SAME Silver 80/90/100.4/100.6 Tractor 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 specialization 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 memory 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. WORKSHOP MANUAL SILVER 80 SILVER 90 SILVER 100.4 SILVER 100.6 Seat and headquarters: V.le Ing. F. Cassani, 15 24047 Treviglio (BG) Tel. 0363/4211 Telex: 311472 Samtra I 1

List of contents SILVER 80-90-100.4-100.6 tractor configurations ...................................................................................................... 5 Dimensions and weights ............................................................................................................................................. 6 Capacities ................................................................................................................................................................... 7 1 - ENGINE Engine section views .................................................................................................................................................. 8 General characteristics ............................................................................................................................................. 16 Lubrication system(specifications) ............................................................................................................................ 18 Fuel supply system (specifications) .......................................................................................................................... 19 Turbocharger for SILVER 90-100.6 (specifications) ................................................................................................ 20 Cooling system (specifications) ................................................................................................................................ 21 Cylinder block ........................................................................................................................................................... 22 Timing cover .............................................................................................................................................................. 23 Cylinders ................................................................................................................................................................... 26 Crankshaft ................................................................................................................................................................. 29 Connecting rods ....................................................................................................................................................... 34 Pistons ...................................................................................................................................................................... 35 Counterbalance weights ........................................................................................................................................... 40 Flywheel .................................................................................................................................................................... 41 Camshaft .................................................................................................................................................................. 43 Cylinder heads .......................................................................................................................................................... 45 Lubrication system .................................................................................................................................................... 50 Fuel system ............................................................................................................................................................... 53 Injectors ..................................................................................................................................................................... 53 Engine governor (mechanical) .................................................................................................................................. 55 Adjustment of mechanical governor external controls .............................................................................................. 60 Adjustment of anti-hunting device ............................................................................................................................. 63 Electronic rpm control ............................................................................................................................................... 64 Putting the electronic rpm control into service ......................................................................................................... 68 Injection pump ........................................................................................................................................................... 74 Engine timing ............................................................................................................................................................ 75 Injection pump timing ................................................................................................................................................ 76 Injection pump calibration ......................................................................................................................................... 79 Fuel prefilter .............................................................................................................................................................. 81 Fuel filter.................................................................................................................................................................... 81 Checking the fuel supply pump ................................................................................................................................. 82 Cooling system.......................................................................................................................................................... 83 Fan unit ..................................................................................................................................................................... 83 Pulley alignment ....................................................................................................................................................... 83 Belt tension adjustment ............................................................................................................................................. 85 Intake and exhaust .................................................................................................................................................... 86 Turbocharging system............................................................................................................................................... 86 Engine air filter .......................................................................................................................................................... 90 Tightening torques .................................................................................................................................................... 90 Engine assembly ....................................................................................................................................................... 92 Refitting the engine ................................................................................................................................................. 107 Fault diagnosis ........................................................................................................................................................ 108 2 - CLUTCH Engine-gearbox clutch ............................................................................................................................................ 110 Clutch pedal adjustment ......................................................................................................................................... 114 Bleeding air from the hydraulic system ................................................................................................................... 114 Fault diagnosis ........................................................................................................................................................ 118 Agroshift .................................................................................................................................................................. 119 Specifications .......................................................................................................................................................... 119 Operating diagrams ................................................................................................................................................ 120 Assembling the clutch ............................................................................................................................................. 123 Adjustment of end-float ........................................................................................................................................... 125 Fitting the clutch assembly to the gearbox (main operations) ................................................................................ 126 Testing the clutch control unit supply pressure....................................................................................................... 129 Fault diagnosis ........................................................................................................................................................ 132 3 - GEARBOX Gearbox, general characteristics and configurations ............................................................................................. 133 Views of the gearbox............................................................................................................................................... 138 Removal of gearbox from tractor ............................................................................................................................ 148 Dismantling the gearbox ......................................................................................................................................... 149 Examining the gearbox components ...................................................................................................................... 150 Adjusting the bevel drive ......................................................................................................................................... 154 2

