Pulled from the factory shelf, this 464-page Fiat-hitachi FD 255 Service Manual PDF walks you through every system on the crawler dozer, from engine rebuild to steering clutches, final drives, and undercarriage. You get full wiring diagrams for the electrical system, hydraulic schematics for the blade and ripper circuits, and a real troubleshooting section spanning engine, transmission, steering, brakes, and hydraulics. Inside: exploded views, page after page of torque tables and clearance data, plus hour-based maintenance schedules from 10 to 3000 hours. Fill the engine with AMBRA SUPER 15W40, then pull grade-10 M10 x 1.5 nuts to 5 daNm before you button anything up. A dozer sitting dead in the yard earns nothing. Bookmarked with a genuine text layer; search any spec, jump to any section, and get your tracks turning again.
What's Inside This FiatAllis FD255, D255-1T Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Rules and Decals | 3-24 | General Safety, Start-Up, Operating and Shutdown Precautions, List and Position of Safety Decals |
| Identification and Specifications | 11-17 | Serial Numbers and Identification Data, Engine, Power Train, Undercarriage and Hydraulic Specifications, Operating Weights |
| Controls, Instruments and Operating Instructions | 25-47 | Controls and Instrument Panel, Starting and Stopping the Engine, Fuel Reservoir, Cab Heating and Ventilation |
| Machine Operation | 48-62 | Dozing, Ripping, Towing and Transport, Working on Slopes, Operating Techniques |
| Maintenance Schedule | 63-81 | Every 250 / 500 / 1000 / 2000 Hours, When-Required Tasks, Lubrication Points, Filter and Fluid Changes |
| Electrical System and Troubleshooting (Operator Section) | 82-94 | Fuses, Master Switch, Batteries, Operator-Level Troubleshooting, List of Residual Dangers |
| Generalities and Technical Data | 95-128 | Technical Data Tables, Standard Torque Values, Lubricant Grades, General Service Instructions |
| Engine | 129-213 | Troubleshooting, Removal and Installation, Cylinder Head and Valves (Head Bolt 100 Nm, Intake Clearance 0.25 Mm), Cooling and Fuel Systems, Net Flywheel Power 177 kW @ 2100 RPM |
| Transmission | 214-287 | General Description, Troubleshooting, Torque Converter, Clutch Packs, Control Valve, Disassembly and Assembly, Pressure Tests |
| Steering Clutches and Brakes | 288-343 | General Description, Troubleshooting, Steering Clutch Disassembly, Brake Bands and Linkage, Adjustment Procedures |
| Final Drives and Sprockets | 344-362 | Disassembly and Inspection, Bearings and Seals, Sprocket Segments, Wear Limits |
| Undercarriage | 363-397 | Track Chains, Track Adjustment Mechanism, Rollers and Idlers, Track Frame, Wear Measurement |
| Hydraulic System for Bulldozer Equipment | 398-437 | Blade Tilt and Lift Circuits, Rapid-Release Coupling, Hydraulic Pump and Control Valve, Cylinders, Pressure Tests |
| Electrical System (Service Section) | 438-464 | Wiring Diagrams, Fuses and Relays, Master Switch, Starting and Charging Circuits, Instruments and Sensors |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine oil type | AMBRA SUPER 15W40 | p. 85 |
| NUTS (ZNT) Strenghth grade: 10 (R 80) M10 x 1.5 low type | 5 daNm | p. 212 |
| NUTS (ZNT) Strenghth grade: 10 (R 80) M10 x 1.5 with polyamide ring low type | 6 daNm | p. 415 |
| Total capacity at 1st filling | 22 litres | p. 204 |
| Net Flywheel Power (ISO 2534) | 177 Kw at 2100 rpm | p. 13 |
| Max. Torque | 101 daNm at 1400 rpm | p. 13 |
| Operating Weight (with semi-U (HSU) blade and ROPS cab) | 27000 Kg | p. 106 |
| Cylinder Head Bolt Tightening Torque (First phase) | 100 Nm | p. 202 |
| Valve Clearance - Intake | 0.25 mm | p. 13 |
FiatAllis FD255, D255-1T Common Problems This Manual Covers
Fiat-Hitachi FD 255 engine hard to start, runs irregular, smokes black under load
Check the engine troubleshooting charts starting on page 129; they walk no-start, low power, and black smoke in sequence. Verify the fuel filters and lift pump screen are clean per the 250 hour service on page 63, then set intake valve clearance to 0.25 mm using the calibration procedures.
