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Same Dorado F 55 70 75 90 100 service repair workshop manual

It is workshop manual for Same tractors. Models included:
F 55
F 70
F 75
F 90
F 100

language:english
number of pages: 556 (full digital version)

Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................. 1
INTRODUCTION.................................................................. 1
DESCRIPTION..................................................................... 2
1.1 HOUSING...................................................................... 3
1.2 HML ASSEMBLY........................................................... 4
1.3 GEARBOX AND SHUTTLE ASSEMBLY
(Version with HML) ........................................................ 5
1.4 GEARBOX AND SHUTTLE ASSEMBLY
(Version without HML with 5 speeds)............................ 6
1.5 CONTROL ROD FOR SHUTTLE - UNDERDRIVE ......... 7
1.6 SPEED CONTROL ROD (5-speed version) ................... 8
1.7 RANGE AND PARKING BRAKE ASSEMBLY................ 9
1.8 RANGE CONTROL ROD AND PARKING
BRAKE LEVER............................................................. 10
1.9 FOUR-WHEEL DRIVE ENGAGEMENT ASSEMBLY.... 11
1.10 DIFFERENTIAL ASSEMBLY...................................... 12
1.11 BRAKES AND REAR AXLE ASSEMBLY ................... 13
2. REAR PTO......................................................................... 15
2.1 PTO CONTROL CLUTCH ASSEMBLY........................ 16
2.2 2-SPEED PTO ............................................................ 19
2.3 2-SPEED PTO AND SYNCRO PTO............................. 20
3. FRONT AXLE .................................................................... 21
3.1 FINAL DRIVE ............................................................... 22
3.2 PINION, DIFFERENTIAL AND DIFFERENTIAL LOCK . 23
4. HYDRAULIC SYSTEM..................................................... 24
DESCRIPTION................................................................... 24
4.1 HYDRAULIC DIAGRAM (standard version) (1/2)......... 25
4.2 HYDRAULIC DIAGRAM (standard version) (2/2)......... 26
4.3 HYDRAULIC DIAGRAM (full optional version) (1/2)..... 27
4.4 HYDRAULIC DIAGRAM (full optional version) (2/2)..... 28
4.5 STEERING CIRCUIT GEAR PUMP.............................. 29
4.6 LIFT CIRCUIT GEAR PUMP........................................ 30
4.7 POWER STEERING..................................................... 31
4.8 HML SOLENOID VALVE ASSEMBLY.......................... 32
4.9 AUXILIARY SERVICES CONTROL VALVE.................. 33
4.10 TRAILER BRAKING VALVE ....................................... 34
4.11 SERVICES SOLENOID VALVE ASSEMBLY .............. 39
4.12 LIFT CONTROL VALVE ............................................. 40
1. DIAGNOSIS TOOLS ........................................................... 1
1.1 ALL ROUND TESTER ......................................................... 1
1.1.1 DESCRIPTION OF THE KIT....................................... 1
1.1.2 NOTES ON CORRECT USE...................................... 2
1.1.3 DESCRIPTION OF THE TESTER............................... 2
1.1.4 GENERAL NOTES ON CONNECTING AND
POWERING UP THE TESTER .................................... 3
1.1.5 SELECTION OF THE DISPLAY LANGUAGE............. 3
1.1.6 SETTING THE SERIAL PORTS.................................. 5
2. CONNECTION OF THE ART® TO
THE CONTROL UNITS ..................................................... 7
2.1 CONNECTING TO THE LIFT AND ENGINE
CONTROL UNITS................................................................ 7
3. INTRODUCTION TO THE ELECTRONIC SYSTEM
OF THE TRACTOR ............................................................ 9
3.1 ENGINE CONTROL UNIT ................................................... 9
3.1.1 ELECTRONIC ENGINE CONTROL SYSTEM............. 9
3.1.2 ELECTRONIC PRE-HEATING CONTROL SYSTEM 10
3.1.3 HML UNIT ELECTRONIC CONTROL SYSTEM....... 10
3.2 ELECTRONIC LIFT CONTROL UNIT ................................ 11
4. COMMISSIONING THE TRACTOR ................................ 13
4.1 INTRODUCTION ............................................................... 13
4.2 RENEWAL OF ENGINE CONTROL UNIT ......................... 13
4.2.1 SETTING TYPE OF ENGINE INSTALLED................ 13
4.2.2 CALIBRATING THE HAND THROTTLE ................... 15
4.2.3 CALIBRATING THE ACCELERATOR PEDAL .......... 18
4.2.4 CALIBRATING IDLING SPEED................................ 20
4.2.5 CONFIGURING FOR HML....................................... 22
4.2.6 CONFIGURING THE TYPE OF PRE-HEATING ....... 23
4.2.7 CONFIGURING THE WHEELS PARAMETER.......... 25
4.2.8 CANCELLING ALARMS........................................... 27
4.3 RENEWAL OF LIFT CONTROL UNIT ............................... 28
4.3.1MAXIMUM HEIGHT CALIBRATION LIFT................. 28
5. ALARMS .......................................................................... 31
5.1 ENGINE CONTROL UNIT ALARMS ................................. 31
5.1.1 LIST OF ALARMS DISPLAYED ON THE INSTRUMENT
PANEL (MEM WARNING LIGHT)............................. 31
5.1.2 LIST OF ALARMS DISPLAYED ON THE INSTRUMENT
PANEL (PRE-HEATING INDICATOR LIGHT) ........... 31
5.1.3 LIST OF ALARMS DISPLAYED ON ART ................. 32
5.2 LIFT CONTROL UNIT ALARMS ........................................ 61
5.2.1 LIST OF ALARMS BY FLASH SEQUENCE ON LIFT
CONTROL BUTTON................................................. 61
5.2.2 LIST OF ALARMS DISPLAYED ON THE ART ......... 62
6. ENGINE CONTROL UNIT TEST METER ........................ 73
PRESENTATION SCREEN ...................................................... 73
MAIN MENU ........................................................................... 73
1. ENGINE ...............................................................................74
1.1 CONFIGURATION.................................................... 74
1.1.1 ENGINE TYPE .......................................................... 75
1.1.2 HAND THROTTLE CALIBRATION............................ 76
1.1.3 ACCELERATOR PEDAL CALIBRATION................... 77
1.1.4 IDLING SPEED CALIBRATION................................. 78
1.2 CALIBRATION............................................................. 78
1.3 MONITOR.................................................................... 79
2. HML .....................................................................................80
2.1 HML CONFIGURATION .............................................. 80