External mechanical controls .................................................................................................................................. 157 Tightening torques .................................................................................................................................................. 159 Attaching the gearbox to the rear axle, lift and engine ........................................................................................... 160 Power take-off ......................................................................................................................................................... 164 Views of PTO controls ............................................................................................................................................ 164 Operating diagrams ................................................................................................................................................ 166 Specifications .......................................................................................................................................................... 168 Assembly of the rear output shaft ........................................................................................................................... 169 PTO clutch .............................................................................................................................................................. 169 PTO clutch specifications ....................................................................................................................................... 170 Views of the PTO clutch ......................................................................................................................................... 171 Checking the clutch ................................................................................................................................................ 174 Testing the clutch operating pressures................................................................................................................... 175 Checking end-float of the PTO clutch front shaft .................................................................................................... 176 Refitting the PTO assembly (main operations) ....................................................................................................... 177 Fault diagnosis ........................................................................................................................................................ 179 4 - AXLES Views of the rear axle ............................................................................................................................................. 180 Fitting the rear axle half-shafts ............................................................................................................................... 183 Removal and dismantling of the rear axle epicyclic reductions.............................................................................. 185 2WD front axle, general description and specifications.......................................................................................... 186 Removal and refitting of axle on the front support .................................................................................................. 188 Wheel hub ............................................................................................................................................................... 192 Inspection and checks ........................................................................................................................................... 193 4WD front axle, specifications ................................................................................................................................ 195 Adjusting wheel alignment and steering angle ....................................................................................................... 195 Section views of 4WD axle ..................................................................................................................................... 196 Checks and adjustments ........................................................................................................................................ 197 Section view of 4WD hub........................................................................................................................................ 198 Epicyclic reduction .................................................................................................................................................. 199 Special refitting operations and adjusting the preloading of the hub carrier bearings ........................................... 200 Half-shafts ............................................................................................................................................................... 201 4WD axle tightening torques................................................................................................................................... 202 4WD bevel drive adjustment ................................................................................................................................... 204 Internal adjustment of differential lock .................................................................................................................... 205 4WD axle fault diagnosis ........................................................................................................................................ 206 SBA System............................................................................................................................................................ 207 Fitting the steering angle sensor ............................................................................................................................ 208 Removal of differential unit from front axle ............................................................................................................. 209 Removal of front wheel drive and differential lock clutch ....................................................................................... 209 Adjustment of front bevel drive with SBA System .................................................................................................. 210 Fitting the differential unit on the front axle............................................................................................................. 212 Front wheel drive clutch on models with SBA System, specifications ................................................................... 213 Front and rear differential lock clutches on models with SBA System ................................................................... 214 Fault diagnosis ........................................................................................................................................................ 226 5 - VEHICLE Brakes, general description and specifications ...................................................................................................... 215 Brake pumps, disassembly and examination ......................................................................................................... 216 Examining and adjusting the brake assembly ........................................................................................................ 219 Checking the parking brake linings......................................................................................................................... 220 Bleeding air from the hydraulic braking system...................................................................................................... 221 “Separate Brakes” valve ......................................................................................................................................... 222 Operating diagram for “Separate Brakes” valve ..................................................................................................... 224 Fault diagnosis ........................................................................................................................................................ 226 Electronic power-lift controls .................................................................................................................................. 227 Electronic power-lift specifications ......................................................................................................................... 230 Operation of the electronic power-lift ...................................................................................................................... 230 "All Round Tester"................................................................................................................................................... 234 Electronic power-lift self-diagnosis ......................................................................................................................... 239 Putting the electronic lift into service ...................................................................................................................... 242 AUTO-MAN procedure for entering the constant wheel value for an undefined tyre size ..................................... 243 Calibrating the draft sensor..................................................................................................................................... 244 Calibrating the steering sensor ............................................................................................................................... 244 Functional testing of system components .............................................................................................................. 244 Electronic power-lift hydraulic control valve............................................................................................................ 247 Testing the hydraulic lift operating pressure........................................................................................................... 248 Electronic power-lift operating diagrams ................................................................................................................ 249 Views of the lift ........................................................................................................................................................ 253 Section views of the draft sensor ............................................................................................................................ 256 Installing the draft sensor........................................................................................................................................ 258 On-board radar ....................................................................................................................................................... 259 3

