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25

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TRANSMISSION ASSEMBLIES

CLUTCH

The master clutch assembly is composed oi two dry, single-plate clutches, one for the tractor transmissiondrive and the other for the power-take-off drive.The unit is controlled by one single pedal which, during the first part of its travel, disengeges ihe mainclutch (transmission) and En the following one, the power-take-off, but only when this attachment isdirectly driven by the engine (independent powewtake-oh).The three diagranns of Fig. 82 illustrate, respectively:a) the clutch engaged; ii) the main clutch disengaged; 0} clutch completely disengaged.

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Fig. 82. - Clutch functional diagram.

a - engaged clutch. b A main clutch. disengaged. c - clutch, completely disengaged.F we Power take-off dm-en plate - C = Gearbox driven plate - P = Lever points.

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Removal and stripping of clutch.

Removing the clutch assembly from tractor:

Paris to be removed. Operations and cauiions.The batteries.The exhaust pine.The engine, with the front axle (Fig. 83}. 'Disconnect the following components:

‘ »~— the hydraulic pump oil lines, the steering shaftlever longitudinal iie~rod, the board‘ from the bailerysupport and this support from the gearbox case, theaccelerator pedal fife-rod from the transmission shaft;the electric cables central connection;

~»— firf two‘ wooden wedges on the froni axle, attachthe engine assembly to a lift and place the gear-box case on a stand;

¢— remove the screws assembling the engine to thegearbox and facilitate {he removal by acfuatlngthe clutch pedal. "

Nofie. - To pull the flywheel inner pllol bearinguse fool A 619827.

Fig. B3. - Removal of engine, with front axle.53

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=1 Si’ in of clutch cm device A “I'HOE3fA Fig. 85. - Fro

nt view of a tie-rod and oriemaiion of

Fig. a - ‘i "pp Q I i elastic pinsA. Disengagemeni {ever adjustment nuts - 1. Elastic pins

2. Lever pivots - 3. Forks - 4. Fork adiusfing nuis.

Stripping of ciuirchz

Inspection of clutch dismantled parts.

(See the last figure for references).

Mount ciuich on fixfure A 711063 or on fixtureA 711063_lA, remove the elastic pins (1, Fig. 84) andpush out the disengagement lever pivot pins (2).By siackening the siua‘ boffs fasiening the cluich £0fixture, a1! parts become free.If the clevises (3) must be removed urzscrew themfrom the pressure plate after slackening the adjustingnuis (4).

Check the oiutch components as follows. according to the data of fable at page S7:

- check condition of friction linings and of metai surfaces contacting them; ii necessary smooth them.- I‘ nd surface brushing arelf the rings are soaked with oii, replace them, as washing in Q0150 me ainsufficient;

-— check cléarance between the clutch driven disk hub teeth and splined shafis;

-— check the throvwout bearing, and the clutch shaft piiot bearing, located in the flywheei;

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- check ciearance between bushes and disengagement lever pins;

- check piate spring characteristics;

- check the throw-out coiiar working siiding surface. If wear does not exceed the permissible iimiis.the shaft can be mounted again after rotating it ‘i8G°; if necessary replace the parts when grease

I drips due to excessive clearance.ii

‘ Assembling and adiusting the cluich.

1_;_,i;,;i¢a1§Qn_ Smear iighiiy the foiiowing oomponenis beforeii assembling using quaiity chassis grease:

— the clutch disengagement lever pivots, the cievisends confaciing the disengagement fevers (3.Fig. 34), the c1uZcn~gearb-ox and the clutch power

* iaise-off shaft splines, the baii ends of pushlevers (P, Fig. 88), the ciei/is fever ends whereconfaciing the disengagement collar; in additionservice the bearing housing in engine fiywneei.

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‘ * ~ 'Cf.._‘\" ,_W _“Fag. av. 1 Cluich section., Fig. 83. - Clutch piaie centering with reference to points P.

} Assembling the ciutch components. it is easiiy performed by foiiowfng Figs. 86 and 8?' and caring that the ciuich-gearbox piate is centeredi with reference to the caps and that the eiasific pinsare oriented as shown in Fig. 35.

Clutch assembly £0 be performed on fixture A 711063,using if on the side marked with the tractor number.

For clutch adjustment ii is noi necessary io placeupon the fixture A 'I11i}63 the power take-off disc,which remains outside the assernbiy, and is subsu-iuted by a ring (Fig. 89) superposed to fixture E.

Ciutch adiustment.

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Ctutch adjustments should be made as follows:

G H .-sE - D v__,, /____ 33 a) adjustment of the complanarily 0;’ the clutchll Q’ _ disengagement three lever ends. The adjustment

1,1 to be made according the Fig. 89 :'.e., by checking,

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Fig. 89. - Clutch adjusiment using fixture A 711863

5,6,1»-I Fixture cornpcnenis - D Spacer bearing No. M1 R,used also for other wheel types belonging to fihe series 490.

Clutch contro! adiusirneni.

Assembiy of clutch on engine.

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Fig. Q0. - Clutch adjustmeni on engine, using ioulA 11'£fi63, complete.

B Clearance €,5-2 mm (0.059!-0.078‘? in.).

56 ‘

using feeler gauge, that between the lever endsand the checking elements laid upon the spacerthere is a max clearance of 0,1 mm (0.0039”);a different clearance requires to unscrew thefastening nut and adjusting the proper screw.

Mote. - lfclutch is installed on fixture A 'l1‘l063lA.the adjustment may be made after the assembly onthe tractsr, using fixture A 117683 provided with asuitable flange (Fig. 96).

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b) Adjust the clearance (E, Fig, QB} of the powerlake~off pressure plate clevis. Check that clear-ance be 1.5 to 2 mm (0.059'l"' to 0.0787"), andif different, unscrew the loclmui and screw onor unscrew the sleeve. The clearance adjustmentmay also be made when the clutch is mountedon the tractor through the gearbox side cover.

The free travel of the clutch pedal is 25 to 35 mmM19843" to 7.37190" ). Plate wear, however, decreasesfine free travel. Unscrew the pedal lie-rod clevis asmuch as n€cessa1'y to reestablish the previous value.

The centering oflhe assembly on the engine flywheelis facilitated by using fixture A 117083 (Fig. 91) thatmay also be used for the disengagement leversadjustment, when tilted with the proper plate (Fig. 90).

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Fig. Bi. - Mounting clutch on engine using tool 11 ‘.1'l0fi3.

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FLEXIBLE COUPLING BETWEEN CLUTCH SHAFT AND GEARBOX

Noisy transmission.

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Fig. 52. - Diagram of flexible tolxpfing for clutch-gearbox' shafts.

CLUTCH COMPONENTS: SPECIFICATEONS, ASSEMBLY CLEARANCES

Calls for the dismantling of the elastic coupling tocheck the rubber block e;‘i‘7ciancy,' if blocks haveexcesslve wear, replace them.When reassembling ascertain the correct function-ing by locating coupling and shaft splines correctlyaccording ihe drawing of Fig. 92, in addition iighienthe fastening bolts of {he flanges to a torque of2,5 kgm (18 ff./la).

AN D PERM1SS1BLE WEAR

. Wear iimitsI e ce mm .Assemby cl aran s In mm m,

Between wheel drive splinad shaft and its disc

Between powe: take-off clutch spiined shaftand its disc . , . . . . . . . . . . . . . .

Between wheei""drive shfiaftvspline flanks and€1exib!ejoim': collar . . . . . . . . . . . . .

Setween disengagement lever bushes and theirglns . . . . . . ._ . . . . . . , . . . . . .

Between shaft and ciuich throw-out collar .

0,010 to 0,105 0.0004 to 0.0042

0,013 To 0,115 0.0005 to 0.0045

-0,024 ‘£0 -0,072 -0.0809 in -0.0028

0,613 to 0,064 CLOUDS to l3.fiG25

0,930 to 0,145 0.8912 to 0.005?

0,35

0,35

0.20

0,30

0,30

0.6138

0.0138

0.0079

0.0113

0.9118

Clutch driven disc thickness (wheel drive andpower take-off), complete whh friction fining B,6 0.3386 T 0.2755

Tightening torque for flexibie coupling flangenuts (Fig. 92) . . . . . . . . . . . . . . . 2.5 kgm 18 ft.Ib

Clutch spring speciiiazafions

Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.? mm (26024 in)Spring {ength under check load . , . . . . . . . . , . . . . . . . . . . . 45.2 mm (£3795 in)Check load . . - . . . . . . . . . . . . . . . . . . . . . . 112,810 124,6 kg (248.7 to 2':'4',7 lb)

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GEARBOX AND EPECYCLKC REDUCTION GEAR

Dismantling - Stripping of components.

Remove the gearbox from tractor as toilows:

Pgrts to be disassembled.

The engine, with its from axle.

The steering box.

The two foot-boards, the rear temps cable andthe dutch disengagement tie-rods.

Operations and cautions.

Follow the sequence described on page 53 for themain clutch removal.

if the tractor is provided with oil lines rfiihning fromthe hydraufic pump to the lift, remove them.

The stripping of gearbox components is ’§aci§itaied by instaiiing it on the rotary stand ARR 2284 (Fig. 93).

The centrai clutch shaft and the throw-out collar.

The gearbox and the epicyciic reduction gearshifter rods. r

"-.:—--.

Remove the two screws fastening the clutch throw-out collar .5UppOI"i to the gearbox, and remove ittogether with the engine clutch shaft and the fie-xI'biecoupling.

Remove the gearbox cover with the shift lever;remove the shifter forks, after puliing the fasteningpins, beginning from the central rod (2, Fig. 95);siide out the reduction gear control sleeve withshifter forks and rods;take away the 3 springs {Section C-C, fig. 108) andthe detent balls.

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Fi . Q4. - Removal of gearbox casing from tractor.Fig. 93. - Gearbox casing mounted an rotary stand Q

ARR 2204.

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Fig. 95. - Upper view of gearbox control gears and shifterforks.

1. Shifter forks for 1st, 4th gears and reverse - 2. Epicyclicreduction gear control fork - 3. Shili fork controlling 2nd and

5th, 3rd and Sih gears.

Primary shalt.

Reverse gear and its shaft.

Secondary shaft.-04-.

Fig. 96. - Disassembly of primary shaft.

(Arrows show the wooden wedge and lhe punch).

Note. - When also {he secondary shaft is to bedisassembled, engage lwo gears in order to unscrewthe fronf end fasrfening nut.

Take away the primary shaft front cover and removethe shafé by hammering on rear end.Prevenl the rear bearing from coming off togetherwith the shaft by placing a w0oo’en wedge as shownin Fig. 98.lf necessary pull out the hearing also using punchA 9613703.

Remove the slop and slide out the shaft togetherwifh ihe gear.Should fhe shall‘ removal offer some dlfiiculty, applya screw to the threaded hole in the axle.Remove bush from gear using the punch A 928251.

Remove ihe epicycllc reducllon unit and fhe gearboxwall lnner thrust disc;slide out the secondary shafl with a bronze punchhammering ll on its front end.

Checking the stripped out components of the gearbox and epicyclic reduction gear.

Check gearbox and eplcycllc reduction gear components against specifications of page 63.Neither gear teeth nor chamfered surfaces should he damaged.Check if the teeth of mating gears are working on the whole face length, and if the surfaces are smoothand free from signs of scoring or hammering.The sliding gear hub internal splines should be free from marks 0% wear or seizing, and ali splines shouldhave their corners without signs of hammering.The splined primary shaft should be absolutely free from pitting or scoring. especially on gear sliding sur-faces. Slide the gears on the shaft and check for clearance between the gear guide flanks and the cor-responding shaft spline flanks.

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'@Fig. 9'1. - Gearbox and epicyciic reduction gear parts. 62

1. Clutch~ge-arbox coupling - 2. Cover gasket - 3. Primafy shaft frombearing - 4. 1st speed and 4th speed gear ~ S. 2nd and 5th, 3rd and 5th

'~ ff 1speed gears ~ 6. Primary shaft rear bearing - 7. Reverse gear mounted Q 1 ...;._;,;on its shaft - B. Secondary shaft bearing retainer ring - Q. Secondary ‘“" ‘l §i:.,_W.;;..,c%-: __shat? front bearing - 19. 1st and 4th speed driven gear - 1?. Srd and 20 J ir 5;=e?;i;"~:6th speed and reverse driven gear - 12. 2nd and 5th speed driven gear -13. Secondary she'll rear bearing - 14. Thrust ring -15. Epicyclic reduc- e__lion fixed gear - 16. Thrust outer plate - 17. Epicyciic reduction driven ®/gears -18. Shim rings -19. Reduction gear engagement sleeve- 20. Driver. jgear shims - 21. Stop ring for pivots - 22. Driven gear axle rollers. iNote: Starting from chassis No. #27935 helical teeth have been super-seded by straight teeth.

The reverse shaft should be smooth and without scoring; it the permissible clearance between the hushtitted on the gear and its shaft is in excess of the wear limits, replace both bush and shah.The bail bearings should be perfectly smooth in operation, without clatter. The epicyclical reductiondriven gears roller bearings and those for the bevel pinion shaft should have an assembly clearance notexceeding the value listed at page 63 and the surfaces mating such components should not be damagedin any way.The gear control forks should be checked for deformation and hardening characteristics of the workingsurfaces. They should slide freely with shifter rods in the box guide holes.Replace gaskets whenever worn or damaged.The epicyclicai reduction gear thrust rings should be checked and it presenting signs of wear should bereplaced.At gearbox major overhaul, remove the control lever sector plate, located under the cover (Fig. 98), inorder to check its components efficiency, especially the ratchet (3) and the control lever dowels £1},which are subject to wear.

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Fig. 93. - Gear shift lever. Fig. 99. - Assembling of epicyclic reducfion gear ongearbox secondary shaft.

1. Control lever doweis - 2. Sector plate fastening screws - 6. Primary shaft rear bearing - 14. Shim _ R = Reverse Bea,-3. Gear selector pivot ratchet. shaft » V = Shim pin,

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Gearbox and eplcychc reduchon gear reassembly.

To reassembfe geaubox components proceed as roiiowsz

Paris to be assembled

S-=cond=ry shaft

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Operations and cautions.

Assembfe on the shaft the rear ball bearing afterheating ii in an oil bath to a lernperature 01‘ 80° C.&ppr0X.,'install in éhe gearbox fhe front bearing after sfidingin the shaft from the box rear end, and mount onit the gears according to Fig. 97.

Note. — The shaft nut tightening sjmuid 59made after the insfaliafic-n of the primary shaff, asif could be facilitated by meshing two gears af thesame time.

If the bush has been replaced, after reassembfy itmust be reamed using reamer U 8321, up to thedimension of page 53.Fasfen fire reverse shaft (R) as shown in 1~'ig.9B.

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1!-21’-31 I-2 3 a e |ndxcat|ng respectively ‘ls’: End, 3rd 4th 5th and Bth speed, obtained by the displacement of the epicycfic§'%dLECtiUfl gear sieeve according to the a row lZ!H'ECfiOi"l indicated by r or opposite tn 5:,

Ra Taper ro¥l r bearmg adjustment shims Rb Rmg for centering the pinion on bevel ring gear ~ Section C-C ihmughCGSIFQ fflrward wail, ar'd correspondmg to tne control rod - As Rod - Sf. Balls - Mm Bali sprin ~ b. R r '95 eve se gear sechon.

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Fig. ‘E01. - Epicyciic reductiun components.(Note: Skirting from chassis No. 427935 up helical teeth have been superseded by straight teeth).

Epfcyciical reduction gear (Fig. 191}.

Primary shaft.

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Rods and forks for the gear contra! (Fig. 95).

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Fig. ‘I63. - Orientafion of the various spring pin cuts withreference io direction of force (F) or of rotation.

Gearbox cover with control lever (Fig. 93}.

62

Assemble the epicyclic reduction gear c0m,00fl8niSaccording to Fig. 101.Mount on the gearbox the primary shafi rear bearing{6} and fasten by its pin (V), the inner thrust disc(14), having its lubrication passages Iocéied as inFig. 99.

Mount on shaff front end the bearing, the oil baffleand the efasiic rings;slide-in the shafi from the case front side and fiton it the first, second and third speed gears;mount the primary and secondary shafts front Coversand their gaskeis.When mounting the first cover, slide if on fixtureA 137003 which avoids the oil sea! gasket beingdamaged by the primary shaft splines Confacf(Fig. 102).

Fig. 102. - Mounting ihe primary shaft front cover usingtoo? A 137803.

Introduce through the gearbox wall holes the threedetenf springs and mount the ball and the firstgear shifter rod with its spacer and fork;introduce through the waif middfe no/e ihe twoepfcyciic reduction gear control roe‘ check belfs (seediagram C-C, Fig. 106) and compleie the assembfy byinfroducing {he two balls from the reievamf hole andrnoum.‘ ihe rod, ine spacer and fork aciuaiing thesecond and the third gears.

Note. - The cuts of the p:'ns fastening forks iorods should be oriented so thaf the strain expand ihepins in their holes (Fig. 183).

Mount the lever and the two dowels in the coverand add the cap and snap ring;

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mount to fhe co-/er lower section the sector pia-fie andfasten it wiih the two screws (2, Fig. 93); mountalso the gear selector pivot (3).Before mounting ihe cover, shift in neufrai all gears.

Mount on gearbox-clutch contra! shaft, the flexiblejoint, the suppcri, the bearing, and its disengagements/eeve.

Gearbox-ctufich control shaft.

Before mounting all parts on the primary shaft, besure that the sea! ring is 1'nsz‘afied (Fig, 97),

NOTE: Shift the gear shift fever backwards, thus disengaging the reduction gear, in order to faciiitatethe operation of fastening the gearbox to the transmission casing.

GEARBOX AND EPKCYCUCAL REDUUHON GEAR COMPONENTS:SPEGFICATIONS, ASSEMBLY CLEARANCES AND PERMESIBLE WEAR

, WearBat? _ Assembly ciaaranhes T mm (In) limits

‘ mm (In) ' mm (in)

Between gearbox shaft ‘ 0,010 to 0,105 0,35splines and their driving - {Q0004 to 0.0042) (03133)and driven gears ,

Beiween gearbox driving w 0,10 to 0,20 0,503 and driven gear toath flanks , (Q0039 to 0.0079) (O-.0197)

i Between driver: gear pinion . _ W‘ tooth flanks and the flanks _ 0.07 to 0,13 2 0,35

1 1 of epicyclicai fixad redu<:- (Q0028 to 0.0051) ’ (Q9135) ‘: tion gear j E

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Epicyciical reduction driven gear ; 20,41to20,¢3 ,needie seat diameter § 10.5035 to 0.8043) Y

1 , 0,01 m one 2 orj Epyciclicaf reduction driven gear 2.99 10 3-9° 1 8e‘W?en ‘?°“°HB$ an?‘ axie?’ 5 (M004 to 0,0024) ’ (0.0'0§9)need,“ éiamaiel. _ (91177 to 93131) of eprcychcai reductlun dr|-, ‘“ ' Q ven gearS

E-Ipicyciicai reduction driven gears axis 14,-$00 to 14,389 Idiameter (05669 to 0.5665) _

I

Reverse shaft bush inner diameier 25,065 to 25,098 _.{obtained by accurate tapping) 5 (£19868 to 0-9881) _

= - Between bush inner diam- 1; 0,065 to 0,119 0,30 ,WV ""”""W WW Z" 1"" gr 7”" 777‘ Bier 9-fld H5 F9‘/9l'$9 5115“ ! (919925 £0 Q0947) . (Q0118)

Reverse shaft diameter = 25,000 to 24.979 E '1 (09842 to 0.921.243 ; V

_ 7_ I '__ _____ ___ ___ , _ ____"

ii5 Control rods release spring Gearbox seieciion release springs

g 1Spring free Iength _ _ , , , _ , , _ _ _ 36,5 mm (14370 in) ‘ Spring free length . . . . . . . . . 21,2 mm (0.8-345 in)Spring length under check load . . . . 31,5 mm (1.24CI2in] , Spring length under check Toad . . . 16,5 mm (£16495 in)Check iuad . . . . . . . . . 14,710 15,3 kg {32,4 to 35.9 Ib) Check load _ . . . ‘ . . . {SA to 20,4 kg [40,6 to 45 lb) ,

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BiFFERENT!AL AND LGCK

The rear half of the tractor body is a case housing the differential assembly and its lock; it is closedat the rear by a cover through which the power take-off shaft projects; the belt pulley unit may be attachedThere/:0.The case upper opening allows the fitting and removal of the power take-ofi drive and driven gears.

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Fig. 104. - Removal of engine and gearbox from reartransmission casing.

Disassembly.

To remove the differential case from tractor and

Paris to be removed.

The hydraulic lift.

Drain lubrication oil.

The gearbox from the dii-Ierential case (Fig. 10¢}.

The final drives (Fig. 195).

The soar.

The transmission case rear cover (Fig. 165).

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Fig. 105. - Transmission casing rear cover removal.

to dismantle it, proceed as follows:

Operations and cautions.

Remove, if installed, ihe /lfl unit, its oil lines, andthe implement hitch.

Remove the two plugs found under the tractor body.

Disconnect the rear light cable connection.Place the differential casing on a stand and lift thegearbox with a winch; remove bolts connecting suchtwo components and disconnect them by a lever.

Remoi/e the rear wheels and their discs.To help the disassembly ofthe various units, removethe mudguarcls.

The seat should be removed lo facilitate the oper-ations which follow.

Remove the dlfierenlial case upper cover and seithe power fake-off control levers at the position<< MOTORE n (engine).Unscrew the rear cover fastening screws and removethe cover by pulling and lowering it very slowly, {'0allow the removal of the front bearing of the powertake-off shaft from its housing.

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ARR 2204.

The differential iock controi.

Differential gear Casing supports.

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Fig. 167. - Lock conirol spring mounting using toolA 237033.

(OFI WP. the spring is represented before assembiy (A) andafter assernbiy (B) on the tool).

At the same time, remove from the upper opening thegear which is thus free from the shaft’ end, to avoiddamages from its faffing in the box,

Note. - To easify disengage the rear cover fromthe transmission casing, set the power take-Offengagement fever in the <1/VIOTORE» (engine)posiiion.

To inspect or rep/ace parts remove the rear cover,ihe pedai compiete of aiiachmeni, the plug from theshafi /eff end, in order to make ii possibfe ham-mering it out from fhe right side.

Fasfen the casing on support ARR 222$, mounieo‘on rotary stand ARR 2204 (Fig. 106).Remove {he gear casing supports and remove thebevel gear, complete.if ihe difiereniiai casing inner bearing races have tobe removed, use puller A 537105.

—, .1_ Q V‘__;;._¢:>k~_*__—:;‘ iii-_:r?;1i;;;;;:';;~$_‘~..~ *' _\Y'§Z'.§s,¢j§l_

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Fig. 108. - Beve! ring gear assembly with differeniiai.

1. Differential lock.

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Fig. $59. - Rear iransmission components.

1. Differential loci. - 2. Power take-off driving gear - Ra. Bevel pinion roller-bearing adjustment shims - Rb. Ring for centeringbevel pinion on ring gear ~ Re, Ring gear adjustment shims.

Unscrew the beve! pinion shaft fastening nut usingwrenches A 711109 and A 611108 and stoppingthe rotation with the brass hammer A B61322.Remove the shaft by applying a bronze punch uponifs front end, and hammer it out.The power £ake~ofi' driven gear and the spacer areremoved from the casing upper opening after settingihe power taI<e»off engagement lever in the positionmarked << CAMBIO » (gearbox).

The bevel pinion.

inspection of the stripped components of the differential casing and differential lock.

Accurately clean all stripped out components and check if the gear meshing surfaces are in good con-clitionsi

»— check the diiferentiai gear thrust rings, and the pinion bushes and thrust bearings vs. ihe wear limitsoi page 59. When replacing bushes, after assembly, ream with expanding blade {earner U 6‘lf814to achieve the prescribed clearance;

-— check the copper lining on crown wheel hubs. and replace such parts if the coating is not sufficient;- check the taper roller bearing and the differential axles oil seals;

— check the difierenfial lock collar working suriace and the pin fastening. Check the differential lockcontrol spring (Fig. 107) by a comparison of its characteristics with {he specifications on page 69.

D iffereniial casing asse mbiy.

See Figs.1H9 and 118 and in addition bear in mind ihatz

- the planetary casing is secured to the be-vei gear by bolts fastened to a torque of 4.5 to 5 kgm (32 to36 it.lb);

—~ the differential. pinion axle is held in place by two special head bolts, the same which secure thecasing is the bevel ring gear;

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L.2z'&,e_F’— the assembly of the taper roller bearing inner

* races on the casing should be made afterheating the bearings in an oil bath ‘co a tem-perature of 80° to 90° C; the same procedure

5 applies to two bearings and to the power take-off driving gear, on the bevel pinion shait (2,

_; Fig. 109);

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~— the differential lock control spring is installed" as shown by the Fig.10'I, using tool A 23"i'lI}33.