2.2 TESTS ......................................................................... 81
2.3 MONITOR.................................................................... 82
3. PRE-HEATING .....................................................................83
3.1 CONFIGURATION....................................................... 83
3.2 TESTS ......................................................................... 84
3.3 MONITOR.................................................................... 85
4. ALARMS ..............................................................................86
4.1 INITIALIZATION........................................................... 86
4.2 ALARM LOG................................................................ 87
5. BELTS ..................................................................................87
5.1 CONFIGURATION....................................................... 88
5.2 BELTS ......................................................................... 88
5.3 MONITOR.................................................................... 89
6. WHEELS ..............................................................................89
6.1 CONFIGURATION....................................................... 90
6.2 MONITOR.................................................................... 90
7. PTO ......................................................................................91
7.1 CALIBRATION............................................................. 91
7.2 TESTS ......................................................................... 92
7.3 MONITOR.................................................................... 92
8. ENGINE LIST .......................................................................93
7. LIFT CONTROL UNIT TEST METER .............................. 95
PRESENTATION SCREEN ......................................................95
INITIALIZATION .......................................................................95
MAIN MENU ............................................................................96
1. CALIBRATIONS ...................................................................96
1.1 MAXIMUM HEIGHT.................................................. 97
1.2 UP SPEED................................................................... 97
2. MONITOR MENU .................................................................98
2.1 LIFT ............................................................................. 98
2.2 DRAFT......................................................................... 99
2.3 POSITION.................................................................. 100
3. TESTS MENU ....................................................................100
3.1 SENSORS ................................................................. 101
3.2 VOLTAGES................................................................ 101
3.3 INPUTS...................................................................... 102
PUSH-BUTTONS: ........................................................... 102
POTENTIOMETERS: ....................................................... 102
4. ALARMS ............................................................................103
FRONT HOODS............................................. 1
Removal...................................................................... 1
Refitting ...................................................................... 2
WHEELS......................................................... 3
FRONT WHEELS.............................................................3
Removal...................................................................... 3
Refitting ...................................................................... 3
REAR WHEELS...............................................................4
Removal...................................................................... 4
Refitting ...................................................................... 4
SAFETY ROLL BAR....................................... 5
Removal...................................................................... 5
Refitting ...................................................................... 5
FUEL TANK.................................................... 6
Removal...................................................................... 6
Refitting ...................................................................... 8
RADIATOR..................................................... 9
Removal...................................................................... 9
Refitting .................................................................... 10
FRONT SUPPORT....................................... 11
Removal.................................................................... 11
Refitting .................................................................... 13
PLATFORM.................................................. 14
Removal.................................................................... 14
Refitting .................................................................... 22
FRONT AXLE DRIVE SHAFT ...................... 23
Removal.................................................................... 23
Refitting .................................................................... 23
ENGINE........................................................ 24
Preparation before separating the engine from the
transmission ............................................................. 24
Preparation for removal ............................................ 24
Separation or removal .............................................. 25
Refitting .................................................................... 28
CLUTCH ASSEMBLY.................................. 29
CLUTCH ........................................................................29
Removal and renewal of the clutch plate ................. 29
Checking clutch plate wear ...................................... 29
Refitting the clutch plate .......................................... 29
CLUTCH RELEASE BEARING.....................................30
Renewal .................................................................... 30
STARTER MOTOR.......................................31
Removal.................................................................... 31