Precautions regarding electronic apparatus ........................................................................................................... 259 Checking the mechanical components of the electronic power-lift ......................................................................... 260 Mechanically controlled power-lift, specifications ................................................................................................... 262 Section views of the mechanically controlled power-lift .......................................................................................... 263 Fitting the control lever lock screw and lever shaft cam ......................................................................................... 265 Fitting the ring seal on the lift piston ....................................................................................................................... 265 Hydraulic control valve for mechanically controlled power-lift, views and hydraulic circuit diagrams .................... 266 Adjusting the controls of the mechanically controlled power-lift ............................................................................. 272 Checking the lift mechanism ................................................................................................................................... 273 Testing the operating pressure ............................................................................................................................... 273 Removal of the lift control valve .............................................................................................................................. 273 Disassembly of the lift control valve ........................................................................................................................ 276 Sensing arm ............................................................................................................................................................ 277 Auxiliary lifting cylinders .......................................................................................................................................... 279 Specifications for control valve springs................................................................................................................... 280 Fault diagnosis ........................................................................................................................................................ 281 Front hydraulic power-lift, general description and specifications .......................................................................... 282 Checks .................................................................................................................................................................... 282 Hydraulic accumulator and anti-shock valve for front power-lift ............................................................................. 283 Front power take-off, general description and specifications ................................................................................. 285 Hydraulic operating diagrams for front PTO ........................................................................................................... 286 Front PTO views ..................................................................................................................................................... 288 Installing the “Ring-Feeders” .................................................................................................................................. 290 Checking the front PTO clutch ................................................................................................................................ 291 Checking clutch plate clearances ........................................................................................................................... 291 Checking the front PTO operating pressure ........................................................................................................... 291 Front PTO fault diagnosis ....................................................................................................................................... 292 Specifications for front PTO springs ....................................................................................................................... 292 6 - CONTROLS Hydrostatic power steering, general description and specifications ....................................................................... 291 Examining and testing the hydrostatic power steering system............................................................................... 294 Assembly instructions for the hydrostatic power steering control valve ................................................................. 297 Hydrostatic power steering operating diagram ....................................................................................................... 301 Mechanical controls ................................................................................................................................................ 302 Electrohydraulic controls ......................................................................................................................................... 310 System configuration............................................................................................................................................... 311 Electrohydraulic valves ........................................................................................................................................... 314 Hydraulic operating diagrams ................................................................................................................................ 318 Rear differential lock control cylinder for models with SBA System ....................................................................... 326 Front wheel drive disengagement cylinder for models without SBA System ......................................................... 326 Adjusting front and rear differential lock controls for models without SBA system ................................................ 327 Adjusting front wheel-drive controls for models without SBA System .................................................................... 328 MULTIFUNCTION CONTROL ................................................................................................................................ 329 PERFORMANCE MONITOR .................................................................................................................................. 334 Putting the performance monitor into service ......................................................................................................... 338 PERFORMANCE MONITOR retrofit procedure ..................................................................................................... 340 7 - BODYWORK Platform .................................................................................................................................................................. 341 Cab .......................................................................................................................................................................... 342 Instructions for fitting the front windscreen and lower side glass ........................................................................... 344 Fitting the seal ......................................................................................................................................................... 345 Cab air filter ............................................................................................................................................................. 346 Removal and refitting of the cab and platform ........................................................................................................ 347 “Normal” electric heating system ............................................................................................................................ 352 “High-power” electric heating system...................................................................................................................... 357 Cab air conditioning system.................................................................................................................................... 364 8 - SYSTEMS Hydraulic system..................................................................................................................................................... 376 Auxiliary hydraulic systems ..................................................................................................................................... 381 Hydraulic trailer braking ......................................................................................................................................... 391 Electrical system .................................................................................................................................................... 399 Specifications and components .............................................................................................................................. 399 Wiring diagrams ..................................................................................................................................................... 418 9 - APPENDIX Conversion tables ................................................................................................................................................... 448 Parts ........................................................................................................................................................................ 449 4

