FiatTrattori aes 355 C 455 C 505 C 605 C Workshop ManualFiatTrattori Gg 355 C 455 C 505 C 605 C Workshop Manual DIREZIOWN E QUICK-REFERENCE INDEX CONTENTS . ss GENERAL 5 wy ENGINE, . 5 MASTER CLUTCH... GEARBOX . . BEVEL DRIVE . . BRAKES - STEERING CLUTCHES HUB-REDUCTION FINAL DRIVE POWER TAKE-OFF, BELT PULLEY. . UNDERCARRIAGE, HYDRAULIC LIFT SYSTEM ELECTRICAL SYSTEM TIGHTENING TORQUE FIGURES SERVICE TOOLS » + 1973-SERIES TRACTORS Page 13 7 78 84 97 102 104 106 124 198 169 174 179 COMMERCIAL EIMPORTANT The Imperial weights and measures are given for operators” convenience and, though the closest approximation is sought, they are normally rounded off for practical reasons. In case of discrepancies only the metric units should be considers: The wear allowances indicated for some items are given for guidance only. Any reference made in the manual to “front”, “rear”, “right-hand” and “left-hand” is as viewed facing the direction of forward travel from the driver's seat. A.M. = Ante-modification — P.M. = Post-modification. COPYRIGHT BY FIAT S.p.A All rights reserved. Reproduction of text and illustrations 1s nob permitied ie any form. PRINTED IN ITALY FIAT TRATTORI S.p.A. - le delle Nazioni, 55 - S. Matteo - 41100 MODENA - Italy NORMATIVA E FORMAZIONE - Pubblicazioni - Print No. 603.54.162R -IIl-1981-200 -P.G.S. MODENA. iraeAGRICULTURAL CRAWLER TRACTORS Model 355C Model 455C Model 505 C Model 605 C4 TRACTORS 365 C - 455 C 505 C - 605 C CONTENTS GENERAL Foreword Specification Capacities Identification Data Spare Parts ENGINE Description Performance Data Compression Test To Remove To Refit Engine Block and Cylinder Head Block and Head Data Engine Block Cylinder Liners Cylinder Head Oil Sump . . Valvegear Valvegear Data Camshaft ae Valves, Valve Guides and Springs Tappets, Push Rods and Rockers . . Valvegear Inspection and Timing Crankgear Crankgear Data Crankshaft Main/Big End Bearings and Caps Pisions and Rings Connecting Rods... Flywheel Flywheight Type Dynamic Balancer (605 C) Fuel System Fuel System Data Air Cleaner Page " 12. 12 13 14 16 7 7 18 18 18 19 20 2 22 23 24 25 26 28 29 30 31 32 32 35 36 Fuel Tank . Bei Fuel Filter (355 C) é Fuel Filtess (455 C-505 C-605 C) Fuel Lift Pump (355 C) Fuel Lift Pump (455 C-505 C-605 C) Automatic Advance Device (355 C) FIAT Injection Pump (355 C) — To Overhaul — To Test and Calibrate the Injection Pump — Injection Pump Calibration Data — Injection Pump Refitting and Timing — To Check and Adjust Throttle Linkage and Engine Idiing Surge : BOSCH Injection Pump (455 C-505 C) — To Overhaul — To Tost and Calibrate the Injaction Pump — Injection Pump Calibration Data C.AV. Injection Pump (455 C-505 C-605 C) — To Overhaul — To Test and Calibrate the Injection Pump = Injection Pump Calibration Data. a BOSCH/C.A.V. Injection Pump Timing — To Adjust Throttle Linkage and Check Engine Running : Fuel Injectors ‘Thermo-starter Lubrication System Lubrication System Data... Oil Pump Oil Filter Oil Pressure Warning Light Cooling System Cooling System Data Water Pump Radiator Thermostat To Adjust Belt Tension . . Water Temperature Gauge and Werning Light TACHO-HOURMETER . . . FIAT Page 37 37 38 39 39 40 a a 43 45 45 46 47 48 50 52 54 55 58 61 63 64 64 64 65 65 66 66 70 70 n 73 73 73 73FIAT CONTENTS 5 Page Pege MASTER CLUTCH oe ie Master Clutch Data 74 Tock Raters: ae) Description 35. Top Idler Whee! (608 C) ngs eornaie 75 Fitting Notes ng To Adjust 77 Roller and Wheel Lubrication 121 Track Carriage Assemblies 121 — To Adjust 123, GEARBOX AND SPEED-REDUCTION UNIT Suspensions . 123 Gearbox and Speed-Reduction Data 78 Description and Overhaul 79 HYDRAULIC LIFT UNIT Hydraulie Lift Unit Data. 124 BEVEL DRIVE Descriotion (955 C) 127 Boaione Geel 24 Hydraulic Lift (355 ¢) 129 ee oncnne c 34 — To Overhaul Lilt Control Velve 129 fo Adlust 87 — lift Contiol Valve Bench Testing 130 = To Overhaul Litt Cylinders 130 = To Check and Adjust flit Valve Setting 130 BRAKES - STEERING CLUTCHES - — To Adjust Maximum Lit Arm Travel 131 HUB-REDUCTION FINAL DRIVE — Auniliary Control Valve 132 Description (455 C-505 C-605 C) 134 Breke/Steering Clutch/Final Drive Data Bl, apesurtliniaen eon cease! i Brekes %2 = To Onetaul Lit Convol Vaive 135 a 24 — Hydraulic Lift Bench Testing Pe 140 arm ee earl Sree 8 _ To check and Adjust Relief, Safety end Unload Valves . 140 POWER TAKE-OFF = To Adjust Lit Arm Travel and Spool Response 141 — Autiliary Control Valve 143 PTO. Data 102 Three-point Linkage 144 Desorption and Overhaul 103 Hy¢raulic Pump 145; = Output Test 146 nas Fault Finging Chan 147 Belt Pulley Data ee Description and Overhaul 104 Charging System . . 148, UNDERCARRIAGE re pear ue — Alternator 149 Undercarriage Data 108 — Voltage Regulator 183 Track Cheins : 109 — Alternator Warning Retay 153 — Track Link Renewal 112 — Fault Finding Chart 154 Track Tension Assembly . 112 Battery 156 — To Check and Adjust Track Chain Tension 113 — Data 186 Front Idler Wheel 114 — Servicing 1866 TRACTORS 355 C - 455C - 505C - 605C Page Starter 187 — Data 187 — Description 160 — To Overhaul 161 — Bench Tests. . 165 Accessories aes 166 — Master Switth .......... 166 — Starter/Thermostarter Switch... . 166 == Fike Unk, jini y ciated nibs M87 — Bubs (eamee eee 167 — Headlamp Alignment ewe 168 TIGHTENING TORQUE FIGURES 169 SERVICE TOOLS. 174 1973-SERIES TRACTORS Identification Data Engine — Fuel Injection Pumps — Spray Nozzles — Performance Data — FIAT Injection Pump Cz Data (355 C) — BOSCH Injection Pump Calibration Data (485 C-605 c) : — CAV, Injection Pump Calibration Data (485 6-505 €-605 ¢) 5 Gearbox and Reduction Unit Hydraulic System (455 C-05 C-605 C) 179 179 180 180 180 183 183 185 187 187FIAT GENERAL 7 GENERAL FOREWORD The information given in this manual applies to the standard versions of Models 355 C, 455 C, 505C, ‘and 605 C. Data and deseri foronce apply to the four models. ions which do not carry any typo SPECIFICATION IDENTIFICATION DATA Chassis Type 355 C 632.500 455 C 632.200 505 C 634.200 605 636.200 ENGINE Taster Tee wee wets coe Engine Type oasozers | $088022100) | soasoasra cw | $o4802211 0) cycle 3 Diese! Diese! Diese! Diesel Strokes - : Four Four =| Four Four No. of cylinders... 2 3 3 4 Bore 400 mm, 100 mm 100 mm. 100 mm. (3.94 in.) (3.94 in.) (3.94 in) (3.94 in.) Stroke is 110 mm. 110 mm. 110 mm. 110 mm. (4.33 in.) (4.33 in.) (4.33 in.) (4.33 in.) Capacity jews 1728 cm* 2592 cm* (2592 cm 3456 cm* (106.44 cu. in.) | (19.16 cu. in.) | (189.16 cu. in) | (210.88 cu. in.) Compression ratio : 17 101 17101 1701 1701 Camshaft rotation (a8 seen from fan side) | Clockwise | Clockwise Clockwise | Clockwise ‘Main bearings | Three Thee Three | Three Firing order «| 1 (180°)-2 (540: 1-2-3 1-2-3 i) 1-3-4-2 Rated engine speed . . 2500 r.p.m. 2400 rpm. 2600 rpm. | 2200 p.m. Max. no-load speed 2700 rpm | Ze00 rem. 0) | 2800 rpm. | 2400 rpm 2600 rp.m. @) 650107 00r.p.m.(")| (650t0700r.p.m.(")| '500,00/000 cam: { 650 r.p.m. () gee [ 650 rpm. () Alternator-to-engine speed ratio 183 t0 1 1.83 to 1 1.83 to 4 1.83 to 1 Oil pump-to-engine speed ratio 5tot 5 to1 5 tot 5to1 Water pump/fan-to-engine speed ratio 1.42 to1 142 to1 1.42 to1 1.42 to1 Hourmeter rating . 1750 r.p.m. 1600 r.pm. 1840 r.p.m. 1600 1.p.m. Output (fan, air cleaner and exhaust silencer removed) 35 HP 45HPp | 50 HP || S56 HP (2) Boseh injection pump, ©) CAV. injection pump.8 TRACTORS 355 C - 455 C - 505C - 605C Valvegear Pushrod operated overhesd valves. Inlet opens 3° B.1.0.C. Inlet closes 23° ABDC. Exhaust opens 48° 30° 6.B.0.C. Exhaust closes 6" ATDC. Valve clearance = — For timing check - - 45 mm (.018 in) — Normal: hilt = 2 ba ee y 2emm M10M iBahauet! 