To facilitate the reassembling of the differentialcase to the gearbox, we suggest placing very near

I to the shaft {Font ends -— by manoeuvering thel relevant levers —— ihe power ts5<e~0fi driven gear

Bevel pinion and ring gear adiustmeni.

lowed:a) bevel pinion shaft bearing adiuslment;

1 b) differential case bearing adjustment;‘ c) tooth bearing adjustment;

cl} tooth backlash adjustment.l The sequence of operations is as follows:

al lr:-stall the bevel pinion shaft and its bearing,

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R: 7 Ring gear shaft adjusirnent shims - a = Drive wheelshaft and spacer, up io iracior no. 4-33¢S5§.

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Fig. ‘E11. - Bevel pinion and gear correct tooth hearing.

and the reduction gear engagement sieeve.

When chécking or replacing the bevel pinion and gear, the following adjustmeni sequence should be iol~

the power take-off driving gear, the spacer and theadjustment shims Ra (Fig. 106}. To calculate the shim thickness, subtract from 58,5 to 59,5 mm

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Fig. 112. - Rear view of tool A ‘£37010 for bevel pinionand gear adjustment.

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(2.362? to 2.342") the sun": of the gear width and the spacer width. Finally, check the shalt tor treerotation and mount in place of the foregoing shims others having their total thickness minus 6,05 mm(0.G{J2”), which will set a 50 ltgimm (ill) lb} pre-load on the pinion bearings.

b) Remove the bevel pinion and mount the bevel gear complete with differential pinions and supports;tighten one of the pinions with its screw and check with a teeter gauge, at the other support, theoverhaul thickness of the bevel roller bearing shim rings. Divide it by two placing each ct’ the twohalves Rc on the two supports and check it rotation is tree but without end"piay.

c) For a correct tooth bearing (Fig. 111) pay attention, at pinion assembly, to the number stamped uponthe smaller base and marl-ted by -+~ or —~; this is C§Ul’E8* necessary to determine that thickness ot ring Rh,which will be most tit to avoid noises during operation.We suggest the following sequence:

»- mount the bevel pinion shaft titted with all its parts and with a ring Rb oi any thickness;— mount on the casing the tool A 133110, according to Figs. ‘E12 and 113;

—- rotate the tool shalt clockwise so that the eccentric zone contacts the pinion base, and read onthe quadrant graduated from 92 to 94 mm £3.62?’ to 3.700”) the value at which rotation stops. it thisvalue, indicated on the quadrant, exceeds the one calculated by adding or subtracting from thetheoretical distance existing between the pinion smaller base and the bevel gear axis (93 mm - 3.661”)the number marlzed on the pinion (not proceeded by any letter mark}, it will be necessary to replace‘ring Rb.The ring to be mounted should have a thickness increased of an amount equal to the differencebetween the two values.On the contrary, it the value read on quadrant results less than the one read on the pinion afteradding or subtracting (accotding to the + or M sign) from 93 mm (3.6614”), the thickness Rb shouldbe decreased.

Reading on the fool quadrant 93.-1 mmMeasure read on the pinion ~{~ 0.2 mm

Example No. 7.

Distance between pinion and bevel gear:93 + 0.2 = 93. 2 mm ($6614 -i— 0.0978 = 3.5692”)

The ring Rb should be 0,2 mm thicker than the oneinstalled, calculated by subtracting 93.4-93.2=0,2 mm in order to set the pinion at a distance of93.2 mm according to the indication marked on ii.

68

Reading on the tool quadrant 92.6 mmMeasure read on the pinion —0,3 mmDistance befween pinion and bevel gear:

93 —~ 0,3 = 92,? mm.The ring Rb should be 0,1 mm thinner {ham the oneinsta/fed, caicu/aied by subtracting 92,7 -— 92,6 === 0,1 mm.

Exampfe No. 2.

d) Check with a dial gauge the tooth backlash which shouid be 0,20 mm (U.O08”J; the correct backlashcan be obtained by shifting adjusting shims Rc from one support to the other, in order ta set thebevel gear farther or nearer the pinion as required. The overhaul thickness, determined according toparagraph b} should not be aitered.

SPECIHCATIONS, ASSEMBLY CLEARANCES AND PERMISSHBLEWEAR OF THE DEFFERENTIAL COMPONENTS

Wear iimits 5 Wearlimits. Assembiy clearances mm :1 (in) mm 1 (in)

i

(0.008) 1(0.unc4 to 0.0042)

(00059)(00008 to 0.0037) \(00031 to 0.0052) .(0.004? to 0.6697)

1 Between pinion and crown whee! taeth backlash . . 0,20Beiween splines of differential axles and their gears . 0,010 te 0,105Diiferentiaipinion and geartoeih backlash . . . . . . 0,15

i Between bushes and differential pinion axle . . . . 0,020ia 0,093‘ Between casing and differential gears . . . . . . . 0,030 to 0,153

Beiween differential lock coiiar and casing . . . . . - {}_120{¢0,245

0,4 i0,50,25o.ss0,5

(0.015?)(0.019?){0.0E]98)(011133)(0.0? 9?)

Specificaticns i mm (i rs}

‘ Crown wheel adjustment ring s!1im)thicknesS (Ra, . ‘

_._—‘3-Ii-U1 r-0-I-PO0 -1-A (DU!

NIO1‘ Differential gear ihrust ring thickness (1) . . . . .

‘ Differential pinion round thrust washer thickness .i - .

i :I

e.1s§n (i 0.0008} .

{i 0.0004)0.0531 E0 0.65090.0551 fo 0.0536

3 Fig-1103 - - ~ - - - - - - . - . . . . . . . . i 0,3-0,5-0.7 (toier. -30,02) 0.011s-c.0197-0.0215(=1-_a.0ooa>1 Bevéi pinion sifiiii adjustment shim ticim:-ass (between Q 3,g.3!g.¢.4,1.4,g.4_3-4,4.4,5..4,5- . g_1495-0,;535_g_1575_g_15q4_g_1554_

Biniw and fear fairer bearing) - - - - - - - - - - 4,?-¢,s (toiar. :1: 0,02) 1 0.1693-0.1732-0.1772-a.1a11-u.sa59-1 Beveipifliw shaiibearins adiustmentshim pa¢kihi¢i<- ij 1,1-1.754,s-as-2-2,1-2,2-2,25-2,3 0.0569-0.05894:.07u9-o.o'14s~o.0?s7-\

‘ mess - - - - - - - - - ‘ ~ - - - ‘ - - - - - - - - § (toler. $0.01) . 0.0827-0.0866-0.0386-nneoe .

1 Tightening torqué of bolts assernbiing pianetary gear ‘casing to crown wheel . . . . . . . . . . . . . . 4.5 Y0 5 F4901 ,

32' to 36 ftib

i Differential ¥ock control fork spring ‘

Spring free ienth . . . . . . _ _ . . . . . . . . . . 188‘ Spring length under check ioad . . . . . . . . . . 126,5

. Check load . . . . . . . . . . . . . . . . . . . . . 28.5 to 31,5 ks ‘7.40364.9803

62,8 to 69,4 ib_, _ H ,_;.,__f_. _ » ,_ » _., .._.. V____ .. _________[

(1) Rings of oversized thickness of 0.1 mm (00039 in) are avaiiabie. Wear iimii of a shim: 1 mm (00394 in).

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FINAL BRIVES

f ha ‘n individual casings, mounied lateraiiy to the differential and drivenEach consists of a pair O gems VI Qby it (Fig. 110).

Final drive overhaul.

‘iiThe majsr overhaul thereof should be made as .0 ows:

Removal from tracter (Fig. 114).

Shipping out of components.

Fig. 114. - Removal of final drive casing from tractor.

YO

Remove the electricai cabfe energizing the rearlighting from connection, and take ihe mudguardaway;place the transmission casing on fhe stands andremove the whee! assembiy, with disc and fire.Remove the final drive casings frcm the tractor andnull outwards to slide out the difierenfiai axle frombevel gear. .r

Mount fire assembiy on the roiary stand ARR 2284with support ARR 2221, and remove the brake drumfasfening nut.‘Remove the drum using a universai puiler (Fig. 115};remove boih finaf drive casing cover and drivengears;remove the axie inner bearing stop ring {see Fig. 116)and push it out the casing.

Note. - The final driven gear remova! does notnecessarily require removal of the casing fromtractor.To unscrew the driven shaft nui of the final’ drive,mount £00! A 137014 to stop gear roiaiion (Fig. 116);ihen use a universal puffer provided with 2 screws{diameter 15 MB, pitch 7,5 mm} (Fig. H7),

Fig. 115. - Removal of brake puiiey using the universaipuller.

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Check the or‘! sear’ of the difierentfal axles and of thedriving wheel shafi‘, to prevent off feakage on brakebands and fiom {he driving wheel.Check “bearings for free running and iooz‘/1 backlash(see specifications an page 'Ir’3).

lnspeflfion of components.

When reasssmbling avoid damaging the sea! iocafedin the chfierenirar’ bevel gear support.

Assembling,

BRAKES

The pedai and hand actuated band brakes act-on the puiiey keyed on the differential axies. The tractorwhen used on roads requires sudden and quick braking and therefore the peda¥s can be connected bya lock which ensures simuttaneous braking action. This fact must be born in mind when setting thepedal free travei which should be equai for both.

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| : -= ' 'TmFig. 118. - Brake assembly, pedal and hand conircls.

a. Clutch contra! pedal assembly - b. Brake pedai assembly.A ¢ Cievis lock nuts - B 1 Caps ~ R’ = Brake band centering screws * S = Inner arm - '1‘ = cute; arm - v 5 1,-me, am-,fastening screw - Z 1: Brake band pivot pins.. 1 Z - J 1" I - <~ /4»’/Mmn? 5_;€_%__ .‘}\¢v¢; J"/1: -- 5:'?'n1¢1Js /10! ' "'9 “73"'$/C /"°" J"

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Brake overhaul.

To be performed as follows:

Removal from tractor-

inspection.

Assembling.

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Brake adiustment.

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To remove brake bands:— drain transmission casing oil and remove from

the iracior the final drives, according to page ‘F0instructions,’

- remove the differential casing lower covers andunscrew the screws (V, Fr'g.119) remove the pedalsprings, remove the adjusimeni rod ends B fromouter arm and slide it out;

-— remove the braking band end pins from the innerconfrol arm (Z, Fig. 118) and lake them away‘.

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Checlr the brake pulley surface and rr necessaryiurn it down, avoiding faking deep culs whichwould impair its resistance;check the dlfierential axle seals for oil leakages;correct any leakages smearing the ferodo lining;replace bands if soaked with oil using tool A 513007for riveting;in addition check the shall and pedal bushes forwear (Fig. 113 a and b).

A/lake sure that:— the screws (V. Fig. 119) are fasiened by wire lo

the internal levers (5, Fig. 118);— screws are facing the tractor rear end; if not,

the exiernal levers T have been interchangedand no braking action would be possible;

- when mounting final drives, avoid damaging thedifferential bevel gear support seal wilh thedifferential axle end.

Fig. 119. - View of brake hands ané ccmtrois. 'A = Clovis lockouts - B = Caps - R =- Brake band centering

screws ~ T = Outer arm - V = inner arm screws.

When mounting brakes on irecior:- unscrew [he two nuts and compleiely screw on

the brake band tenierlng screws (R, Fig. H9)then unscrew {hem lhrouglv a complete Zurn, andre-lighten the nuts;

- slacken nuis A and unscrew rods (B, Fig. 119)until the free travel of each pedal is taken up, thanscrew them again two turns so that the brakepedal travel is about 50 mm (1 .969”).

Before adjustment, the brake control lever shouldbe set all live way down with respect lo the sectorplate.

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mm (in)

s (£10059 to 0.0098)Clearance between driven gear driven shaft splines ané gear hub . -0,050 to 0,048

I (~0.002G Yo 0.0019)Brake pulley diameter . . . . . . . . . . . A . . . . . 4 ‘ , _ . . = 210= (8.287?)

Brake band shoes thickness . . . . . . . A . . . . 4 . . . . . . l E

Final drive pinion and bulb gear tooth backlash . . . . . . . . . 0,15 to 0,25

6‘ (02362); Clearance bet-ween bushes and brake pins . . , . . , . . . . . . 0,120 to 0,144

1 (Q0016 to 0.0857) _I l

0,5(0.019?)

0,20{0.D\'J?Q)

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STEERHQG AME FROM?‘ AXLE

STEERING BOX AND LINKAGE

Removal and disassembly.

The steering box removal and disassembly should be made as follows:

Parts £0 be removed. Operations and cautions.

The batteries.

The dashboard.the gearbox;Remove if wiih ifs frame from the batéery box and

detach the rear /ighfing cable from central cormec-tion.

Steering arm from drag link.

The steeri ng box.gearbox;5/acken the 4 screws fastening the baféery box to

remove screws fastening the steering box to gearbox;remove the steering box with the dashboard {lift thebattery box firsi).

Clamp the steering box in auvise and remove the following components:

$%@e-"ire arm. Use puller A 735003.Shaft and roller, Remove the adjusting Screw 1'Q¢k,r7uf and {he ,0/ye,

shaft side cover (see Fig. ‘$23),

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Fig. ‘E2<}. - Steering box perspective view.R == Roller washers » S = Screw to roller tooth aligningshims ~ T =1 Taper roiier bearing adiusténg shims - Gg and

Gp = Roller shall seals » VI’ =1 Adjusting screw.

Remove the steering whee! and {he board; remove{he screws fasiening the sfeering column to thesfeering box and remove the steering shaft and ifsbearings.

Mole. - When d:'smam‘lfng the ro!/er bearingouter races from the sieering box, do not alter theshim pack (S, Fig. 120).

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Fig. 121. - Steering box muunied on iractor.

hlspection of stripped out componenis of steering box and steeréng unit.

Check mating surfaces of roller and worm gearfor notches or traces of seizing. Check alignment of rollerand worm gear, this signifying that the roller and worm screw reciprocal position is correct; if otherwise,the shims should be changed (S, Fig. T28).Check for clearance between bushes and the roller shaft, according to specifications of page 76 andreplace bushes when iimits are exceeded, in order to maintain proper mesh between roller and worm gear.

Ream bushes after assembly, using reamer U 611916 to achieve the correct diameter. ‘H roller shows end play, due to wear of the two washers (R, Fig. 122}, replace the shaft also, being theparts riveted together.Check the taper roller bearing for free play and the roller shalt oil seal.

Check eieering arm and drag links for straighthess; if bent, straighten ihem anci make sure ihat theirstrength is u nlmpaired.

Steering box assembiy.

Parts to be assembled.

The roller shaft bushes.

74

Operations and cautions.

If bushes have been replaced, after reassembiy reamthem using reamer U 611916 up to fine rfiameéerspecified In page 76.

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The lower taper rolier bearing outer races andshims (S, Fig. 122).

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To avoid eitering the setting of roiier and wormgear, the shim pack S thickness shouid be varied ifthe worm gear, the roller or the steering box havebeen replaced; the shims pack should the/7 beadjusted as foiiows:a) mount the worm gear assembly, after smearing

it with red lead compound, and adjust rj‘/f,-‘&(3_r;§Qof taper roller taearings;

b) mount the roller, shaft, cover and the steeringarm;

C} adjust theroiier and worm gear bearing afiggfdsing to indications following.Note. - Each variation of shims S, calls for a

new adjustment of bearings with shims T.

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Fig. 122. - Roller tooth cross~sectinn. Fig. 123. - Longitudinal section of rolier tooth shaft.R = Rc-Her washers - S = Shims centering screw to roifer - E; Gg and Gp = Sears - Vr : Adjusting sci-9W_

T = Centering shims taper ‘nearing adjusting shims.

The worm gear, with the taper roiier bearing act-justingshims (T, Fig. 122).

The roller shaft, the cover and the steering arm.-...,,

Adiustment of rofier and worm gear bearing.

Mount the worm gear shaft with its bearing shimsand check it for flee rotation which must be ac-complished without excessive effort.

The correct functioning of the mechanism requiresthat the distance between roiier and worm gear beas sm aii as possible and corresponding to the originalspecifications.To this end, after mounting the unit and positionedthe steering arm as in Fig. 122(this corresponding tostraight forward motion of the tractor) the adjustingscrew (Vr, Fig. 123) should be screwed on, in orderto take up the piay between roiier and worm screw;in addition, check that this condition remains un-varied as the steering wheel is turned 30°, ieft andright.After adjustment, tighten the lock nut of screw E/r.

To refit the guide box assembly to tractor reverse the dismantling procedure.After assembly, service the guide box with SAE 90 oi! and the drag link grease nippie with chassis grease.

75

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Steering {@518-

After adjustment. check the steering wheeis aiignment with the tractor axis; nevertheless a toe—in of abeut5 mm (0.‘|Q69”) and a camber of 2° are acceptable.Check tightening of the steering lever baits and the cross tie~rod ciamps and check tie-rods and leversfgf gtraightness, to avoid eariy front tire wear.

sP£c%r=z<:A"r1o:~ss, ASSEMBLY CLEARANCES mm PERMISSEBLE WEARVOF swaaamsmscmmssm rsvzsrasm BOX), "ma-zoos AND LEVERS_ ~—~ * — *' "f "W ! *" "' ' "*** ””""" 3 ' ' ' ' 7"" "' i: 5 1 i ii g Wear 1

r i nah?) , Assernbiy clearances mm (in) E limiis 3I mm U" I mm {in}i i

Steering box bush inner diameter 34,925 to 34,050 ‘ 20.3750 to 1.3160} ~ -Between steering roiler shaft | 0,025 to 0,075 . 0,15and its steering box bush (00010 fio 0.0030] E (00059) k

Steering roiier shaft diameier 34, Q00 to 3d B75~ 0.3740 xG 1.3.30) , 5 ‘

P ....

i Coverbushinnerdiameier{afierpress | 34[g12m 34.93? Ii fining) 1 (13745 to1.3755) ‘ _i l Ba-.weera steering roiler shaft 0312 10 {L052 5 ‘"i ”” mi i iwl anditsbush °“s‘e“"‘g hm‘ (00005 \° 00024) - moose) ‘

Steering control rolier shaft diameter 34,875 to 313,900 Cover - ;1 (153730 ‘I0 1.3740) ‘

Y Upper bush inner diameter of steeringtransrnissinn lever

29,020 10 29.0729};_ (1-1425 *9 31445) Between upper bush inner

_ _ _ ,_ __ i_, _ _ diameter and ihe steering 0,020 to 0,105 : 0,35i ' transmission lower iever (00003 to 0.0041‘) (00138) ;

Steering transmission ieverpivot diam- 28,96‘! to 29,000(°) pivot _i 9421' (Section A-A, Fig. 126) (‘M404 io 1.1417) ' '

i !inner diameter of lower bush of steer» 38,025 ta 38,087 w

¢ !mg arm 0.4910 to 1.-£995} B ,0 I b h . ;EIWEEI1 DWQF U5 IHFEEF E 0625100126 0'35

~ K —— ---z' V —r — i diameter and the steering 5 '6 . ' rarm iower pivot - ((100.0 10 0.0050) (00138) iSteering arm pivot diameter ! 37,961 to 32,000 1 ZI 07 (14945 in 1.-mar) i

i __ _____ _ _ _____________ ___§ __ _________i M _ ________ _ __ _________ __,__| " " i . 1I i1 M‘ Drag-link bush inner diameter 12,000 to 12,043 ;

‘ ' (04724 to 0.4741)___ _W___ W __ _,_ Beiween drag-fink end bush 0,000 is 0,070 0,3 ‘f and its paw (mono to 0.0025) <u.e11a)

; Drag-fink pivct djameier '2 1i,9T3 to 12,000 '= i (06714 To 0,4724)

1 Note. - The steering arm upper and iuwer bushes shali be mounted into their seats on the support wiih an inierferenceii of 0,05 io 0,28 mm (CL0020 in 0.0091 in), bushes §or steering bu: side cover shalt be mounted with an inierferencei, of o,o1s to 0,053 mm 01.0005 to o.ua2s in}. ' 5

Assembiing iorque sf steering transverse tiered ciamp screws is of 2.5 kgm {:83 ‘it.ib).

(O) The data are the pre-modification ones; the post-modification ones (from Tractor with irame Na. 402251) have been increasedof 1 mm (D.il391$“ in}.

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FRONT AXLE

Checking the front axie.

Remove! (Fig. 124).

Dismantling.

Checking components.

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Piece the engine sump on a stand or hydraulic jack,’drain radiator water and s/acken the rubber sieevesband stamps;

disconnect the drag /in/< from the steering arm andthe radiator shutter control’ from its front end;

disconnect the head iamp cebie connection; fastenthe two ends of a rope in the radiator upper sectionand insert wooden two wedges to stop front axleosci/iation; remove the sump screws fastening itsforward end to the radiator support and move thefront axle assembly forward,"remove the radiator cowifng and the radiator.

Apply front axfe to rotary stand (see Fig. 125).To strip it out refer to fig. 126,

Afier mounting the hubs check bearings whichshould rotate freely without any noiiceebfe end play;check surfaces and plays of king pins and of theaxle pivot pin with their bushes;check the bronze thrust rings thicimesses andreplace them if in excess of wear ifmitsfsee tableon page T9).

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Fig.124. - Remove! of front axle and radiator from engine. Fig. ‘I25. - Front axle mounted on rotary stand for over-

hauling.

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Assembling.

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Fig. 1&3. ~ Front axle section.

Check the wheel nub cover rubber seals which mustensure protection against slush and moisture infil-tration from outside into the bearing; set near tothe wheel a surface gauge and rotate the wheel tocheck the disc and rim for deformation: this checkconcerns both steering wheels.Check the camber of the steering wheels by laying asquare in the vertical plane along the wheel axis,and checking if for any two opposite points on therim, the difierence between measured distances isconstant; _check front tires for wear and replace them if theircentral steering ribs are too worn.

Assemble axle according to Fig. 126; no difilcultyshould be experienced.

Note. - The lower bronze thrust bearing of thesteering knuckle shall he installed with its lubricationpassages facing the steel upper thrust bearing.End the assembly by greasing the hinge pivot, thesteering knuckles, the front wheel hub cover and thefront wheel hub with chassis grease.

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Data we”- 1 Assembly cfearances mm (in) ;' limits 3mm (ml mm (in) ‘

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Axle hinge pivot bush inner diamtfzer 32 025 t 2 08? - '(dimension to be obiaaned &?ter H5603 is iéfiss) _ ‘bush press~1‘ittir:g) (1) 1

l Min . Between bush and from axle 5 0,025 to 0,112 0,35 _‘ " W W’ WW ' W’ " ' ‘ hing!-1 Pivvf f (0-9019 '50 E‘-99“) (OMS-B) ‘

Axle hinge pivot diameter f 31,975 to 32,660 Q 1 3Z (12589 to 1.2598)

‘ -_ h- _t ___ ___ ‘ fiftinimum ‘Axle support thrust HFIQ t ickness (onisgég is gfigso) I = thickness 2’ ‘ ‘ {0.0?87} Y

5 Sfeering knuckle bush inner diameter 38,025 to 38$”

bush pressmflng} (1) a n ear: bush ' <1‘ m @025: cm 5 asse v .. Inner sa - ‘ , 0 ', g ,1- A-" * ' ' ' ' -i ‘ eter and king pin (011010 ‘:0 0.0044) £03138) 1Steering knuckle pivot diameter 37,975 to 33,000

(14951 EC 1.4951)

1 Axie thrust bearing cup thickness Minimum0,91 10 1,09_ 410.0358 to 0.0429) - — jthickness 0,6 §

n _ g (0.022:-5; 1

Axie hinge thrust bearing thickness 3.925 to 4.600 _§ Minimum(031545 to 0.1575) 1; —~ »— thickness 3

(Q1181)11... W WK. ._;_W _ ,_ _,_(1) Axle hinge pivot bushes and steering knuckie bushes shall be mounted into their seats with an intederence af 0,05 to 0,23 mm

{c.0020 to 0.0091 in).

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Fig. 127. - Electrical diagram cf tractors series 400.