Refitting .................................................................... 33
HML UNIT.....................................................34
COMPLETE ASSEMBLY..............................................34
Removal.................................................................... 34
Refitting .................................................................... 37
Checking the reduction unit end float ...................... 39
CLUTCH UNITS............................................................40
Disassembly ............................................................. 40
Assembly .................................................................. 47
PLANET CARRIER ASSEMBLY...................................53
Disassembly ............................................................. 53
Assembly .................................................................. 54
GEARBOX AND SHUTTLE ASSEMBLY .....57
COMPLETE ASSEMBLY..............................................57
Removal.................................................................... 57
Refitting .................................................................... 61
Separating from the transmission ............................ 62
Reassembly .............................................................. 66
Disassembly ............................................................. 67
Assembly .................................................................. 67
SHUTTLE - UNDERDRIVE SHAFT ..............................68
Disassembly ............................................................. 68
Assembly .................................................................. 71
PRIMARY SHAFT .........................................................73
Disassembly ............................................................. 73
Assembly .................................................................. 74
SECONDARY SHAFT ...................................................75
Disassembly ............................................................. 75
Assembly .................................................................. 83
GEAR SELECTOR ROD ...............................................89
Disassembly ............................................................. 89
Assembly .................................................................. 89
SHUTTLE AND UNDERDRIVE SELECTOR ROD .......90
Disassembly ............................................................. 90
Assembly .................................................................. 90
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL.....91
Removal.................................................................... 91
Refitting .................................................................... 91
Disassembly ............................................................. 92
Assembly .................................................................. 93
HYDRAULIC PUMPS .................................. 94
PUMP FOR STEERING CIRCUIT AND
SOLENOID VALVES..................................................... 94
Removal ....................................................................94
Refitting .....................................................................96
PUMP FOR HYDRAULIC LIFT AND
AUXILIARY SERVICES ................................................ 97
Removal ....................................................................97
Refitting .....................................................................98
HYDRAULIC TRAILER BRAKING VALVE................... 99
Removal ....................................................................99
Refitting ...................................................................100
HYDRAULIC LIFT
(VERSION WITH MECHANICAL GOVERNOR)..... 101
COMPLETE ASSEMBLY............................................ 101
Removal ..................................................................101
Refitting ...................................................................104
Disassembly ............................................................105
Assembly.................................................................111
BUSHES...................................................................... 112
Renewal...................................................................112
HYDRAULIC LIFT CONTROL VALVE ....................... 113
Removal ..................................................................113
Refitting ...................................................................114
Disassembly ............................................................115
Assembly.................................................................118
LIFT CYLINDER ......................................................... 120
Disassembly ............................................................120
Assembly.................................................................121
MECHANICAL DRAFT SENSOR............................... 123
Removal ..................................................................123
Refitting ...................................................................123
Disassembly ............................................................124
Assembly.................................................................125
REMOTE CONTROL VALVE..................... 127
Removal ..................................................................127
Refitting ...................................................................129
REAR AXLE ............................................... 130
RIGHT AND LEFT AXLES.......................................... 130
Preparation for removal of the right axle.................130
Preparation for removal of the left axle ...................132
Removal of the complete rear axle .........................133
Refitting ...................................................................134
Disassembly ............................................................135
Assembly.................................................................138
PLANET CARRIER ASSEMBLY ................................ 140
Disassembly ............................................................140
Assembly.................................................................140
BRAKES..................................................... 141
REAR AXLE BRAKES ................................................ 141
Renewal of brake discs...........................................141