2 2) at oe ‘35 mm (014 in) Fuel System Oil-bath air cleaner. Fuel pump outlet line filters:— — One cartidge, water separator (355 C). — Twin, in-line, cartidge (water separator on first) (455 C-505 C-605 C). Fuel injection pump:— — In-line, plunger type pumping elements (355 C) — Distributor type, Bosch or C.A.V. (455 C-605 C-605 C) Litt pamp:— — Piston type (355 C) — Twin-diaphragm type (455 C-505 C-605 C). Automatic Advence Variator:-— — Mechanical (355 C). — Hydraulic (455 C-505 C-605 C). Four-orifice nozzle injectors Release pressure 225 to 235 kg/cm (3,200 10 3,342 psi.) Lubrication System Forced-feed, gear type pump, regulating valve. Normal lubricating oil pressure Oil fiters:-— — Inlet line, gauze. — Outlet line, full-flow, cartridge type, by-pass valve. featuring oil pressure 3 t0 4 kg/m (42.7 to 56.9 psi.) Cooling System Vane type centrifugal water pump. Wax type thermostat. Vertical tube radiator core and fan. Bm FIAT MASTER CLUTCH Dry single plate, overcentie engagement (355 C-455 C- 505 C). Dry twin plete, overcentre engagement (605 C). Manual lever, mechanical. GEARBOX AND SPEED-REDUCTION UNIT Sliding-mesh gear, three forward and one reverse ratios. Integral speed-reduction unit for a total of six forward and two reverse ratios. Single gear selector lever. BEVEL DRIVE Centre bevel gear train in axle cass, BRAKES Band-type on steering clutch drums. Two independent pedals. Brake lock lever (parking) STEERING CLUTCHES Dry, multi-plate, thrust spring, withdrawal slecve, Manual lever HUB-REDUCTION FINAL DRIVE ‘Spur gear train. POWER TAKE-OFF Transmission type. Manual lever. Engine speed at standard 540. rp.mi— — Models 355 - 455¢ - 505 ¢ — Model 605 C ~ + 2160 rp.m. 1970 rpm BELT PULLEY Manual lever Diameter width 250 x 150 mm. (9.84 x 5.90 in.) Rated speed:— — Model 355 ¢ 1300 rpm. — Model 485 ¢ 1248 rpm.FIAT GENERAL _ 9 — Model 505 C 1352 rpm. Track carriage assemblies with five track rollers and one — Model 605C . . 1144 rpm. top idler (605 C). Recoil spring type track tension assembly. UNDERCARRIAGE Four track roller carriage assemblies (385 C-455 C-505 C). ‘Transverse leaf spring front suspension, Transverse rear suspension bar resting on track carriages. TRANSMISSION RATIOS AND TRAVEL SPEEDS eavor | Seees | 3ute* oe MRE ACRLPRS Gear }e2rbOx | Raduction| , Speed Ratios |"Ratos|M*2UUOM| toda! | Model | Model | Medel | Model | Model rac ios | ssc | 455¢ | so5c | cosc | a55c | 455c 605 C | Ast : 7 148.431] 145.075 164.923] 148.431| 1.7 ja i st ss | case | 148 x . ras ee eae | tae) | 195) | ci " (1.08) 2nd 81,428| 80.135 90.475| 81.428} 3.1 | 3.0 ey 34 (1.82) | (1.88) | @2 08) | (182) 3rd. 59.242) 58.301) 65.824) 59.242) 4.3 42 45 42 (2.67) | (2.61) | (2.79) | (2.61) 4th 43.099| 42.418| 47.888| 43099, 59 | 57 | 62 | 58 (3.66) | (3.54) (3.85) | (3.60) Sth clays 32.499| 31.983] 36.110] 32493, 78 | 76 | 82 | 77 (4.24) | (4.72) | (6.09) | (4.78) elhivance 23,644) 23.288 26.271 23.644| 107 | 104 | 11.2 | 106 (6.65) | (6.48) | (6.96) | (6.59) ‘ot Reverse: 79.952| 77.699| 97.725| 79953) 32 | a1 | 34 | 32 (1.98) | (1.92) | (2.11) | (1.98) 2nd Reverso | 43.213] 42.626] 48.126 43313, 62 | 6.7 | 61 58 | (3.60) l (B54) (3.80) | (3.60) Bevel drive ratio: — Models 365 C-455 C-605 C (10/44) . 4.400 to1 — Model 505 C (9/44) oa 4890 to1 Hub-reduction final drive ratio:— — Models 356 C-505 C605 C 6.300 to 1 — Model 455C. . . 6.200 to1 Overall ratio (bevel and hub):— — Models 355 C-605 C (27.720 to1 a EN OE i es we 27.280 to 1 = Minlal RS se ne a ee 30.800 to 1 P.T.O. drive ratio:-— — Models 355 ¢ - 455¢ - 505C 4,000 to 1 = Me TOE swe » 3.642 to1 Belt pulley drive ratio 1.9230110 TRACTORS 355 C - 455.C - 505C - 605C FIAT HYDRAULIC LIFT UNIT Position-controlled lift with integral single cylinder (Models 455 C-505 C-605 C) and two single acting external cylinders (Model 365 C). Engine driven gear type hydraulic pump drawing from litt body (485 C-505 €-605 C) or gearbox (355 C). Reted output:— — Model 365 ¢ 186 lites/min. (4 Gall/min) — Model 485 ¢ 17.8 lives/min. (3/5 Gali.) — Model 405 C 19.3 litres/min. (41/, Gall./min.) — Mode! 605 C 16.3 litres/min. (3*/2 Gall./min.) 14510 155 kg/em? (2,062 to 2,204 p.si) Three-point linkage capacity: — Models 355 C-455 C Category 1 — Models 505 C-605 C Category 1 and 2 Relief valve setting... Rated load:— — Model 355 ¢ + 1000 kg (2,208 Ib.) — Models 455 C-505 C- 605 ¢ 1200 kg (2,646 Ib.) Nominal lift capacity: — Model 355 ¢ = 880 kgm (6,365 Ib. f.) — Models 455 C-505 C- 605 C 840 kgm (6.075 Ib. ft.) ELECTRICAL SYSTEM (12 Volts) Battery capecity at 20 hour discharge rate:— — Model 365 ¢ — Models 455 ¢-505 C — Model 605 ¢ Alternator — Moximum rating Voltage regulator Alternator warning relay - Starter: — Model 385 ¢ — Models 455 0-505 C — Model 605 Output 1 — Models 385 C-455 C- 505 C — Model 605 WEIGHTS Operating weight:— — Model 365 ¢ — Model 485 ¢ Medel 605 C — Made! 605 = 2500 kg, 17 Ah 110 An 136 or 143 Ah FIAT A112 M - 124/12/42 X-M 53 Amps. FIAT RC 2/128 SIPEA or WEPOO FIAT M125 - 3/12 V.2 FIAT M125 - 3/12 MARELLI MT 38.G A - OB 2035 kg. (4,487 Ib.) 2140 kg. (4,718 Ib.) (5,512 Ib.) 2780 kg. (6.063 Ib.) Model a]el]e o |e | # tile) a 3556 tas | 3200 | 2490 | 2m | so0 1605 ain | cov | @n | Go | bom (a7) a5s.c 1210 | 1292 | 2675 | 50 | 010 | s292 | 250 | too | — | — | — 477) | Go) | 105479 | (40) | 9%) | 60") | 0) | (65) 505 ¢ 120 | isis | 2675 | a0 | 1100 | r440 | 270 | 1055 | — | — | — cB1) | GI | cosa | azz | aay | GRP) | doxs | 65% 605 ¢ w | an | a | a0 | soo | s440 | 270. | 1655 | 1230 | 1528 | 2785 cary | A370 | GeV | Gory | @s% | ABM | (oo% | GOsFIAT GENERAL " CAPACITIES | Type of Fia Description Ko. | Utes aa FIAT Desigration | Intonatone! Designation Fuel:— | — Mode! 385 ¢ — | 34 | 7% Gat |) Diesel oit (decanted — Models 455¢-505C-605c | — | 54 12 Gall | and fitered) Coolant:— — Model 355 C = 1) e ‘Ts Gell — Models 455 C - 605C — | 18 | 2% Gell |F Water () — Model 695C . . = |e 3 Gall Engine oil ‘Sump, filters and lines @):— | | — Medel 255 ¢ 2. | 38 | 42 | 7% Pine —Mode's 465c- sosc .. | 68 | 75 | 1% Gall = Mode! 605 ¢ 105 115 | 2% Gall Sump: only ()— — Mods 955¢ ...... | 32 | 36 | ov, Pins — Modes 4856-6056 .. | 60 | 68 | 1% Gal — Model 695.6. 95 | 105 | 2% Gall Injection pump/governor oil) | (255 ¢) 15} 16) % Pine Air cleaner oil (2):— — Model 3856... 50} 85) 1 Pint — Models 455 C-505C-605C | 95) 94 | 1%/, Pints SAE 20W-40 Cae et doe (485 C - 505 C - 605C) oil ia [125 | 2% Gal | ros ctesmarntay Goarbox/bovel rive/P.T.0. and | EP additives hydraulic lift (255 C) oil @) 15.75 | 176 | 4 Gall Hub-reduction oil (each):— — Models 385C - 4550. 