SILVER 80 - 90 - 100.4 - 100.6 TRACTOR CONFIGURATIONS CAB - ventilation + heating - with ventilation + heating + air conditioning GEARBOX Fully synchronised: - 12 Forward 12 Reverse: 4 speeds x 3 ranges + Reverser - 16 Forward 16 Reverse: 4 speeds x 4 ranges (including one creeper range) + Reverser; - 24 Forward 12 Reverse: 4 speeds x 3 ranges + with Mini-reduction-Reverser - 32 Forward 16 Reverse: 4 speeds x 4 ranges (including one creeper range) + Mini-reduction-Reverser - 15 Forward 15 Reverse: 5 speeds x 3 ranges + Reverser - 20 Forward 20 Reverse: 5 speeds x 4 ranges (including one creeper range) + Reverser AGROSHIFT GEARBOX - 45 Forward 45 Reverse: 5 speeds x3 ranges + Reverser + - - version - 60 Forward 60 Reverse: 5 speeds x4 ranges (including one creeper range) + Reverser + - - version CONTROLS - mechanically operated rear PTO - electrohydraulically operated rear PTO - mechanically operated 4WD and differential locks - electrohydraulically operated 4WD and differential locks - electrohydraulically operated 4WD and differential locks + SBA System - with electronic engine accelerator - with Multifunction control (on models with electronic power-lift only) MECHANICALLY OPERATED REAR POWER-LIFT - with supplementary rams - without supplementary rams ELECTRONIC REAR POWER-LIFT - with supplementary rams - without supplementary rams - with slip control - without slip control - with SBA System + RADAR + Slip control MAIN EQUIPMENT - front PTO - front lift - high-capacity hydraulic pump 22.5 l/min - hydraulic trailer braking - 4-way or 6-way or 8-way control valves with "Flow Divider" - PERFORMANCE MONITOR - etc. SILVER 80 - 90 2RM WITH ROLL BAR 2RM WITH CAB 4RM WITH ROLL BAR 4RM WITH CAB SILVER 100.4 - 100.6 4RM WITH ROLL BAR 4RM WITH CAB 5

DIMENSIONS AND WEIGHTS SILVER 80-90 SILVER 100.4 SILVER 100.6 2 WD 4WD 4WD 4WD Max. length without linkage (A) mm 3783 3783 3783 4108 - with rear linkage (B) mm 4118 4118 4123 4413 - with front linkage (B1) mm - 4818 4818 5078 Min.-max. width min./max. (C) mm 2000÷2500 2000÷2500 2000÷2500 2000÷2500 Max. height - at bonnet (D) mm 1745 1745 1745 1770 - at cab/safety frame (E) mm 2660 2660 2660 2685 - at silenceral (F) mm 2635 2665 2635 2665 - at steering wheel (L) mm 2010 2010 2010 2035 Ground clearance - beneath front axle (G) mm 515 445 445 475 - beneath front axle, wheel zone (G) mm 515 530 530 560 - beneath rear axle (M) mm 475 475 475 500 - beneath tow bar (M) mm 235 235 235 260 Wheel base (H) mm 2468 2373 2468 2633 Front track (I) min. mm 1400 1500 1500 1600 standard mm 1400 1600 1600 1700 max. mm 2000 2000 2000 2000 Rear track (N) min. mm 1500 1500 1500 1600 standard mm 1600 1600 1600 1700 max. mm 2000 2000 2000 2000 Front tyres 7.50-18 14,9R24 420/70/24 16,9R34 Rear tyres 16,9R34 16,9R34 480/70/34 520/70/34 Operating weight with safety cab - without PTO - front lift and ballast kg 3460 3850 3900 4250 with driver platform - without PTO - front lift and ballast kg 3200 3600 3700 3940 Min. turning radius (with standard width) - without brakes mm 3000 3000 3000 3500 - with brakes mm 3600 5000 5600 5300 6

Prescribed lubricants and fuels (amounts in litres) Part to be supplied Amt Oil type Product Engine 11 80-90 100.4 15 100.6 multi-grade engine oil SHPDO S+L+H OM - 1991 API CE- MIL-L-2104 E level CCMC D5 SAE 15W 40 AKROS TURBO Special Formula SAME Gearbox and Rear axle Power-lift Auxiliary Systems Hydrostatic steering 71 S+L+H OT - 1891 API GL 4 SAE 10W30 AKROS MULTI Front PTO 2,5 Front - wheel drive • Central axle • Side reductions 10,5 2,5x2 Brakes control Max. level ATF DEXRON II AKROS MATIC Lubrication points NLGI 2 LITIO/Ca AKROS GREASE T2 Fuel tank 140 180* * Optional, only for SILVER 100.6. WARNING: The engine oil sump has been replenished in the factory with AKROS MOTOR OIL 30 SAE 30, to be replaced subsequently after 50 work hours. It is advisable to always use the same type of oil when replenishing. AKROS is available in the following types: SAE 30, SAE 40, SAE 15W40. 7

Fig. 1 - SILVER 80 - Engine cross section - 4 cylinders. engine engine section SILVER 80 1 8

Fig. 2 - SILVER 80 - Longitudinal section - 4 cylinders. engine SILVER 80 engine section 1 9

Fig. 3 - SILVER 90 - Engine cross section - 4 cylinders. engine engine section SILVER 90 1 10

SAME Silver 80/90/100.4/100.6 Tractor Service & Repair Manual

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