Same Dorado 55 60 65 70 75 85 service repair workshop manual

Same Dorado 55 60 65 70 75 85 service repair workshop manual

It is workshop manual for Same tractors. Models included:
55
60
65
70
75
85

language:english
number of pages: 684 (full digital version)

Main sections:
Introduction
Safety sections
Tractor configurations DORADO 55 – 60 – 65 – 70 – 75 – 85 ………………………………………………………………………….6
Dimensions and weights………………………………………………………………………………………………………………………….7
Prescribed lubricants and capacities …………………………………………………………………………………………………………9
Conversion tables…………………………………………………………………………………………………………………………………10
Parts …………………………………………………………………………………………………………………………………………………..11
1 – ENGINE
Engine section ……………………………………………………………………………………………………………………………………..12
General characteristics ………………………………………………………………………………………………………………………….20
Timing specifications …………………………………………………………………………………………………………………………….21
Lubrication system – specifications………………………………………………………………………………………………………….22
Fuel supply system – specifications …………………………………………………………………………………………………………23
Turbocharger – specifications …………………………………………………………………………………………………………………24
Cooling system – specifications ………………………………………………………………………………………………………………25
Engine cylinder block…………………………………………………………………………………………………………………………….26
Installing bushings into the camshaft journals …………………………………………………………………………………………..26
Adjusting backlash between the gear teeth of the auxiliary engine drive ………………………………………………………27
Support for hydraulic pumps or air compressor located between engine block and timing cover ……………………..27
Timing idler gea ……………………………………………………………………………………………………………………………………29
Cylinders……………………………………………………………………………………………………………………………………………..30
Main bearings ………………………………………………………………………………………………………………………………………33
Crankshaft …………………………………………………………………………………………………………………………………………..35
Connecting rods – connecting rod bearings and bushings ………………………………………………………………………….38
Pistons ………………………………………………………………………………………………………………………………………………..39
Piston rings ………………………………………………………………………………………………………………………………………….39
Counterweights for 4-cylinder engines …………………………………………………………………………………………………….44
Engine flywheel ……………………………………………………………………………………………………………………………………45
Checking camshaft ……………………………………………………………………………………………………………………………….48
Checking camshaft bushings………………………………………………………………………………………………………………….48
Checking timing gear …………………………………………………………………………………………………………………………….48
Cylinder heads – valves – valve rockers ……………………………………………………………………………………………………49
Cleaning cylinder heads ………………………………………………………………………………………………………………………..50
Checking engine compression ……………………………………………………………………………………………………………….53
Oil pump …………………………………………………………………………………………………………………………………………….54
Checking pressure relief valve ……………………………………………………………………………………………………………….54
Fitting shims between engine oil pan and front support ……………………………………………………………………………..55
Fuel injection nozzles ……………………………………………………………………………………………………………………………56
Mechanical-type engine governor …………………………………………………………………………………………………………..58
Assembly of the governor unit ………………………………………………………………………………………………………………..60
Fitting and adjustment of the external controls of the mechanical governor …………………………………………………62
Engine governor control assembly ………………………………………………………………………………………………………….64
Electronic engine governor ……………………………………………………………………………………………………………………66
Installing and checking the pick-up………………………………………………………………………………………………………….68
Installing and checking actuator ……………………………………………………………………………………………………………..69
Fitting and checking the accelerator pedal (1st version) ……………………………………………………………………………70
Fitting and checking the accelerator pedal (2nd version). ………………………………………………………………………….72
Fuel injection pumps……………………………………………………………………………………………………………………………..76
Injection pump control system ………………………………………………………………………………………………………………..76
Installing injection pump control bar guide supports…………………………………………………………………………………..77
Engine timing ……………………………………………………………………………………………………………………………………….77
Positioning the pumps …………………………………………………………………………………………………………………………..80
Fuel prefilter …………………………………………………………………………………………………………………………………………83
Fuel filter ……………………………………………………………………………………………………………………………………………..83