8. Generator - M. Starting motor - C. Glow plugs. - B. 12V Battery - A. Horn, optional ~ PA. Horn button — FPA. Hornfuse - P. Headlights, with a 5€J_='1.‘5 W bulb - GR. Control box - PC. Fuse box ~ FPG. Control bax éuse - LS. Battery chargewarning iight - F0. Dashboard lamp - CLA. Lighting and starting key switch - CA. Starting lever switch » FP. Right taiflghl ~

' FPT. Combination number plate and lelt tall light - GP. 2-pole socket - FR. Rear lamp (optional).

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ELECTRICAL SYSTEMDESCREPTION

The tractors belonging to the 460 series are equipped with a 24 V system, including generating. startingand lighting units. The diagram of Fig. 12? includes:

No. 1 Fiat generator {type R 115-Mt},-‘24-1600 Var. 2), HG W, replaced by a generator typeDC115f24[7!3 C starting from engine No. 005045 up.

No. t Fiat control box Mod. A53-140,l2f$, replaced by a Mod. GP 1,-"24,!7 unit.

CAUTHIEN: The control box Mod. A,"3-140,-‘24 may be used with both generator types, whilst theGP1,"2-ti? unit must be used with generator Mod. DC1'l5__~‘24[7/SC only. See details in the respectivechapters. _

— No. T fuse (16A) for the control box protection;

»- No. 2 batteries (12 V), of 54 Ah capacity at 28 hrs. discharge, connected in series;

- No l electric starter (3 Kw) equipped with a solenoid Mod. E115-3124;

-~ No. 1 five~position starting and lighting switch;

~» No. 1 three-position lever type switch tor starting and glow plugs;

-W No. =1 glow plugs (140 W};

for parking light‘

— No. 1 dashboard lamp with 10 W bulb;

—- No. 1 battery charge warning light (10 W) bulb;

-~ No 1 fuse box with tour SA fuses for equipment protection;

-— N0. 1 tailight with ‘ll? W bulb; ‘

~.» No. 1 combination number plate and taiiight with 19 W bulb;

— No. 1 two~pole rear socket; .

—- No. 1.rear floodlight (optional);

— No 1 electric horn with push-button control and 8 A fuse (optional).

Lighting and starting switch.

Each position of the key on the switch corresponds to a_ circuit, and precisely:

—— position 0: 30 3011 - All circuits off;

3[l_./1 - Starting switch - battery charge warning light;~ position ‘l: 30-51

3011-58 - Starting switch - battery charge warning light - frontparking light ~ dashboard light - number plate andtaiiights - two-pole socket - t00 mm dia. floodlightwith built-in switch.

—— position 2: 30-51

81

‘t‘rlI‘.T.~T.“L‘:-;l -F 11% ‘— No. 2 three~light headlamps, each with a 50,145 W bulb for driving and passing lights and a ll) W bulb C

30-51 30/1-58-56%: -- Starting switch ~ battery charge warning light - tron’:parking lights ~ dashboard light - number plate and

. tailtghts ~ two-pole socket — 100 mm dia. tloocllightwith built in switch - passing lights.

— position 3:

£51-56a 3611-58 -— Starting switch — battery charge warning light - frontparking lights — dashboard light - number plate andtailights - two~pole socket - 100 mm die. tloodiightwith built-in switch - driving lights.

- position 41

The key can be removed when at position 0 onéy.

Starter switch.

The starting switch operation is dependent upon the position of the combination lighting and startingswitch.

Each position of the iever on the switch corresponds to a circuit, and precisely:

~— position £1: 15/54 —— All equipment off.

~— position ‘t: §5;'54-19 —— Glow plugs.

~— position 2: 15,r'54-‘E9-filla - Glow plugs - starting.

The lever returns automatically to position 0 from levers 1 and 2.

Fuses.

The equipment belonging to the electrical system is protected by tour 8 A fuses contained in a box piecednear the dashboard and by two other tuses. I

— Fuse 54,3 protects: L. H. side front parking light - R. H. side taliight ~ 100 mm die. tloocilightwith built~irr switch.

— Fuse SUEZ protects: Driving lights.

-— Fuse 301'? protects: Passing lights.

— Fuse 54,"2 protects:plate light ~ two-pole socket.

protects the control box;protects the electric horn (optional).—~ Other fuses 1:

The generator with spy-light, the starter and the glow plug circuits are without fuse protection.

Find the cause ot fuse failure prior to repiacing a fuse.

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R. H. side tront parking light - dashboard light - L. H. tailight and number

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GENERATOR TYPE R 115-140;'24-1600 Var. 2

Specifications. '?jd:1LE‘~f; 7;/‘W7 éffififjd 1'00."-*1 fin)

Fiat generator type R 115- 146,!24- T660 Var. 2 (see fig. 128) having the foiiowing specgifications. has beenmounted up to engine No. 005644; it has than been repiaced by generator type D(3115_/24,f?;'3 C.

Maximum continuous output (24 V) . . . . . . . . . . . . . . . . . . . . . . , ‘HG WMaximum continuous current output (Ampére—fimitaf:ion at 28 V) . . . . . . . . . 4,75-5,25 ASpeed at maximum continuous current ouiput, at 24 V and 20° C (68° F} . . . . . 1400-1880 R.P.M.Maximum continuous speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 R.P.M.Excitation . . . . . . . . . . . . . . . . ‘ . . . . . . . . . . . . . . . . . shuntDirection of rotation, as viewed from driving side . . . . . . . . . cfockwiseReguiator group type . 1 ". . . . . . . . . . . . . . . , . . . . . . . . . A53-14-0j24

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Fig. 128. - Seciional View of generator iype R115-‘§48,"24-1EDO Var. 2.L Radial brushes - 2. Fieid coiisr - 3. Pole shoefasiening screw - é. Pole shoe A 5. Driving side support » 6. Frame ~ T. Armature -

8. Comrnutatcr ~ 9. Lubrication wick - 10. Lubrication chamber -_11. Field coii terminal.

Bench testing the generator.

Test generator efficiency, according the checks Jisted hereafter:Generator shoufd aiways function coupled with regulator type A/3-'14€!,f24.

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G. Generator ~ V. Voitmeter, 30 V ,€op reading - A- Amrneter,top reading. (B?-1?9='5' should suppiy slightiy more than 2:1 V,

V as current is TA).

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The arrangement consists in connecting fermfnais67 and 51. shoré cfrcuifed, as shown in Fig. 129.Generator shaif be fed as an electrical motor aé 24 V.Check that afasorbed current, under such a voltage,is 3-5,5 A at 9504150 R.P.M.As test is finished, immediately disconnect terminals57' and 57 (short circu/Ted), to avoid damaging thefieid coils as generator speeds up.

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{Cut-in speed at 24 ‘v'.: 12OD»‘lé(}0 F?.F.M.).

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Fig. 13?. - Wiring diagram for the output curve pioiting{ampére versus R.P.M.) at 2 constant voitage of 24 V.Ni. Generator actuating motor - G. Generator - V. Voitmeter,

30 V "lop reading ~ A. Ammeter, 20 A top reading.

Temperature test.

84

The output curve shown in Fig. ?3B has been obzfainedwith generator heated after a period of operaiion.Therefore, before plotting the characteristics, mounithe generaior on five tesf bench, according to diagramof Fig. 13%; rim it through a moior for about 30 rmlnuies, at 20-00 R.P.M.The current output (5-5,5 A az‘ 28 V) shouid be Sup-piied by a rheosiai,

Siop generator, and disconnect ioao‘-rheostai. Fioéaiegenerator, graduai/y increasing ifs speed uniii ihevoiimefer reads 24 V, Eben measure the generatorspeed.

Such e speed represenfs the cui-in speed {hot con-ditions) and shouid lie between 1230 and 1360 R.P.i‘vi.(points on abscissa ~ diagram of Fig. 139).Sfop fhe generator, inseri the /cad-rheosiaf, andmeiniaining constant fise voltage, check againsi thevarious speeds fine current values included in thecross-haicheo’ area of diagram in Fig. 138.Diagram piofiing should be made rapidly whengenerator performance is beyond iés rated outputand therefore overioaci mighi damage ii.

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M. Generator actuating motor - G. Generator - V. Voitmeier,30 V top reading - A. Amrneter, 10 A top reading.

(The reguiator group to be coupled to the generator shouldbe of the A;‘3-140f24 type).

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if in doubt es lo the maximum temperature of thegenerator during operation mount if on the iesibench, with pulley and regulator group, accordingto diagram of Fig, 132.

Run generator coring 45 minutes at 2000 R.P.M. andduring Y5 minutes at 4000 R.P.ii/i. supplying to aresisior a current of 4,95 to 5,55 A at 28 V.Overheafing measured by pyromeafer, should be:

— on generator frame: 45° C (113° F), or less;

W on commuiafor: 90°C $794" F}, or less,

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Field-winding resistance at 20°C (68° F) should be7-<!.5 to 15,5 ohms, and may be measured betweentermin ai 67 and ground, when generator is assembled.Armature resistance at P0" C (63° F) is 0.520 to0,545 ohm; it should be measured only exceptionallyto avoid damaging the commutator bars, owing tothe soldering of two pieces of wires spaced of 780".

Checking ohmic resistance.

Fig. 133. ~ Field winding test.(Connect the measuring instrument ends to terminal 67 and

to ground).

Bisassembly.

Proceed as follows:

- remove the commutator head, disconnect terminal 67, unscrew and remove the through-bolts:-» remove commutator end bracket and slide out the armature with the other bracket;-— clamp armature in a lead-jaw vise and remove the drive pulley and the remaining bracket.

Troubles ~ Repairs.

Battery charging faulrs may be due to:

~1‘auity generator;- other trouble in the system.

Make sure to locate trouble first. The tell-tale lamp may furnish an indication with engine stopped orrunning at different speed rates.if the generator is faulty, the cause may be sometimes found elsewhere, and particularly in the regulatorgroup or in the circuits; "therefore. the operator should take care of generator efficiency and also checkthe regulator §?oup and the whole system in order to prevent repetition of the generator trouble after itsreconditioning.The battery charge spy lamp may be helpful to detect trouble. li when introducing the starting and lightingkey, and setting it’on position 1, the battery signal lamp remains lighted, the generator is normal; ifengine is being started and accelerated to a given speed, the light should go out. -If, on the contrary, the lamp goes out only when engine has reached high speeds, the trouble may bedue to faulty windings (grounded or short circuited), or to the armature.Generally, the higher the R.M.P. rate at which the charging begins, the higher the potential damage.ll the lamp remains lighted, this indicates an interruption between the generator cables and the regulatorgroup; or shows that the group contacts are oxidized, and internal connections dissolclered; or that somegenerator coil is interrupted, or completely grounded.ii the above procedure leaves the light out and the trouble persists also after replacing the bulb thissignifies that the trouble is to be found between bulb holder and switch, or between switch and the con-nections oi the components branched upon it.When the battery indicator light goes out to go on again the engine speed being steady the fault is pro-bably due to the regulator group or fuse or to‘ the electric connections (the jacks),

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Generator repairs are to be carried out as foilowsz

a) Brushes.

li broken, chipped, or worn out, replace them with spare parts furnished by the FIAT Company ~ SezioneRicambi. Be sure to avoid the installation of other brush makes, as FIAT spares only can ensure a regularand iong lasting operation ot both commutator and generator.

b) Field-winding. A

Check field coils by circulating test bench current though them (Fig. 133) and measuring the voltage andthe current with the bench instruments, then calculating the coils resistance.if connections alone are interrupted, repair them carefully; but it the winding is damaged replace the es-sembly with a new FtAT spare. We do not suggest maicing {laid coils, as a speciai procedure i§‘requlred.Poie-shoe’screws shouicl then be fully tightened to set the air gap at its previous vaiue. Reboring cfpoie~shoes must never be resorted to, if the air gap (see table on page 87] is not obtained; we advisewarning up somewhat the coiis, which are already shaped, to facilitate their installation.

0) Armature.

Commuiator. - li commutator bar surface contacting the brushes is worn or out-of-round, turn downthe commutator. Be careful when fixing the armature in a lathe and centering it, as the instailationof armature assernbly between centers is not possible. Commuiator centering should be most accurate,as commutator out-of-round, measured on brush ways should not exceed 0,01 mm {0.0004"). Aftercommutator turning undercut the mica between bars using a saw blade to a depth of 1 mm (0.0394”}.

Armature winding. —~ If damage is in the armature winding, replace the whole assembly. it is not advisableto attempt making a new coil, as a special procedure would be required. Armature checks are to bemade with the instruments illustrated in Figs. 134 and 135.

Fig. 135. - Checking the armature on the testingapparatus using a blade.

(Blade vibrates at short circuiis).

Fig. 134. - Checking the armature with twin-contact tool.(The interruption is located by the no indication of the

ammeter).

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Reassembiy of generaéor.

After any repair or replacement and before reassembiing the generator proceed as foiiows:

a) biow away aii dust — chiefly carbon dust — from aii components. using an air jet;

b) oiean brush hoiders and the commutator end bracket from grease and carbon dust deposits, usinga dry cioth; "

0) ciean commutator surface, removing carbon dust between bars. Avoid using emery paper or ciothsoaked with gasoiineg or soivenis.

d) check brushes for play inside brush-hoiders, against the vaiuee iisted beiow:

—~ cross clearance . . . . . . . 0,1 to 0,3 mm (0.603? to 0.6113";

—~ and ciearance . . . . . . . . . . . . . . . . . i1,2’:o 0,5 mm (0.6£i78” to G.0f9?”}

e) check brush spring pressure which shouici be 69 to ‘F6 kg (1.521 to 1.675 1b.);

1‘) service with high meiting point grease the baii bearing, the commutator and bracket bush and therecess at the end of the bushes (Hi, Fig: 123) and replenish with oii SAE 50 HD the wick of the samebracket

The sequence shown in the chapter << Covering disassernbly» shouici be reversed to reassernbie thegenerator. Mind that when assembiing the drive end bracket, its introduction may be facilitated by holdingiateraiiy both brushes and springs. -After reassembiing, repeat the functionai checks as shown in paragraph << Bench testing the generator»,

FIAT GEEERATOR R 115-14€];’24 - 1600 Var. 2 - SPECIFICATIONS

i; Items i Values

Speed . . . . , . . . . . . . . . , . . r.o.m. 9504150Voltage . . . . . . . . . . . . . . . . . Q4 vCurrent . . . . . . . . . . . . . . . . . 3-55 A iSpeed . . . . . . . . . . . . . . . .. f.§3.rn, goon ‘Voltage . . . . , . . . . . . . . . . . , 28 vCurrent . . . . . . . . . . . . . . . . . 5-55 A i

- oi 4:“: min. ai 2006 r. .m.i .~ R““m“9 ' ' ‘ ‘ ' ‘ ' ‘ ' ' " 3 of 15 min. afi woe r.§.m.

Output current . . . . . . . . . . . . . 535$ 0,3 A I’r . Voitage . . . . . . . . . . . . . . . . I QB V ii ‘ Commutator temperature

( increment . . . . . . . . not more than: 90° C (£940 F} ‘|Casing temps-raiure '

increment . . , . . , . . not more than: 45° C (1130 F)

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Operational test as motor

' Running genegaior before piotting oi the curve (hot condi-tion-run duration: 50 minutes}, amp. versus re-vs . . .

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‘ Resistance, at 20°C: 3—fieid-coils . . . . . . . . . . . . . . . . . . . . . . 3' 14,5-15,5 ohm.

i— armature . . . . . . . . . . r . . . . . . . . . . . . ‘i 0,520-0,545 ohm. i

r Commifiator bar maximum aiiowed out-of-round . . . . . ‘ 0,01 mm (().0OO39”)r Brush duration . . . . . . . . . . . . . . . . . . . . . 5

1500-2500 hoursI Pressure by springs on brushes (new) . . . . . . . . . _= 0,59-0,76 R9 (1.521~‘i.675 lb.)‘ Brush cross clearance inside brush-holders . . . . . . . ‘ 0,1-0,3 mm (0.I3D39”-U.0f18")

Brush end clearance . . . . . . . . . . . . . . . . . . 0,3~0,6 mm (0.011?-0.0235’)r Diameter between poie shoes midlde fine . . . . . . . . i 70,6-?0,8 mm (2.'I79” -2,737”)

Air gap . . . . . . . . . . . . . . . . . . . . . . . . . 0,3~Ei,-$57 mm (0.Q1i8"-0.0186") r“ Tightening éorque of drive puiiey not . . . . . . . . . . 7 kgm (50.63 ft.ib.)

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GENERATOR TYPE DC ‘l'§5/'24,"7;’3 C

Witt‘: -Eli» mm’ {O-Q it M)Specifications.

The generator type DQ115124/7;‘3 C, illustrated in Fig. 136, has been mounted beginning from engineNo. 005045; its specifications are:

Voltage . . . . . . . . . . . . . . , , . . . . . , . . . . . . . . . 24 V

Maximum continuous current (ampere - limited) . . . . . . . . . . . . . . ‘I AMaximum current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 A

. . . . . . . . . . . . . . . . . . . . 195 W233 W

Maximum continuous power . . . .Maximum power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cut-in speed, 24 V, 26°C (68° F) . . . . . . . . . . . . , . . . . . . . . . . . 1550 to 1550 R.P.l\fi.Speed of maximum continuous current, ‘FA, 26°C (68° F) . . . . . . . W25 to 'lB'i£i R.P.Ni.Speed of maximum current, 8,5 A at 20°C (68° F) . . . . . . . . . . . . ‘£776 to i930 R.P.iii'l.

58% R.?.M.

Rotation (trorn drive side} . . . . . . . . . . . . . . . . . . . . . . . . . . . ciockvrriseshunt

i A""‘-$46124Regulator group . . . . . . . . . . . . . . i . . . . . . . . . . . . . . . . . type ; ’;P1,.24!7

Maximum continuous speed . . . . . . . . . . . . . . . . . . . . . . . . . .

Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . .

Main features of this generator compared with the preceding one are: completely enclosed, more power,reaction type brushes.Reaction brushes are advantageous as vibrations against the brush-hoiclers are reduced, compared tothe radial type. .For equal brush sections they allow a larger contact surface on the commutator, thus reducing bothsparkling and temperature: the excitation current also ls reduced, and the regulator group contacts,voltage and current regulators have longer life.When the generator is coupled to regulator group GP 1,-‘24,|’7, starting (cold), it may generate a currentgreater than the maximum one; but it is reduced when the internal continuous running temperature hasreached appropriate levels {thermal equilibrium), without any damages to the components.The feature is due to the current regulator, which, as explained when describing the regulator group, isthermostabilized.

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-1 aFig. 136. - Longitudinal and cross section of generator type DC ‘H5124/"7,'3 C.

Note: A bracket is fastened by screws (hot represented in the figure) to the generator frame. Bracket must be required separately.

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Therefore, if required by the equipment inserted in the system, the generator may be overcharged withoutany damage to windings: in tact, they are at ambient temperature at the start of operation and thereforeare not yet thermally stabilized.

When, after 20-30 minutes of functioning, due to ohmic resistance, the group and generator becomestabilized, the current regutator reduces the current to a vaiue continuously possibte.

c knba hThe temporary overcharged operation of the genera-.or, allows a quic -r artery rec arge, especially ifits charge level is tow, due to repeated and cold startings.

The timiting current is a function of the surrounding temperature; and therefore during the summer thelimiting current will be Jess than during the Winter, and the generator temperatures during the variousseasons are more uniform.

Checking the generator: troubles and re-medias.

Consult diagrams of Figs. 129-131432 for thegenerator checks, and for the coit check theFigs. 133-134-135. lTests to be carried out as for generator type’r'E'l15~14t3;’24-1680 Var. 2. For specifications, seetabie on page B9.

Plotting the output curve (Fig. 137), requires theprevious inspection of the brushes, that shouldbe completely seated upon the commutator, whichtakes place after ten hours of operation, with acurrent output of 7 A at 2900 R.P.i\/l.See page 85 for the generator trouble ~ shootingand repairs.

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GENERATOR FIAT DC 115_."24,1?;’3 C - SPECWICATIONS‘ 1 __. *1. 1 1 _ 11 11 1_. _ _. , 1 1 1 1

lItems ’ Values

-...

condition-run duration 30 minutes) . . . . . . . _ . .

l Heating test . . . . . . . . . . . . . . . . . . . . . . .

-- Fteld-coils (between terminal 67 and ground— ArmatureCammutato: bar maxrmum aliow-d out of-roundE‘-rush end play with f19SP€Ct to holders)

i Pressure by springs on brushes (new)i

i Operational test as motor . . . . . . . . . . . . . . . .

Running generator before piotting or’ A]r.p.m. curve {hot

Diameter between pole shoes middle tine . . . . . . . .t Air gap . . . . . . . . . . . . . . . . . . , . . . . . .

Tightening torque of drive pulley nut . . . . . . . . . .

sti

i— — 7' A__-. i _____ __**_ !______i;_ —_—__ *7 - — — __ —-—— _ W ; _ i ..__ __ _ _ _ _

Speed . . . . . . . . . . . . . . . . . 1170-1330 r.p.m.Voltage . . . . . . . . . . . . . . . . . 24 VCurrent . . . . . . . . . . . . . . . . . 4,5-6,5 ASpeed . . . . . . . . . . . . . . . . .Voitage . . . . . . . . . . . . . . . . . 28 VCurrent . . . . . . . . . . . . . . . . . 6.75-7.25 A

. ‘ 5 of 45 min. at 2300 r.p.rn.Rmmmg ' ' ' ‘ ' ' ‘ ' ' ' ' Z of15 min. at 5800 r.p,m.Output current . . . . . . . . . . . . . 5,75-7.25 AVoltage . . . . . . . . . . . . . . . . . 23 VCommutator temperature, not more than . 90° C (1940 F)Casing temperature, not more than . . . 60°C 840° F)

15 5-159 Ohm030 O32 Ohm

001 mm (0 oooae)or 04 mm recess"-<1 0157)

o.ee~o 75 kg (152-1 67 lb)ro,rs-10.15 mm (2.*17s"-2.135")o,a-0,45 mm (o.o11a”~o.ot1r")

1 kgm (50.6 ft.ib.)

lResistance at 20° C [63° F) ohm: ,

. . . . . . . . . . . . . . . . . . , . l . - .

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89

I

COHTROL EOX MOD. A,t3-1-£€l,i24

Description-

The Fiat A,‘3~14G,»‘24 regulator unit: contains three elements: voltage regulator, current limiting regulatorand circuit-breaker. These three elements (Fig. 138), fastened to the block, are enclosed in a sealingcover, equipped with gasket, which prevents shocks, dust and dampness.

Mote. — A distinction will be made in the test between modifications made on regulator units with numbersup to 088917 and on those with numbers starting 088918 up; the numbers are marked on thecoven

Figs. 139 and ‘I40 represent voltage regulator and circuit breaker; the current limiting regulator iooksquite similar to the voltage regulator.Fig. 141 represents the wiring diagrams of the regulator units mounted on tractors series 400, and bearingthe production number up to 088917 and from number 088918 up. The diagrams have thick lines to representthe coiis in series on the generator recharge circuit, to differentiate them from the shunted ones gm thesame circuit.Ali armature stops are of the spring blade type, and adjust their toad according to the calibration value,through the screw located at each regulator unit element side.The temperature increment due to the shunted circuit currents and deriving thermal expansion. mightinfluence the calibration values of the voltage regulator and of the circuit breaker. This is prevented bythe Contact hinges, which, being bimetallic, are thermally compensated.The group bears the following terminal numbers:— 51 - connected to positive generator terminal;- 67 - connected to generator field coils;- 31 - grounded;- 30 - connected to the battery positive terrnirral and to etectric system.

The wiringdiagram oi Fig. 127, points out the valve (FPS) protecting the regulator group.

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Fi§- T33» ' R99?-liilifll‘ unit (from no. 083918 up) as seenfrom the circuit breaker side.

i. Terminal 31 - 2. Terminal 51 - 3. Terminal 30 - 4. Vottageregf.1latorto_current regulator connection - 5. Current reguiator“"95 ‘*‘""di"Q _terminai soidered to circuit breaker - 8. Cur-FQRT Feilvlator rixect contact connection with the regulating

resistance.

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Fig. 139. ~ Cross section of reguiator unit: (section showsvoitage regulator}.

1. Armature adjustment spring - 2. Calibration screw ~ 3. Vol-tage regulator body - 4- Armature - 5. Fixed contact holderscrew - 6. Fixed contact bridge - 7. Hinge steel spring (the

bimetallic blade is located on top).

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Fig. 14-8. - Cross section of regulator group.(Across circuit breaker).