85) 95 | 1/, Pins — Models 505C - 605C .. | 5@) |550)) 9% Pims | Belt pulley cil ci 4 | 44] % Pint Track rollers and idler wheol =| = Hydraulic lift oil (485 ¢ - 505 ¢ - 605 c) . . : 32 | 38 | 6% Pins |, Grease nippels . a | = | grassofiat G9 | Lithium-base | ‘grease to NLGI | No. 2 () At the beginning of the cold season use Fat or other approved ant ©) Use AMBRA 10 W/30 (SAE 10 W-30) for tomparaturoe Below O° C ©) 7kge 78 lies (1%), Gall) for Hil vesion12 TRACTORS 355 C - 455C - 505C - 605C FIAT IDENTIFICATION DATA Engine Number Chassis Number Fig. 2 - Location of Identification Data on the Tractor SPARE PARTS Whenever replacement parts are required it is essen- tial that only genuine spares should be fitted to ensure efficient running. When ordering, please state:— — Tractor model. — Chassis type and number. — Engine type and number. — Spare part number (see the Spare Parts Catalogue).FIAT ENGINE: DESCRIPTION 13 ENGINE DESCRIPTION Tho FIAT ongines fitted to crawler tractors Medele 356 C- 455 C.505 C and 605 C are high-speed, 4-stroke, in-line Diese! units Engine Block - Single casting, dry cylinder tines, crankshaft and camshaft housings, valve tappot bores. Cylinder Head - integral valve seats. Valvegear - Helical train, pushrod operated camshaft, overhead valves. Inlet valves incorporate a fin to increase air turbulence. Crankgear - Crankshaft running on 3, 4, 5 bearings (Models 358 C, 455 C and 505, 605 C respectively) of the thin-shell type. Light-alloy pistons, one compression ring and two oil control rings. A flyweight-type dynamic balancer in the engine sump (605 C) reduces engine and engine-induced vibrations. On models 455. C and 505, an analogous result is obtained through a suitable belt pulley/engine flywheel balance. Air Breathing - Through an oil-bath air cleaner, Fig. 3 - Right. (2) - Model 355 ¢ (2) © Models 480.0 and 505 ¢ {e) : Modal 608 ¢ A niet maifold-F, Fst fel er - Fe. Second fel iter «Py FIAT (Goxeh Tewnee) iin fue inpetion jump." Pa CAV. aitibuor ‘ype fu! iniecion pump = Ps. Bosch disrbstor ype fuel inietion Pump = Pe PistonSype fuel it pump = Po: Diaphrogi-type Tul Iitpump «Pe Hyarauhe ttt pump”. Pool tne,“ St: Phemonarr bow! = T. Thermostat - 1. Fua injection pump inlet line 2 Ful Irakbock line =3: Fuel otuin line “8: FuctTeakebeck into second fuel ite - 8. Fusl ines to injeston » 6 Torotle bver~ 7. Throte linkage Er Shut-off linkage14 TRACTORS 355 C - 455 C - 505C - 605C FIAT Fuel Injection System - In-line piston type injection Cooling System - Centrifugal water pump, radiator pump (355 C), Bosch or C.AV. distributor type injection and fan. Wax element thermostet. ump (455 C-505 6-608 C) and 4-oriice fuel injectors. Lubrication System - Forced-feed, camshaft driven Engine Starting - 12 Volt electromagnetically operated pump. Pressure relief valve on outet line. starter motor. Thermostarter (if applicable). PERFORMANCE DATA TEST PLAN Injection timing B.T.D.C. cylinder No. 1 on compression - ; stroke:— Engine on bench with fan air clesner and exhaust silencer wrogel 388 C soseies removed — Model 485 ¢ Atmospheric pressure 740 + 5 mm. Ho. 7+to 9° Ambient temperature 20° + 3° 16° to 18° 16°10 18+ Fuel doneity 830 10 gramflit. - Model 605 ¢ Injection pump leak back fuel temperature G4* 42°C, — Bosch Tto 9° (Bosch and C.A.V. injection pumps only). — CAV. 15*to 17° PERFORMANCE DATA (BENCH) Engine H.P. Time to burn 100cm?| Model 355 ¢ Engine ® (ecu ing of toet Pm 2 hour run-in | 60 hour rnin)" sotonds Maximum (full load) () 2500 318 orover | s3arover | 47.40r over Maximum torque ¢) 1690 208 or over | 21.5 orever | 80.4 or over Maximum (n0-I030) ¢) up 10 2700, S = = Minimum (no-load) 600 to 650 Ss - = P.O. at 540 p.m. () 2100 = 29.7 or ever | 88.1 or over Enoine HP Time to burn t00em Model 455 C = (6 cu. in.) of fuel 2 hour run-in] 60 hour rancia ne | [36.7 or over (*) Maximum (full load) ( 24 7 | laximum (full load) (*) 00 azorover | 4a-crover |{ re Oren Maximum toraue:— — Bosch (") 1400 28.5 or over 30.5 or over 53.5 or over — CAN. () 1600 30 or over 32 or over 50.8 or over Maximum (no-load) :— | — Bosch ('} up to 2650 = =x = — CAN. () up to 2600 = | = | Minimum (no-load):— — Bosch @) 650 to 700 = - — CAV. (} 650 = = = [43,2 or over (*) | [38,7 or over (*) PTO. ot 640 rpm - em) — (032 cor over (') |[38 or over (*) €) Full throttle - (2) Throttle.at idle - ©) Bosch pump - (9) CAN. pumpFIAT ENGINE: PERFORMANCE DATA 15 Performance Data (Bench) - Continued. ean Engine HP. ine bun 100 on Model 508 Fain en a 2 hour runcin | 50 hour wivin |. “seconds Maximum (full load) (*) : 2600 47 orover | 49 orever | 31.5 or over Maximum torque ¢) sae | 1600 S2orover | 34orover | 478 0" over Maximum (no-load) ¢) 22 | upto 2000 | = = Minimum (no-load) @) 850 = = = PTO. at 640 rpm. 0). 2160 = 43.8 or over | 37.7 o ovor = Engine HP. Fine bun 250 cn Model 605 ¢ | Eaaeo (82 earn) of fel rs a re nan |g] sian [gem 9 Maximum torque:— Boch () ss 1600 a0 orover | 4 orover | 1034 or over — Cav. 0) 1400 34 orover | 36 or over | 1127 or over Maximum (no-load) ¢) E up to 2400 = = = Minimum (n0-load):— = Bosch @) .. . = | 650t0 700 = = = — CAV. Go... 660 = | = = PTO. at 540 r9.m, () 1970 = sgcrome | feo O PERFORMANCE DATA (P.T.0.) Same test conditions as for bench testing vom Enone WP Tine tobuin 1000n" Model 355 ¢ ean or tc Engine Pio. 2 pourrunin | 60 nour wana |” “Ssaoonde Maximum (full load) () 2500 626 B0orover | 31dorever | 47.4 orover Maximum torque (’) 1600 400 198 orover | 204 or over 80-4 or over Maximum (no-load) (') | upto2700 | up to 675 = = = Minimum (no-load) ) | 600%0650 | 18010162 | — = PIT.O, at 640 rpan, () 2160 840 = 283° over | §6.1 orover Model 455 ¢ Maximum (full load) () 2400 659 39.9 orover | 41.8 or over fee 7onsvs @) 136.4 or over (*) Maximum torque:— = Bosch (') 1400 274 orover | 28:1 or over | 63.9 or over = CAV. 1... 1600 285 or over | 304 or over | 50.8 or over Maximum (no-Ioad):— | = Bosch () .. upto 2650 | upto728 | — = = — CAV. 0) up to 2600 upto713 | - = - Mein (road) = Bosch () 65010700 | 17810 192 = = = cay. |): 650 178 = = 7 | 41. or over () | [98,7 or over () PIO. at 640 pam. () 2160 woo foacrone (| i[ze eee (Full ihrotie - () Throwle at idle - @) Bosch pump - () CAN. puma16 TRACTORS 355 C - 455 Performance Data (P.T.0.) ~ Continued. C - 505C - 605C FIAT eam. Engine H.P. Frimeto burn 100 em Model 505 ¢ (O-cu, in) of uel Engine PTO. 2 hour run-in | 50 hour run-in Seconds ‘Maximum (full load) (?) 2600 650 447 orover | 466 orover | 31.5 or over Meximum torque (?) 1600 400 304 or over | 328erover | 47.8 or over Maximum (no-load) (}) | upto2800 | upto 700 = = Minimum (no-load) @) 650 162 = = P.O. at 640 rp.m. () 2160 540 - 41.6 or over | 37-7 or over Engine HP. Frimeto burn 250 en Model 605 C (152 eu.) of fuel Engine Pro. 2 hour rurin | 60 how von-in |" aeconae 7 [48 or over () 77 or over) Meximum (full load) (') 2200 604, { a7sorover()| 223%" | 6S or over) Maximum torque:— = Bosch @) 1600 438 374 or over | 389 rover | 103.4 or over — CAV. () 1460, 384 323 or over 34.2 or over | 112.7 or over Maximum (no-load) () | up to 2400 up to 658 = = Minimum (no-load): — Bosch @) 65010700 | 178 to 192 = = — Cay. @) 650 178 = 7 : [85 or over () P.T.O. at 540 rp.m . () | 1970 540 - | 465 or over | J4 Oy over () (C) Full throttle - (2) Throttle at idle - () Bosch pump - (’) CAN. COMPRESSION TEST If engine performance is found 10 be unsatisfactory, check the Injection sysiem (overhauling nozzles and injection pump) and the comproscion in each cylinder To check engine compression use tester Part No. 291310 proceding as follows:— Remove the injector from each cylindor. Fit dummy injector Part No. 292631 in place of the injector of the cylinder under test, and seal the housing Using the associated copper washer. Hold the injection pump in engine stop conciti ‘and take the readings driving the engine through the start In good running conditions, compression should be 26 to 28 kg/em? (370 to 398 psi.) as recorded at 40 °C ‘sump oil temperature, 760 mm. Hg (sea level) atmospheric pump pressure with the engine running at 210 to 280 r.p.m. The minimum compression which is acceptable for @ used engine is 22 kg/om* (313 p.si.). The maximum compression differential between cylinders is not to exceed 3 ka/em* (42.7 psi.) In this connection it should be noted that every 100 matres (328 ft) altitude increase trom sea level results | in 1% (approx) decrease in