-2104 D or Service API "CD" specifications. p. 81
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