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1. Fixed contact bracket - 2. Pre-load shim - 3. Hinge spring __ -L"-» 1*‘ “(-3(steel) bearing mobiie coniact - 4. Body - 5. Armaiure stop - ’-JP ‘*1-§Q.,.!£=§:i - K; ,5. Calibration screw — 7. Adjustment spring - L. Thermal la | .compensation by~metaiJic biade - (a. Up to No. 088917 - 5 I Jb. From No. 088976 up). ~ R. Armature rivet - C. Cuniact ‘ ‘~" - —- --~, - =1 7gap 0.7-0.85 mm (.00275-043334”) for armature, fiiied withrivet R for rivetiess armature, the distance between contacts

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The wiring diagram of Fig. 12"? shows the regulator group fuse.The diagram of Fig. 142 represent ‘she characteristics of the poshmodification and the pré-modificatigngroups. Thejunction zones between the two hatched strips, represents the-functional limit beiween voitageregulator and current reguiator.

important.

1. The regulaiion group type A,"3-14Uf24, should function only with generaior ijrpe R115-14!),/24~16G0 andtype DC ‘I‘!5,’24,!?,!3 and derived.The group shaii never be used with a third brush generator even if of size corresponding to thegenerator prescribed above; the elimination oi the third brush would not change things; even worseit wouid be to connect a third brush generator as if it were controlled by a reguiation unit.The reason is that both groups and generator circuits, mainly the fieici coiis of the generator, thatare so reciprocaiiy arranged as to get the best performance for the whole combination.

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a) up to group No. 088917, 2)} from group No. 0869i8_

Fig. 14$. - Regulaiion unit type Af3 ~ 148/24 electric diagiflm.(As group is at resi, with generator running at iow speed the voltage regulator and Curréflf regulaior conracts are cioss-ci whilst

fhose of the circuit breaker are open}.

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a) Characteristic obtained as generator runs at 2000 R.P.M.§ ’e) Characteristic obtained as generator runs at 2600 R.P.M.,for regulation group up to No. 088917. for regulation group irom No. 088918 up.

Fig. 142. - Output characteristic on battery, with group at 50$ 3° C (1221 37.4“ F].

2. Avoid connecting group terminal 67 to generator terminal 51, even momentarily, because i'reavy'spar-kling and group contact oxidation would follow and contact welding would also eventually fellow. it isthus irrctispensable to connect terminals having the same number; as even it wrong connections areeventually corrected and the group functions regularly, its usefulness would be nonetheless shortened.

3. Shocks to regulator unit should be avoided, especially to its lower part containing the adjustment reel-stance (Fig. 146). During the bench-testing, the group shall be mounted with its terminals placed down-wards, and an insulating sheet shall be -interposed between the fastening support and the base.

4. Connection between group terminal 31 and tractor grounding shall be well secured, otherwise theregulation effect would fail as both the current and the shuntcoils are lacking. This case allows thegenerator to increase its voltage as speed increases and windings are burned and voltage regulatorand cut-out contacts are damaged, owing to excess of current excitation of the generator.

Regulator group bench "testing.

To avoid miscalculations, the regulator group performance data must be measured by instrumentspe-rioclically calibrated and according to the prescribed rules and methods.No removal of group seals is allowed for taking such measurements.

Checks. Gperatlons and cautions.

Test efiiciency of regulator group as follows:a) a fest bench will be provided with a HAT Fr’ H5-

740,»'24~160lJ Var. 2 or FIAT DC 115;'24j'?l3 C ge-nerator, coupled £0 a motor whose speed may begradually stopped;

ta) insfallaiion should have the measuring devicesand in slrumenis, concerning the testing of cutoutrelay, current and voltage regulators, accordingto instructions and rules hereafter.

Cl-li~f>1lT r'9l<'=1§/- 1) Closing voltage.Wiring should be as shown in Fig. 143:- generator speed should be gradually increased;

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M. Motor 01' test bench - 6. Generator - V. Voitrneter.

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._ 1‘Fig. $44. - Electricad diagram for testing the inversion

current.M. Motor of test bench - G. Generator W A. Ammeter -

V. ‘voltmeter.(iafieries are connected in series and must be fuity charged,

at a capacity of 60 Ah).

Voltage regulator.

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Current regufator.

5313 3‘! 6? 51

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Fig. 145. - Electrical caonnecfion diagram for the check-ing of the voltage regulator and of the current regulator.M. Motor of the ‘(est bench - G. Generator - V. Voitmeiar -

A. Ammeter.

-- check the vohfmeter vaiue when cut-out relaycloses; it must he read at the moment the lampof24 V, 5 W, lights; insert lamp between terminal39 and ground.Closing value must be 25,1 to 25,9 V, for bothpre-rnodification and post»moo’ification groups.Checks shouid be made when cold, before col}temperature increases.

2) Back current at 25¢ F0“ C (F73 50° F),Wiring should be made according to Fig. 144 andgenerator run to 2000 R.P.M. during about 5 minutes.making sure that voltmeter reads at least 29 2/, thandecrease the generator speed.The ammelfer pointer which was indicating a certaincharging current will decrease and approach 50 gemand begin to show the inverted current value.As the generator progressively slows down theammeter dial will show increased vaiues, up in a ¢@,-tain iirnit; after that a sudden fall to zaro v/ii! beobserved, due to the opening of the cut-out relaypoints. Such a current value will be not largerthan 3 A for groups having production number upto 088917 and within 5 to 10 A for groups fromnumber 088918 up.

Note. - Such a test should be carried out quiclrlyto avoid battery discharge. When repeated, startfrom a stopped generator.

Regulation voltage at hair’ load on batteries, at566313306 (.12:?i37.4°F).Close the cover and connect it according to the dia-gram of Fig. 145 and operate the group until the coil’temperature reaches 41" to 53° C (11? to 127'" F).Start the generator and siowly run it up to the speedrate of 2000 l?.P,M.;adjust rheostat so that generator delivers a currentof 4 A fhalflload currenz‘);Check that at such current value, the voltage isabout 28,? to 29,7 V.

Limitation current on batteries.Connect group according to wiring of Fig. 145, andcheck the limitation current on batteries immediateiyafter the foregoing test, using the same instruments;proceed as follows:-— rheostat should be set at its maximum resistance

value;-— resistance shall then be reduced until the current

limitation value of 5 to 5,5 A has been reached,for groups up to No. 088917’, and of 4,75 to 5,25 Afor groups from No. 088918 up (correspondingvoltage: 28 V); '

-~ said currents should not decrease when resistanceis reduced, and on the contrary, voltage shouldgo down nearly to 24 V (for groups up to No.088917‘).

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Regulator group repairs.

For ihose groups with numbers from 088918 up,{he resistance being decreased, the current shallincrease up to 5 A, approximately, and the voltagedecrease down to 24 V.

in most cases when the unit does not perform correctiy, it is advisable to substitute it instead of attemptingto repair and calibrate it.Exceptionaily, ii in need of repair, follow the bench checks already described; successively, according tothe data, obtained replace the resistance, Fig. 146,and faulty elements. Always replace completeunits. vComponents elements as wet! as resistancesshould be kept into suitable containers, whichprevent their being damaged deformed, smearedby grease or foreign matter, etc.

Fig. ‘I46. - Regulator group bottom view.1-2. Screw and nut, fastening the resistance - 3-4. Nut andcup fastening the cut-out reiay - 5. Nut fastening the voltageregulator - 8-'1. Nut and cup fastening the current regulator.

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Note. ~ Mosi taiiu-res, especialiy the important ones, such as:— excessive wear, or cut-out relay contact sticking;—- oxidation of voitage and current regulator points;-- burnt or fitted points;— short-circuited coils;— coil burning;may be due to causes originating outside the regulator group and chiefly to generator rnisiunc-tion, as, for example, to field winding resistance alteration, impaired circuits (cables, etc.).Therefore the operator should make the group operate correctly, but in addition extend hischecking to the generator and to the charging system.

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Fi9- 147- - Reeufator Qrfitip {up to No. essem as seenfrom cut-out relay.

1. Terminal tube 31 i_or shunt winding end -.2, Terminaltube at - 3. Terminal tube 30.

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Fig. £48, - Regulator group (up to No. 688917) as seenfrom voltage regulator side.

1. Terminal tube 31 - 2. Terminal lube 51 - 3. Terminal tube an -4. Connection from current regulator to voltage regulator -5. Current regulator series winding and ~ 6. Connection of

reguiator to the adiustment resistance.

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Dismantling and reassemi;-ling of group.

Remove lead seals; unscrew the nuts fastening the cover to base, remove both cover and gasket anddismantle according to needs.Unweld the coil terminals connected to other elements, and unscrew the nut fastening it to the base.When checking or reassembling such elements, make sure that the setting screws are not being tamperedwith, as during manufacturing they have been sealed with varnish.For coil terminal seldering use exclusively a neutral flux, avoiding acids.Carefully watch the insulating washer assembling.Beeora reinstalling the group cover, make. sure that:

- the open contacts distance of the cut—0ut relay, when at rest, is 0,?!) to 0,85 mm 63.0275” to 0.0334”)for rivet-type groups (R, Fig‘ 140), and 1,15 to 1,30 mm (Q0452 ”to 0.0512") for non-riveted groups;

- Check the group insulation by applying 500 V at 50 cycies between the magnetic coils and the base,ad between terminal 30 and the base. '

Mount cover when group is hot, to avoid moisture condensation after closing,

CHECKING AND CAL§BRATiOH VALUES OF REGULATOR GROUP A13-’i4i}f24

Cut-out relay ' Voltage regulation (when heatediwhflfi COW) to 50° C - 122° F on battery)

Cutwut relay (when ‘cold on battery) F

" " " '— e e - I ~>,_—=_~_ e~_

Group I _i ’ Regulation voltage

> Closing voltage inversion current ; Battery at halt load onj battery@ v A Ah I v ;

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A ‘I*———~ _ —— — .* _.. W __ I _ _ 5, __,_,,_ 1 __ ,____ ,_

Up to No. 08891‘? 25,1-25,9 not more than 5 8t1{Nca. 2 batteries 28,1-‘-29,7 55,5l in series} (with 4 A) ~

‘ Fwm ?~lr>- 088918 up 25.1~25,e ; s m 10 (with so (No. 2 batterie 2a,1-29,1 l 4,1:»s.2s 3wiring of Fig 144) in series) -(with -1 A) '

in

Adjustment resistance of gii-oup (Fig. 148) at 20° C (68° F) is 138442 chm.

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465‘b'885cortTRor_ BOX rnoo. on-r/24/7 (PadNo.

Description.

The Control Box Mod. GP ‘i/24/7 is composed E:-y three units: cut-out relay, current regulator and voltageregulator.Both the voltage and the current regulators (Fig. 149) consist of a U—shaped body with a bend on theand oi one arm and a tongue (5) on the other. An armature (2) supported by a tension spring (1) isfastened to the body (9). The spring is made of two blades lying flat on each other, one of steel and theother bi-metallic.

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Fig. 150. - Sectional view of the cut-out relay.cl. Air gap (EL64 to 0,76 mm = 0.025 to 0.030 in).

Fig. 145. - Sectional view of the voltage regulator.c. Air gap between core extension and armature (to bemeasured at the position indicated by the axis 0-0 10,99

to 1,11 mm or 0.039 to 9.044 in).1. Hinge spring {steel and bi-metallic). - 2. Armature. - 3. Adjusting spring. - 4. Fixed conlact supporting lip. - 5. Adjustingspring supporting lip. - 6. Regulation resistance. - 7. Additional resistance in series with the shunted winding of the voltagereguiator. - 8. Base. - 9. Body. - 10. Damping resistance. - 11. Additional resistance in series across the shunted windingsof the current regulator and cut-out relay. ~ 12-13. Plates ciamping the leads of the windings to the additional (7) and

regulation (5) resistances. - 14. Resistance terminals insulators.

The contacts points of the elements are fixed to the armatures (2) and to a support applied to theelements. Point resetting is carried out by using a special tool on the tongues which carry the fix-adcontact points. The cut-out reiay is similar to the other two elements and is also equipped with a hinge(1) made of one sleet and one bi~metalllc ieaves. ,The armatures of the three units are equipped with adiusting springs (3). Adjusting is done by loadingthe tongues £5) of the springs. The three units are fastened to the base by the threaded ends on theircores and sealed by a cover with a rubber gasket. The base is provided with three terminals, the num-bers of wlch are marked on the cover connected to the cables as follows: ' .- 51, connected to the generator positive terminal;- 6'1, connected to the generator field coils;- 30, connected to the electric system.The following resistances are riveted under the base (Fig. 159):--~ the additional resistance for the shunt winding of the voltage regulator (7) and additional resistance

tor the shunt winding to the current regulator and cut~out (11);- the regulator resistance (6) connected in series to the acceleration winding {a}; damping resistance

(10) shunted to the generator field~wincling (between the current regulator body and ground).

O peration.

At iow speeds the generator voitags is not sufficiently strong to induce in the shunted windings of thecontrol box units a magnetic flux apt to attract the armature to the cores. All ermatures are thereforeat rest and the out-out contacts are open, whilst the current and voitage regulators ones are closed.

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ifiAs the generator speed increases the voltage and the currentoutputincrease creating a stronger magneticflux, when the generator reaches predetermined values oi speed and voltage the magnetic flux becomessufficiently strong to win the resistance of the tension springs and so attract the armature to the cut-out core to close the contacts. A current is then circulated from the generator positive terminal throughthe series windings of the units (Fig. 151) to the electric system equipped and positive terminai of thebattery and returning to the negative brush of the generator.

The magnetic flux induced in the series windings is added to the one induced in the shunted windingsto hold the cut-out contacts more securely closed. As a rule, otter the cut-out is closed and the ge-nerator voltage keeps on raising, the contacts of the voltage reach the predetermined setting value. Asthe contacts open due to the magnetic flux induced by the shunt winding and acting on the armature, anacceleration winding (a) and the regulation resistance (6) are inserted in the tield winding circuit of thegenerator. The regulation resistance lowers the current through the generator iieici winding and conse-quently the generator voltage until the voltage regulator contacts close again.

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6. Regulation resistance - I. Additional resistance in series vn_=_=gn=r _across the shunted wintzling otthe voltage regulator-10. Damp» _ 2_ “‘9"":1___L§1 _, -=s~1i{i€1 I For -o==__:1_=v 1ing resistance -1?. Additional resistance 1|‘! SEHES across the ' ;|l i;.-.-»?. %§[““'F-;;;. x ;,l;%_‘;_._“':‘_:"_='-5;-, !

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shunted windings of the current regulator and cut-out relay - ; -_a. Accelerator resistance in series with the regulation res- ,| ___£=__ i I Z = - 3 3istance (6) - B. 12 V batteries connected in series - G. Gem , __,_ 1erator model DC 115/'24]'7/3 and its modified versions ~ ”""‘"' *‘ "" ' ‘*m L-*'>*~"~—' i30‘ Electrical equipment terminal -31. Ground - 51. Generator

positive terminal - 6?. Generator field winding terminal, \_ J“W W H Mic? z‘|’2o*’*'(Note: The windings of the three elements of the control

box drawn with light lines are shunted across the generator "-- _circuit, those drawn with black lines are connected in series}. E

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J;Then the field winding current and consequently the generator voltage increase resulting in there-openingof the contacts. The cycle repeats itself and an oscillation of the at-matures is maintained to keep thovoltage within the setting limits.

The function of the acceleration resistance (a) is to increase the oscillation frequency or the voltageregulator which reduces its pull on the armature (2). in tact, as the contacts open the field windingcurrent going through the acceleration coll creates a magnetic field which is subtracted from the onecreated by the“'regulator shunt winding and therefore reduces the magnetic pull on the armature, favouringits release.

Should current consumption exceed a certain limit, or the battery be discharged, a great current outputwill he required from the generator: this current induces a magnetic pull on the current regulatorarmature sufficient to close it against the action of the springs. The contacts open and insert throughthe generator field winding circuit the regulation resistance and the acceleration coil with the sameresults described above in the case of the voltage regulator, in this case it is the current which is con-tained within set limits. if the current output requirements remain above said limit, the current regulatorarmature keeps on oscillating substituting the voltage regulator one, which remains at rest.

To conclude, the current regulator limits the maximum current output of the generator, whilst thevoltage regulator ensures through the system a voltage ranging within pre-determined limits (calibrationlimits), not harmful to the battery, for all the charging range which requires an output below the maximumvalues from the generator, equipment and battery.

The maximum power is reached at the operational limit between the two units (current and voltageregulators} and is also known as peak-load.

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The damper resistance coil (10) protects the voltage and current regulator contacts from the sparkingdeg-iying from the electromagnetic energy of the field coils during the opening cycles by grounding partof the energy»

When the generator slows down to a‘ point where its voltage is lower than the battery voltage, a reversecurrent is produced from battery to generator. This reverse current will go through the series windingsof the current regulator and cut~out in the opposite direction. No consequences will derive to thecurrent regulator, as the current is not strong enough to pull the armature, but it will cleznagnetize some-what‘ the cut-out relay which has the contacts closed, so that as soon as the reverse current will reacha certain value the armature will be released causing the contacts to open and consequently dischargingfrom battery to generator will be prevented.

Finally note the functional importance of the bi-metallic blades which together with the steelgones makeup the fastening hinges of the armatures (1, Figs. £49 and 1503. ~

The passage of current across the shunted windings oi the control box units causes a temperature rise,which produces an increment of the ohmic resistance, and consequently the quantity ol current goingthrough them is reduced. As for the armature-s, the current reduction results in less magnetic pull,there-lore a voltage higher than the set values would be needed in Summertime to open the voltage regulatorcontacts and close the out~out contacts.

To compensate the reduction of the magnetic pull on the armatures, the bimetallic blade which makesup the hinges is so disposed as to gradually reduce the tension in the spring as the temperature rises.

in the case of the voltage regulator the action of the bi—metalllc blade is more than sufficient to maintainthe set voltage against the variations of ambient temperature (thermal overcompensation), therefore thesetting is slightly lower in the summer and slightly higher in the winter. This setting value ot the voltagewhich varies slightly according to the temperature favours long lite of the batteries the voltage of which,when current passes through, decreases as the electrolyte temperature increases, and on its part elec-trolyte also is sensitive to the surrounding temperature.

Therefore, should the voltage setting of the voltage regulator not follow the requirements of the batterytemperature conditions, the following trouble would develop:-- when room temperature is high, the voltage would exceed the set limits and the battery would be

compelled to absorb a very strong current resulting in excessive electrolysis and consequently wearof plates, insulators, etc.;

— when room temperature is low, the voltage would be scarce and could not ensure a correct recharg~ing rate.

Also in the current regulator, the bi-metallic blade (1, Fig. 152) which is part oi the spring hinge of thearmature is so disposed as to gradually reduce the tension as temperature rises.

But, as explained‘el:iove regarding the other two units (voltage regulator and cut~out}, as the shunt windingtemperature rises the current put across it decreases and consequently also decreases the magnetic pullon the armature. When the unit is cold this results in a higher regulated current and when it is hot alower current because of the hi-metallic blade.

The bi-metallic spring of the current regulator works as thermal compensation of the current goingthrough it and determines the following advantages:-~ at the start or aster an interval of about 2 hours from the last period of operation, the control box is

at room temperature (that is, not thermally stabilized) and theretors, as explained beto re, the regulatedcurrent is higher than the maximum continuous permissible one tor the generator, and should the$Y$l9l"='l “squire it, the generator DC.l‘l5_l24,l7,'3E can be overloaded. 'when the control box and generator temperatures rise, the l:>i~metalli<: blade reduces (in about 20to SD minutes) the regulated current to a value which the generator can tolerate. therefore the tem-

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porary overload oi the generator not only does not damage the windings but is good for the batteryparticularly when the charge is lOW, Whifili may happen after diiticuit or repeated coid starting or afterthe kind of work which requires repeated startings for short hauls;

f - the regulated current is dependent upon thetemperature of the surroundings and will behigher or lower depending upon a low (Winter)or high (Summer) temperature, which for thegenerator means more uniformity of tempe-rature through the seasons.

The curve of a hot control box is piotted in Fig. 153and as one can notice it starts with an almosthorizontal line which shows that the current ismaintained constant up to a certain voltage, thendrops quickly.

The junction area between the two strips showsthe operating iimit between the voltage and cur-rent reguiators.

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Fig. $52. - Front view of the control box.1. Current regulator armature hinge - 4. Fixed contact supporttip - 5. Adiusting spring support lip - 51~5T-30. Terminals.

This regulation system takes tuli advantage of the generator output and maintains the battery at a goodlevel of -charging even after difficult or often repeated starts. Should the battery be discharged, it willbe recharged with the maximum output current up to a high charge (28 V) and when the latter is exceeded(29,5 V} the voltage regulator intervenes to reduce the generator charge (all electrical equipment oft).When the battery is charged, the delivery current is reduced to a few amperes to prevent excessiveelectrolysis, overheating, insulator damage.

IMPORTANT

1. — The control box mod. GP‘i,"‘24,-’7 must only operate together with the generator rnocl. DC1t5,"24;'?;'3;this iimitatienis necessary tor two reasons:

a} only the generators specified above can be overioaded at cold starting;

b) the controi box has been designed to suitthese generators and the field windings havebeen designed to suit the control box. Shouldthe latter be connected to a different genera-tor, the operation wouid be incorrect, thesettings would change, the useful life of thecontacts would be pratically shortened andthe generator would soon be put out of use.

2. ~ An incorrect connection of the control boxterminal No. 67 with the generator terminal No. 51produces immediately a strong sparking effectwhich oxidizes the contacts of the elements ofthe controi unit, it orotracted longer it caneaslly

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cause Spark welding of the contacts. it is therefore absolutely necessary to connect terminals bearingthe same number, keeping in mind that even if the wrong connections are corrected and the operation be-comes normal again, the useful life has been nonetheless shortened.3. - The control box should never undergo shocks of any kind, particularly the lower side which housesthe resistances (Fig. 159).During bench testing the box must be positioned with the terminals downwards, and with an insulatorlining between the bench mounting and the base.

4. - The grounding connection between the control box and the tractor must be secure, otherwise therewill be no regulation there being no current going across the shunt windings. In this case the generatorvoltage output which increases with speed (es it is not regulated). will burn the winding ends and dete-riorate the voltage and current regulator contacts clue to the excess of current across the field windingof the generator.

Bench testing ~ Instructions.

To check the performance of the control box rnod. GP1;’24,l7 start with the following operations withoutunseallng the unit:— piece on the bench e generator model DQ113124,/‘i_l3 (regardless oi modification 5%., E, etc.};- connect the generator to an electric motor the speed of which can undergo tine variations over a wide

range and provide a 30 V battery;

— make ready the instruments end gauges necessary to the elements oi the control box keeping in mindthat dependable results are dependent upon the observance of the ruies and procedure which willbe given below.

Caution: The test must absolutely be performed at the temperature specified for each control and afterat least 30 minute operation i. e., when the temperature condition specified has been reached.This requires a special oven suitable for the thermal stabilization of the control boxes. Tests performedotherwise will not give dependable results.

a} Contact closing voltage at 25°i'I0°C (77@;j;gt; 50° F) ambient temperature.

Cut-—out relay check.

in suri-oundlngs with the temperature specified aboveconnect the control box according to the wiringdiagram of Fig. 154 and run if idle at 30 V for T5

3| |;. to 18 minutes.5! E? 30 This preliminary operation allows the unit to reach

the thermal level allowing the cut-out shunt wino'fogand the bimetallic spring blade to reach thermalstability after en initial period during which thevoltage oscillates considerably,

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ll-Fig- 154» Electrical diagram of the arrengementforiesting

the ':“t'°"t 'Bi*'1Y Contact closing temperature.M. Test bench electric motor - cs. Generator DC l15;'24f7_/3and its medlfied versions ~ V. Voitmeter, 39 V top reading.

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lmmecfialfely after obtaining thermal siab1'lity, star-ting from an inactive generator, gradually increasethe speed to check the voltmeter for the value ofthe cut~out contact closing voltage, which shouldreal:-‘ 25.1 to 25.9 V when the light goes on.

la) Reverse current (in ambient temperature of25°i10° C = ?7°i 50° F}.

This test soufd be performed immediately after thecontact closing voltage tesi, in order to keep thethermal stability reached in the preceding test.

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testing the out-out reiay return current.M. ?es': bench electric motor - G. Generator DC €15,i24;’7;'3and its modified versions — A. Amrne1er- V. Votimefier, 30 V

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Voltage reguiator check.

Current reguiator check.

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fasting ‘the voltage and current regulators.

M. Test bench eiectric motor - G. Generator DC 115,"24/7'13and its modified versions - V. Voltrnefer, 30 V top reading -

A. Ammetar. 10 A top reading.

Hook up according to the wiring diagram of Fig. 157and run the generator up to 3500 l?.P.M. ho/clingit at this speed for 5 minutes.