compression, j Insufficient compression may be due to faulty valves ‘and seats, pistons and associated rings, cylinder liners ‘or cylinder head gaskets. Note: The purpose of the compression test is to assess the consistency of compression in the cylinders and to ‘obtain an indication of the degree of weer affecting the parts which help to seal the combustion .chambers. ‘Therefore, the test results should not be teken as an absolute indication of engine efficiency.FIAT ENGINE: TO REMOVE - TO REFIT 17 4 Removing the Front Mounting, Radiator and Front ving (or Rofitting) the Power Unit using End Par (455 ¢ - 805 ¢) ing Chain Pare No. 290740 (455 C - 505 C) 1. Front mounting - 2, Suspension - 3. Battery - 4, Air clearer TO REMOVE TO REFIT — Fill the clutch shaft housing in the flywheel with Drein the cooling system, remove the lower side and grassofiat G9 or other approved grease. centre panels, disconnect battery positive lead and starter positive cable, — Attach the power unit to the transmission case with caution to avoid jamming the fiywheel teeth against the clutch drive plate. Remove two slippers (28) and two suspension spring mounting brackots (27) (ses Fig. 107). Place a stand — For the correct tightening torque figures see page 169. under the gearbox. Attach a lifting chain (see Fig. 4) and take up the weight, Femove the suspension retaining screws. disconnect the piping and the electrical cables and lift off the mounting with attached battery, radiator and front end panelling. Disconnect and remove the dashboard, take off the bonnet, the firewall (disconnecting the mester switch ‘and throttle linkage) and the fuel tank assembly. Disconnect the hydraulic lift pipes (if applicable) from the associated pump. Attach lifting chain Part No. 290740, take up the weight, remove the gearbox retaining screws and withdraw the Power unit (see Fig. 5) To overhaul, place the engine on rotary stand Part No. |A. Front brackets part Nos. 290737 and 290738 - B. Rear bracket 280090 using the brackets shown in Fig. 6. part No. 290739 (488 C - 505 C),18 TRACTORS 365 C - 455C - 505C - 605C FIAT ENGINE BLOCK AND CYLINDER HEAD BLOCK AND HEAD DATA Engine Block Liner bore diameter machining oversize (see Fig. 8) . - .2 mm (008 in.) Tappet housing machining oversize range (see Fig. 18) . | 1 - .2 = 3 mm. (.004 - 008 - .012 in.) Camshaft bearing housing diameter on See Fig. 14 Main bearing housing diameter » | 80587 t0 80.607 mm. (31727 to 3.1735 in.) Cylinder Li A.M. standard liner LD. ():— — Grade A Sanne 100,000 to 100.012 mm. (3.8370 to 3.9974 in.) — Grade B. . 100,012 to 100.024 mm. (3.9374 to 3.9379 in.) P.M. Standard liner 1.D. (1) (see Fig. 8) 100,000 to 100.018 mm. (3.9370 to 39377 in.) LD. machining oversize range 2- A - 6 - 8 mm (008 - 016 - .024 - .032 in.) Spare liner 0.D. oversize . . £3 2 mm. (,008 in.) Interference fit... 2... (080 to .160 mm. (,0031 to .0062 in.) Cylinder Head | Valve guide oversize (see Fig. 9). | 2 mm, (.008 in.) | Nominal height . . i 92 mm. (3.622 in.) | () Fited tner dlamete: to be obtained sfterrebering and re-dressing. A maximum.1 mm, (004 in.) mechining oversizeis allowed in production, (3 The tolerance of each A.M. liner oversize is024 mm. (0009 in) to be divided in two grades, A and 8 (.012 mm. - .000® in.-each). ENGINE BLOCK Ensure that the block is free from damage. Wesh the casting in hot water and soda, subsequently rinsing in cold water. Clean the internal passages using petrol and blow dry with compressed air. Prior to fitting head and sump gasket ensure that the associated biock faces are clean, check face parallelism ‘and, if necessary, reface with a grind CYLINDER LINERS AM, standard liners are graded as A and B according to their bore (sce Data Table). The letters are stamped on the Cylinder Liner 1:0. using @ Dial Gouge —_bIOCK top next to each liner (see Fig. 7). P.M. liners are ‘rows indicate the grade of fit (AM.) ungraded. iFIAT ENGINE: ENGINE BLOCK AND CYLINDER HEAD. 19 103,020] {2.890}, i080 | wesio Mi Nr a) Fig. 8 - Liner and Block Details ‘ited liner éimension (For A.M. ti 2, b. Liner bore measuring points - C. P. Assassment of piston fi reading to be taken in plane b = X. Liewr Teading to be taken in planes.a and b - 1, 2, 3. New/rebored liner dimensional check points; readings to be taken in pl Inspect the liners for wear as follows:— — Check the liner bore over the working length (see Fig. 8) as swept by the piston rings. — The diameter reading should be taken in both the upper and lower part of the working length in plane parallel to the crankshaft (a) and in plane at right angles to it (b). — Compare the reading to establish the amount of liner out-of-roundness and taper. To assess the piston working clearance check the liner bore diameter in lower part (2) in plane (b) only. If out-of-roundiness or taper in excess of 12 mm. (.0047 in) in detected, rebore to the oversize values specified in the Data Table, fitting pistons of the same grade (AM istons and liners only) and oversize. If AM. oversize pistons are fitted, measure their diameter to assess the Grade (not stamped in production). To renew the liners press the old liners out from the bottom, Of the crankcase, using plato Part No. 292507 and pross~ fit the new liners from the top using plate Part No. 29101, Then bore and grind each liner as specified. Check the bore diameter by means of a dial gauge positioned in 2 and b (see Fig. 8) and take tho roadinge in planes 1, 2 and 3, If considerable out-of-round is detected, rebore to .2 mm. (008 in.) oversize and use oversize liner. ingpection length for sesgesment of out-of roundno CYLINDER HEAD Check head flatness by placing the cylinder head on a surface plate and, if necessary, re-dress by scraping, or grinding if distortion is more severe. When grinding, the maximum amount of material which can be removed should not exceed .5 mm. (.02 in). IO realty — 4,5 — "baa TT] swan ip al Fig. 9 - Valve Seat and Valve Guide Details ‘A. Inlet velve - S. Exhaust valve20 TRACTORS 355 C - 455C - 505C - 605C 3 ala 2/ Fig. 10 - Checking Fuel Injector Protrusion (a) and Valve Depth in Cylinder Head ‘When grinding place a copper washer of suitable thickness inside the injector seat to maintain protrusion value unchanged (see a, Fig. 10). FIAT To recut the valve seats use tool Part No. 291113 and hand cutter Part No. A. 60419 (292913). Check that the valve depth in the cylinder head is as shown in Fig. 10. When refitting the cylinder head note the following:— — Thoroughly clean both crankcase and head surfaces. — Fit the gasket (self-adhesive) with the mark ALTO see d, Fig. 11) facing toward the cylinder head, — Position the eylinder head and tighten the retaining screws according to the sequence given in Fig. 11. OIL SUMP In the course of overhaul, wash the oil sump in hot water and soda and rinse in cold water, Ensure that the sump is free from damage or distortion, ‘and inspect for oil leaks. Check split seals (6 and, Fig. 25) and, if necessary, renew. Using jointing compund, apply the gasket assembly onto the sump and retighten the screws to the specified torque. Fig. 11 + Cylinder Head Tightening Sequence (2) Model 395 C - (b) Models 485 C - 505 C - (c) Model €05 C - (d) Cylinder head gasket (ihe shaded area shows the adh portion)FIAT ENGINE: VALVEGEAR 21 VALVEGEAR VALVEGEAR DATA Valve Timing Data Inlet opens . Exhaust opens. Inlet closes Exhaust closes Valve clearance : — For timing check 3: BTDC 48°30’ BBDC 23° ABDC 6° ATDC 45 mm (.018 in) Journal running clearance (see Fig. 14) — Wear allowance. . Bearing interference fit = Normal Pied irs 25 mm (.010 in) = Exhaust... 