Same Explorer 75 85 95 Workshop Manual manuals in PDF

Factory Service Repair Manual For Same Explorer 75 85 95 Tractors. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Same Explorer 75, 85, 95

Contents

INTRODUCTION
SAFETY NOTES
GENERAL SAFETY RULES
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING
OPERATIONS
LIFTING INSTRUCTIONS
HOW THE MANUAL IS STRUCTURED
HOW TO CONSULT THE MANUAL
HOW TO USE AND UPDATE THE MANUAL
STANDARD TIGHTENING TORQUES
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS
CONVERSION FACTORS
-Section 10
1 TRANSMISSION
INTRODUCTION
DESCRIPTION
Clutch Housing (For Versions Without Hydraulic Shuttle)
Clutch Housing And Hydraulic shuttle Assembly
Hml Unit
Gearbox And Shuttle Assembly
5 -Speed Gearbox With Mechanical Shuttle And Underdrive
5-Speed Gearbox With Mechanical Shuttle And Hml Unit
5-Speed Gearbox With Hydraulic Shuttle And Hml Unit
Bevel Pinion And Range Gearbox
Versions With 3 Range Gears
Versions With 4 Range Gears
4Wd Engagement And Parking Brake Assembly
Differential Unit
Version Without Sba
Version With Sba
Brakes And Rear Axle Assembly
REAR PTO
DESCRIPTION
Pto Control Clutch Assembly
2-Speed Pto And Groundspeed Pto
2-Speed Pto And Groundspeed Pto
FRONT AXLE
Final Drive
Pinion, Differential And Differential Lock (Version Without Sba)
Pinion, Differential And Differential Lock (Version With Sba)
HYDRAULIC SYSTEM
DESCRIPTION
Steering And Services Hydraulic Circuit(Basic Version)
Steering And Services Hydraulic Circuit(Version With Hml)
Steering And Services Hydraulic Circuit(Version With Hydraulic Shuttle)
Steering And Services Hydraulic Circuit(Version With Hml And Hydraulic Shuttle)
Lift And Auxiliary Services Hydraulic Diagram (Basic Version)
Lift And Auxiliary Services Hydraulic Diagram (Full Optional Version)
Steering Circuit Gear
Lift Circuit Gear Pump
Power Steering
Hml Solenoid Valves (Version Without Hydraulic Shuttle
Hml Solenoid Valves (Version With Hydraulic Shuttle)
Hydraulic Shuttle Solenoid Valves (Version Without Hml)
Hydraulic Shuttle Solenoid Valves (Version With Hml)
Services Solenoid Valves (Version Without Sba) 39
Services Solenoid Valves (Version With Sba)
Pressure Control Valves
Auxiliary Services Control Valve
Hydraulic Lift Control Valve
Function
Operation
Electronic Lift Control Valve
BRAKING SYSTEM
DESCRIPTION
“Separate-Brakes” Valve
Function
Operation
Trailer Braking Valve
Hydraulic Trailer Braking (Italy Version)
Hydraulic Trailer Braking (Export Version)
Air Trailer Braking (Italy Version)
Air Trailer Braking (Export Version)
Pressure Limiting Valve
Trailer Braking Valve (2-Way)
Trailer Braking Valve (1-Way)
-Section 20
DIAGNOSIS TOOLS
All Round Tester
Description Of The Kit
Notes On Correct Use
Description Of The Tester
General Notes On Connecting And Powering Up The Tester
Selection Of The Display Language
Configuring The Serial Ports
CONNECTION OF THE TESTER TO THE ELECTRONIC CONTROL UNITS
Connecting Art To The Hydraulic Lift And Engine Control Unit
INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR
Engine Ecu
Preheating Ecu
Lift Ecu
Hydraulic Lift System
Sba Traction Control System
Sba Ecu
Shuttle Ecu
Shuttle Electronic Control System
Hml Unit Electronic Control System
Hml Ecu
PUTTING THE TRACTOR INTO SERVICE
Introduction
Renewal Of The Engine Ecu
Setting The Type Of Engine
Calibration Of The Hand Throttle
Current Calibration At 1400 Rpm