Manual Section: Engine p. 129Machine sluggish in all gears and converter transmission oil overheating during heavy dozing
Check converter and transmission oil level at idle, then change oil and filters at the 500 hour interval on page 66. Clean the suction filters under the 1000 hour service on page 70. Trace pressure problems on the hydraulic schematic, , and torque a replacement low pressure sensor to 3.5 daNm (page 455).
Manual Section: Transmission p. 214One steering lever pulled to full stroke but the dozer keeps tracking straight
Check the steering clutches and brakes troubleshooting tables beginning on page 288; a clutch that will not release usually points to the control valve or worn discs. Inspect the suction filter for wear debris before committing to a teardown. If you rebuild the clutch pack, torque the outer drum screws to 10.8 to 12 daNm per page 342.
Manual Section: Steering Clutches and Brakes p. 288Blade drifts down with the distributor in neutral and cylinders move very slowly
Lower the blade to the ground and stop the engine. Cycle the control lever, then loosen and retighten the hydraulic tank plug to release residual pressure (page 420). Check the distributor and rapid release valve in the section starting on page 398, probing for leaks with cardboard, never your hands. Torque M10 polyamide ring nuts to 6 daNm on reassembly.
Manual Section: Hydraulic System for Bulldozer Equipment p. 398EDM monitor shows wrong oil level and pressure warnings with engine running normally
Check sensor connectors at the harness first; corroded plugs cause phantom EDM warnings. Verify actual transmission oil level per the when-required checks on page 77 before trusting the display. Test suspect circuits against the wiring diagram on page 441. Replace a faulty transmission oil low level sensor and torque it to 1.5 daNm (page 457).
Manual Section: Electrical System p. 438Frequently Asked Questions
What are the torque specifications for the FIAT-HITACHI FD255 hydraulic pump bolts?
The tightening torque for the hydraulic pump cover fixing screws (C1) is 11 daNm. These screws have a 12 x 1.25 thread. This specification is found in the tightening torques section of the manual. p. 434
What are the torque specifications for the FIAT-HITACHI FD255 engine mounting bolts?
The engine to frame support screws have specific tightening torques: C1 (M16 x 1.5) is 47.5 + 52.5 daNm, C2 (M14 x 40) is 17 + 19 daNm, C3 (M16 x 1.5) is 22.5 + 25 daNm, C4 (M16 x 1.5 x 30) is 22 + 24.5 daNm, and C5 (M16 x 1.5 x 35) is 22 + 24.5 daNm. p. 212
What is the engine oil capacity for the FIAT-HITACHI FD255?
The total engine oil capacity for the FIAT-HITACHI FD255 is 22 liters (20 kg) at first filling. For periodical oil changes, the engine sump capacity is 15.5 liters (14 kg), and with the filter, it is 18.6 liters (16.8 kg). p. 85
What is the cooling system capacity and recommended antifreeze mixture for the FIAT-HITACHI FD255?
The cooling system capacity for the FIAT-HITACHI FD255 is 65 liters. A 50-50 mixture of water and PARAFLU 11 antifreeze is recommended, providing protection down to -35°C (-31°F) against oxidation, foaming, corrosion, scaling, and freezing. p. 85
What are the specified valve clearances for the FIAT-HITACHI FD255 engine?
The specified valve clearances for the FIAT-HITACHI FD255 engine are 0.25 mm for intake valves and 0.50 mm for exhaust valves. These clearances should be checked and adjusted with a cold engine. p. 13
How will I receive this Fiat-hitachi FD 255 Service Manual?
A 464-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Are there any print restrictions on this Fiat-hitachi FD 255 manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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