BRAKING PISTON ..................................................... 142
Disassembly ............................................................142
Assembly.................................................................142
FRONT AXLE BRAKES.............................................. 144
Removal of brake discs.......................................... 144
Refitting the brake discs......................................... 145
Piston disassembly ................................................ 146
Piston assembly ..................................................... 146
PARKING BRAKE ...................................................... 148
Removal of the friction shoes................................. 148
Refitting the friction shoes...................................... 150
Disassembly ........................................................... 152
Assembly................................................................ 152
BRAKE CYLINDERS.................................................. 153
Removal ................................................................. 153
Refitting .................................................................. 154
SERVICE VALVES ASSEMBLY .................155
Removal ................................................................. 155
Refitting .................................................................. 158
Disassembly ........................................................... 159
Assembly................................................................ 161
3-POINT LINKAGE.....................................162
Removal ................................................................. 162
Refitting .................................................................. 164
TOWING HITCH .........................................165
Removal ................................................................. 165
Refitting .................................................................. 165
REAR PTO..................................................166
PTO INPUT SHAFT .................................................... 166
Removal ................................................................. 166
Refitting .................................................................. 167
PTO CLUTCH............................................................. 168
Removal ................................................................. 168
Refitting .................................................................. 170
Disassembly ........................................................... 171
Assembly................................................................ 175
PTO OUTPUT SHAFT
(2-SPEED + GROUNDSPEED VERSION) ................. 176
Disassembly ........................................................... 176
Assembly................................................................ 180
GROUNDSPEED PTO DRIVE SHAFT....................... 181
Disassembly ........................................................... 181
Assembly................................................................ 182
RANGE GEARBOX AND
REAR DIFFERENTIAL ASSEMBLY...........183
COMPLETE ASSEMBLY ........................................... 183
Disassembly ........................................................... 183
Assembly................................................................ 183
PUMP DRIVE PTO ..................................................... 184
Disassembly ........................................................... 184
Assembly................................................................ 186
DIFFERENTIAL UNIT ................................................. 187
Removal ................................................................. 187
Refitting .................................................................. 189
Disassembly ........................................................... 190
Assembly................................................................ 192
PINION.........................................................................193
Disassembly ........................................................... 193
Assembly ................................................................ 196
RANGE SELECTOR ROD...........................................197
Disassembly ........................................................... 197
Assembly ................................................................ 198
4WD AND GROUND SPEED PTO OUTPUT SHAFT.199
Disassembly ........................................................... 199
Assembly ................................................................ 203
BEVEL GEAR PAIR.....................................................204
Preparation of adjustments .................................... 204
Adjustment of the differential bearings preload ..... 206
Adjustment of the pinion position........................... 208
Adjustment of the pinion and crown wheel ............ 210
INSTRUMENT PANEL............................... 211
Removal.................................................................. 211
Refitting .................................................................. 213
POWER STEERING................................... 214
Removal.................................................................. 214
Refitting .................................................................. 215
CLUTCH MASTER CYLINDER................. 216
Removal.................................................................. 216
Refitting .................................................................. 217
FRONT AXLE............................................. 218
Removal.................................................................. 218
Refitting .................................................................. 220
STEERING CYLINDER ...............................................221
Removal.................................................................. 221
Refitting .................................................................. 222
EPICYCLIC REDUCTION UNIT..................................223
Removal.................................................................. 223
Refitting .................................................................. 224
Disassembly ........................................................... 225
Assembly ................................................................ 227
STEERING KNUCKLE HOUSING AND
HALFSHAFT................................................................229