See that the voltmeter reads at least 29 V, thangradually decrease the generator speed. The ampem-meter indicator which had shown at first a certainamount of charging current, will graduaily go tozero, then will show the reverse current on theopposite scale. As the generator speed graduallydecreases, the reverse current will increase up to ,3given limit at which it will drop to zero (cut-outcontacts open). Said limit represents the maximumreverse current value which should be 6 to 14 A,

Note. ~ To repeat the test, if necessary, beginfrom a stopped generator to avoid incorrect readingsdue to residual magnetism in the magnetic materialof the cut-om‘.

Regulation voltage on half-charged battery (ambienttemperature of 50° i 3° C or i22‘° i 37.40 F).

Connect the group according to the a‘ia_qram ofFig. 156 and operate it at 50°;!;3°C temperaturefor about 30 minutes, with e half-charge currentoutput corresponoing to 5 A.

immediately afterwards. maintaining the box at anambient temperature of50° i 3° C stop the generatorand run it again at a gradually increasing speed upto 3500 rpm; adjust the rheostat so to set the ge-nerator half-charging with e current of 5A at 28,7to 29,7 V.

Regulation current on battery: this check must im-mediately fol/ow the preceding one.

Connect the unit according to the diagram of Fig. ‘£56and connect the rheostat maximum resistance;operate the unit at 50°i 3° C ambient temperaturefor 30 minutes, at regulation current speed (to thisend decrease the resistance of rheosiat until thecurrent remains about constant and the voltagedrops) and at the specified 28 V. At the enci checkthat the output current has become stable (i. e.,thermal stability has been reached); stop the generatorand connect the rheostat maximum resistance, startit again and run it up to 3500 F?.P,M.;

decrease the resistance graclually until the voltmeterindicates 28 V and the ammefer a regulation currentof 6.6 to 7AA.

As the resistance continues to decrease the currentshould slowly rise, and the voltage drop sharplyalmost to 24 V.

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Trouble-sh00i1'fiQ- Q

The various cases which may occur during the operation of the control box are the following:

A - Low charging rate with a fully charged battery.This is the condition of a generator-control box system working correctly.

B - High charging rate with a fully charged battery.This condition indicates that the voltage regulator does not limit the output as it should because a highcharging rate not only damages the already iuiiy~chargecl batteries, but also the equipment oi the system.The causes are the following:

a} high voltage regulator setting;

b) detective voltage regulator windings or additional resistance (7, Fig. 159};c) short circuit across the generator positive terminal and field winding which prevents the current from

passing through the regulation resistance at voltage regulator contacts opening;cl) insuiiicfeni connection between control hex and generator through mass;

e) high temperature which reduces the battery electromotive force reacting to the charge, so that thebattery absorbs a high charging current even if the regulator set voltage is normal;

l‘) self-welding of the voltage and current regulator contacts.

in all the above cases, excluding case e), one of the two following conditions will occur on disconnectingthe cable 67 from generator to control box:1) Output remains high (trouble covered by point c).2) The output stops completely (the trouble lies in the control box which should be checked as to points

a), b), d) and i).

Note ~ If the generator output remains high even after a long period oi charging but neither trouble norhigh temperature show up in the control box. the battery is old or maintenance wrong. It does not absorbany more current, the voltage does not rise above a certain value and the generator current does not decrease.

C ~ Discharged battery and high charge.

Condition of correct operation of the generator and control box unit.

D - Discharged battery and low or no charging rate.

This condition is due to the following:a] burnt control box fuse » b) interruption of the additional resistance of the cut-out relay shunt winding(H, Fig. 159} - c) loose connections, detective cables - d) detective battery - e) charging system highresistance - t) voltage or current regulator low voltage setting - g) voltage or current regulator oxidizedcontacts - h) generator trouble.

Should the above condition be caused by the failure of the additional resistance (ii, Fig. 159} repiace it.

ii on the other hand, it is caused by fuse failure, search tor the cause of tuse burning before replacing it.The reason may be found among the toliowing:— the out-out relay contacts do not open as the engine stops;

—~ short circuit;

-— reversed generator polarity.

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Finally, if the trouble is not due to one of the causes described at paragraphs a), b) and c), look for it inthe battery, control box, or generator. To find out whether the trouble is due to the battery replace theexisting one with a new one discharged so that it the output still goes to the maximum evidently the faultis in the battery. it not, look for it either in the control box or generator by shorting momentarily theterminal 67 with the 51 and increasing the generator speed. Should the output, previously absent or verylow, either reach a set value or increase, the trouble is due to one oi the following:

- low current or voltage regulator setting;Fl-4 current or voltage regulator contacts oxidized;

~~ undue resistance, interruption oi the generator field winding or inside the unit.

Otherwise, look tor trouble in the generator.

REPAIR ¥NSTRUC'£'iONS

As a rule it is preferable to repiace the control box rather than repairing or acliusting it, therefore onlyexceptional cases may justify handling it. The repairs which can be done. provided that it has beenfound for sure that it is the cause oi trouble, are: repiacing the cover, the additional resistances (‘i‘, 11,Fig. 159}, the damping resistance (10), and the regulation resistance (6).The spares are furnished in special containers to avoid contacts with foreign material.

Most of the faults oi the trouble, particularly the more serious ones such as excessive consumption orwelded cut-out relay contacts, oxidized or pitted voltage or current regular contacts, coil shorts and wind-ing overheating, are due to faults outside the unit and particularly to the same faults of generator com~ponents (field winding resistance altered, wrong brushes, faulty cables, etc.).

Therefore, the repair man should not content himself by replacing the control box, which has anyhowa high factor oi safety in operation, but rather check the generator and the whole charging system.

Cover replacement.

Shouldlthe replacement be due‘ to bruises or warping we suggest to check the control box prior toreplacement, according to the testing procedure of page 100 and following.

When replacing the cover check the seal gasket and place spring washers under the screw heads of thebase, then tighten the screws until the two ends of the washers come in contact. Finally, apply a paintseal on the head oi one screw.

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Replacing the regulation and damping resistances (6, 1&3, Fig. 159).

Here follow the causes and their respective consequences in case of wire interruption or shorts of theresistances (5, 10, Fig. 159):

a) control voltage low or very low; a) oxidized voltage and current regulator contacts;b) control voltage rising because out of control; h) voltage regulator contacts stuck because of

self-Welding;c) control current rising because out of control; c) current regulator contacts stuck because of

self-welding;d) control voltage very unstable particularly at ti) temporary sticking of the voltage regulator

high generator speeds. contacts.

Paragraphs e), lo), c) concern the control resistance, paragraph cl) the damper resistance.

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If still in doubt, repiace these resistances which are fixed to the base by rivets. Drtil the rivet headfirst, then drive the rivets out with a punch paying attention not to damage the Wires soidered to thepistes (12 and 13, Fig. 149). To prevent the current regulator core from rotating whiie removing andrefittina the resistances use tool A 127650 as shown in Fig. 157. The new resistances shaii be fasteneddown zvith the screws, spring washers, and nuts specified tor the replacement.The vaiue of the control resistance (8) is 136 to '14-4 ohm, that of the damping resistance (10) is 60 ohm.Check that the air gap between the armature and the expansion edge of the current regalator core (atposition B-0 of Fig. 149) is 0,99 to 1,11 mm (-3.039” to 0.044"). To correct the air gap use tooi A 127051on the fixed contact support (4, fig. T52} and check with a magnifying iens it the contacts are atignedcerrectiy. The gap between contacts of the cut-out reiay shouid be 0,64 to 0,76 mm (0.026 to 6.030”) andthe air gap measured on the expansion edge of the core facing the contacts (Axis A-A, Fig. 158} andwith contacts ciosed shouid be 0,25 mm £0,010").Then toiiow test bench checks, reported on page 100, to ensure that the troubie has been compieteiyeliminated and reassernbiy has not altered in any way the operation of the various parts.

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Fig. ‘i5'!.- Control box GP‘!/241'? withiool A12?B5U instailed Fig. 158. - Rear view of the control box.to replace resistances 6 and 10, Fi9- T59- 1. Cutout reiay armature hinge - 3. Setting spring - 4. Fixed

5_ getting spring, suppmt tam} contact support tang -3?. getting Spring, support tang -. roun .

Ftepiacing the resistance on the voltage reguiator shunt winding and the resistance of the currentreguiator and cut-out relay shunt windings ('7, 1'1, Fig. 159).

It the voitage setting of the reguiator has changed, that is:-— reguéating voltage is low;~— reguiating voitage rises to high values because out of controi;

the cause can be attributed to the resistance of the voltage regulator shunt winding (7, Fig. 159} whichcan be aitered (short) or interrupted.

A coil short increases the absorption on the part at the voitage reguiator shunt winding (because theresistance ts connected in series to said winding} and increases the puii on the armature resuiting in aiower regulating voltage. Shouid the reststance he interrupted, the voitage regulator shunt winding doesno longer get across to the generator but remains Ensuiated.

Théfeififth as the flow of current is interrupted the core cannot putt the armature, contacts do not openand the voitege, out of control, rises.

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3,Th esistance value is 73 to 77 ohms at 29°C (sew F), ii {he cut-out contact closing Vglfage 53 fmmd R,e rbe low or the conlacis remain open even at high generator speed, check the resistance (11, Fig. 139) to!

ascertain whether the cause musi be attributed lo altered value or to an interruption of the wire.

Fig. 159. - Botfiom view of ihe comb-oi box GP 1124,17.

B.- Regulation resistance » 7. Additional resisiance connectedto the vollage regulator winding - 18. Damping resistanceshunted across the generaior between current regufator andground - 11. Addiiional resistance for current regulator andout-out relay shunt windi:-|gs~ 38. Electrical equipment terminal- 51. Terminal connected to the positive pole of the generator ~

67. Terminal connected to the generator field winding.

of a coii short the value of the resistance decreases while the current regulaéor and out-omin case ,relay shunt winding absorbs more (as the resistance is connected in series to these windings and closes

‘ ' 1 h r tthe circuit to ground) that is, it creates a greater pull on the armatures, partacuiary on t e cu -ou one,where the magnetic effect is greater and therefore the contacts close at a lower voitage.

"houid the resistance wire be interrupted, the cutout and current regulator shunt windings have noo. .current flowing through them as the circuit is not closed across the generator casing, therefore the

tout contacts remain open, which is signaled on the dashboard by the battery charge warning lampcu ~which remains lighted. Resistance trouble has no effect on the current regulator.The resistance value is 73 to T7 ohms at 20° C (E8° F). Replacing one resistance calls for repiacemeniof the other one, too. To replace them proceed as for resistances 6 and 10.

Conirol box seiting.

The setting of the control box on the test bench should be performed without the cover, placing the boxverticaliy w§th_ihe terminals facing downwards.

Cautions: if the control box has remained for a certain iength of time at ambient temperature below- | 0 -“ Q15° C (590 F} or above 85° C (95° F), place it for about one hour at a temperature of25°I10° C 07°: :10 F).

Wire the control box according to the diagram ofFig, 160 and p/ace the insfrumenis as follows:- potentiometer P at minimum (1/oiifmefer at zero);— switch T open;-.~ rheosiai R all on (max. resisiance);~ swiich T1 open.7) Contact poinis closing voltage (at a femperature

of 25°i 70° C 2 77°7’;5O°!-‘j.Close switch T. Stabiffze the temperature of fheunit, equipped with its own cover, by feeding itior about 75 ‘£0 18 minutes at a voltage of 2 30 l/.through potentiometer P;

Cui~ou?t reiay setting.

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Fig.'i5I1. - Electrical diagram oithe arrangement for settlngthe cut-out relay.

B,. 2V battery - B2. 40V battery » A. Ammeter, 20A ioprerxriing {I% accuracy} - V. \/olimeter, 30V top reading(0.5% accuracy, class) connected across terrninais 51 and 31 -P. Potentiometer, volrage acfiusting; capacity must be suchthat the I:ut~ou'£ reiay shunt winding coil consumption doesnot create notab§e variations oi the no~Ioad vcléage measuredby the voltmeter ~ S. Warning Iight indicating opening andclosing of contacts (2 V-3 W bulb) - R. Rheostat 4 ohm -213 A - R1. Drop resistance sufiIcient to allow lighting up oithe warnings, Iighrs S by switch T1 with the cu?-out reiay

contacts ogxen.

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Fig. ‘IE1. - Electrical diagram for setting the voltage andcurrent reguiators.

G. Generaior DC I15/24/7,l3 and its versions - V. voltmeter,30 V Iop reading (0.5% accuracy cIass} - A. Ammeter, I0 Atop reading ~ R. Rheostat, 3 ohm-20A - B. 12 ‘I! - 190 Ah

batteries connected In series, I‘uI%y charged - I. Switch.

Current regulator seiting.

106

once thermally stabilized, firing the I/oliage lo 25.1to 25.9 V through potentiometer P;adjust the load on the calibration spring (3, Fig. ‘$53)by bending its rneial tongue (5) unfil the light Sgoes out;bring poieiiomefer P setting back to the minimum.increase the voliage again acting once more on thepofenfiomeier and check fhaz‘ the light’ S goes out aithe specified setting.The contact points emflre closing stroke shoulci occurat a voltage variation lower than 0,2 V.2) Reverse current (at a temperature of 25°_-'-; 10° C

= rrfl i 50» F).This test rnusi immedia1‘ely follow the preceding onein order to take advantage of the thermal sfabiliiyachieved by the unit.With switch T closed, bring the voltage lo 27 If byacting on the potentiometer F‘ “(the cut-out relaycontact points are closed and light S ofi',I;t1'ose switch‘P, increase the reverse current through the rheoslatR. and check that the light S goes on when thecontact points open. The opening may result to beunstable eviclenceo‘ only by a ringing noise;chock the ammelar reading of the reverse currentwhich starts the confacts opening (6 to I4 A}.Should the reading be uncertain or should the lighigo on like iolerance limit, bring the reverse currentback to minimum and increase if again working onthe rheosiat R, as instructed before;open switches T and T1 and bring the sliders of thepotentiometer F’ and rheostat R back to minimum.

Provide the conditions suitable lo mainiain the unilat a temperature of 50°;I; 3° C (7221 37° F).After wiring the unit according to the diagram ofFig. ‘£61, wind {he adjusfing spring of the currentregulator by shaping the adjusting fongue (5, Fig. 152);close switch I, star! the generator and stabilize thelemperalure of the unit, for 30 minutes, af 2 30 V.by varying the generafor speed;open the swiich I and bring the generator speed uplo 3500 R.P.lI/l.; adjust [he load of the adjustingspring of the voltage regulator by bending thetongue, and the rheoslat R, so to obtain a regulaiingvoltage and a medium charge current of 28.7 to29.7 V and 5 A, respectl:/ely;check stability and accuracy of the regularfion voltage’by sr'o,oplng the generator and running ii again upto the speed of 3500 R.P.M.

This test musi immediately follow the precedingone, holding the fest temperature at 50°i3°C(l22°i 37° F), and using the same instrumenis andthe same wiring diagram (Fig. 161);close the switch I, start the generator, adjust itsspeed and rheosfai R £0 obfain a volfage and a currentof 28 I-’ and 5.-5 to 7.4 A., respecEive!y,'

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after 30 minutes of operation at’ the above conditionsstop the generator and open the switch I. Bring thegenerator back to a speed of 3500 R.P.M.; aofiusi iheload of the adjusting spring by acting on the tongue(5, Fig. 152), and the rheostazf R fo obtain a regulatingcurrent and voltage of 6.6 to 7.4 A and 28 1/, checkthe sfabi/iiy and the accuracy of the regufafingcurrent by stopping the generator and running rr

A again up to a speed of 3500 R.P.M.

Performance check and sealing of the unit.

Once set, close the hot control unit with cover and gasket before it undergoes the bench test as frominstructions of page 100 and following. Then put the paint seal on one of the cover fastening screw headsbefore returning it to the owner.Overhauling or repairs must be entrusted to FIAT Service Shops only.Whenever a control box is opened for overhaul or repair, operate if for a certain length oi time withoutthe cover on so that it will warm up and eliminate any residual dampness on its elements, if any.

W ’ WCiO»NTRfOl. Box GP1_i24,i‘i sneoarrcznrsons (inf

-_._-______.,. . . - - W_. _ W __ -.. ._ _.Description I Data 3.

lCut-out relay:

5 -~ ‘lead current for thermal stabilization . . . . . . . , . . . . . . . . . . . . ,1; 30 V—- out-in voltage . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 4 25,1 to 25,9 V

_ — voltage variation for Contact closing stroke . . . . . . . . . _ . . . . . . ' > 0,2 VI‘ ~ reverse current . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . 6 to 14 A

‘ — air gap, contacts closed (axis A-A. Fig. 159) . . . . . , . . . . . . . . . 6,25 mm (0.010 in)

6 D I --~ gap between contacts (cl. Fig. T50) . . . . . . . . . . . . . . . . . . . . . 0,64 to 0,? mm [ A325 to 3,830 in)

li Voltage regulator:— batteries capacity at 30V . . . . . . . . . . . . . , . . . . . _ . . . . . 100 Ah l— average load current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 A

i —~ rated voltage after thermal stabilization at a room temperature of 50°i~ 3° C ;(122: 3?“ F} for 30 minutes . . . . . . . . . . . . . . . . . . . . . , . . 28,? to 29,7 V

»~ feed voltage for thermal stabilizaeion . . . . . . . . . . . . . . . . . . . . ;~= 38 V ll— air goo (C. Fig. 149) . . . . - . . . . . . . - . . . . . . . . . . . . . . . 0,98 to 1,11 rnm [(3.039 to 0.044 in} 1

1 13 Current regulator: 2— rated current on battery at 50°i 3° C {t22i 37° F} room temperature, after I

thermal stabilization . . . . . . . . . . . . . . . . . . . . . r . . . . . . ; 5,6 to 7,4 A- rated current check voltage . . . . . . . . . . . . . . . . . . . . . . . . 28 V

l — air gag: (C, Fig. 149) . . . . . . . . . . . . . . . . . . . . . . . . . I 0,99 to l,1fi mm (0.039 to 0.044 in)

Resistances, Fig. 159: EI — regulation resistance (5) . . . . . . . . . . . . . . . . . . . . . . . . . . l 136 to 144 ohm ‘‘ -» damping resistance (10) . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ohm

— additional resistance for voltage regulator (7) . . . . . . . . . . . . . . . 73 to 77 ohm’?-~ additional resistance for cut-out relay and current regulator (11) . . . . . . ?'3 to Tr‘ ohm*

l

Note: The generator check and adjustment speed is 3500 r.p.m. V i(‘fl See data for modified groups under the ioilowing heading.

CONTROL BOX TYPE GP ‘H24/7, MODIFIED (Dwg.n0 4035433).

The modified control box 4085433 diners from the previous type (4055883) as follows:—~ the series and parallel windings of the cut-out relay are mounted in succession instead of being super—

imposed;~ the value of supplementary resistances for the voltage regulator (7, Fig. 151}, cut-out relay and current

regulator (1i, Fig. 15*!) have been lowered from Y3-7? ohms. to 56,5 to 63,5 ohms. These resistances.together with those placed under the base oi the control box, are not furnished as spare parts.

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Specsficabons and damensions

Electroixte level checking and ’cop—up

Battery charge check

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Tractors are equipped with two 1' 2V batteries, Capagjfy56 Ah {measured at 20 hours discharge) conneciegin series, to reach the generator voltage of 24 5/,The main battery characteristics are:1. Connections, covered with mastic insulating

material to prevent current a'is;Jersiohs and prg.tect against corrosion the connections and thepole terminals.

2. Separators, for protection of battery lead platesfrom vibrations, made of extremely thin parougrubber, or of poiivynil plastics.

3. Self-levelling and splash-proof plugs, allowingelectrolyte self-levelling, and preventing its splash-ing from the vent. holes, when tracts; jolts inoperation.

Sizes:— length . . . 368 to 372 mm (f4‘4882“ t0 l1i.6-455")-— Width . . . 173 i0 777 i‘l’?m( 5.31 l0“ to 5.9555” j~— height . . . 197 to 200 mmf Z7559" to 7.8739”)Battery makes: '— Marelii 6 TF 9;- Titano 6 CR 4 F.Weight (with electrolyte) approx. 24 kg (52‘Q10 lb).

Keep batteries clean and dry, particularly the upperparts, thus avoiding, especially after the recharge,the corrosion of the element sealing compound,‘smear terminals with pure Vaseline, avoiding the useof lubricating grease as it reacts with sulphuric acidof the electrolyte (vapour or liquid).

Electrolyte should completely cover the elementplates, and top-up them of about 5 mm (0.1969").Distilled water only should be used for topping-upthen make sure the plugs (A, -Fig. 162) are fullytightened.For longer battery life, avoid any contact betweenwater and metallic containers. >

Unscrew the plug, and introduce the hydromeier ineach element; the specific gravity represents thebattery charge conditions, as follows:

1,28 100%1,25 75%1,22 ; 511%1,19 . 25 %

I 1,15 I nearly discharged

Electrolyte gravity E Condition of battery charge I2

iE

1,13 l completely dischargedi

Fig. 162. - Batteries mounted on tractor.A. Funnel of levei control plug for water filling - C. Cover

for levei control plu.

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Refitting and removing from tractor.

Therefore a battery may he considered charged ifthe electrolyte gravity reads between 1,28-7,24 at25° C g'77° F). Avoid letting the battery to dischargecornpletely; recharging should be made when grarityis not less than 1,16‘ (20° at). The recharging currentrate should never exceed 6 A.in order to rnaintain the battery charging withinactual conditions the checks should not be madewhen:

I. the electrohrte is clifierent from the prescribed one.if distilled water is being poured in, take time toset a uniform distribution,‘

2. battery is hot, or immediately after repeatedstartings, or when electrolyte is cold. The mostsuitable temperature is between 15° and 25° C(59-77F). .

if the battery cells have a specific gravity with dif-ferences exceeding 0.02 or high or low gravities,accompanied by excess of heat (more than 10° C -50° F, above the ambient temperature), call theService Organization of the battery supplier.

During operation, the batteries are not to he perio~dically recharged, as the tractor charging plant canmaintain their efiiciency.When discharged (excluding after long tractor stopswhich cause battery self-discharge), the batteriesindicate abnormal functional conditions.These may he traced to:

.1. Faulty recharging system (generator, regulatorgroup): see service instructions.

2. Current dispersion, due to insulation clefacts inthe electric system. This may take place afterheavy current draw due to the insertion of extraaccessories, A rapid check is made by insertinga microarnmeter between battery positive terminaland its disconnected clamp, after having stoppedthe engine and excluded all equipment. Thecurrent rate should not exceed l miliiarnpere.

3. Extra accessories in addition to the standard onesinstalled by the manufacturer are dependent uponthe electric system capacity.

4. Tractor short hauls, using gears at lowspeeds and with frequent stops.To maintain the generator at its normal recharg-ing speed rate, use low gears when running atlow speeds.

5. Sulphated battery; short circuited elements, orinterrupted.

No difficulty should be met in installing or removingthe battery from tractor; to avoid heavy discharges,he sure to disconnect the grounding cable, beforeworking, in addition use proper wrenches, andnever use pliers to screw or to unscrew the terminals.

109

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STARTING MOTGRSpecificaiions. 7

- . . HAT E‘l15-8/'24 Var. 2 ''l'ype.._... _- 24V‘

Rated output . . . . . . 3 KwExcitation . . . . . . . . . . . . CcmpgundDirection of rotation [pinion side) . . . . . . . . . . . . . . . . _ . . . . <;l@¢;;<w;SeThe starting motor mounted on tractors of series 400 is a direct current 4-pole motor with solenoid, am}free—wheel engagement pinion drive (Fig. 163).

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Fig. 163. - Starting motor.

1. Remove-conirol switch ‘terminal - 2. Terminal ior motorfield coil - 3. Rem-ole control switch - 4. Pole piece fasteningscrew - 5. Starting pinion - E. Bell for brush prDY'.EC‘IiOr! -

7. Through bolt nuts.

Tesi bench checks.

As voltage, during rests, should be approximately constant, the starring motor shall be energized l:-y largecapacity batteries.The specified voltages, applied to the motor terminals, shall determine the prescribed current drains,through the setting of a rheostat. No result would be reliable if such conditions were disregarded, withthe exception of the torque reading, and only approximately.To verify The motor performance check the electrical and mechanical specifications as follows.

