Same Dorado 55 60 65 70 75 85 Tractor Complete Workshop Service Repair Manual

introduction This publication is intended for the trained technician who must operate on our tractors. It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhauling and adjustment procedures as well as the main instructions for dismantling and reassembling operations. The workshop manual is a natural summary for the mechanic who has attended the vocational training and specializa- tion courses, which are held every year at our Service School, to permit him to perform a precise and qualified work on tractor. Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his me- mory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic to have at his disposal this publication, so that it may be consulted quickly when necessary. We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to make this publication more complete. 1 WORKSHOP MANUAL Seat and headquarters V.le Ing. F. Cassani, 15 24047 Treviglio (BG) Tel. 0363/4211 Telex: 311472 Samtra I DORADO 55 DORADO 60 DORADO 65 DORADO 70 DORADO 75 DORADO 85

List of contents 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 idl er 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 3

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 4

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 5

TRACTOR CONFIGURATIONS: - DORADO 55 - 60 - 65 - 70 - 75 - 85 DORADO 55 - 60 - 65 - 70 - 75 - 85 2RM WITH PLATFORM 2RM WITH CAB 4RM WITH PLATFORM 4RM WITH CAB CAB - ventilation - ventilation + heating - ventilation + heating + air conditioning GEARBOX Fully synchronised: For tractors with driving position with footsteps only - 16 Forward + 8 Reverse: 4 speeds x 2 ranges + mini-reduction + shuttle - 24 Forward + 12 Reverse: 4 speeds x 3 ranges + mini-reduction + shuttle For tractors with driving position with plataform/cab only - 20 Forward + 10 Reverse: 5 speeds x 2 ranges + mini-reduction + shuttle - 30 Forward + 15 Reverse: 5 speeds x 3 ranges + mini-reduction + shuttle - 45 Forward + 45 Reverse: 5 speeds x 3 ranges + shuttle + version AGROSHIFT - - CONTROLS - electro-hydraulic Agroshift control with 2 pushbuttons located on gear lever - rear P.T.O. clutch with electro-hydraulic control and mechanical speed selector - groundspeed P.T.O. with mechanical engagement/disengagement control - front P.T.O. with electrohydraulic control - 4WD with mechanical control or optional electro-hydraulic control - differential locks with electro-hydraulic control - electronic engine throttle (for tractors equipped with electronic governor) MECHANICALLY OPERATED REAR POWER-LIFT - with supplementary rams - without supplementary rams ELECTRONIC REAR LIFT - with auxiliary rams - without auxiliary rams - with auxiliary control pushbuttons mounted on fender HYDRAULIC SYSTEM The hydraulic system is equipped with two pumps: Standard: - 11 cc pump with 27 l/min capacity. Supplies power steering, electro-hydraulic control unit and gearbox lubrication circuits. - 14 cc pump with 34 l/min capacity. Supplies auxiliary service control valves and hydraulic lift. Optional: - 11 cc pump with 27 l/min capacity. Supplies power steering, AGROSHIFT control unit, electro-hydraulic control unit and gearbox lubrication circuits. - 19 cc pump with 47 l/min capacity. Supplies the hydraulic trailer breaking control valve, auxiliary service control valves and hydraulic lift. MAIN EQUIPMENT - front P.T.O. - economy P.T.O. - front lift - electronic lift - electronic engine governor - 3-point linkage with hydraulically adjustable right-hand lift rod and stabilisers - 4-way or 6-way control valves with “Flow Divider” 6

DIMENSIONS AND WEIGHTS DORADO DORADO DORADO 55 60 65 2WD 4WD 2WD 4WD 2WD 4WD Tyres - front 7.50 - 16 320/70 R 20 - rear 14.9 R 28 420/70 R 28 420/70 R 28 Length - without front linkage (A) mm 3330 3720 3725 3370 - with front linkage (A) mm 3700 - 4240 3720 Width - min. (B) mm 1790 1920 1920 - max (B) mm 2230 2320 2320 Ground clearance (D) mm 445 355 345 445 355 Wheel base (E) mm 2105 2056 2105 2056 2105 2056 Max. height - at safety frame (C) mm 2380 2400 2380 - at cab (standard) (F) mm 2400 2400 2400 Front track - min. mm 1300 1440 1300 1340 1300 1440 - max mm 1800 1740 1600 1740 1800 1740 Rear track - min. mm 1400 1400 1500 - max mm 1840 1900 1900 Min. turning radius without brakes mm 3060 3650 3200 3650 3060 3650 Operating weight - with driver platform Kg 2400 2800 2360 2530 2400 2800 - with cab Kg 2600 2850 2550 2700 2600 2850 Max. permissible load - front Kg 1300 2300 - 2300* 1300 2300 - rear Kg 3200 - 3200 3200 - total Kg 4500 5000 - 5000 4500 5000 *: Data applies to reinforced type tyres 7