Removal.................................................................. 229
Refitting .................................................................. 233
Adjusting the bearings preload .............................. 235
PINION-DIFFERENTIAL ASSEMBLY.........................238
Removal.................................................................. 238
Refitting .................................................................. 238
DIFFERENTIAL LOCK ................................................239
Removal.................................................................. 239
Refitting .................................................................. 241
Adjustment ............................................................. 242
BEVEL GEAR PAIR.....................................................245
Disassembly ........................................................... 245
Assembly ................................................................ 249
Adjustment of the differential preload .................... 254
Adjustment of the pinion and crown wheel ............ 258
Completion of assembly......................................... 258
DIFFERENTIAL ...........................................................260
Disassembly ........................................................... 260
Assembly ................................................................ 261
THE STRUCTURE OF THE UNIT .....................................1
HOW TO CONSULT THE UNIT ........................................2
1. INTRODUCTION ............................................................3
1.1 LIST OF WIRING HARNESSES ......................................... 3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ............ 4
1.3 GENERAL RULES.............................................................. 5
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/
ELECTRONIC CIRCUITS ......................................... 5
1.3.2 MAIN WIRING FAULTS........................................... 5
1.3.3 REMOVAL, REFITTING AND DRYING OF
CONNECTORS AND WIRINGI ................................ 6
1.4 DIAGNOSTIC INSTRUMENTS........................................... 7
1.5 WIRE COLOUR CODES .................................................... 7
2. INDEX ............................................................................8
2.1 INDEX BY PART DESCRIPTION........................................... 8
2.2 COMPONENT CODE INDEX .............................................. 11
2.3 CONNECTOR INDEX.......................................................... 14
3. COMPONENTS ...........................................................21
3.1 CONNECTOR LAYOUTS................................................. 21
3.2 COMPONENT TECHNICAL DATA................................... 23
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC
CONTROL UNITS ............................................................ 28
3.3.1 ENGINE CONTROL UNIT (CODE 2.8519.054.0)... 28
3.3.2 HML CONTROL UNIT (CODE 0.010.8869.4/20).... 30
3.3.3 ELECTRONIC LIFT CONTROL UNIT
(CODE. 0.011.2992.4/20) ...................................... 31
3.3.4 PREHEATING CONTROL UNIT
(CODE 2.8519.023.0/10) ........................................ 32
4. SYSTEMS ............................................................... 33
4.1 EARTHING POINTS......................................................... 33
4.2 STARTING AND PREHEATING
(ELECTRONIC GOVERNOR VERSION) ........................... 34
4.3 STARTING AND PREHEATING
(MECHANICAL GOVERNOR VERSION) .......................... 35
4.4 ELECTRONIC ENGINE CONTROL
(ELCTRONIC GOVERNOR VERSION) ............................. 36
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT
(ELECTRONIC GOVERNOR VERSION) ........................... 37
4.6 LIGHTS - STEERING COLUMN SWITCH UNIT
(MECHANICAL GOVERNOR VERSION) .......................... 38
4.7 DIAGNOSTIC ACCESSORIES
(ELECTRONIC GOVERNOR VERSION) ........................... 39
4.8 DIAGNOSTIC ACCESSORIES
(MECHANICAL GOVERNOR VERSION) .......................... 40
4.9 INSTRUMENT PANEL
(ELECTRONIC GOVERNOR VERSION) ........................... 41
4.10 INSTRUMENT PANEL
(MECHANICAL GOVERNOR VERSION) .......................... 42
4.11 BRAKES
(ELECTRONIC GOVERNOR VERSION) ...........................43
4.12 BRAKES
(MECHANICAL GOVERNOR VERSION) ..........................44
4.13 TRANSMISSION AND HML
(ELECTRONIC GOVERNOR VERSION) ...........................45
4.14 TRANSMISSION AND HML
(MECHANICAL GOVERNOR VERSION) ..........................46
4.15 ELECTRONIC LIFT CONTROL
(ELECTRONIC GOVERNOR VERSION) ...........................47
4.16 ELECTRONIC LIFT CONTROL
(MECHANICAL GOVERNOR VERSION) ..........................48
4.17 FRONT AND REAR PTOS
(ELECTRONIC GOVERNOR VERSION) ...........................49
4.18 FRONT AND REAR PTO
(MECHANICAL GOVERNOR VERSION) ..........................50
5. WIRING ................................................................... 51
CENTRAL WIRING
(VERSION WITH MECHANICAL GOVERNOR) (1/4)..................51
CENTRAL WIRING
(VERSION WITH MECHANICAL GOVERNOR) (2/4)..................52
CENTRAL WIRING
(VERSION WITH MECHANICAL GOVERNOR) (3/4)..................63
CENTRAL WIRING
(VERSION WITH MECHANICAL GOVERNOR) (4/4)..................64
CENTRAL WIRING
(VERSION WITH ELECTRONIC GOVERNOR) (1/4) ..................71
CENTRAL WIRING
(VERSION WITH ELECTRONIC GOVERNOR) (2/4) ..................72
CENTRAL WIRING
(VERSION WITH ELECTRONIC GOVERNOR) (3/4) ..................85
CENTRAL WIRING
(VERSION WITH ELECTRONIC GOVERNOR) (4/4) ..................86
ENGINE WIRING (3-CYLINDER VERSION) (1/2).......................93
ENGINE WIRING (3-CYLINDER VERSION) (2/2).......................94
ENGINE WIRING (4-CYLINDER VERSION)(1/2)........................95
ENGINE WIRING (4-CYLINDER VERSION) (2/2).......................96
ROTATING BEACON WIRING ..................................................97
WIRING FOR ROLL BAR LIGHTS.............................................98
PREHEATING AND FUEL SYSTEM WIRING
(3-CYLINDER VERSION).........................................................107
GLOWPLUG AND FUEL SYSTEM WIRING
(4-CYLINDER VERSION).........................................................108
ELECTRONIC LIFT WIRING (1/2)............................................113
ELECTRONIC LIFT WIRING (2/2)............................................114

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