Draining water from fuel filter ………………………………………………………………………………………………………………….83
Fan assembly ………………………………………………………………………………………………………………………………………85
Turbocharging DORADO 65 – DORADO 85……………………………………………………………………………………………88
Engine air filter ……………………………………………………………………………………………………………………………………..92
Tightening torques ………………………………………………………………………………………………………………………………..92
Instructions for engine assembly …………………………………………………………………………………………………………….94
Diagnosing malfunctions ……………………………………………………………………………………………………………………..108
2 – CLUTCH
Gearshift clutch…………………………………………………………………………………………………………………………………..110
General specifications …………………………………………………………………………………………………………………………110
Spring specifications to Belleville washer for the clutch engagement …………………………………………………………110
Cecking clutch ……………………………………………………………………………………………………………………………………114
Adjusting clutch control pedal……………………………………………………………………………………………………………….114
Bleeding air from the hydraulic circuit…………………………………………………………………………………………………….114
Stripping the slave cylinder…………………………………………………………………………………………………………………..115
Stripping the master cylinder ………………………………………………………………………………………………………………..116
2
Diagnosing malfunctions ……………………………………………………………………………………………………………………..118
Agroshift unit, general specifications……………………………………………………………………………………………………..119
AGROSHIFT unit detach from the gear box……………………………………………………………………………………………122
Assembly of AGROSHIFT unit ……………………………………………………………………………………………………………..133
Re-assembly of the Agroshift unit………………………………………………………………………………………………………….135
Fitting the oil manifolds of the Agroshift unit ……………………………………………………………………………………………137
Diagnosing malfunctions ……………………………………………………………………………………………………………………..142
3 – TRANSMISSION
General specifications …………………………………………………………………………………………………………………………143
Technical specifications……………………………………………………………………………………………………………………….143
Speed change configurations ……………………………………………………………………………………………………………….144
Section through transmission ……………………………………………………………………………………………………………….149
Section through transmission with Agroshift unit……………………………………………………………………………………..150
Range selector rods and forks………………………………………………………………………………………………………………157
Removal and refitting operations…………………………………………………………………………………………………………..158
Separating the front gearbox from the engine…………………………………………………………………………………………159
Dismantling the gearbox………………………………………………………………………………………………………………………160
Removal of the gearbox input and P.T.O. shafts……………………………………………………………………………………..160
Separating the AGROSHIFT unit from the gearbox …………………………………………………………………………………160
Removal of the gear train positioned in the front gearbox…………………………………………………………………………161
Disassembly of the inversor control rods and forks………………………………………………………………………………….162
Dismantling of the gearchange rod and fork assembly …………………………………………………………………………….163
Dismantling of the gearchange selector rods and forks assembly ……………………………………………………………..164
Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive……………………165
Removal of the range gear shaft …………………………………………………………………………………………………………. 165
Examining parts removed…………………………………………………………………………………………………………………….166
Adjusting play of the gearbox shafts by means of the thrust plates on the mini/inversor
shaft and the secondary shaft ……………………………………………………………………………………………………………..167
Warnigns related to assembly of the gears of the P.T.O. unit, the range reduction unit and synchronised
P.T.O. shaft ……………………………………………………………………………………………………………………………………….171
Assembly of the P.T.O………………………………………………………………………………………………………………………..171
Installation of the range reduction unit, the gear for the front-wheel drive shaft
and the parking brake discs…………………………………………………………………………………………………………………171
Points where sealant is to be used………………………………………………………………………………………………………..175
Tightening torques………………………………………………………………………………………………………………………………176
Bevel drive adjustment ………………………………………………………………………………………………………………………..179
Servicing operations ……………………………………………………………………………………………………………………………180
Rear power take-off …………………………………………………………………………………………………………………………….181
P.T.O. clutch ………………………………………………………………………………………………………………………………………186
Technical specifications……………………………………………………………………………………………………………………….186