DIMENSIONS AND WEIGHTS DORADO DORADO DORADO 70 75 85 2WD 4WD 2WD 4WD 2WD 4WD Tyres - front 7.50 - 16 360/70 R 20 - rear 420/70 R 30 420/70 R 30 480/70 R 30 Lunghezza - without front linkage (A) mm 3850 3855 3530 3575 - with front linkage (A) mm - 4370 3850 3850 Width - min. (B) mm 1920 1920 2070 - max (B) mm 2320 2320 2330 Ground clearance (D) mm 365 445 380 465 400 Wheel base (E) mm 2235 2186 2235 2186 2235 2186 Max. height - at safety frame (C) mm 2430 2400 2420 - at cab (standard) (F) mm 2420 2420 2440 Front track - min. mm 1300 1340 1300 1440 1300 1440 - max mm 1600 1740 1800 1740 1800 1740 Rear track - min. mm 1400 1400 1500 1590 - max mm 1900 1900 1900 1910 Min. turning radius without brakes mm 3300 3800 3200 3800 3200 3800 Operating weight - with driver platform Kg 2470 2720 2400 2800 2400 2800 - with cab Kg 2660 2890 2600 2850 2600 2850 Max. permissible load - front Kg - 2300* 1300 2300 1300 2300 - rear Kg - 3200 3200 3200 - total Kg - 5000 4500 5000 4500 5000 *: Data applies to reinforced type tyres 8

PRESCRIBED LUBRICANTS AND FUELS (amounts in litres) Part to be supplied Amt Oil type Product Multigrade engine oil 6,7 ACEA E3-96 55 - 60 - 65 HP API CF Engine SDFG OM-1991A AKROS TURBO MIL-L-2104 E level Special Formula SAME 11 SAE 15W40 (15 ÷ +40 °C) 70 - 75 - 85 HP SAE 10W30 -25 ÷ +30 °C) Gearbox and Rear axle Power-lift 41 Auxiliary Systems Hydrostatic steering SDFG OT - 1891 API GL 4 AKROS MULTI Front P.T.O. 2,5 SAE 10W30 Front - wheel drive Central axle 6 Side reductions 1,5x2 Brakes control and clutch max. level ATF DEXRON II AKROS MATIC Lubrication points NLGI 2 LITIO/Ca AKROS GREASE T2 Fuel tank 90 litres WARNING: The engine oil sump has been replenished after the first 50 work hours. It is advisable to always use the some type of oil when replenishing. 9

CONVERSION TABLE FROM FROM TO multiply by: inch cm 2.540 cm inch 0.394 foot m 0.305 m foot 3.281 yard m 0.914 m yard 1.094 Eng. miles km 1.609 km Eng. miles 0.622 Sq.in. cm2 6.452 cm2 Sq.ft. 0.155 Sq.ft. m2 0.093 m2 Sq.ft. 10.77 Sq.yard m2 0.835 m2 Sq.yard 1.197 Cu.in. cm3 16.39 cm3 Cu.in. 0.061 Cu.ft. Liter 28.36 Liter Cu.ft. 0.035 Cu.yard m3 0.763 m3 Cu.yard 1.311 Imp.gall. Liter 4.547 Liter Imp.gall. 0.220 US gall. Liter 3.785 Liter US gall. 0.264 pint Liter 0.568 Liter pint 1.762 quart Liter 1.137 Liter quart 0.880 oz. kg 0.028 kg oz. 35.25 lb. kg 0.454 kg lb. 2.203 lb.ft. kgm 0.139 kgm lb.ft. 7.233 lb/in. kg/m 17.87 kg/m lb/in. 0.056 lb./sq.in. kg/cm2 0.070 kg/cm2 lb/sq.in. 14.22 lb./Imp.gall. kg/l 0.100 kg/l lb./Imp.gall. 10.00 lb./US gall. kg/l 0.120 kg/l lb./US gall. 8.333 lb./cu.ft. kg/m3 16.21 kg/m3 lb./cu.ft. 0.062 cu.ft./lb. m3/kg 0.062 m3/kg cu.ft./lb. 16.21 Nm kgm 0.102 kgm Nm 9.81 kW PS 1.36 PS kW 0.736 bar kg/cm2 1.014 kg/cm2 bar 0.981 dm3 l 1 l dm3 1 10

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Same Dorado 55 60 65 70 75 85 Tractor Complete Workshop Service Repair Manual

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