35 mm (014 in) ite f- inlets 5.705 mm. (.2248 in.) cam it { Oiheust 5.777 mm. (2273 in.) Inlet. 93 mm. (366 in.) Nave we Exhaust . 10.2 mm, (402 in.) Camshaft 080 to 160 mm. (.0031 to .0062 in.) 20 mm. (.008 in.) .070 to .150 mm. (.0027 to .0059 ) Valves, Valve Guides and Springs Valve stem working clearance (see Fig. 16) — Wear allowance oA Standard valve guide 0.D. Spare valve guide 0.D. oversize Valve guide interference fit Valve spring data:— — A.M. inner spring .023 to .053 mm. (,0009 to .0020 in.) 20 mm. (.008 in.) 13.988 to 14.016 mm. (6507 to 5517 in) 2 mm. (.008 in.) 008 to .050 mm, (0002 to .002 in.) ‘Spare crowned tappet oversize range (st Tappet working clearance... . — Wear allowance . Fig. 18) . Free length 51 mm, (2.008 in.) Lenath under 6.55 to 7.55 kg (14.44 to 16.64 Ib.) (valve closed) 37.510 38.5 mm. (1.475 to 1.516 in.) Length under 15.4 to 16.7 kg (33.86 to 36.82 Ib) (vaive open) 7 : ; 26.8 to 28.8 mm. (1.085 to 1.139 in.) — A.M. outer spring: Free length 63 mm. (2.480 in.) Length under 19.3 to 21.7 kg (42.65 to 47.64 Ib.) (vaive closed) 40.5 to 41.5 mm. (1.898 to 1.639 in.) Lenath under 36.4 to 39.4 kg (60.26 to 86.87 Ib) (vaive open) 29.8 to 31.8 mm. (1.173 to 1.251 in.) — P.M. single spring ():— Free length 665 mm, (2.617 in.) Length under 30.1 t0 33.9 kg (66.37 to 74.74 Ib.) (valve closed) : 40.5 t0 41.5 mm. (1.593 to 1.633 in.) Length under 481 t0 52.1 kg (106.06 to 114.88 Ib.) (vaive open) : ee ie 29.8 to 31.8 mm. (1.173 to 1.251 in.) Tappets 2-3 mm. (004 - .008 - 012 in.) .030 to .068 mm. (.0012 to .0027 in.) -15 mm. (.0060 in.) A ted mark 3 single springsValvegear Data - Continued Rockers Rocker bush 0.D. Bush housing diameter Bush interference fit Fitted bush LD. Rocker shaft diemerer Rocker working clearance in shaft — Wear allowance . Rocker spacer soring:— — Free length Length under 47 t0 8.3 kg (104 19 11.7 Ib) Valve Timing Gears Backlash Idler gear jackshaft diameter Idler gear bush fitted 1.D. a Idler gear bush running clearance on jackshait . — Wear allowance . Idler gear thrust washer thicknoss 22 TRACTORS 365 C - 455 C - 505C - 605 C FIAT 21.080 to 21.060 mm. (8279 to £291 | 20.939 to 20.972 mm. (8243 to .8256 in.) | 058 t0 121 mm. (.0023 10 .0047 in.) | | 18.016 to 18.034 mm. (7092 to .7099 in.) 17.982 to 18.000 mm. (7079 to .7086 in.) 016 to .052 mm. (.0006 to 0020 20 mm. (.008 in.) ) 59.5 mm, (2343 in) 44 mm, (1.732 in.) | = 08 mm. (.003 in.) 31.975 to 32.000 mm. (1.2589 to 1.2598 32.050 to 32.075 mm. (1.2617 to 1.2627 in.) {050 to 100 mm. (.0020 t0 0040 in.) 15 mm. (,0060 in) 1,450 to 1.500 mm. (.0580 to 0590 in.) ‘CAMSHAFT To take out the camshaft, remove the thrust plate (7) retaining screws (5, Fig. 13). 10-48 mm. (0177 in) ance 1 = 16" to 18 (358C) 7 to 9%, Bosch pump (456 C- 605 C); 16° 10 18%, CAN. pump (iss C605 C); 15° t 17%, CAV. pump (696 C). To inspect, place the camshatt over V-blocks and, using fa dial gauge, check the eccentricity, which should not exceed .02 mm. (.0008 in.) Check both camshaft journals and associated bearings for wear and excessive running clearance. if the running clearance is found to exceed .20 mm. (O08~in.) the bearings should be renewed, if necessery, together with the camshaft itcolf. To withdraw the bearings use a universal extractor and to refit use punches of suitable size. YJ fe pF 1.13 - Sectional View of Camshaft Drive 5, Thrust plate retsining screws - 6. Drive gear ~ 7. Thrust plete - CamshaftFIAT ENGINE: VALVEGEAR 2: B New fitted bearing bore diameter should be reamed to the values specified in Fig. 14. ee VALVES VALVE GUIDES AND SPRINGS oe =a To romovo and rofit the valves use tool Part No. 291050 (ceo Fig. 15). After removal, clean the valves and check the stems for distortion and score marks If the valves show signs of defective seeling, hone together with the seats using 2ir honer Part No. 290064 or hand honer Part No. 290891. Subsequently, the parts involved should be carefully washed to eliminate all abrasve matter If necessary, rebore the valve seats (see Pages Fig. 15. Removing (or Rofitting) the Valves and A.M. Springs 19nd 20) and regrind the valves as necessery (see Fig. 16). ‘The minimum land below valve head chamfer should 9. Valve lock eap - 10. Split cones - 11. Upper cup - 12. Outer spring = 13 Inner spring - 14. Intake valve lower cup - 18. Intake @ de not be less than .5 mm, (.020 in). valve ~ 16. Valve guide Oo 0 Uo oto) af a) {50.470} agro) [50.080] $1080) [$0970] [50.80] [50.470] [49970 aa Li {50’500 | {sioo0) [50.13] 51330, | 51.000) ([s0'6m) [50 {sono | (aa 130 5.35] Sars 53875 5 (5330 i F ae 50.289 54305 [5070] | 50s00 50375 | scab Fig. 14 - camshatt, Bearing and Housing Detai (2) Mode! 355 C - (b) Models 455 C = 505 ¢ - (c) Model 005 6, Mohn ieee i eames 8 LOKTRACTORS 355 C 8.023 8018 455.C - 505C - 605C FIAT 14,000 Ses0T A) | 38,50 ya Fig. 16 - Valve and Guide Details To renew the valve guides use drift Part No. 291046 (see 9, Fig. 17). The valve guide bore surface should be perfectly smooth and free from score marks and evidence of pick-up. The guides must be tight in their seats, otherwise renew using oversize guides (see Data Table). fas Ah as yy } WK % Fig. 18 - Tappet and Housing Details After refitting, each guide should be reamed with tool Part No. 291177 (b, Fig. 17). Check spring length (see Data Table). Note: On refitting, make sure that the smaller pitched coils face toward the cylinder head mating plane. TAPPETS PUSH RODS AND ROCKERS Check tappet working clearance (see Fig. 18). If excessive clearance is detected, renew using oversize tappets and open out the associated housing bores (see Data Teble). The surface in contact with the cam should be perfectly smooth, without any pits or dents, Tho push rods should be porfectly straight, the contact surfaces between rods and adjusting screws should not show any sign of pick-up or abnormal wear. Renew as necessary.. FIAT To separate end bracket (20, Fig. 19) from rocker shaft (17) withdraw screw (V,). Check both the rocker shait and bushes for wear and play. The contact surfaces of adjusting screws and rockers should be smooth and free from any sign of pick-up. Inspect the rocker toes. When re-grinding becomes necessary, take care to romove as little matorial as possiblo. TO ADJUST THE VALVE CLEARANCE Use spanner Part No. 290886 and a fesler gouge (s00 Fig. 20). The correct clearance is .25 mm. (.010 in.) for both inlet and exhaust valves. To adjust the valve clearance of 2/3-cylinder engines (855 C-455 C-505 C) proceed as follows:— — Bring the valves of the cylinder involved in a condition of balance, turn the crankshaft by one full turn and adjust the clearance. — Repeat the same procedure on the remaining cylinders. In practice, the adjustment of 3-cylinéer engines (piston at T.D.C, on compression stroke) can be performed when ‘two valves of tho other two cylinders (inlot valve for ‘ona and exhaust valve for the other) balance in the meximum opening position. Cylinder matching for valve clearance adjustment on four-cylinder engines (605 C) is 1-4 and 2-3. Adjust a cylinder when tho valves of the matching cylinder aro in a condition of balance. VALVE GEAR INSPECTION AND TIMING Check the gears for damage or excessive wear. ‘Also check the tooth contact surfaces of each gear train which should be smooth and free from dents; running clearance should be .10 to .12 mm. (.0040 to .0047 in.) When the Bosch or C.A.V. injection pump drive gear is 10 be renewed, note that it is marked with the engine ‘model designation as the angular position of number ‘4", indicating the meshing position with respect to ENGINE: VALVEGEAR 25 . 