Correct positions of P.T.O. sensors and cables ………………………………………………………………………………………187
Clutch inspection ………………………………………………………………………………………………………………………………..189
Checking clutch hydraulic pressures……………………………………………………………………………………………………..190
Checking the end-play of the front shaft of the P.T.O. clutch …………………………………………………………………….191
Renewal of the rear P.T.O. clutch …………………………………………………………………………………………………………192
Main operations for removal of the rear P.T.O. unit …………………………………………………………………………………193
Diagnosing malfunctions ……………………………………………………………………………………………………………………..198
4 – AXLES
Rear axle …………………………………………………………………………………………………………………………………………..199
Installing the rear half-shafts ……………………………………………………………………………………………………………….199
Removal and disassembly of the epicyclic reduction unit……………………………………………………………………………..202
Fitting lateral stub axles of the wheel …………………………………………………………………………………………………….203
2WD extendible axle……………………………………………………………………………………………………………………………204
Removing the axle from the front support ………………………………………………………………………………………………206
Centre steering lever …………………………………………………………………………………………………………………………..209
Wheel hub …………………………………………………………………………………………………………………………………………210
End float adjustment……………………………………………………………………………………………………………………………212
Front-wheel drive………………………………………………………………………………………………………………………………..213
Specifications …………………………………………………………………………………………………………………………………….213
Epicyclic reduction unit ………………………………………………………………………………………………………………………..217
Side hubs…………………………………………………………………………………………………………………………………………..219
Tightening torques………………………………………………………………………………………………………………………………220
Adjusting bevel gears ………………………………………………………………………………………………………………………….222
Adjustment of the internal control of the mechanical differential lock………………………………………………………….223
Installing the differential assembly into the drive axle ………………………………………………………………………………223
Diagnosing malfunctions ……………………………………………………………………………………………………………………..224
5 – VEHICLE
Brakes – General information………………………………………………………………………………………………………………..225
Hydraulic pump…………………………………………………………………………………………………………………………………..226
Assembly of brake master cylinder ……………………………………………………………………………………………………….228
Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks ………………………………..229
Adjusting service brake pedals……………………………………………………………………………………………………………..229
Correct installation of inspection cover for parking brake discs………………………………………………………………….230
Checking parking brake pads ……………………………………………………………………………………………………………….232
Bleeding air from the brake hydraulic system………………………………………………………………………………………….233
Separate Brakes valve ………………………………………………………………………………………………………………………234
Diagnosing malfunctions ……………………………………………………………………………………………………………………..238
Hydraulic lift with load sensing ……………………………………………………………………………………………………………239
Installing the lift and front cover plate of the gearbox ……………………………………………………………………………….240
Lift mechanism …………………………………………………………………………………………………………………………………..240
Checking the safety valves…………………………………………………………………………………………………………………..240
Checking the protrusion of the non-return valve………………………………………………………………………………………241
Adjusting the lift ………………………………………………………………………………………………………………………………….243
Lift hydraulic circuit ……………………………………………………………………………………………………………………………..244
Sensing arm assemblyMontaggio dell’organo sensibile ……………………………………………………………………………252
Power-lift distributor valve spring setting specifications ……………………………………………………………………………253
Electronic lift ………………………………………………………………………………………………………………………………………254
Control panel ……………………………………………………………………………………………………………………………………..255
Control level or depth control knob………………………………………………………………………………………………………..255
Mix position/draft control………………………………………………………………………………………………………………………255
Lowering speed control knob………………………………………………………………………………………………………………..256
Maximum lift height control knob …………………………………………………………………………………………………………..256
Up/Down control switch ……………………………………………………………………………………………………………………….256
Up control ………………………………………………………………………………………………………………………………………….256
Control/Float mode ……………………………………………………………………………………………………………………………..256
Lift status indicator light ……………………………………………………………………………………………………………………….256
Remote pushbuttons for lift operation from ground ………………………………………………………………………………….256