Configuration Of The Wheels Parameter
Renewal Of The Lift Ecu
Configuration For Presence Of The Radar
Configuration Of The Wheels Parameter
Calibration Of The Minimum Lift Height
Calibration Of The Maximum Lift Height
Calibration Of The Steering Sensor (For Versions With Sba Only)
Cancelling Alarms
Renewal Of The Shuttle Ecu
Initialization Of The Ecu
Calibration Of The Clutch Pedal
Configuration Of Optional Equipment
Cancelling Alarms
Notes Regarding The Clutch Calibration Procedure
Notes On The Clutch Calibration Parameters
Notes On How To Change Parameter Settings During Manual Calibration
Automatic Calibration Of The Shuttle Clutches
Manual Calibration Of The Shuttle Clutches
Renewal Of The Instrument Panel
ALARMS
Engine Ecu Alarms (Code 285190520 – Sw Ver Ec0052Af)
List Of Alarms Signalled On The Hold Light
List Of Alarms Signalled On The Art
Lift Control Unit Elc2 Alarms (Code 285190060) 5
List Of Alarms Flashed On Lift Control Button 59
List Of Alarms Displayed On Art
Shuttle Ecu Alarms (Code 285190170 Sw Ver V37J0)
List Of Alarms Signalled On The “Alarm” Light
List Of Alarms Displayed On The Art
ENGINE ECU TESTER
Presentation Screen
Engine Tests
Engine Param
Autoprogram
Engine List
Check
Hand Throttle
Pedal Sensor
Actuator
Manual Prog
Low Idle Rpm Programm
Droop
Minimum Current
Adj ActCurrent
Throttle Pedal Sensibility
Adjustment Handgas
Pedal Sensor
Actuator
Engine Rpm Check
Autodiagnosis
LIFT ECU TESTER
Presentation Screen
Main Menu
Monitors Menu
Lift
Consolle
Sba
Alimentation
Parameters Menu
Speed Constant
Setting Menu
Minimum Height
Maximum Height
Steering
Lock Speed
Alarm List
SHUTTLE ECU TESTER
Presentation Screen
Main Menu
Calibrations
Clutch Pedal
Optional Equipment
Test Menu
Solenoid Tests
Automatic Solenoid Tests
Hardware Test
Monitor
Miscellaneous
Controls
Diagnostics
Calibration
Manual Calibration
Automatic Calibration
Alarm List
-Section 30
ENGINE HOOD AND SIDE PANELS
Removal
Refitting
RADIATOR
Removal
Refitting
STARTER MOTOR
Removal
Refitting
FENDERS
Removal
Refitting
WHEELS
FRONT WHEELS
Removal
Refitting
REAR WHEELS
Removal
Refitting
FRONT LIFT
LIFT CYLINDERS
Removal
Refitting
Disassembly
Assembly
FRONT PTO
COMPLETE ASSEMBLY
Removal
Refitting
Disassembly
Assembly
PUMP ASSEMBLY
Disassembly
Assembly
CLUTCH – BRAKE ASSEMBLY
Disassembly
Assembly
SOLENOID VALVE ASSEMBLY
Disassembly
Assembly
FRONT AXLE DRIVE SHAFT
Removal
Refitting
FRONT SUPPORT
Removal
Refitting
FRONT AXLE
COMPLETE AXLE ASSEMBLY
Removal
Refitting
End Float Adjustment
STEERING CYLINDERS
Removal
Refitting
Disassembly
Assembly
PLANETARY GEAR UNIT
Removal
Refitting
Disassembly
Assembly
STEERING ANGLE SENSOR
Removal
Refitting
STEERING KNUCKLE HOUSING AND AXLE SHAFT
Removal
Refitting
Adjusting The Bearings Preload
BEVEL PINION-DIFFERENTIAL ASSEMBLY
Removal
Refitting
DIFFERENTIAL LOCK (Versions Without SBA)
Removal
Refitting
Adjustment
DIFFERENTIAL LOCK (Version With SBA)
Disassembly
Assembly
BEVEL GEAR PAIR
Disassembly (Version Without Sba)
Disassembly (Version With Sba)
Adjustment Of The Differential Preload (Versions Without Sba)
Adjustment Of The Pinion And Crown Wheel (Versions Without Sba)
Completion Of Assembly
Adjustment Of The Differential Preload And Pinioncrown Wheel Backlash (Versions With Sba)
DIFFERENTIAL
Disassembly
Assembly
EXHAUST PIPE (versions with cab)
Removal
Refitting
ENGINE
Preparation Before Separating The Engine From The Transmission
Preparation For Removal