19 » Rocker Assembly Vy. Bracket-to-shaft retaining screw, featuring lubication hole - 1, Recker shaft ~ 18. Spring - 19. Rockers ~ 20. Bracket - 21. Thrust washer - 22. End cup, the shaft key, differs with the make of distributor typo pump, as follows — Model 455 C, Bosch 127° 82 min, & 15 min, pump, matked 8035, — Models 455 C-505 C, C.AV. pump, marked 8035, 188° 84 min. + 15 min. — Model 605 C, Bosch pump, marked 8045, 52° 53 min. + 15 min. — Model 605 C, CAV. pump, matked 8045, 173° 24 min. £15 min. Fig. 20 - Adjusting Valve Clearance 4, Detail of rocker adjusting screw - A. Spanner Part No. 290886 - 1 Locking nut'- 8. Feeler gauge = V,. Adusting screw.26 TRACTORS 355 C - 455C - 505C - 605C FIAT 21 = Valve Th (a) Medel 356 ¢ - (b) Moddls 455 - 505 - 605 C - (2) Detail of flywheel timing pointer indicating 1.D.C. (P.MS.) of riston 1 ‘he snows point to mfarence numbers 1-1, 2-2, 3-3 and &:8 whch should line up when cyinder No. 1 is at TD. (PALS) on ‘compression stoke. 8 and 82. Camshalt dive gear - 28 and 28a, Drive pinion - 29 and 299, idler gesr - 30 and 30s. Hydraulic lit pump gear - 31. Fuel lift pump gear ~ 32 and 32a, Fuel injection pump gear. Following gear removel, refit and time the valve gears — Refit the drive gears and line up pairs 1-1, 2-2, 3-3, (see Fig. 21) as follows:— 4-4 (see Fig. 21) — Rotate the crankshaft until the piston of cylinder No. To check the valve timing angles (see Fig. 12) adjust 1 is at T.D.C. (P.M.S) in compression stroke. the valve clearance to .45 mm. (.017 in.) CRANKGEAR CRANKGEAR DATA Crankshaft and Bearings Main journal running clearance. = SR .043 to .090 mm. (,0017 to .0035 in.) — Wear allowance... . . 180 mm. (0071 in) Crankpin running clearance .021 to .058 mm. (,0008 to 0023 in.) — Wear allowance... . see 180 mm. (.0071 in.) ‘Spare main and big-end bearing undersize range (see Figs. 22 ondh28)/O) seare ie os hres : 254 - .608 - .762- 1.016 mm. (.010 - .020. - 030 - .040 in.) Main journal crankpin machining undersizo rango (soo Fig. 22) () : 5 254 - 508 - .762 - 1.016 mm. ((010 - .020 - 030 - .040 in.) Crankshaft end float ei : .082 to .334 mm, (,0032 to 0131 in.) — Wear allowance goon =e -40 mm. (.0187 in) ‘Spare thrust washer thickness oversize. . 127 mm. (.0050 in.) lL €) Crankshafts featuring .1 mm. (,0080 in.) uncersize main journals/erankpins and be ings may be fitted in production only.FIAT renkgear Data - Continued. ENGINE: CRANKGEAR 27 istons ‘Standard diameter, at 50 mm. (1.97 in.) from skirt base (see Fig. 27) applicable to:— — AM. pistons (1st solution) Grade A Grade B — A.M. pistons (2nd solution) Grade A Grade 6 = P.M, pistons (9rd solution) = Stondard diamotor ot tho base of the skirt and on tho main axic, applicable to-— — AM. pistons (1st solution) . — AM. pistons (2nd solution) — P.M. pistons (3rd solution) Spare piston oversize range P.M. piston working clearance st 50 mm. (1.97 in.) from the skirt base 5 Weor allowance (AM. and P.M. Ring side clearance:— — 1st compression ring Wear allowance — 2nd cil control ring — 31d ll scraper ring 2nd and 3rd ring wear allowance Ring gap:— — 1st compression ring — 2nd oil control ring — 31d oil scraper ring Maximum wear gep Gudgeon pin clearance in pistons Spare gudgeon pin oversize Gudgeon pin bore machining oversize in piston stone) Connecting Rods Gudgeon working cle — Wear allowance Small-end bush interference fit Small-end bush bore dia. machining oversize nce in small-end (see Fig. 29) Flyweight-type Dynamic Balancer (605 C) Intermediate gear running clearance (19, Fig. 32) Flyweight drive gear shaft running clearance ¢) Drivo goer shaft running clearance () Sleeve spline tooth backlash Flyweight drive gear shaft end running clearance Flyweight pin working clearance Bush interference {it Idler gear running clearance (°) Gear tooth backlash 99.834 10 99.846 mm. 99.846 10 99.858 mm. (3.9304 to 3.9309 in.) (3.9309 to 3.9314 in.) 99.822 10 99.834. mm. 99.834 10 99.846 mm. 99.828 10 99.840 mm. (3.9300 to 3.9304 in.) (3.9304 to 3.9309 in.) (3.9302 to 3.9307 in.) 99.886 10 $9.910 mm. (3.9325 to 3.9335 in.) 99.874 to 99.898 mm. (3.9320 to 3.9329 in.) 99,880 10 99.892 mm. (3.9322 to 3.9327 in.) (02 - 04 -.06 - .08 mm. (.008 -.016 -.024 -.032iin.) 160 10.190 mm, 20 mm. (.0063 to .0075 in.) (0118 in.) 090 to.122 mm. 50 mm. (050 to 082 mm, 040 to.072 mm. 20 mm. (.0035 to .0048 in.) (020 in.) (0020 to .0032 in.) (.0016 to .0028 in.) (008 in.) 35 to.65 mm. (0138 to.0216 in) 3010.45 mm. (0118 to 0177 in) 25 to.40 mm. (,0098 to .0187 in.) 1.00 mm. (.040 in.) 003 t0.017 mm. (.0001 to .0006 in.) 20 mm. (,008 in.) 20 mm. (.008 in.) 014 to.029 me. 08 mm. 063 to 140 mm, 20 mm. (005 to .0011 in) (0024 jn.) (.0025 to .0055 in.) (008 in.) 050 t0.100 mm, (050 t0.100 mm, {050 to .100_ mm. 028 to.108 mm. 013 0.061 mm, 020 10.073 mm. 040 to 100 mm. 013 10.061 mm, .080 mm, (.0020 to .0040 in.) (.0020 to .0040 in.) (.0020 to .0040 in.) (0011 to 0042 in.) .0005 to .0024 in.) (.0008 to .0029 iin.) 0016 to .0040 in.) (.0005 to .0024 in.) (0031 in.) (Bush inertsrerce fit 963 to 140 mm. (0025 to 0055 in) terforence fit 037 to 101 mm. (0014 to 0040 in.) lt28 TRACTORS 355 C - 455C - 505C - 605C FIAT CRANKSHAFT — Score marks, ovality or taper in excess of .050 mm. (.002 in.) necessitate journal skimming to the nearest, oversize dimension (see Data Table). Afier re-grinding, blend the journal fillets and round lubricating hole edges as shown in Fig. 22 Withdraw the belt pulley hub using tool Part No. 291504 to take out the crankshaft. Wash the shaft and inspect carefully. Even the slightest Subsequently, check the crankshaft noting thet:— ‘cracks necessitete érankshaft renewal. — Ovality of the journals should not exceed .008 mm. (0004 in) Check both main journals and erankpins:— — Taper of each journal should be lower than .012 mm. (.0005 in). — Pick-up or scratch marks can be remedied by means ~— Maximum misalignment with the shaft over V-blocks of zero grade emery cloth. should be .05 mm. (.002 in.) (see D, Fig. 23). 7 = 7.87 355200 {76.200 | 5 A qa c od | | H J lo| fe EE BU as (EAH 338 7.15 i Taw 8,70 5 i me ny i} 55 NLem 178 es = 14,750 asl 25,000 oN e335 Sa (@) Model 385 C (8) Models 455.6 7 ‘and 505 C = (¢) Model 605 C - (4) SE Lu c ‘otal of mein journev/ernkpo fitets.