Calibration of the AUTOMATIC …………………………………………………………………………………………………………….257
Lift operation………………………………………………………………………………………………………………………………………258
Electronic circuit diagram of the ECU…………………………………………………………………………………………………….259
Calibration of the AUTOMATIC …………………………………………………………………………………………………………….260
Emergency manual lift control ………………………………………………………………………………………………………………260
List of electronic lift tests ……………………………………………………………………………………………………………………..261
Position sensor calibration ……………………………………………………………………………………………………………………266
Precautions for electronic equipment …………………………………………………………………………………………………….271
Checking the electronics system …………………………………………………………………………………………………………..271
Checking mechanical components………………………………………………………………………………………………………..271
Front hydraulic liftSollevatore idraulico anteriore……………………………………………………………………………………..272
Hydraulic accumulator and antishock valve for front lift ……………………………………………………………………………273
Front power take-off – General information……………………………………………………………………………………………..275
Section of the P.T.O. …………………………………………………………………………………………………………………………..278
Fitting the “RING-FEEDER” rings………………………………………………………………………………………………………….280
Checking the clutch …………………………………………………………………………………………………………………………….281
Diagnosing malfuntions ……………………………………………………………………………………………………………………….282
Spring specifications……………………………………………………………………………………………………………………………282
6 – CONTROLS
Hydrostatic steering …………………………………………………………………………………………………………………………….283
Inspections and checks ……………………………………………………………………………………………………………………….284
Steering pump ……………………………………………………………………………………………………………………………………284
Directional control valve ………………………………………………………………………………………………………………………284
Check the setting of the pressure relief valve………………………………………………………………………………………….284
Bleeding the hydraulic circuit ………………………………………………………………………………………………………………..284
Assembly of orbital pump unit ………………………………………………………………………………………………………………284
Teering wheel shaft and steering cylinders ……………………………………………………………………………………………285
Instructions for the hydrostatic steering distributor assembly…………………………………………………………………….287
Diagnosing malfuntions ……………………………………………………………………………………………………………………….294
Mechanical controls …………………………………………………………………………………………………………………………….295
Electro-hydraulic controls …………………………………………………………………………………………………………………….300
Front P.T.O. clutch engagement control…………………………………………………………………………………………………300
Rear P.T.O. clutch engagement control …………………………………………………………………………………………………300
Differential lock engagement control ……………………………………………………………………………………………………..300
Front-wheel drive engagement control …………………………………………………………………………………………………..300
Rear P.T.O. engagement control…………………………………………………………………………………………………………..300
Gearbox …………………………………………………………………………………………………………………………………………….300
Front and rear lift ………………………………………………………………………………………………………………………………..300
Hydraulic circuit diagram ……………………………………………………………………………………………………………………..301
Solenoid valve – Specifications……………………………………………………………………………………………………………..307
Adjustment of front and rear differential lock control ………………………………………………………………………………..312
7 – BODYWORK
Platform …………………………………………………………………………………………………………………………………………….313
Cab – General information ……………………………………………………………………………………………………………………314
Cab air filter ……………………………………………………………………………………………………………………………………….316
Screen wash………………………………………………………………………………………………………………………………………316
Screen wipers (front and rear)………………………………………………………………………………………………………………316
Removing the driving platform complete with cab……………………………………………………………………………………317
Breakage of the top hood release cable…………………………………………………………………………………………………319
High visibility cab roof ………………………………………………………………………………………………………………………….320
8 – SYSTEMS
Ventilation ………………………………………………………………………………………………………………………………………….321
Heating System ………………………………………………………………………………………………………………………………….321
Air conditioning unit for cabs ………………………………………………………………………………………………………………..325
Operation and maintenance of the air-conditioning system ………………………………………………………………………326
Water dripping from the points at which condensate drain lines are connected to the conditioning unit …………327
Checking system ………………………………………………………………………………………………………………………………..329