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Fig. 164. - Electric diagram for bench test of éiariing mcrior.M- siaiilfifi lTl0'rOr_- V. Yoltmeier, 30 V top reading ~ A. Arrrrneier, 10% A, top reading - B. Baiteries, 12 V, 100Ah, connecied

an series, fully charged ~ R. Rheostat, carbon plate type, 1000 A, lop reading - I. Switch.a) Starling motor electrical diagram.

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Checks. Operations.

Operational test (under load). woe up agcgrding 50 1-79, 154,

Use a test bench ,1‘Ftzfed with a ring-gear having 5ratio tastween pinion and gear of about 1 to 1'0; moiresome startings of short duration. and check, bybraking the motor until a current of 285 A is rem-17e,;.'that its torque is about 7,85 to 2,15 kgm (11-14 gof57ftlb)at1510to?o‘10l?PMth = U79-V A - l -. .e voltage being

Checking motor torque when stopped.

should than deliver a torque of 4,62 to 4,?5 kgm(33.4 to 34.3 ft.l/5).

_ld?lm; lest Of fl'1OlOF- Clear away the ring-gear, to prevent its meshing

with the pinion.Shut the starting switch and adjust the terminalvoltage at 24 V.Motor should then absorb a current not exceeding30A at 4090 to 5000 R.P.M.

E?@<3?F@m@Qnel run. The mobile contact of e/ectromagnet should perform

a run of 6,4 to 8,45 mm (0.25? to 0.333"); the corebeing Of 3,5 {O 10,7 mm (0,331?! {O 0.397”).

Motor internal total resistance. The test data of the motor when Sfappgd 5/gow

calculating the motor total res/stance, by the ratiobetween the voltage applied and the current, ,4:40° C (104° F) the resistance should be of 9.0205 to0,0275 Ohm.

Field col I resistance 1') The main field coil resistance (in Series), at 200 c

(58° F), should be of 0.0060 to 0.00%? Ohm,2) The secondary field coil resistance (shunted), at

2:100 (saw-') should be of 1 to mt Ohm,C0“ FQSESHHCE. The efesffofnagngf fesjsl‘an€e) at /680;)

should be of 1.36 to 1.46 Ohm. ‘Mechanical characteristics.

See data on page 115.

Guide for finding starting motor troubles.

Faults in the charging system may he localized either in the electric motor or somewhere else in thesystem; it is the-retore necessary to localize trouble first in order to avoid a waste of time by lookm 1°

g orfaults in the electric motor not being there or clue to outside causes, so that repairs would be use-lessas trouble would repeat itself.Therefore, if cranking is very slow or absent, the defect must be localized. To this end, as engine isstepped, the headlights can be used.Comparativeiy scarce illumination can be traced to low battery charge, damaged cables, or terminals notlightened. Naturally, the check is made taking for granted that the headlight circuit and its Cflmponenfjsare efficient and without tension losses for poor contacts at the switches, bulb-sockets, etc.It happens less often that the recharge plant is defective, and this may be ascertained through the regulatorchecks. Anyway, the battery recharge, without having found out the causes, will not eliminate the troublethat will repeat.

Stop the test bench ring gear; switch on, and aajigysfvoltage to motor terminals, so that .-'1‘ will ecsorh acurrent of 620 A at I2]-13 V. The starting motor

r,_ .

The battery being normally charged, and the starting motor operated, causes the iollowgi-,9 headfigmbehaviour:

1) No light: traced to poor connections between battery and motor, or corroded battery terminals,

2) Considerable dimming as engine is started, and the latter runs slowly or stops:

a) excess of oil crankcase density;

b) armature spindle bent, bushes and support worn, and polar shoe screws toose;c} commutator damaged, series field coil or armature coils grounded or short-clrcuited.

3) Bright headlights, and starting motor cranking slowly or stopping:a) ioose terminals of the motor solenoid contacts oxidized or insulated by foreign matter intrusion,

or damage of the excitation circuit and commutators circuits; .,b) poor or iauity brush contact on commutator.

Troub§e~shooting instructions.

item 1) of the preceding chapter, increases the ohmic resistance laetween batteries and motor and maybe measured by a voltmeter, when motor is running. 'The voltage drop measurements to be taken are as follows: between tractor body and battery negativepole; between tractor body and the electric motor frame; between battery positive poie and the solenoidterminal, where the battery feeding cable ends.Each measurement should not give more than 0,1 V, when the starting motor is running.However, if the voltage drop is excessive, disconnect the cables, clean the battery terminals and smearthem with vaseline, to prevent corrosion.items 2} and 3) oi the preceding chapter, call for a commutator check for efficiency and the removal ofthe starting motor, to perform its test with no load and when stopped (torque test).The following cases may occor when such tests are being performed.

l - Torque current and speed up to specifications,

it - Low speed and torques with no»load; high current drain: trouble to be traced to armature windingpartly short circuited, or grounded; or to rnechanicai defects, such as worn-out bushes, armature shaftbent. loose poiar shoe screws.A simpie inspection may indicate that some armature turns are grounded, as the corresponding corn-mutator blades would be deteriorated by heavy current passage that wouid take place through thebrushes.

Ill-Motor does not start and high current drain: might be caused by the armature or the iieid coil completelygrounded.

IV-Motor does not start and no current drain or less than 24 A: no current drain requires checking thesolenoid contacts on the commutator, and of the brush spring performance.Very low current drain signifies that the tieid series winding is interrupted.The solenoid winding interruption may be checked with a test lamp.

V‘ LOW Speed. with no load low current and torque, the fault may be traced to the internal resistance orThe m0f<>F, or to commutator expanded bars due to centrifugal force.The first trouble is reacliiy detected when the motor is dismantled, the second one may be caused bythe tree~wheei too hard to turn or by field coil connections unsoidere-d from the commutator bars.

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Sect. A-A. ~ Cross secfion on fork Eever. Sect. B-B. - Cross section an commutator.

Fig. 155. - Sectional views on starting meter type iE1€5-3i24-Var. 21. Starting drive pinion ~ 2. Fork lever - 3. Solenoid core - 4. Selenoici coif - 5. Solenoid tea-minai - 6. Fixed contacts - 7. Ciampfur mater fieid coil end - 8. Commutator - 9. Armature -10. Fieid coil ~1f.S1eeve -12. Overrunning clutch hub - 13. Over.-unningcluich ~ A. Solenoid corg trayei (8.5-1Q.1 mm m 0.334”-0.397”) - B. Solenoid bi] ta » “ ' "

mo e con ct travel (6.4 8.4:: mm m 0.252’-9.333 ) -C. Armature shart end piay (0,35-0.75 mm = 0.0138"-0.0295”). ~ D. Sulenoid terminals.

Mow! disassembiy.

The starting motor can be dismantied into the foilowfng subassemblies: sofenoid unit, commutator andbracket assembfy, armature assembly, clutch assembly, pinion end bracket assembly. motorframe assembiy.

Paris to be remaved. Operations and cauiions.

The sofenoid. Remove the screws fasiening it to the support, afso

the fieid coif end from terminaf (2, Fig. 163). L/'7?the solenoid assembly and fake it away.To dismantle ii remove the upper cover (in order todisengage the coil end) and make free the ceniralpart of the soienoid body (3) from five screws fasten-ing it to the support. and ;‘7/om the terminal ends.7'0 remove {he solenoid coil core, remove the splitpin and éhe mobile contact nut.

113

Remove the nuts and the tie-rods fastening wehead to the frame (7) and the protection strip (6)..free the field coil leads connected to the brushes,‘and remove the complete head. ’

Commutator end head.

Slide it out from the frame with the armature; removethe pinion engagement control fork pivot and pg”upwards the fork to disengage the pinion.

Pinion end bracket.

Remove split pin, unscrew the nut, remove thepinion stop ring, and slide the free-wheel out.To strip the free—wheel, remove the spring cup 510;;ring, and slide out components; remove the ringfastening the wheel to the bell and carefully slideout the spindle, to prevent rollers and springs fromjumping out.

Free-wheel.

Starting motor troubleshooting and component checks.

Brush replacement En the commutator is comparatively simple: raise the springs and slide out brokenor worn brushes. Use only original brushes supplied by FlAT — Sezlone Rlcambl, which ensure a longservice.Check the solenoid contact which, if oxidized or burnt, should be cleaned using emery cloth, then removeall metal and emery dust before reassembly. 'll necessary, replace the solenoid, and the starting motorlield coils using original spares, without attempt-ing to repair them or to wind a new coll, as good performance cannot be obtained by such means. Alterhaving tightened the coils under the polar shoes, check that the air gap corresponds to specllicatlons;to facilitate the essemlqly warm up the windings to about 50° C (122° F).Check commutator for out-o"l~round, which should not exceed 0,02 mm (0.00078"); if necessary, and if thecommutator bars have not been thrown out-ohound by centrifugal force, turn them down, then undercutthe mica of? mm (0.039") using a saw blade.Check armature conditions with the same device used for the generator and ll grounded renew it.

Fig. 166. - Parts of starting motor clutch.1. Clutch rollers way - 2. Clulch rollers - 3. Push rod for

clutch rollers - 4. Clutch hub.

Reassembly instructions.

To reassemble the starting motor reverse the sequence used for dismantling.Before assembling, clean armature and brackets with a strong air jet, and clean the commutator usinga dry cloth.

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STARTING NIDTQR PERFORMANCE DATA

‘ or K 7 ..~_W — - F1 Ti ,7 ___ _ ___

Specifications Values

' current . . . . . . . . . . . . . . . .Q 235 A

1 Operational test (under load) <v torque" ' ' ‘ ' ' ' ' ' ' ' ‘ ' ' ‘ ' I L55 to 2,15 Rgm (13.3 ‘to 15.5 Ftlb.); i speed i-are . . , . . . . . . . . . 4 _ ’ 1510 to 1610 !‘.p.m.

ii . voltage . . . . . . . . . . . . . . . . 1 l9 V1 . li I3 ‘current . . . . . . . . . . . . . . . . 620 A '

1 Checking motor ‘torque when stopped > voltage . . . . . . . . . . . . . . . . 5 12.7 to 13 V

’ 4000 to some r.p.m.Comrnutator out-of-round . . . . . . . . . . . , . . . , . . . . . . , . . . 1

‘ internal iotal resistance of motor, when stopped (at 40°C - 104° F) . , . . . . 0.0205 to 0.0215 ohm

. l =30l<-Bflvld " solenoid internal coil resisrance when heated . . . . . . . . . . . l 1.36 to 1.46 ohm

A _ 8,5 lo 10,1 mm (0.334 lo 0.391") l

r _ torque . . . . . . . . . . . . _ . . . 4,52 lo -4,15 kgm (ss.4 to 34,3 ftib.)l current. . . . . . . . . . . . . . . . . 36 A

r speed rate . . . , . . . . . . . . . .l>,l_)2 mm (0.GOD'?8")

‘ Pole shoes inner diameter . . . . . . . . . . . . . . A . . . . . . . . . . . ‘ 75.83 ‘zo 76 mm (29855 to 2.992l”}

i Resistance of main field coil {in series), at 25°C E68“ F) . . . . . . . F 0.0060 to 8.0070 ohmResistance of secondary field coil (shunted), at 20416 (58°F') . . . . . . . . . ~ 1 to 1.14 ohm

r solenoid liii force, with a current of 9 A and an air gap of 5 mm (0.1'S-"} g not less thou H kg (24.2 lb.)l Solenoid mobile coniact travel . . . . . . . . . . . . . . . . . . . . . . . . =

‘ Brush spring pressure (new brushes) . . . . . . . . . . . . . . . . . , . . I 1,15 to 1,30 kg (0.52 to 0.58 lb.)‘ Armature axial play (C, Fig. 165) . . . . . . . . . . . . , Q . . . . . . . . . l

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_; ldling test of motor (under no load) 4 voltage . . . . . . . . . . . . . . . , 24 V

Armaluro outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . ?4,95 To 75 mm {Z9508 to 2.9528”) ‘

, l‘ ‘ energizing current at 24 V, (2G° C - 58° F} . . . . . . . . . . . . . Z 17 A

. 6,4 ‘£0 8,45 mm (0.252 lo 0.333”) l= Solenoid core travel . . . . . . . . . . . . . . . . . . . . . . . , . . . .

V 0,35 to 9,75 mm (013138 f0 0.0295”) Il_ 7 _ _ _ 77”’, '_—___—:_~s'_— ___ _;' ___'_____;

GLOW PLUGS

The glow plug ‘consists of a thin wire helix, contained in an insulaior and surrounded by a metallic shellIwhich is hosted by the incandescent coil to 856" C (?562° F) through the insulator when energized by a

24 V current. V’The glow plugs are shunt branched (nominal voltage 24 V, MOW each}.

na-rcemovai and cleaning.

Before unscrewing the plugs, free their terminals. Clean them with a metallic brush, wash in gasolineand blow them dry.

Checks on fhe fest bench.

a) Check the plug current absorption at 24 V (5.82i0.2 A};b) Sealing. The plug is screwed in a seal similar lo the one existing on the engine in a vessel the

pressure of which can be raised to 30 kglcmi (426.70 p.s.l.).Air leaks, against the atmospheric pressure of 760 mm (29.92l3"') of mercury, shall not -exceed 2 cm“110.1220 CU.il‘l) of air. '

115

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ATTA€i-EMENTS

POWER "i"Ai{E-OFF

The power take-ofi assembly is Located inside the transmissien casing rear cover and may be actuatedby a lever directly from the crankshaft or from the gearbox (through a gear instalied on the bevel pinicnshaft, Fig. 81}.In the first case, the power iai<e~o1’"i shaft runs at a speed prapoiflonai to the engine (575 r,p,m=, enginerunning at 2300 r.p.m.), and in the other case the speed is proportional to the tractor forward travel(3.75 revoiuticns per rneier of forward travel).

Major overhaui.

Removai.

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A. Driving shaft componenis. I \\:B. Driven shaft componenis.

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fxiote. - If tractor is fiffeo’ with hydraulic ./1',-‘t, {hereis no need to remove ii; we suggesi, instead, toremave the bait pulley transmission cover, ifmounied,to simplifl the assembly.

Mount the assembly on rotary siand ARR 2204(see Fig, 167).

Fig. 16?. - Cover-rear transmission, with power takemff,mounted on rotary stand ARR 220-i.

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Dismantiing. See A. B, Fig. 168 represeniing the disassemblingsequence of the various components, from iheirseats.

inspection of components. Check gear teeth and shafi and hub splines con-difions.The power take-ofl" driving shaft s/idfng gear can bechecked and also disassembied by removing theiransmission casing upper cover.Check the bearings for smooth running and ihepower take-ofi’ driven shaft oil seal conditions.See page 118 for main assembling cfearances andpermissible wear limifs.

Assembiy. Reverse the dismanfling sequence.

Note. ‘- To fit ihe power fake-off driving shaftinto the siiding gear hub, turn the power take-offdriven gear by hand.

BELT PULLEY

The belt pulley assembly is mounted in piece oi the power take~ofi cover (Fig 81) and m bV - 55’ e= set withthe puiiey either on the right or left side, according to the required direction of rotation in both case

~ sthe vent" shouid be mounted on top and the drain piug at bottom (Fig. 159); if necessary, interchangethe position of the parts. AThe unit is coniroiied by the power ta-1ke»oi"f Fever shifted info KMCFTORE >> (engine).

Major overhaul.

Dismantling. Drain Iubricafion oif, remove the puiley from driynshafi end, and fake away the o,oposii‘e ‘end cover:remove the snap ring from the driving shafi supporé,and hammering‘ on a bronze punch from the inside,remove the shaft and ah’ ifs parts.

-..».,,__ The ro/fer bearing outer race, ifnecessary, is removed 7from its seat afier taking away the snap ring; -orfrom the pulley driven shafl‘ remove fhe nut and itsspfif pin and, using a bronze punch, push out thedriven shaft.The roller bearing outer race and the ball bearingremain in their seats, and may be removed aftertaking away ihe snap rings.

Fig. res. - Belt puiiey unit.

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Reassembling and adiusfing the pulley assembly.

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Check bevel gears and shaft splines accom'ing {Q Qcfafa of page 118;check bearings for correct functioning and Sfmfiseal for oi! leaks.

Refer to Fig. 178 and reverse {he sequence ;'of!ow@dfor dismantling.

zhe shim rmg P of a'rr|/mg pinion and shim flng ;__of bevel cmwn gearThe suggeeied clearance for bevel pmron and wh.;-9,1rs of 0 “'5 mm (0 0059 ,l am shoufd be Obfdlfiéd by/arymg the L and P shzm ring thicknessesService wiih SAE 140 oilfhe belt pulley assemblyunifl level reaches the plug faceted on the coveropposiife to the same, "

Bevel pin/‘on and wheel adjusfmenf made by varying

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SPECEFICATFQNS, ASSEMBLY CLEARANCES AND PERMISSIBLE WEAR OF POWERTAKE-OFF AND BELT PULLEY COMPONENTS

F We e 1 , _ er V 1 er e »_ “IIData Wear limits

1 Between driving gear splines and power take ‘

i 2

Between gear splines and power fake-off driven

Assembly clearances " 7' " * Vfl W" ’—| ~ "*7 ‘mm in. mm i in. ‘

' Tal;e»off gear backlash . . . . . . . . . . . 0.19 :0 0,20 3 oaoss :0 0.04119 9,4l . 4

uff control shaft . . . . . . . . , . . . . . 0,010 ‘E0 0,105

ll shafi . . . . . . . . , . . . . . . . . . . . 1 -0,024 is 0,012 I-0.0009 to 0.0005 _ _ -Bel? pulley pinion backlash . . . . . . . . . 6,15 0.0959 E 0,4

l i - 7 ;

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Fig. 17%. - Hydraulic pump mounted on fractal‘. Fig. 172. - Hydrauiic iifi mounted on tractor.

A. Lift control lever - B. Seleclion lever (position coairoirequires the lever lo be shifted down) - M. Spring for reaction

strut.

Hereafter are the main components of the lift mounted on 411 R tractors:~»~ a gear hydraulic pump, driven by engine timing gears (Fig, 171];

— a iii-t, with integral‘ oil tank composed oi a ram (simple efieci) acting through a ball-heeded linl-: on alever keyed on the lifting arm shaft;

— a three point implement hitch, adjustable with a screw controlled by a hand wheel on the right link,allowing the cross adjustment of the implement position (Fig. 127);

—~ a control valve, optional, to be applied in place of the control valve cover for supplementary attachmentcontrol (Fig. 193).

HYDRAULIC PUMP '%cé/ fig’? 7%“/"~The hydraulic pump needs no maintenance, checking or adjustment even eiter long operation. This isQ, or ‘ , .ue to the factrlhal clearance between “me gears and bushes [S taken up automatically by the oil pres-sure in the pressure side.The bushes have their side facing the delivery fitted with a fillet (1, Fig 1'53), which the oil crosses tr ro h

. I : {jgto act upon a surface recessed on the two covers and defined by two rubber gaskets shaped as aheart, and laid eccentrically (2).

Pump general overhaul.

See Fig. 173 r'or the disassembling and assembling sequence of the hydraulic pump components. Theexplanations of the preceding paragraph should facilitate a correct assembly and disassembling; senseof rotation oi the drive shaft is indicated on the pump cover.in addition, notice that assembly and disassembly require no special tooling, as the high finish ofh.mac med surfaces would be damaged by a careless assembly.Never disassemble a hydraulic pump if original spare parts are not available: if repairs are necessaryentrust them to FJAT Service Organization.

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We give hereafter the specifications oi the hydraulic pump, to check its performance:

._ ratio between engine and pump R.P.M. . . . . . . . . . . . . . . . . . -L152_ pump speed (with engine at rated speed, 2390 R.P.M.) . . . . . . . . . 2.000 R.P.m_H gump rotation, as viewed from driving shaft end . . . . . . . . . . . . (clout-(W339_ suction heed . . . . . . . . . . .~ . . . . . . . . . , . . . . . . $380 mm (,+_‘l2.8Hi}"}__ deliveries {oil at temperature at G kg/'sq.cm (O p.s.i.) . . . . . . . . . 1? litersfmin (3.75 lmp,gal‘_]

or 5005 -1409?) at 150 l<g;'sq.cm (21335 p.s.i.) . . . . . . 16.5 litersfmin (3.fi5lfl1p,gal_)- pressure valve opening pressure (marked C or E) . . . . . . . 145-‘SS5 kg/sq.cm (2862-2205 p.s.l.)

To secure a good performance of the lift hydraulic pump, use exclusiveh/SAE 20 hydraulic oil avoidingall mixtures. l .The customer shall be warned that periodical checks and cleaning of the hydraulic lift oil filter is absolutelynecessary. After the first 20 hours from any oil change clean accurately to remove dirt from the litter.

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Fig. 173. - Hydraulic lift pump components.1. Shahi bushes - 2. Forward cover - 3. Delivery port.

HYDRAUHC POWER LIFT OPERATION

The power litt consents performing two different operations: position control and draft control. Tochoose either one just move lever B (Fig. 172) downwards in the former case and upwards in the latter.

The lever can be actuated only when the litt arms are raised.

The lift arm raising or lowering control is performed by lever A. in the position control operation, atevery position of lever A corresponds a dltterent height of the lift arms, and consequently of the imple-ment. in the draft control operation most of the excursion in the quadrant is used to determine the draft atthe implement during work.

Whenever lever A is moved, the control valve spool rotates and according to its sense of rotation letsoil pass in ditiereni conditions through the valves of the hydraulic circuit which control the raising or thelowering of the arms. in the position control operation, the height of the arms can be controlled throughlever A only, white in draft control also intervenes the reacting force which the implement passes on tothe spring M, Fig. 175. The deformation of the latter consents the rotation of the control valve spool,(the strain of the spring being transformed by a lever mechanism) and consequently a movement oi thearms which brings the resistance encountered by the implement in the ground back within the limitsestablished by the position of the lever A in its sector.

In position control operation the selector lever B, acting on the relative position oi levers and rockersof the linkage cuts oh‘ the control valve spool from the effects oi the strain set by the implement onspring M.

Fig. TF6 illustrates the hydraulic diagram of the system. For further details on the power lift operationsee the Technical information Bulletin, Form No. 324.192.

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S. Arms lifrlng.'i“l1e control spool P is ro_2a'l.ed so to let oil pass from {he pump onto the top cl the llft Eoniroi waive plunger 2. ensuring?) its closure. The preg-Surized 0l| can thus llawm to the cyimder through valve 5 and dlsolace ‘lhe piston to lnt the arms.

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F. Arms floating.As soon as the oislon moves. the confrol spool F relates being conneclcd to lhe Inner arm through levers F, E, D. The spool rotallorlal mov-ement causes tho cl! under pressure which kepi the valve 2 closed by pressing on lts top to discharge Into the reservoir through the grc-Quemachined along the spool axis. The pressure of the oil coming from the pump and aciing on the bottom of the valve wins ‘lhe resistance. thevalve opens and the oil flow is conveyed into the reservoir Instead oi the cylinder.

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A. Arms Lowering.To lovqer the arms, the valve spool opens by cam action the discharge valve (4), which allows the oil to outflow lowards ihe tang undgy the 9,93-Mme or the plston.

Fig. 175. - Working diagrams of the hydraulic sysiem for different arm positions.

(Note: The oilfiow patrern in the circuit is ldenilcal both for position and draft control operation) -1. Pressure relief \'fillF9— 2. Controlgllvg - 3. Cylmder saretyyalve T Cylinder discharge valve - 5. Cylinder lnlakg valve - D. Link ~ E. Rocker - E Yoke link -

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17. Valve block - L. Linkage control lever ~ O. Cotter pin21. Screws which fasten the levers to the inside arm - L. E.in?<~ conneciing the link to the control spool lever - Q. Set screwa e trol ‘ ‘g con lever. CGl‘||'§BCtifl§ zhe control lever to the ccmfrol spool - R. Access

port lor removing screw ‘R (gee Fig. 182} ~ t. Confrol spooladlustmg plug.

Dismanfling the power lift.

To remove the unit from the tractor so t h-para e t e arms from the implement hitch first, then disconnectthe two oil Zines and remove the screws wh?the power lift proceed according to the following sequence:

Components to be removed. Operations and cautions.

Filter (H, Fig. 133). Pu/H

Outside 3he paris out 1'/we lift box.

iifi box and spring support.Cover (13)-. Can be removed éogether with the spring Suppgri,

" ., ll“: ‘' “'“"““' Fig. 119. - Cylinder discharge valve Parts.

4. Plunger.

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lnkago (12). Remove the comp/ate assembly freaing it from zfha

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Fig. 182. - Lifl outside and inside control linkage.