‘and “Crankpin Alignment (a) Deval of maximum misalignment (of crakpins with respect to the main Jounale A and 8. Flange run-out stylus position ~ D. Maxmum rain ournal misalignment. — Meximum misalignment of each pair of crankpins (or of the two crankpins in the 2-cylinder engine) with respect to the main journals should not exceed £25 mm. (010 in.) (see Fig. 23). — The allowance on the distance from top of crankpin to crankshaft rotetional axis should not exceed £10 mm. (+ .004 in.) (see Fig. 23). — Run-out, as measured with the dial gauge stylus in (A) at the periphery of the crankshaft flange, should not exceed .02 mm. (0008 in.). Moreover, eccentricity in (B) should not exceed .04 mm. (.0016 in.). Check the core plugs for leakage with of at 18 kg/cm? (213 pai). To renew the core plugs, press fit, peen in Position and ra-check for oil lake Following crankshaft refitting and main bearing cap re-tightening check the end float at the last bearing cap but one (see Fig. 24). If excessive play is detected fit oversize thrust washers (3). CRANKSHAFT FRONT AND REAR SEALS Oiltighteness at the front end of the crankshaft is obtained through two metal-reinforced double-lip rubber seals featuring a coil spring and fitted in timing gear case Cover (6, Fig. 25, a) and in a suitable carrier (9, b) respec- tively. Check the seal face for wear, coil spring for failure and lip for damage. To renew the seal: ~ Wipe off all races of oll and dry the seal seat thoroughly. — Soak the seal in engine cil for 30 min. Subsequently. fit the seal applying a uniform pressure over the entire seal ring, using a drift so that the seal will bed-in correctly. — Lubricate the lips with a film of thick oil and pack the cavity with grease to prevent the seal from being damaged during initial running owing to lack of lubricant. MAIN /BIG-END BEARINGS AND CAPS The bearing caps are numborod for correct rofitting. The reference marks should line up as illustrated in Fig. 24. Fig. 24 - Chocking the Crankshaft End Float (Arrows point to reterence numbers, which should ine up on tefiting bearing caps) - C,, Bearing cep self-locking screws - 2. Bearing cap = 3, Thrust washers,320 TRACTORS 385 C - 455 C - 505C - 605C FIAT Fig. 25 - Sectional views of Crankshaft Front and Rear Seals (@ and b respectively) ‘a4, Detail of crankshaft seal fining nut - Cy. Flywhee! sett. seews = 4. Pulley nub - 8. The bearings should be renewed whenever their working The bearing running clearance with respect to the crank- surfaces are found to be scored ot worn. shaft can be checked using Perfect Circle Plastigage Calibrated wire (see Fig. 26), as follows:— — Place a length of calibrated wire over the bearing. — Fit the bearing cap and tighten. — Remove the cap and compare the width of the com- pressed calibrated wire with the reference scale printed on the wire container. Perform the same check on big end bearings. PISTONS AND RINGS AM. standard sizo pistons (let and 2nd solution - see Data Table) ae selected, according to the measure taken at 50 mm. (2 in.) from the skirt base, into two dimensional grades A and B. P.M. standard size pistons (3rd solution) are not graded. When renewing the pistons, note the following points: — AM. pistons (1st and 2nd solution) ate interchangeable Cloarance provided the came grade is retained; moreover, they, 2. Calibrated wire in position on main bearing cap - b. Compatin it liner Gacin of compeneed calinctel wre wihwelsent scriaercae © SNOUld be matched with AM. liners of the semg brated wire - 7. Graduated scale printed on wire container. grade. | Fig. 26 - Checking Crankeheft”Journal RunniFIAT — a ENGINE: CRANKGEAR _ 31 | | Y LE es i” Ee ae Fa [—4 ig. 27 - Standard Piston, Pin and Ring Details A. Fitted ring gap - &. P.M. piston diameter, as measured at 50 mm. (2 in.) from skirt base (See Data Table for A.M. pistons) - , Maximum P.M. piston ameter, as measured at the skirt base (See Osta Table for AM. pistons). — P.M. pistons can be fitted in replacement of AM. Fit the piston rings (compression ring and oll control pistons of both grades, consequently, they cen be sings) using pliers Part No. 291159. fitted to A.M. liners regardless of grade Check thet piston ring side clearance (sve b, Fig, 28) — AM. pistons of the second solution, as far as grade A 274 gap (s00 ¢) aro as prescribed (sce: Data Table). is concerned, cen also be fitted to P.M. liners. Renew: es necatsan? Should the gap be smaller than prescribed, grind the ends. The grade, if any, and the weight are stamped When refitting the pistons, make sure that ring ends are on the piston crown, staggered at 180° from each other (see b, Fig. 31). | Clean the pistons by scraping off all combustion deposits and wash with petrol, paraffin or solvent. CONNECTING RODS ‘Ascoss piston and liner weer as shown in Figs. 27, 28 end, If the clearance is found to be in oxcose of 20 mm. (012 in.), rebore the liners and fit aversize pistons and rings (see Data Table). Check that big end bearings are tight and flush with big end sides. Check bearing inner faces for seizing o1 score marks; | Should it become necessary to renew the pistons, make if score marks are detected ream using expansion reamer sure the weight of new pistons is within a tolerance of or tool Part No, 290280 placed on a standard conte 10 grams (.36 02) lathe Fig. 28 - Checking the Piston and Rings % Checking piston diameter at 80 mm. (2 in) from skit bese - b. Checking piston ring side clearance - ¢, Checking piston ring cap. Be32 TRACTORS 355 C - 455°C - 505 C - 605C ig. 29 - Connecting Rod, Big End Bearing, ‘and Standard Gudgeon Pin Dotal ‘A, Fittad dimension alter rearing. ‘Subsequently, make sure that the gudgeon pin running clearence is not in excess of .06 mm. (,0024 in.), otherwise ‘open out up to 2 mm. (.0078 in.) oversize and fit oversize pin. Should 2 mm. (.0078 in.) oversize renew the bearings. To check connecting rod alignment use gauge Part No. 292172 (see Fig. 30); maximum misalignment betwoon not sufficient Fig. 30 - Checking Connecting Rod Alignment H. Piston crown lubricating hole - 1. Liner lubricating hole FIAT big and small end axes should not excsed .05 mm. | FI (010 in.) in any direction when measured 125 mm. | fy (8 in.) away from the rod centroline. Any slight distortion may be remedied using a suitable press. g In case of connecting rod replacement, ensure that the new rods are selected to obtain a maximum weight | (: difference of 10 grams (.36 02). sic Also make sure that piston and liner lubricating holes | of (H and |, Fig. 30) are free from. scales. 1 Note: Whenever the connecting rods are dismantled renew the cap retaining screws, TO REFIT CONNECTING ROD/PISTON ASSEMBLIES Refit rods and pistons so that the connecting rod identi cation number corresponds to the number of the associated cylinder and is located on the same side of the marks (FIAT trade mark, weight, dimensional class) stamped on the top of the piston (see b, Fig. 31). T Check equareness using gauge Part No. 292172 (see a) Refit the piston with attached ring and rods into the associated liners using sleeve Part No. 291048. Make ‘sure that the identification numbers are on the side opposite the camshaft (V). Atter refitting, at T.D.C. pistons should protrude .46 to 79 mm. (018 to .031 in.) from block top surface. FLYWHEEL The flywheel is secured to the crankshaft in 2 perticular fiting position to prevent incorrect reassembly. When renewing bearing (8, Fig. 25), fit the dust seal facing the clutch and pack the associated housing with grassofiat G9 or other approved grease. FLYWEIGHT TYPE DYNAMIC BALANCER (605 C) The flyweight type dynamic balancer is housed in a casé bolted to the inside of the engine sump. Fig. 33 sho\ the schematics of the dynamic balancer. When removing, note the following pointe:— — Drain engine sump oil and remove the lower cover. — Take off oil pump scoop, retaining screws (Cy, Fig. 32) and take out the weight assemblies.ar al h me | ‘“ sition with respect to fitted position with resp (The arows point to the ring gaps hich should be staggered at 180° ‘to one another) Ci. Cap retaining screws - M. Stamp Icéation (trade matk, weight, dime Sonal class) = No Raferonce’ numb ‘of corresponding oylinder ~ V. Cam: Shaft. = 10. Compression “ting 41, Oil control ting = 12. Oil scraper “14. Cap ~ 15. Big end bearing — If necessary, remove lubricating pipe (24), rotaini screws (9). drive gears (18) and flange (16). To dismantle the weight essembly proceed as follows:— — Withdraw spring pins (25, Fig. 34) and weight cariiers using a drift — Remove flange retaining screws (7), snap ring (30) and flyweight