Separation Or Removal
Refitting
FUEL TANK
Removal
Refitting
CAB
Removal
Refitting
HYDRAULIC SHUTTLE
COMPLETE ASSEMBLY
Removal
Refitting
Disassembly
Assembly
End Float Adjustment
CLUTCH UNITS
Disassembly
Assembly
INTERMEDIATE GEAR
Disassembly
Assembly
INTERMEDIATE SHAFT
Disassembly
Assembly
CLUTCH HOUSING
COMPLETE ASSEMBLY
Separating Clutch Housing From The Transmission
Reassembly Clutch Housing From The Transmission
HML UNIT AND GEARBOX
COMPLETE ASSEMBLY
Removal
Refitting
HML UNIT
COMPLETE ASSEMBLY
Removal
Refitting
Adjustment Of The Planet Carrier Assembly End Float
“L” AND “M” GEAR CLUTCH UNIT
Assembly
“H” GEAR CLUTCH UNIT
Assembly
PLANETARY GEAR UNIT
Disassembly
Assembly
GEARBOX ASSEMBLY
COMPLETE ASSEMBLY
Removal
Refitting
COMPLETE ASSEMBLY (versions with HML)
Disassembly
Assembly
Adjustment Of The Hml Output Shaft End Float
GEARBOX SUPPORT PLATE AND GEAR SELECTOR RODS (versions with HML)
Disassembly
Assembly
Adjustment Of The Secondary Shaft Bearing Play
GEARBOX INPUT SHAFT (Versions With Hydraulic Shuttle)
Disassembly
Assembly
SHUTTLE AND UNDERDRIVE SHAFT
Disassembly
Assembly
MAIN SHAFT
Disassembly
Assembly
SECONDARY SHAFT (Versions With Hml)
Disassembly
Assembly
SECONDARY SHAFT (Versions Without Hml)
Disassembly
Assembly
HML UNIT OUTPUT SHAFT
Disassembly
Assembly
REMOTE CONTROL VALVE
COMPLETE ASSEMBLY
Removal
Refitting
REMOTE VALVE COUPLERS
Removal
Refitting
REMOTE VALVES ASSEMBLY
Disassembly
Assembly
TOWING HITCH
Removal
Refitting
HYDRAULIC LIFT
COMPLETE ASSEMBLY
Removal
Refitting
Disassembly
Assembly
LIFT CYLINDER
Disassembly
Assembly
BUSHINGS
Renewal
LIFT CONTROL VALVE
Disassembly
Assembly
ELECTRONIC LIFT CONTROL VALVE
Removal
Refitting
MECHANICAL DRAFT SENSOR
Removal
Refitting
Disassembly
Assembly
3-POINT LINKAGE (Versions With Mechanical Lift Control)
Removal
Refitting
REAR AXLE
COMPLETE ASSEMBLY
Preparation For Removal Of The Right Axle
Preparation For Removal Of The Left Axle
Removal Of The Complete Rear Axle
Refitting
Disassembly
Assembly
PLANETARY GEAR UNIT
Disassembly
Assembly
REAR PTO
PTO INPUT SHAFT (4-speed)
Removal
Refitting
Disassembly
Assembly
PTO CLUTCH
Removal
Refitting
Disassembly
Assembly
PTO OUTPUT SHAFT (4-speed version)
Disassembly
Assembly
GROUNDSPEED PTO OUTPUT SHAFT
Disassembly
Assembly
GROUNDSPEED PTO SELECTOR
Disassembly
Assembly
SERVICES SOLENOID VALVE
ASSEMBLY
Removal
Refitting
HYDRAULIC PUMPS
HYDRAULIC PUMP FOR HYDRAULIC LIFT AND AUXILIARY SERVICES
Removal
Refitting
Removal
Refitting3
RANGE GEARBOX AND REAR DIFFERENTIAL ASSEMBLY
COMPLETE ASSEMBLY
Removal
Refitting
DIFFERENTIAL (Versions With Mechanical Engagement)
Removal
Refitting
Disassembly
Assembly
DIFFERENTIAL (Version With SBA)
Removal
Refitting
Disassembly Of Differential Lock Side
Assembly
Disassembly Of Crown Wheel Side
Assembly
BEVEL PINION
Disassembly
Assembly
RANGE SELECTOR ASSEMBLY
Disassembly
Assembly
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL (Versions Without SBA)330
Disassembly
Assembly
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL (Versions With SBA)332
Removal
Refitting
Disassembly
Assembly
4WD OUTPUT SHAFT AND PARKING BRAKE
Disassembly
Disassembly
Assembly
BEVEL GEAR PAIR
Preparation For Adjustments
Adjustment Of The Differential Bearings Preload
Adjustment Of The Pinion Position
Adjustment Of The Pinion And Crown Wheel
PUMP DRIVE PTO
OUTER GEAR
Disassembly
Assembly
INTERNAL GEAR
Disassembly
Assembly