(The illustration shows: on ‘lop, the outer leverage removedfrom fhelift; belov.',%l1e insldeieverage placed as during work).A. Lift control lever - B. Selector lever - 1.. Leverage controllever - P. Control spool - Q. Screw securing the control leverto the spool - R. Screw securing the lever L to the rocker.

Remove the rrrr oufer arms; the screws which fasign{he levers to the inner arm (21, Fig. 1??) and slidethe shaft in the direction shown by the arrow/.,

Noie. - To prevent damaging the seal ringlocated on the /eff end of the arms control shaft,more the shafi about 2 cm (25/32”} in the senseoppos/Ye io the arrow and remove the ring (Fig, 177)_

The inner arm wifh its pision n'rl'w'ng strut remainsinside the power lift. -

Fl’e-moi/e pin (0) which fixes {he waive spoof controllever fo his link prior to sliding {he whole unit ofi’the studs.

Nofe. - The for/owing components rerpafn freeinside {he power /ffi:»~ the lever mechanism which is removed by un-

screwing ihe screw (R) first and sliding ofi theouter fever (L) in a second time;

-- fhe pfsfon and barrel. The fatter can be slid ouithe front by applying a slight force.

The vah/es can ah’ he disassembled easily enough asthey all are accessible from the outside, l-vfih theexceptfon of the off inlet into the power cyfindervalve (5) which requires removing the control valvegroup. To disassemble the confrol’ valve slecken thescrew which fixes the control lever (Q), remove {headjusting plug (t) and the side cover of ihe conirolvalve for auxiliary equipment (Fig. 180).Fig. 183 shows the power lh’{ suhassemhlies in thedismantling sequence and Fig. 182 the outside levermechanism (above), and {he inside lea/er mechanismconnected as they are during operation (be/ow).

lnspeciion of components disassembled from ‘the hydraulic lift.

After dismantling the power lift unit check the following:— check conditions of the gasket between barrel and housing and between piston and barrel;-— check the play between the arm control shafi journals and the bushings; if found exceeding the values

specified on the table of page 130 replace ihe bushings;~—- check that the play between the control valve spool and its bore lies within the specified Eimlls.

Note that the valve spool is not furnished singly as a spare, but always Together with the valve blockbeing fitted to the bore;wash 8%‘; replace the oil filter cartricigelli found defectlve)ancl make sure that the filter seat plug is wellwelded lo the plate for carfridge protection to prevent aifsuction on the part of the hydraulic pump;replace the oil seals for the lift arms shaft and the gaskets of covers, plugs and valve seats if they arenot dependable;check sealing characteristics of the discharge valve and of the lift control valve (4, 2, Fig. 185}, grindthe seats if necessary and check spring performance;check the selling of the pressure limiting and safety valves by means of a hand pump equipped withvalve carrier A 197032;'A,/B, Fig. 181. lf data do not correspond, replace the valves. as componentoarts are not furnished separately as spares.

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Fig. 133. - Exploded view of the hycirauiic lifi.6. Piston ~ ii.‘ Oil filter components - 12. Outside linkage - 13. Rear cover with spring mounting - iii. Inside linkage - 15. Armslifting conlrol shaft - 15. Inside arm with ram - 17. Control unit - TB. Barrel - 19. Lift body - 29. Breather plug - 21. Screws

fixing linkage to inside arm.Z) Exploded view of Ehe auxiliary control cc>ci< ~ 1. Pressure reiief valve - r. Control spool.

Power lifi assembly.

Reverse the order of dismantling and follow Closely the instructions given below:- when piecing the/inside and outside arms on the control shaft make their respective stamped marks

to register (see Fig. 184);’— the installation of the seal rings on the arms requires using the protection A 1970El3;'A first, in order

to prevent contact with the teeth of the shaft end, then the use of the punch A 'l9'i9G3,lS (Fig, 135);- the screw which fastens the control lever to the control valve spool (Q, Fig. 182) should be mounted

on the piston side.

Power lifi adjustment. i

The adjustment of the power lift should be carried out by placing the unit on the tr +ac.or or on the benchI 495065 which is equipped with the necessary weights.

a) Confroi valve spool aofliusfmeni. —~ Run the engine to high idle speed, then raise the lift arms, and placethe selector lever on position control (downwards). Remove the cotter pin and slowly screw in theadjustment plug (1, Fig. 138) until the load starts oscillating (vertical oscillations}; unscrew the plughalf a turn and fit the cotter pin.

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Fig. 184. - Register marks for fitting the inside andoutside arms onto the control shaft.

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Fig. 185. ~ Lifi arms control shafi seals fitting.A = A 1El'il3l33,"A Punch - B = A 1971303,/B Proleciion.

in} Arms stroke adjusimenf. - Start the engine and check fhat ihe stroke of arm ends of the implementhitching device (with the links connected in the holes as shown in Fig. 18? is from 580 to 600 mm(22-27,'32” to 23-5/'8"). if the stroke length does not lie within the above tolerance, act on screw(19, Fig. 186) by means of spacers.Note that when the implement hitching device arms are at their highest position there must be amargin left, which is controlled by raising by hand the lift arms.

c) Aojusimenf of ihe distance between the iifi co:/er and strut support. - Whenever parts have beenreplaced (spring, strut support or lift cover) or after a major overhaul check the following:

ii Remove the strut and check that distance l (1, Fig. 190a) is 153 0,5 mm (O.590"i0.02”). if other-wise change one or two spacers H between spring and support. Note that it would not be Comvenieot to use a large number of shims H to decrease the clearance I because that would vary theload and conditions of the spring M.

Fig. 186. - Valve block.5. Pressure relief valve - 2. Lift control valve - 3. Cylinderpressure safely valve » 4. Discharge valve -. ‘iii. Lift armsstroke adjusting screw - t. Control spool adjusimeni plug.

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Fig. 187. - Hydraulic iifi linkage installed on the tractor.1. Top link, acljusiabie - 2. Removalale pin - 3. Fixed pin -4. Left lifting rod - 5. Check chains » 6. Left lower link - 7. Snappins - 8. Right lower link - 9. Levelling iever - 10. Top link

mounting pin.{See new, improved drawbar assembly on page 139}.

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Fig.188.-Adjusting ihetop link supporting spring iension Fig. ¥S9.,~ Hydraulic system pressure reading using ain f I A 7 . ' 'us g 00 $7016 presszzre gauge with fifirng A 191835 mounted in place of

the safety vaive.

2) Iristeli the iever A 197816 in the mounting hoies (Fig. 188) and by pressing downwards take upcompieteiy the ciearance existing between cover and support at the lower siop shown with an arrow(2, Fig. 191) a). In these conditions, the disiance I shouici measure 22,5305 mm ((18865 0.02”);a greater distance means that the surfaces of the iower stop are worn and need added material.The distance I in cases 1) and 2) of Fig. 190a can be checked using the two ends of the << C30 -No ~ Go » gauge C 197i3€5.

Adjusting the pfay befween rofler and sector (F;7g. 190 b). — Move the iift controi fever to the highestposition in the sector slot to get fuii raising oi the arms, and place the seiector lever in draft control(upwards); appiy the iever A 197016 tofhe mounting hoies of the struf to ifs support so as to compieteiytake up the piay existing between cover and support at the lower stop: in these conditions the distancebetween cam and foiiower shouid measure L5 to 2 mm (1/16 to 5/64"). if necessary, the distance canbe corrected by rotating the eccentric on which the foiiower is mounted.

got Note. - Should the working pressure of the lift hydrauiic system need checking, piace e pressure gaugewith fitting A 1933135 in piece of the safety vaive as shown in Fig. 189.

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. . ..,=ii’;Fig. $80 a. - Sefiing {he ciearance between lift cover and

iop link mounfing bracket.1) Setting ihe clearance I (i4,5 to ۤ,E_i mm = 0.571 to 0.510 irs)

between cover and top fink support bracket, spring M beingfree.

2} Sefling the ciearance I (22 to 23 mm -7: 0.865 to 0.905 in)between cover and ‘cop iink support bracket, spring Mbeing loaded.

H. Acijusiing shims - M. Top iink support bracket spring.Ciearance I indicated in sketches 'i and 2 of Fig. 190 must beconsidered as a praticai working dimension; for new iifi uniisthe ciearance is 14,3 to 15,? mm (0.583 to 0.594 in) and 22,2

T0 22,5 mm (0.874 to 6.888 in) respectively.

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Fig. 190 b. - Adjusiing the ciearance between cam andrc-iier.

A. Lift control lover - B. Selector iever - r. Reaction rofier -S. Lif€ arms » P. Load to apply to the sugport bracket to takeup the piay existing beiween the parts indicated by ihe arrow.

127

importantTo be sure to make the best use of the power iiit in every circumstance, read the following lnstruciiong,

Position coniroi opera-Zion.

Move lever B (Fig. 199 b) downwards and inserr the strut support wedge as shown in Fig. 192. in theseconditions the holes oi the support shown in Fig. 176 can be used to mount the top link.

firafi control oporaiiorr. ‘

Move lever B upwards (Fig. ‘£88 b) and take the wedge away from the strut support (Fig. 192), For a maresensitive operaiion use the intermediate hoies but not for implements which determine heavy loads onthe srrui (rippers, disc plows etc.) which require the use of the iower holes. Exceptionaiiy, a_qVci only forvery light work requiring high sensitivity, use the top hoies. Never mount the top fink in the top hole foralt other cases in order to avoid excessive stresses on the spring.

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Fig. T91. - Sectional view of five hydraulic Iifi linkage rods.Di Right iifiing rod - S. Left iifiing rod,

AUXILIARY COCK

The hydraulic power lift can be equipped with a conirol cock unit in piace of the control valve cover inorder to actuate attachments controiled by hydraulic power cylinders, boih single and double acting.

This otiachmeni: is not controlled by the fever which determines ihe raising and Iowering of rho arms,bui rather by a lever which is part of the controi cock lever. This makes the ‘two operations indlpendent

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Fig. 192. » Top link support bracket wedge. Fig. 193. - Auxiliary oil reservoir installer! on the left1. in - 2. Out

fender and supplying a sing|=_=~acting cylinder.l. Breather - 2. Filler plug with dipstick ~ 3. Control cock.

from each other and allows using the same oil contained in the lift unit. The two different types ofoperation cannot function at the same time. Should the application require more than 2 to 2,5 litersi( -3/'4 to 2~1_.f4 imp. quarts) of oil, an auxiliary oil reservoir must be added. Fig. 193 shows the installation

of an auxiliary oil reservoir with a capacity of 9 liters (8 imp. quarts) for actuating a power cylinder witha max. capacity of 11 liters (9.5 imp. quarts).The auxiliary oil reservoir is connected to the hydraulic power lift unit through a tube fixed to the breatherplug by means 0"! a fitting. The plug is then installed on the auxiliary reservoir. Check all the seals beforeinstalling the reservoir to prevent leakages clue to the higher pressure head.The control cock unit shown on Fig. 130 and 193 ls installed on the power lift unit in place of th

. . e controlvalve block cover. From the latter it is possible to recover the gasket and the complete pressure Va" ec. - :1‘which can be installed in the new unit.

The operational diagrams for single and double acting cylinders are shown on Fig. 194.

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B '-~ cHydraulic diagrams showing the operalion of single acting cylinder.

. Fig. 191. - Diagram showing the operation of the control cock dconnects to single and doublwacting Cylinders,4. Pressure relief valve - 5. Control cock pin ~ B. Double-acting cylinder line fitting - 7. Plug 16 M8 x1,5to be used when operating

single acting cylinders - A. Stop position - B. Lifting position - C. Lowering position.

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F-M._..V,-¢.HYDRAUBC LEFT ASSEMBLY DATA

Description

__————~ _=— ..__ — .. _ —— _ __ _, _ _

Data ' . Wear '1 :mm (in)

______ M? __7__ _ __ H _7 mm 5") g\ \\ \ I

Inside diameter of cylinder sleeve 85,036 £0' (3.3479'1O

Assernbly ciearances ; rnm (m) | “mus , ;‘

ss,o?1 1 ; I3.3492) _ 1 s-.,

5 inside diameter 0?’ cylinder 0,036 to 6,10u x -r.

._,YDiameter of piston B4-9135 505 (3.3-451 {O

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— ,‘ Sleeve and piston 00014 to 00041) 1041,03B5,00i}3.3465) , ->:¢='=

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, inside diameter of bushings on arm § 55,108 toI Control sheit (1): réghi end (21693 to

7.100 to.8543 to

' 7 '7 a55.170 § ,2.‘!Y21) Q ! *H.170 5 Arm shaft and bushings: I1.8571) rigm end , 0,100 fo 0,200 ' ,

(QD939 TO 9.0075) } 0'4

1 Diameterofarrncon’zra1shafiatbush- 51 Engs: right end 5 (2

E 4Fefi and l (1

4,970 to.15-f-2 to5,975 to.8é‘5‘5 to

H7, Iéfi end tO55,909 1 (moss to 0.5076)2.1:-:54) Q I ,41000 *1.8504; ;

insidediemeterofbushingsfor rocker § 11 supportlevertpress-fitted bushings) I {D2,016 is

A730 in12,059 l ‘,0.4146) 1 1 ' 1

; inside diameter 01' bushings 1 0,016 to 0,083 6,15

‘ Diameter of draft ccmtrol Fever pin 1, (O 1,973 to.4714 :0

"**“,i and the diameter of the (muons in 0.0034) ‘ (0.005;gglggg t [ever pin0.4724)

_ __.~H_..,._ 7.-_ V —— i

i Inside diameter oi rofler and liftcontrol , 1lever bushings (press-fitted) ‘l (02,032 to

.473? to12,0750-‘T54? Inside diameter of ;J!'esS- 0,032 to 0,122 , 0,25 - V

i _-_ 7, W, _ -~~~7~

1 Diameier of roiler (r, Fig. 1% b) iii? 11,973 ta 12,000\ control lever (L, Fig. Q82) pins ’ (0.47i4 io 0.4‘/'24)

__ ,, W? fitted bushing and their _; {(10013 to 0.0040) (0.0%) - -pins '

I Thickness of friction discs for lift ’| 2 1control lever £01179} F »~ _ - -

H ' i = ‘, _ ,,.-._ __ i_ H ,_|_ _ W_”__ /1 _ __.__ ____Thickness of spacer for Iifl arm run 0,45 to 0,55 j ,-

adjusfing screw {1D, Fig. 186) (0.018 to 0.022) - , _ ' —,___ ,’,_, ,_ V , 7,, _f _ ,

I inside diameter of bushings pFess- 25527210 25,020 1fitted into the upper fink bracket (3) (O.98"H ‘:0 0.9351)

..._.i__. , 1s \>__ _, __ _ _ __ H ,_ Bushings and upper iink 0,02O to 0,130 0,5 ‘ I\

F Diameter of upper link bracket hinge 25,000 to 24,942; axle <e.ss4s to o.ss2o>bracket hinge axle (moses to 0.0051) (@1120)

1 ‘Il , . _ __ , "W __... ___,_E, 4

‘ Valve spring specifications (eylindm-)

Free Eength . . . . . . . . . . . . . . . . . . mm (in) U322]‘ .‘ Compressed lengfh . . . , . . . , . . . . . . . mm (in) (1258)

Test ma . . . . . . . . . . . . . . . . . . , . kg (lb) 25 ‘° 29

Q " W "* =*- ~" -j 1= C t I . .Eaiigfilia Q Discharge 1

S afeiy

46 ' 22(0.82) (6.87) ‘

‘ 20 10(0.79) (0.40) I

1,8 ta 2,2 ' 2,3 fo 2,6(55 to 64> [4 10 4.2) , <5 m 5.7) '

1,

i Opening pressure of relief vaive (1, Fig. 186) (marked worh Jetter C orE)Opening pressure cf cyiimier szdety vaive (3, Fig. 186) . . . . . . . . .Discharge valve (4, Fig. ‘$86) io control valve body wrench iorque . .Cyfinder safety valve (3, Fig. 186} wrench torque . . . . . . . . . . . .

145 in 155 kg_/cm: (2062 £0 2205 p. ‘196 to 205 kg/cm“ (2774 to 2916 p.s

9 in 10 kgm <65 to 72 mu) ‘E4 to 5 kgm (29 to 35 7'1-éb}

.E” L»-1,

(*1 Bushings are fitted mm their housings in ‘(he lift casing with an interference of (1,020 w 9,102 mm (011003 to 0.0939 in). -("*1 Bl-l$i\iflg$ are fitted into their housings with an,inie:%erersce 9+ 0,55 to 0,23 mm 63.8920 is 0.0091).

iI cviriq r 11¢, 0 live, M ,' .. - '130 7/?” 7 {mi n‘ V Lad ?’F§e!:i=I'3 vziae c [mJ¢r 5'7? 1394"? 51%?” 674 35

mm=hw~a-@~_~i.. 44 .__ ."Re.i:§.f‘ ya}-I-2.! 7 1 Ci’ I/5 IQ 65$’ /2' 7% F25 ‘

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lIll

HYDRAULIC HFT SYSTEM FAULT TABLE

FAULT ii POSSIBLE muss 1 ' - -A r Tel‘-lTlONS REQUHED l

Lrll: does not hold thei load in raised positionll (when the engine is

running, theload keepson oscillating up and

is stopped, file load3 drops}.

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V l ‘ 5are -53 raised -‘e§a_.

‘ 'Traces or engine oil in

Niall’ rcrewf§>r'e'='s2<-'l’E¢.i(5 lee ll-' I

the hydraulic fluid. ‘

l

‘ Lift fails to operate. » 1) No oil. 1 Top Up,

lLift lelts. i 1) Oil level very low. ; Top up.

1} Oil leaking through between ' Check the parts involved and re- '

2) Cylinder pressure relief valve = Replace it.fg,2;~- lf0<_;‘-£{l‘l‘lout-of-adjustment. l \ Ida‘ ' '

3) LBW Plump efficiency f*). I Test pump performance and over-

1) Lift arm sircke adjustment screw Take a few shims from underneath lL

2} Control valve sticking. ‘E Dismantle and clean it.3) Hydraulic pump does not werlr. _! Overhaul the pump.

2} Oil filter clogged up. E Clean it.3) Air bubbles in suction duels, ‘ Check fittings and seals.

1) Faulty adjustment of valve spool. Readjustthe valve spool as specifiedH on page 125. l2) Faulty sealing or sticking of Dismantle and check the parts ln- i

discharge valve. l volved; assemble the valve tigl-ate,-,_- ing the plug with a torque wrench l

A setat9to 10 kgm (65io 72 limit) in; order to avoid possible clistor-3 lions.S) Oil inlet valve of hydraulic cylin- Dismantle and check the parts in- l

der leaks. i valved. r4) Oil leeks past lift piston seal or l Replace them. *

cylinder seal.5) Cylinder pressure relief valve 1 Replace ii. 1

leaks. l6) Discharge valve seals damaged. Replace them. l

1) Pressure relief valve ou’c-ol’-ad- ll Check setting. ijustment.

‘ haul ll, if necessary.

0U?"°1'"adll151m@¥flf- _ 5 the screw head (see paragraph << b >> ll‘ oi lift adjustment on page 125).

hydraulic pump and seal. L place the damaged Oi’!-3S. l

{ii) Usually accompanied by a considerable increment of the time required lo raise the load.

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A B61322A $117A 11401A 12131A mowA 19171____A mewA mesaA 117683A mossA mesaA 121051A mansA 131010

. A 187014A reruns,/A/BA 191015 I

' lA 197fl32fA_fBA 197035A 2“1'1’£32B

A 211022/A/eA 227005WA zsmsA mussA sz:-mo?A seamA 323623A 222025A szan.-asA 322023A seamA 3223044A 423112A swearA 511021A same:A sevensA szmsA sameA amasA awareA mazeA swearA 7i1flfi3;'.lkA 11110.»:A mzsnA 735002A 928251A armsARR amARR 22:6ARR 2221ARR momARR mans.c ear:c es?c 731c marsc 517023c mm:massesu 0321u D337/A/Bu 211011u 313030u mmu sumu am-:15

l A z1ress;'A/e,'c;o/e,rF;'s

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IHammer, brass . . . . . . . . . . . . . . . . . . . . . .Swlwel sland, pump overhaul . . . . . , . . . . . . . . . ‘

I Grinder, engine valves . . . . . . . . . . . . . . . . . .Hand pump . . < . . . . . . . . . . . . . . . . . . , . .Adaptor . . . . . . . . . . . . . . . . . . . . . . . . .Dial gauge . . . . . . . . . . . . . . . . . . . . . . . . ,Wrench, injection pump timing . . . . . . . . . . . . . .Wrench, engine timing . . . . . . . . . . . . . . . . . ,PilrJtrod.....~ . . . . . . , . . . . . . . . . . . ..lBushing . . . . . . . . . . . . . . . . . . . . . . , . . lGauge, control box sorting . . . . . . . . . . . . . . . .Gauge, control box selling _ . . . . . . . . . , . . . . . . _Adz-:p£or, gearbox primary shaft . . . . . . . . . . . . . . EGauge, bevel pinion setting . . . . . . . . . . . . . . . . llLock, final drive gear . . . . . A . . . . . . . . . . . . .Driver and prclieciion . . . . . . . . . . . . . . . . . . .Lever . . . . . . . . . . . . . . . . . . . . . . . . . . ._l./alve holder, hydraulic lift . . . . . . . . . . . . . . . . 'Fiiting . . . . . . . . . . . . . . . . . . . . . . . . . .Valve spring compressor . . . . . . . . . . . . . . . . .Curlers and spindle set, for valve seat grénclirlg . . . . . . lDriver, cylinder liner removal and installing A . . . . , . .Puller, injection pump drive . . . . . . . . . . . . . . . .Adepior set, differential lockinstalling . . . . . . . . . .Driver, valve guide removal and insralling . ., . . . . . . .Puller, injection pump plungers . . . . . . . . . . . . . . lWrench set, injection pump adjustment . . . . . . . . . .Support, injectors . . . . . . . . . . . . . . . . . . . . . IPuller, injection pump shafi bearing . . . . . . . . . . . . 1Puller, pump bearing outer race . . . . . . . . . . , . .Retainer forks, lnjecfion pump followers . . . . . . . . . . ‘Tool, injeciicm pump tappet removal and installing . . ‘Screw driver . . . . . . . . . . . . . . , . . . . . . . .Measuréng sel for control rack travel . . . . . . . . . . ,Rivetfng set . . . . . . . . . . . . . . , . . . . . . . . .Wire brush . . . . . . . . . . . . . . . . . . . . . . . .Connection, inlection pump plunger stroke check . . . . . llPuller, injection pump delivery valves . . . . . , . . . . . ‘Connection set with pressure gauge, injectors and pump l

elements check . . . . . . . . . . . . . . . . . . . . . 'Puller . . . . . , . . . . . . . . . . . . . . . . _ . . . .Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .Clamp piston rings . . . . . , . . . . . . . . . . . . . . _Pliers, piston rings . . . . . . . . . . . . , . . . . . . .Puller, pilot bearing in flywheel . . . . . . , . . . . . . . iFixtures, main clutch dismantling and reassernbling . . . .Wrench........................Spring tester . . . . . . . . . . . . . . . . . . . . . . .Puller, steering arm . . . . , . . . . . . . . . . . . . . .Driver, gearbox . . . . . . . . . . . . . . . . . . . . . .Driver, gearbox . . , . . . . . . . . . . . . . . . . . . .Rotary stand, medium size . . . . . . . . . . . . . r . . ‘ 5Rotary stand, large size . . . . . . . . . . . . . . . . . .Stirrup set, for rotary stand ARR 2204 . . . . . . . . . . 3Stirrqp set, for engine installation . . . . . . . . . . . . . 1Engine lifting hook . . . . . . . . . . . . . . . . . . . . EDial gauge, with stand . . . . , . . . . . . . . . . . . .Dial gauge set . . r . . . . . . . . , . . . . . . . . . .Gauge blocs . . . . . . . . . . . . . . . . . . l . . . . '¢< C-So-no-go» gauge . . . . . . . . . . . . . . . . . . . .Fixlure, connecting rod alignment check . . . . _ . . . .Ring gauge, for setting dial gauge C 687 . . . . . . . . .Bench, hydraulic lift . . . . . . . . . . . . . . . . . . . 'Reamer, reverse shaft bush . . . . . . . . . . . . . . . .Reamers set, engine . . . . . . . . . . . . . . . . . . .Esoanslon reamer. . . . . . . . . . . . . . . . . . . . , .Reamer, valve guides . . . . . . . . . . . . . . . . . . . iReamer, pump rack bushing . . . . . . . . . . . .Expansion reemer . . . . . . . . . . . . . . . .Expanslnn reemer . . . . . . . . . . . . . . . . . . . . ,

as391sasas404949as41

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Fig. 195. - Front and side view of tractor 411 R.