drive gear (30). — Remove snap ring (36) and idler gear (34) ENGINE: FLYWEIGHT TYPE DYNAMIC BALANCER (605 C) 33 Check for woar, renew any defective parte, ream tho new bushes using expansion blade reamers Part Nos. 290001 and 291242. To fit the new bushes, pre-heat the weights in oil at 140° 10 160 °C. (284° to 320 °F). On refitting the parts, make sure that weight dive gear (14, Fig. 34) and weights (27) are positioned so that all reference marks are lined up, as arrowed in Fig. 35. (Oil scoop ="13. Sleeve - 14. Snap ring = 1 intemesiate gear - 20, Intermediat in ~ 26. "Fyweight ci carver - 21 and 22. Thrust washers 28 Sap ring 24, Lubricating pipeiet = 27. Flyweights - 28. Flyweight drive gear flange - 29. Thrust washer - 30. Snap ring’ ~ 31. Intormediate ‘gear flange - 32 and 33 Bushes - 34. Ider gear34 TRACTORS 355 C - 455 C - 505C - 605C_ eT | DOOaOW 38 - Layout of the Flyweight Type Dynamic Balancer 10, Case - 11. Flyweight dive gear - 13. Sleeve - 18. Drive gear 18. Intermediate gear ~27. Flyweights - 34. Idler gear - 40. Crankshatt Moreover, note that:— — Idler gear (34, Fig. 34) should be positioned with the longer end oriented towards the case wall. — Split pin holes in weight carriers (26) should be aligned with those in the case. ‘2. Sectional view of idler gear - fowining screws. ~—11. Flyweight drive. ge 26. Flyweight carier 27. Fyweight ~ ‘washer = 30. Snap ring ~ 39. Ider 9 "37 and 38, Thrust ‘washers FIAT 27. Flyweights. On refitting the flyweights, time the gears as follows:— — Bring cylinder No. 1 to T.D.C. — Secure drive gear (18, Fig. 32) to the sump, with the reference marks aligned as shown in Fig. 36. — Leck the weights in position with pin (39) and check reference mark alignment. | | — Place sleeve (13) in position and tighten the retaining screws to the specified torque. i (The arrows peint to the timing reference m: 0, Refiting the lubrication pipalet - 10. Flyweight c 1 i = 18, interme 39. Pesitioning pin.18 ok 1 ae. —“(—tss————————( es FIAT ENGINE: FUEL SYSTEM 35 FUEL SYSTEM DATA ‘Model 355 C Lift Pump. Piston type, injection pump camshaft-driven Pump ouput, 1.21018 kg/en® (17 10 21 psi) — — At 500 rpm, i oo 78 litres/min, (1.37 Pints/min.) — At 1000 p.m. 1.35 litres/min, (2.30 Pints/min.) FIAT/BOSCH Injection Pump Type Direction of rotation (drive end) Firing order Camshaft end float Camshaft shim thickness range (see Fig. 50) In-line, LH. halix plungers PES 2A80B 410: L4/110 Clockwise 1 (180 deg.) - 2 (540 dea.) 02 to .06 mm. (.0008 to .0024 in.) 10, 12, .14, 16 and 18 mm (.0040, .0048, .0086, .0064 and .0072 in.) Mechanical Governor (Kiki) Flyweight shims (S,, Fig. 47) Centiifugal flyweight type NP-EP/RSV 200-1250 2 and .3 mm. (.008 and .012 in) Automatic Advance Dey Maximum advance at governed speed Spring shim thicknass range Outer spring length:— — Free — Under 7.25 to 7.75 kg. (15.9 t017 Ib) — Under 21.6 to 23 kg. (471051 Ib.) Inner spring length:— — Free — Under 3.59 t0 439 kg. (7.9 t0 9.7 Ib.) = Under 21.2 t0 22.6 kg. (46 10 49 Ib.) Injection Pump Drive nner washer thickness (see 78, Fig. 46) Outer washer thickness (76) Hub 0.D. (74) Bush fitted 1D. (69) Hub running clearance in bushes Bush intorferonce fit lies 1, .20 and .60 mm. (.006, .008 and .020 in.) Centifugal flyweight type FIAT, PAV 6° 500 - 1100 ARD 16 6 deg. (to injection pump camshaft) 39.5 to 40.5 mm. (1.555 to 1.594 in) 31.5 mm. (1.240 in.) 255 mm. (1.004 in.) 23.910 25.9 mm. (.941 to 1.019 in.) 244 mm. (961 in) 199 mm. (783 in.) 1.45 to 1.50 mm. (.057 to .059 in.) 2.93 to. 3.00 mm. (115 to 118 in.) 49.975 to 50.000 mm. (1.9675 to 1.9685 in.) 50.050 to 50.075 mm. (1.9705 to 1.9716 in.) 080 t0.100 mm. (.002 to .004 in.) 066 to.142 mm. (003 t0.006 in.)36 TRACTORS 355 C - 455C - 505C - 605C FIAT Fusl System Data - Continued, Models 455 C, 505 C and 605 C fun) Goshen a mane es = Double diaphragm Drive shaft speed 1600 r.p.m, Pump output (min.) | 100 litres/hour (22 Gell hour) Camshaft lobe lit (see 6, Fig. 87) : 3 mm. (120 in.) Lift Pump Drive Drive sheft journal dia. (see 6, Fig. 57)... 31.975 to 32.000 mm. (1.2588 to 1.2598 in.) Bush fitted LD. (see 7). . 32,080 to 32.075 mm. (1.2618 to 1.2628 in.) ‘Shaft running clearance . (060 to 100 mm. (.002 to.008 in.) Bush interference fit... os 598 063 to 140 mm. (,002 to .005 in.) Inner washer thickness (se0 8)... 4.45 to 1.50 mm. (057 to.059 in.) Outer wesher thickness (see 9) | 2.98 to 3.00 mm. (116 to.118 in.) Injection Pumps... Distributor type with integral governor Pump make: — Model 455 ¢ — Bosch a EP/VA3/110 H - 1200 CL 134-4 = CAV: DPA 3233410 — Model 505 ¢ =GAV sous 2 oe DPA 3233420 — Model 605 ¢ — Bosch cc REMI eS Bs EP/VA4/110 H - 1100 CL 136-1 — CAN, a eee DPA 3249460 Diection of rotation (drive end) Anti-clockwise Fiting order: — Models 455 C and 05 C — Model 605 ¢ FUEL INJECTORS .... . ~ gene Four-otifice nozzles FIAT nozzle typé — Model 255 C au DLL 145 $50 F — Models 455, 505C and 605C |. : DLL 145 § 60 F FIAT injector body type ict ok ees KB 70S1F10 Release pressure. hae ORE HL 225 to 236 ky/em? (3,200 t0 3,343 p.si.) Spring data (see 4, Fig. 84):— — Free length . qn 27 to 27.5 mm. (1.063 to 1.083 in.) — Deflection from 161 to 41.8 kg. (24t092 Ib). 8 mm. (.032 in.) AIR CLEANER Renew the oil whenever it is found to be contaminated or if the sediment is % in. deep (10 mm). To ensure sustained engine efficiency the air cleaner Every 200 hours, remove element (4a, 4b), empty the oll should be cleaned at regular intervals. ‘and wash in paraffin, together with bowl and cenit pit Check the oil level in the bowl this Is particularly important Prior to removing the element it may be necessary in dry climates. The correct level is up to the rib (6a and take off a retaining ring. Refill with fresh oil 6b, Fig. 37). Every 400 hours, clean the entire unit by dipping iod oil, pe. 10 ENGINE: FUEL SYSTEM 37 peraffin for thirty minutes; blow dry using compressed air, rebuild the filter and refill up to the correct oil level. Check the pre-cleaner and inlet manifold pipe clips for looseness, to prevent unfiltered air from being drawn into the system. FUEL TANK The fuel tank should be thoroughly cleaned whenever ‘the tractor is overhauled. Occasionally, drain the cendon- sate and sediment by removing the plug screwed in the bottom of the tank. This operation should be carried out When the tank is almost empty, and more frequently if the tractor is used in damp or cold climates, and in areas Subject to sharp temperature changes. Check that the vent hole in the filler cap is not obstructed, Models 455 C, 505 C and 605 C are provided with a deshboard-mounted fuel gauge the needle of which is electrically moved over a red sector on the dial when the reserve of fuel is down to less than 15 litres or 3¥/, Gall, FUEL FILTER (355 C) Every 50 hours, drain the condensate accumulated in the bowl (1, Fig. 38). To do this, back off the drain plug through @ few tuins. Fig. 37 - Section through Oil-bath Air Cleaner 2. Model 385 € = b. a and tb. Cleaner body - 2a and 2b. Fixed elemer 43 and 4b, Removablo element Ja and 7b, Sesle 8. Dust bow! - 9a and 9b. Pi jodels 455. 1805 C and 605 C. Retaining catches. Every 200 hou's, clean the bowl in paraffin and renew the paper cartridge (2) with attached seals. On completion of filter servicing, bleed as follows:— — Open the fuel tank valve, back off bleed screw (3, Fig. $8), crank the engine with the starter until the ing the Fuel System (Model 355 C) plug - 2. Filter cartidge - 3. Bleed Ju 5, injection pump drain pipe tn attached bieed screw.