System safety elements ………………………………………………………………………………………………………………………329
Temperature regulation ……………………………………………………………………………………………………………………….329
Charging the system……………………………………………………………………………………………………………………………330
Filling the metering unit ……………………………………………………………………………………………………………………….330
Refilling the system with oil ………………………………………………………………………………………………………………….330
Verifying operation of the system after recharging …………………………………………………………………………………..332
Directions for tightening air conditioning system pipeline fittings ……………………………………………………………….332
Diagnosing malfuntions ……………………………………………………………………………………………………………………….339
Hydraulic system ………………………………………………………………………………………………………………………………..340
Oil filters…………………………………………………………………………………………………………………………………………….342
Hydraulic pumps…………………………………………………………………………………………………………………………………342
Checking the relief valves of the hydraulic lift system ………………………………………………………………………………342
Stripping the hydraulic pump………………………………………………………………………………………………………………..342
Auxiliary hydraulic spool valves…………………………………………………………………………………………………………….345
Checking the pressure relief valve setting………………………………………………………………………………………………348
Checking the operating pressure…………………………………………………………………………………………………………..348
Conversion of auxiliary spool valves from double acting to single acting operation………………………………………348
Checking the surface of the valve spools ……………………………………………………………………………………………….348
Trailer hydraulic braking system……………………………………………………………………………………………………………349
Trailer hydraulic braking distributor unit………………………………………………………………………………………………….349
Use of the tractor with CUNA 341/01 hydraulic trailer braking …………………………………………………………………..351
Starting ……………………………………………………………………………………………………………………………………………..352
Installing the hydraulic braking valve for trailers equipped with safety brake ………………………………………………….356
electrical system DORADO 55 – 65 (up serial number 1112) 75 – 85………………………………………………………..359
electrical system DORADO 60 – 65 (under serial number 1111) 70………………………………………………………….589
General safety directions……………………………………………………………………………………………………………………..590
Jump start utilizing another battery………………………………………………………………………………………………………..591
Recharge system………………………………………………………………………………………………………………………………..593
Heating system…………………………………………………………………………………………………………………………….593-594
Heating and conditioning system…………………………………………………………………………………………………………..594
Starting system…………………………………………………………………………………………………………………………………..594
Ignition key ………………………………………………………………………………………………………………………………..595 – 596
Ventilation control ……………………………………………………………………………………………………………………………….596
Push button control ………………………………………………………………………………………………………………………596-597
2-Speed windscreen wiper switch …………………………………………………………………………………………………………598
Work ligths…………………………………………………………………………………………………………………………………………598
Screen washer switch………………………………………………………………………………………………………………………….598
Beacon push button…………………………………………………………………………………………………………………………….598
Push button AGROSHIFT…………………………………………………………………………………………………………………….599
Relay ………………………………………………………………………………………………………………………………………………..599
Electronic flasher unit ………………………………………………………………………………………………………………………….599
Switch controlling………………………………………………………………………………………………………………………………..600
Switch controlling: differential lock – P.T.O. clutch – 4RM – 540 1000 rpm/min P.T.O. speed selector –
Economy P.T.O. – Live P.t.o. – electric starter system……………………………………………………………………………..600
Switch for emergency brake …………………………………………………………………………………………………………………600
Fuse box……………………………………………………………………………………………………………………………………………601
Instrument panel with digital display………………………………………………………………………………………………………602
Operation of the broken belts alarm control unit………………………………………………………………………………………604
Engine stop operation with a type 2MH engine control unit ………………………………………………………………………606
Electrical wiring…………………………………………………………………………………………………………………………………..609
9 – APPENDIX
Engine electronic unit ………………………………………………………………………………………………………………………………I
Power lift tester version 1.23a ……………………………………………………………………………………………………………XLVII
Power lift tester version 1.24a ……………………………………………………………………………………………………………..LXV

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