CLUTCH ASSEMBLY AND TORSIONAL SPRING PLATE
Removal
Refitting
BRAKES
REAR AXLE BRAKE DISCS
Renewal
REAR AXLE BRAKE PISTON
Disassembly
Assembly
FRONT AXLE BRAKE DISCS
Removal
Refitting
FRONT AXLE BRAKE PISTON
Disassembly
Assembly
PARKING BRAKE
Disassembly
Assembly
BRAKE CYLINDERS
Removal
Refitting
BRAKING SYSTEM
Brake Bleeding Procedure
Bleeding The Rear Brakes Circuit
Bleeding The Front Brakes Circuit
DASHBOARD
Removal
Refitting
HYDROSTATIC STEERING VALVE
Removal
Refitting
Testing The Maximum Operating Pressure
PRESSURE RELIEF VALVE SETTING
Disassembly
Assembly
SIDE CONSOLE
Removal
Refitting
REMOTE VALVE CONTROL LEVERS
Removal
Refitting
AIR CONDITIONING SYSTEM
SPECIFICATIONS
Operation
Flushing And Recharging The System
COMPRESSOR
Removal
Refitting
Tensioning The Drive Belt
HYDRAULIC TRAILER BRAKING VALVE
Removal
Refitting
-Section 40
THE STRUCTURE OF THE UNIT
HOW TO CONSULT THE UNIT
INTRODUCTION
List Of Wiring Harnesses
Definition Of Components And Symbols
General Rules
Modification Of The Tractor’s Electrical/Electronic Circuits
Main Wiring Faults
Removal, Refitting And Drying Of Connectors And Wiring
Diagnostic Instruments
Wire Colour Codes
INDICES
Part Description Index
Component Code Index
Connector Index
COMPONENTS
Connector Layouts
Component Technical Data
Pinouts And Descriptions Of Electronic Control Units
Engine Ecu (Cod 28519052/50)
Sba Ecu (Cod 001155474)
Pto Ecu (Cod 001077494/30)
Preheating Ecu (Cod 285190230/30)
Hml Ecu (Cod 001088694/20)
Lift Ecu (Cod 285190060)
Shuttle Ecu (Cod 285190170/10)
SYSTEMS
Earthing Points
Starting And Preheating
Electronic Engine Control
Lights – Steering Column Switch Unit (Cab)
Lights – Steering Column Switch Unit (Platform)
Diagnostic Accessories (With Sba Without Shuttle)
Diagnostic Accessories (With Lift Without Shuttle)
Diagnostic Accessories (With Shuttle)
Diagnostic Accessories (With Lift And Shuttle)
Instrument Panel
Worklights (Cab)
Windscreen Wipers
Heating
Air Conditioning
Brakes – Hydraulic Trailer Braking
Brakes – Air Trailer Braking
Shuttle And Hml (Version With Mechanical Governor)
Shuttle And Hml (Version With Electronic Governor)
Shuttle (Version With Mechanical Governor)
Shuttle (Version With Electronic Governor)
Hml (Version With Electronic Governor)
Hml (Version With Mechanical Governor)
Sba (With Lift)
Sba (Without Lift)
Electronic Lift Control
Front And Rear Pto
WIRING
Battery Wiring
Front Wiring (1/2)
Front Wiring (2/2)
Link Box Wiring
Front Pto Solenoid Valve Wiring
Central Wiring (1/2)
Central Wiring (2/2)
Lights Wiring (Cab)
Lower Lights Wiring (Cab)
Underbody Wiring (With Hydraulic Shuttle) (1/2)
Underbody Wiring (With Hydraulic Shuttle) (2/2)
Underbody Wiring (1/2)
Underbody Wiring (2/2)
Cab Power Wiring
Air Sprung Seat Wiring
Screenwash Pump Wiring
Sba Pushbutton Wiring
Sba Wiring
Electronic Governor Engine Wiring
Electronic Lift Wiring (1/2)
Electronic Lift Wiring (2/2)
Rear Wiring (1/2)
Rear Wiring (2/2)
Rear Wiring (With Shuttle) (1/2)
Rear Wiring (With Shuttle) (2/2)
Hydraulic Brake Wiring
Pneumatic Brake Wiring
Roof Wiring (1/2)
Roof Wiring (2/2)
Heatering Wiring (1/2)
Heatering Wiring (2/2)
Air Conditioning Wiring (1/2)
Air Conditioning Wiring (2/2)
Air Conditioning Fan Wiring (1/2)
Air Conditioning Fan Wiring (2/2)
Loudspeaker Wiring – Radio – Rear Wiper
Rotating Beacon – Clock
Front Wiper Wiring
Worklight Wiring

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