Fig. 196. - Rear and side view of {raster 411R.

132 ,

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SPECEFECATEGNS

E.f‘{GlNE

Type . . . . . . . . . . . . . _ . . . . . . . . , . 615.000 F‘;Diesel 4-strske, with turbulence chambers,Numbers of cyiinders . . . . . . . . . . . . . A . . . . . . . . . . . . . ‘ . . . 4Bare and Stroke ‘ _ _ _ _ _ , _ _ _ _ _ . . . . _ . . . . . . . . . . . . . . . 85x1E]i) mm (3.3'i6”x3.93?”)Pistcn displacement . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . 2276 cm“ (138.5 cuin)Compression ratio, appr . . . . . . _ . . . . . . . . . . _ . . . . . . . . . . . i 215:‘!Maximum rated horse pawer {with air cleaner, without fan and exhaust muffier) . . 40 H.P. (1)Maximum l-i.P. developed aé: . . . . . . . . . . . . . . . . , . l . . . , . . . . . 2300 R.P.M.Maximum torque . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . 14,3 kgm {$01 ftib)Maximum torque deveiopeci at: , . . . . . . . . . . . . . . . . . . . . . . . . . . ‘$500 R.P.l‘v'l.Engine weight {with air cleaner, withuut lubricating oi?) . . . . . . . . . . ‘ . . . 275 kg (609 lb)Lubricating oil quantity (in sump and pipes) . . . . . . . . . . . . . . . . . . , . 7 kg (15.5 ib)

0 ><

Timing

I I i opens . . . . . . . . . . . 3° before T.D.C.“Qt - ' - - ‘ - ' ‘ ‘ A ' " ‘ ‘ ' ‘ ' ' ' ‘ ' ' ' " l closes . . . . . . . . . . 23¢ after B.D.C.

i opens . . . . . . . . . . . 23° before B.lIJ.C_Exhaust ‘ ' ' ' ' ' ' ‘ ' ' ' ' ' ‘ ' ' ‘ ' ' ' ' ‘ j cioses . . . . . . . . . . 3° after T.D.C.Clearance between valve stem and rocks: arm for check of timing engine cold . . 0,375 mm (0.014? in)Nnrmal running clearance between valve stem and rocker arm engine coid (inlet and

exhausi). . . . . . . . . . . , A ‘ , . . 4 . . . , . . . . . . . . 4 . . . . . . 0,29 mm (U.0D'.’B in)

Fae! supply

-‘th t ed‘ eni b ‘it . . . . . . HAT FP,»‘KE 22A:L.4;'iPlunger-type fuel {Jump - » - - ~ ' " ‘ E tijithosuedimelri? bo'~vi0i;peyp.e . . . . . . . FIAT FPIKE 22A:48

Operating pressure . . . . . . . . i . . . . . . . . . . . . . . . , . . . . . . .1,2i0’l,5kQ;'cm5:('l?io2i$3.53.}lnjeciion pump {Bosch licence) with 4 l for fuei pump without sediment bnwl, type PES 4A 608 »1TG:L4_f‘§

piungers Ii for fuel pump with sediment bowl, type . PES 4A BBB 4‘l(]:L4,-‘I6Direction of rotaiion of pump shaft (looking on drive side) . . . . . , . . . . . . . clockwiseEnjeciion order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3-4.3Setting of injection assembly on engine. The pump assembly with plunger No. 1 at

tha beginning of clelivery, is mounted on engine having piston No. 1 in the cam»' pression stroke . . . . . . . . . . . . . . . . A . . . . . , . . i . . . . . . . 20°¢ 1° before T.D.C.Nozzie holders type . v . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . KC 55 S B FNozzles type . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 4 . . DN ‘l2 SD 12injectors calibrated ai: . . . . . . . . . . . . . . . . . , . . . . . . 'i2G;_'~ S i-cg,-'cm” (£700 78 p.s.i.j

Govemor

Vacuum governor (embodied with the injeciion pump) type: . . . . . . . . . . . . EPJM 60 A:L45Max. engine speed (no load), not less than: . . . . . . . . . . . . . . . . . . . 2608 R.P.M.Min. engine speed (nu lead). from: . . . . . . . . . . . . . . . . _ . . . . . . . . 420 tn 480 R.P.M.

Lubrication

Lubrication oil pressure (automaiicaliy adiusted by a valve) with hot anczirse =t normalR.P.M.rate..i........... . . . . . . . . . . . . . . 3kQ;'CFi‘i2(*$3p.S.§.)

(*3 Far tractors £11 R and 421 R(3) Engines with 5°,', less pr:-war should be accepted.

133

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StartingEieciric motor with engagement contmlled by eiecfro-magnet type FIAT E1i5-3524 . 3 KWGiow plugs for caid starting . . , . . . . . . . . . . . . . . . . . . . . . . . . . 143 W

TRANSMISSION

1stI-Ind3rd4th5th6th1st2nd

gear . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . .gear . . . . . . . A . . . . . . . . . . . . . . . . . , . , . . . .gear . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . _gear . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . .

£'@VE!'S€ - _ . . . . . . . - . - . , . . . . . . . . . . . . . <

FEVQTSE , . . , . . . . . . . . . . . . . . . . - . . - . . . . . .

Rear reduciion train

gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Bevel gears $850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fina! drives ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Total reduction raiio (bevel gears and finai drives) . . . . . . . . . .

TIRES

Gearbc-x ratios Overall reduction rams

5.901 . 13.749 : 12.938 : 11.825 : 11.632 1 17.283 : 1

2: I

.‘.

- . - . - . . - --

. . ~ . - .-

. = . | . .-

gear . . . . . . . . . , . . . , . . . . . . . . . . . . . . . , . . . 10.863: ‘i 235.449 ; 1

130.276 . ‘¥82.756 I64.84735.87322.738

16i}.344344.151 ».1-...-ll -1-Aha.-ah;-A

.... 3.917%

.... 5.636:‘l22076:?

Tracior ‘type . . . . . . . . . . . . . . . . . . . . . . . . . , . . .

Size of front fires . . . . . . . . . . . . . . .Max. inflating pressure of front tires . . . . . .

;Séze of rear tires . . . . . , . . . . . . . . . . . . . . . . . . . . . i' fieid wark . . . . . . . . . . .

1Nlax. inflating pressure of rear fires mad Work 5

STEERING SYSTEM

TurningraciIus...... . . . . . . . . . . . . ., .

BRAKES

Outer diameter of drums . . . . . . . . . . . .Width of brake lining —~ . . . . . . . . . . . , .

-

DRAWBAR (1;Horizontal swing of drawbar clevis . . . . . . .

i minimumI maximum . . . . . . . . . .

Height of drawbar cievis above ground ' ' ' ' ' ' ' ' ' ' '

!ENMENSIONS AND WEiG¥-[TS

Wheelbase . . . . . . , , . . . . . . . . . . . . . . . . . . . . . , !

R !Front tread . . . . . . . . . . . . . . . . . . . -

515.100(411 R)

|i

515.163(42i R}

8.00-‘I6 ;2,5 kg‘/cm’(35 p.s.i.} '

11-28 iD,8 kg,/cmz(11 p.s.i.)

1,2 to 1,5 kgfcm” [1(17 to 21 p.s.§.) Y

3 m (9 ft. 103:1)|

2100 mm (82%/5"]50 mm (2”)

F669 mm(26") '270 mm (1'c:5;;> Qssn mm(215,'3”)

1525 mm (713/4") 1}1289-1336-1480-i580-1 688-1338-‘!8B0-1989 m m }

5531";-54‘/4-53‘i'¢~ '52‘»’=-55‘r's-79‘/'v

74"-78'(1) See naw drawbar specifications on page 139 for tractors with chassis No, 429451 up.

134

5.50-162,5 kgjcm’ _(S5 p.s.i.) E

11.24280,8 kgfcm’ i11 (p.s,§.) .

1,2 to_1,5 kg,/cm? E(17 to 21 p.s.i.} ‘~

2,2: m (9 fi.2 in) i

2180 mm (825,?) i59 mm K2“) .

660 mm (26”]20$ mm ( mg’)4713 mm (121,/5.";

1815 m m {7'i1;’f)1260-136%]-146$ E1568-1656-1'?6l% .1sea.1eso mm

425/Q-se=,I,-swag Qe1=,/8-es=/,-es=/,

73‘:'<-77%” ‘

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Tracior type . . . . . . . . . . . . . . , . . . . .

Rear tread . . . . . . . . . . . . . . . . . . . . .

' r ! * f‘ ir ..Que all Engm 9 ‘raga ‘Nlih0!.3’[ drawbar . . .:,V~'iH‘l min. tread . . .iwith max. tread . . . . .

,, . " to the to of steering whee!Max height tothetogof bonnet . . .Ground ck-zarance under front axle . . . . . . . . .Ground ciearanne under rear axle . . . . . . . . .Operating weight of tractor . . . . . . . . . . . . .Weight of the two front wheel weights, approx. .Weighi of the four rear whee! weights, approx. . . .

1 with drawbar . . . . . .

fOver-ail width

PERFORWUKNCE AND FUEL CONSUMPTIONSpeeds, with engine at rated speed (on concrete

course}:

1st gear . , . . . . . . . . . . . . . . . . . . . .2nd gear . . . . _ . . . . . . . . . . . . . . . . .3rd gear . . . . . . . . . . . . . . . . . . . . . .11th gear . . . . . . . . . . . . . . . . . . . . . .5th gear .- . . . . . . . . . . . . . . . . . . . . .6th gear . . . . . . . . . , . . . . . . . . _ . . .1st reverse . . . . , . . . . . . . . . . . . . . .2nd reverse . . . . . , . . . . . . . . . . . . . .

Diesoi foo! consumption . . . . . . . . . . . . . .

Maxi:-nurn drawbar puiis on concrete course, with trac-torfuily ballasied (iron disos and 75% water ba|!ast-ed tires):

1st gear . . . . . . . . . . . . . . . . . . . . . .2nd gear . . . . . . . . . . . . . . . . . . . . . .3rd gear . . . . . . . . . . . . . . . . . . . . , .4th gear . . . . . . . . . . . . . . . . . . . . . .5th gear . . . . . . . . . . . . . . . . . . . . . .6th gear . . . . . . . . . . . . . . . . . . . . . .

(*') Whcelsiip is limiting factor.

ELECTRIC SYSTEM

Running at 24 V.See page B1 for instructions on ifs components.

ACCESSOEUES

¢ . . . . . . .-

. . . . . - , 1.

- - . - » . . . .

. < | . . . . . .

- ¢ | . . . . . .

615.000 615.102

§

I

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1

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jrsou kg rages :b)(*>§ ‘

1200»? 300-1400-1500-1500-1?00~1800-1900 mm

=4'1",",-fi11_f¢—55‘,'}.-59%-63-67 -

?0‘,'s-7432.1”2900 mm {‘!14”)282:1 mm (11131500 mm (50"}2200 mm {855,IE”)‘I410 mm (55‘r;,",”)13'?!) mm (540430 mm (1B"'j8”)

‘M20 kg (3130 Ha}70 kg ( ‘$50 Eb)

220 kg ( 4301b)

k.p.h. m.p.h.2.2 ' 1.44.0 2.55.3 3.08.0 5.0

14.5 0.022.9 _ 14.2

3.3 j 2.011.3 ; 1.3

' 3.54 kg {7.7~B.8 lb) 3.5-4 kg (1.7-3.2 I or

I J

the same asfor type 615.100

I

I zasa mm(113§r;)2755 mm(10a=|r;;

‘I490 mm (585/4*’)

||

;fi%mm@Wfl§; 1335 mm (521/2")

1300 mm (5¥1l"}’}. 409 mm ('i5°/1,")

'vn~.

1400 kg (3000 Eb)T0 kg(15fiib} 5

3 220kg-(4B03b}

i k~D-i1- §m.p.h.2.: , 1.3 ..3.3 2,1;5.1 3.8

. 7-7 4.3j 14.0 8.7; 22.1 13.7! 3-2 2.0' 11.4 1.1 j

$500 kg (3,300 Ib)(*)?3500 kg (3,300 lb)(’“) The same as fori 1350 kg (3.000 Sb) type 615.100

750 kg (1.850 lb)450 kg (1.000 Eb} .

i

The performances of the accessories (power éake-off. be-it pufley, hydraulic Hfl] are the same for the severai types oftractors.

Po we? take-off

Diameter of shaft . . . . . . . . . . . . . . . . . . . , , 11;;Speed of Eive power take-off (at rated engine speed} . . . . . . . . . . . . . . . . . . . . . . . . . 57:; R_[-EM.Revoiufions in ground speed . . . . . . . . . . . . . . . 1 revolution for approx. $0?/J’ of forward travel (2? cm)

185

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Bela‘ puffs?puney Speed ai rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . 1195 R.P.M.Belf $§}86G] . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - $5.6 IT?’/'5 (3,070 f.p'm.)

Diameter of pulley . , . . . . , . . . . . . . . . , . . . . . . . . . . . . . . 259 mm (975,)Width cf band . . . . . . . . . .. . ._ . . . . . . . . . . . . . . . , . . . . . . . 159 mm (5,)Weight of pulley (without lubricaimg oil) . . . _ . . . . . . . . . . . . . . . . . . 35,5 kg (53 [5]

Hydraulic lift

Hydraulic gear pump, type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piessey g 13 XReduction ratio between engine shaft and hydraulic pump drive shaft speed . . . . . . 31.162 :1Pump speed (with engine at rated siiasecll . .1’ . . . . . . . . , . . . . _ . . . . . 2900 R_P,m,

+ - -- "Dsliveryifiiiflfapproxl_50°C-140°FJjZ’;150O:;i:<:?cCr-tan(g§éSc|:g.i.}i 3 J J J J J I .... J $2.5 12322 l§tZ§i$§33Zl;§Relief valve opening pressure (Marked with letters C or E} . . . . . . . . . . . . . 150 kg/sq.cm (2190 p_5_;_)Bore of hydraulic lift cylinder . . . . . . . . . . . . . . . . . . . . . . , . . . . . 85 mm (3.3-4")Displacement . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . .. 500 cu.cm. (30.5 cu.in}Maximum travel of iifi iower links . . . . . . . . . . . . . . ‘ . . . . . . . . 580 in 600 mm (1) {22’/," 10235/8’)Maximum weight raised at the end of the lower links . . . . . . . . . . . . . 9£l0to12iJ0 kg (1)(1985'l:o2645lbs)indicated lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . approx. “I51; kgm (5425 ftib)Lifting time (with engine at 2300 R.P.M.) . . . . . . . . . . . . . . . . . . . . . , 3 59,;Weight of draft-and-position-coniroi hydraulic lift, inciuciing pipes and pump {without oil) 82 kg (130 11,}

(1} Starting from chassis No. 4i2é274 up, specifications are as follows:Max. Travel of lift lcwer link . . . . . . . . . . . . . . . . . . . . . . . 559 and 650 mm |f21‘,'s" ancit251/Q")Max. weight raised an lower link ends . . . . . . . . . . . . . . . . . 900 and 1200 kg ($985 and 2645 :53;

CAPACITIES

Part to be filledI V :

QuantityX

Material~ 1- Mk c.,_~u_l..__... A l

l. Cooling system . . . . . . . . .' Fuel tank . . . . . . . . . . . . i 39 I.| Engine crankcase (filters and pipes' included) . . . . . . . . . . ._=

injection pump and governor . . ‘ —l Air cleanser , . . . . . . . . , . 0,5 >>

i Transmission . . . . . . . . . . 12 >>

8kg

;1 Finsldrives (each) . . . . . . . . 2 >>

_ Steering system . . . . . . . . . ‘T —Frcmt wheels . . . —Grease nippies I-\_ .. . . . . . . . -Belf pulls . . . . . . . . . . . c >>

‘l Hydraulic lifi . . . . . . . . . . . >>Generator l slpports . . . . . . V -

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WaterDiesel fuel ‘,SAE 30 HD oil for temperature from 0° C (32° F)SAE10 W oil for temperature below 0° C (32° F)SAE 50 HD oil for temperalure above 35° C (Q5° F) ‘Same oil as used for the engine sump iiSAE 80 HD oil ‘SAE 90 oilSAE140 oil for temperature above -10° C 64° F} 3SAE Q0 oil for temperaiurc below —10° C (i4° F)SAE 90 oil 1Chassis grease ‘Chassis greaseSAE146 oil for temperature above ~»~10° C (1-4° F}SAE 90 oi! for temperature below --10° C (14°) iSAE 20 hydraulic oilHigh meiting point greaseSAE 50 HD oil lHigh melting point grease I

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Starting from the tractor with engine No. 020425 and chassis No. 411789 up, the fuel filter and feed pumphave been modified as follows:

DOUBLE FUEL FILTER

in addltion to the single paper element a cloth element has been added.inspect each 300 hours the filtering elements to check their efficiency and to wash with kerosene the clothene, and replace, ll‘ necessary. the paper element, which must not be washed.

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Fig. . 198- injection pump type PES 4 A 86 B -110:L4;"1fi.1. Cover protecting the pump control sleeve - 2. Referencemarks - 3. Pump €astening nuts - 0. Feed pump fuel filler.

After the filter elements assembly, bleed air as follows:- screw back of two turns the screws (1, fig. 196);— unscrew the knob of the priming pump of lime feed pump and pump till the fuel that flows from the

holes located under said screws is free from air bubbles. Retighten said screws. V

FEED PL¥l‘v‘lP WITH BOWL-?YPE FELTEFE

The iniection pump type PES¢A6€}l'3 1¥l{):l_4_l1.6features a feed pump fitted with bowl filtermounted out side the pump body (figs 198

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U-FLEX TYPE GIL RING -

fix U-Flex type oil-ring has been insiaiied on engines No. i}i6?36 and above. This type ring is higher thanstandard ones, therefore the piston groove has been modified accordingly.Said changes have aéso been made on engines from No. 016266 to 016518;Modified dimensions are shown in Fig. 289.

Z; Z ii iiI Fig. 280. - Dimensions of pisicm ring and its graoue.

1 I 12.5 5.530-5.550 mm 5./I80-5.510 mm 12.6-72.4 mm72.4 (0.217?-0.2184 in.) (0.215?-02169 in.) (28583-2.850-3 in.)

NEVV DRAWBAR AND HITCH

Starting from chassis Na. 429451 up the drawbar and hitch device of the series 400 tractors (exceptmod. 431,‘R) have been modified in order to bring iocatiun of the various parts within the requirements ofinternational standards. Changes are as follows:

~ stronger and simpler frame;

~ more adjustment possibiiities, in fact:

~ the cirawbar plate can be fixed to the tractar at two different heigiizs, and for each one it isfuriermore possible to adjusi the height by turning the drawbar plate upward or downarci, Moreverticai settings are possibie by turning over the cirawbar;

—— the drawbar can be set on 3 iongituciinai and on 3 traverse positions.

~— Besides, the lower links are made 4 cm ionger, and the PT~O shait 1 cm ionger.

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Specifications.

Verticaf distance from ground Fine to top of drawbar at hitchpoint, adjusfabie as foflows . . . . . . . . . . . . . . . . 318

I 0») “JcaHorizontaf swing distance at hiich point . . . . . . . . . . 570 mm E20")Hcarizcntal distance between hitch point and reasrnost point of12.4-28 tyres. adjustabie as follows . . . . . . . . . . . . . 18-455-‘iI}D mm (3f8”-215;”-4”}Horizontal distance between hitch point and end of PT-Oshaft, adjustable , . . . . . . . . . . . . . . . . . . . . . 354-399-44¢ mm (1é"~€5”,/_{’-1782”)Vertical distance between top of cirawbar at hitch point andcenterline of PT-O shaft, acifustabie as foflows . . . . . . . 229-ifilh ififi-49 mm {3?:'3”- 61,»',;"~-‘:»”-‘£1,'2”}Verticai distance from ground line to centeriine of PT-O shaft ‘ 538 mm (21*,’8")Diameter of h=Ytch hole (plus one 115 mm == 11,516” hole at102 mm = 4" ahead of hitch hole) . . . . . . . . . . . 29 mm ("E*_l5"')

139

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TABLE CF CONTENTS

PageForeword and Service Notes . . . . . - - - 3

Engine . . . . . . . . . . 4

Qo<..r1-fk~£=.

(_3enerai_ . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . .Disassembiy . . . . . . . . . . . . - -

Oi/erhau/'5 and C/veks . . . . . . . . . . . 1.1Cylinder biock and barrels . . . . . . . 11Cyiinder head _ . t . . . . . - - - . - . 12

Timing gear . . . . . . . . . . . . . . . 13Valves, guides and springs . . . . . . . 13Valve tappe-is and rocker arms . . . . . 74Camshaft . . . . . . . . . . . . . . . . 15

. Specifications . . . . . . . . . . . . . 76Power chain . . . . . . . . , . . . . . . I7

Pistons . . . . . . . . , . . . . . . . . 17V Connecting rods . . . . . . . . . . . . 19

Crankshait . . . . . . . . . . . . . . . 20Main and connecting rod bearings . . 2?Specifications . . . . . . . . . . . . . 22

' Lubrication . . . . . . . . . . . . . . . . 25Oil pump . . i . . . . . . . . . . . . . 26Oil filters . . . . . . . . . . . . . . . . 26Specifications . . . . . . . . . . . . . 27

Coiifing . . . . . . . . . . . . . . . . . . 2al Water pump . . . . . . . . . , . . . . 28l Thermostat . . . . . . . . . . 28

Radiator . . . . . . . . . . . . . . . . 29Fan . . . . . . . . . . . . . . . . . . 30

IAir feeding . . . . . . . . . . . . . . . . 30

Air cleaner . . . . . . . . . . . . . . . 30I Fuel feeding . . . . . . . . . , . . . . . 30

Fuel tank . . . . . . . . . . . . . . . . 3?‘ Fee-dpump . . . . . 37

injection pump and governor . . . , . . 321 Calibration data . . . . . . . . . . . . 47J -' injectors . . . . . . . . . . . . . . . . 43' Specifications . . . . . . . . . . . . . 44

g Reassembly of engine . . . . . . . . . . . 45I Timing , . . . . . . . . . . . . . . . . 48

Brake test . . . . . . . . . . . . . . . . 50Performance data . . . . . . . . . . . . Sf

Transmission . . . . . . . . . . . . . . . 53- Clutch . . . , . . . , . . . . . . . . . . 53

Fiexible coupling . . . . . . . . . . . , 575F>ech‘:cations . , . . . . . . . . . . . 57

140

PageGearbox and epi'c,'»'c//‘c reduction gear . . 53

Specifications . . . . . . . . . . . . , 53Dffierentiaf and lock . . . . . . . . . . . 54

Specifications . . . . . . . . . . . . . 59Final’ drives . . . . . . . i . . . . . . . 79

Brakes . . . . . . . . . . . . . . . , . , 71Specifications . . . . 73

Steering and firom‘ axis . . . , . . . . . . F3Steering box and linkage . , . , . . . . 73Specifications . . . . . . . . . . . . . 75Front axle . . . . . , . . . . . . . . . 77Specifications . . . . . . . . . . . . . ?9

Eiectrical system . . . . . . . . . . . . 80

Wiring diagram . . . . . . . . . . . . . 5'0Description . . . . . . . . . . . . . . , 37

Generator Type F? 715-740/'24-7600 l/ar. 2 . . 83Specifications . . . . . . . . . . . . . 6'?

Generator Typo DC 115,"24,="7,i3 C . . . . . . 88Specifications . . . . . . . . . . . . . 89

Confrof Box Mod. A_i3-140524 . , . . . . . WSpecifications . . . . . . . . . . 95

Control Box Moo’. GP Ti’24,~’7 . . , . . . . 95Specifications . . , . . . . . . . . . 10?’

Batteries . . . . . . . . . . . . . . . . . 108Starting motor . . . . . . . . . . . . . . 710G/ow plugs . . . . t . . . . . . . . . . . H5

Attachments . . . . . . . . . . . . . . 7'15Power Take-off . . . . . . . . i . . . . . 116Se/t puifey . . . . , . . . . . . . . . . . 1??

Specifications . . . . . . . . . . . . . 718Hydraulic lift . . . . , . . . . . . . . . . 719

Pump . . . . . . . . . . . . . , . . . 119Operation . . . . . . . . . . . . . . . 720Control Cock . . . . i . . . . . . . . . 128Specifications . . . . . . , . . , . . . 236'

Tool list . . . . . . . . . . 73?Specifications . . . . . . . . . . . . . . 733Moo‘ifFcat:'ons . . . . . . . . . . . . . . . 137

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