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Same Dorado S V 70 75 90 100 service repair workshop manual
S70 and V70 Powershuttle
S75 and V75 Powershuttle
S90 and V90 Powershuttle
S100 and V100 Powershuttle
language:english
number of pages: 717 (full digital version)
MAin sections:
Introduction
Safety sections
1. TRANSMISSION................................................................. 1
INTRODUCTION.................................................................. 1
DESCRIPTION..................................................................... 2
1.1 REVERSE SHUTTLE UNIT ........................................... 3
1.2 HML UNIT .................................................................... 4
1.3 GEARBOX ASSEMBLY (Version with HML)................ 5
1.4 GEARBOX AND SHUTTLE ASSEMBLY
(Version without HML)................................................. 6
1.5 UNDERDRIVE CONTROL ROD..................................... 7
1.6 SPEED CONTROL ROD............................................... 8
1.7 RANGE GEARS AND PARKING BRAKE ASSEMBLY.. 9
1.8 RANGE CONTROL ROD AND
PARKING BRAKE LEVER........................................... 10
1.9 FOUR-WHEEL DRIVE ENGAGEMENT ASSEMBLY . 11
1.10 DIFFERENTIAL ASSEMBLY...................................... 12
1.11 BRAKES AND REAR AXLE ASSEMBLY
(Narrow version) ........................................................ 13
1.12 BRAKES AND REAR AXLE ASSEMBLY
(Wide version)............................................................. 14
2. REAR PTO......................................................................... 15
2.1 PTO CONTROL CLUTCH ASSEMBLY ...................... 16
2.2 2-SPEED PTO........................................................... 19
2.3 2-SPEED PTO AND SYNCRO PTO .......................... 20
2.4 3-SPEED PTO........................................................... 21
3. FRONT AXLE.................................................................... 23
3.1 FRONT AXLE (4WD version) ...................................... 23
4. FRONT PTO AND LIFT .................................................... 27
4.1 FRONT LIFT ................................................................ 27
4.2 FRONT PTO ................................................................ 31
5. HYDRAULIC SYSTEM..................................................... 39
DESCRIPTION................................................................... 39
5.1 HYDRAULIC DIAGRAM (standard version)................ 40
5.2 STEERING CIRCUIT GEAR PUMP ............................ 45
5.3 LIFT CIRCUIT
GEAR PUMP............................................................. 46
5.4 POWER STEERING.................................................... 48
5.5 COOLER BYPASS ASSEMBLY ................................. 49
5.6 SHUTTLE SOLENOID VALVES ASSEMBLY.............. 51
5.7 AUXILIARY SERVICES CONTROL VALVE................. 52
5.8 HYDRAULIC 3-POINT
LINKAGE CONTROL VALVE...................................... 55
5.9 SERVICES SOLENOID VALVE ASSEMBLY............... 56
5.10TRAILER BRAKING VALVE........................................ 57
5.11LIFT CONTROL VALVE.............................................. 61
1. DIAGNOSIS TOOLS............................................................ 1
1.1 ALL ROUND TESTER ......................................................... 1
1.1.1 DESCRIPTION OF THE KIT ................................... 1
1.1.2 NOTES ON CORRECT USE.................................... 2
1.1.3 DESCRIPTION OF THE TESTER............................. 2
1.1.4 GENERAL NOTES ON CONNECTING AND
POWERING UP THE TESTER................................. 3
1.1.5 SELECTION OF THE DISPLAY LANGUAGE............ 3
1.1.6 SETTING THE SERIAL PORTS .............................. 5
2. CONNECTION OF THE TESTER TO THE ELECTRONIC
CONTROL UNITS .............................................................. 7
2.1 CONNECTING ART® TO THE HYDRAULIC LIFT
AND ENGINE CONTROL UNITS ........................................ 7
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE
TRACTOR........................................................................... 9
3.1 ENGINE ECU ...................................................................... 9
3.1.1 ELECTRONIC ENGINE CONTROL SYSTEM.......... 9
3.1.2 ELECTRONIC PRE-HEATING CONTROL SYSTEM ..
10
3.2 SHUTTLE ECU ................................................................. 10
3.2.1 HYDRAULIC SHUTTLE ELECTRONIC CONTROL
SYSTEM................................................................ 10
3.2.2 HML UNIT ELECTRONIC CONTROL SYSTEM
.............................................................................. 12
3.3 INSTRUMENT PANEL ...................................................... 13
3.4 LIFT ECU .......................................................................... 14
3.5 CANBUS SYSTEM ........................................................... 15
4. COMMISSIONING THE TRACTOR................................. 17
4.1 INTRODUCTION................................................................ 17
4.2 RENEWAL OF THE ENGINE ECU .................................... 17
4.2.1 SETTING THE TYPE OF ENGINE
INSTALLED ........................................................... 17
4.2.2 CALIBRATING THE HAND THROTTLE................. 19
4.2.3 ACCELERATOR PEDAL CALIBRATION ............... 22
4.2.4 PREHEATING TYPE CONFIGURATION ............... 24
4.2.5 WHEELS PARAMETER CONFIGURATION........... 26
4.2.6 IDLE SPEED CALIBRATION.................................. 28
4.2.7 CANCELLING ALARMS ........................................ 29
4.3 RENEWAL OF THE SHUTTLE ECU .................................. 31
4.3.1 INITIALIZATION OF THE ECU............................... 31
4.3.2 GEARBOX TYPE CONFIGURATION..................... 33
4.3.3 CLUTCH PEDAL CALIBRATION........................... 35
4.3.4 OPTIONAL EQUIPMENT
CONFIGURATION................................................ 36
4.3.5 CANCELLING ALARMS ........................................ 38
4.3.6 NOTES REGARDING THE
CLUTCH CALIBRATION PROCEDURE ............... 39
4.3.7 NOTES ON CLUTCH CALIBRATION
PARAMETERS ...................................................... 40
4.3.8 NOTES ON HOW TO CHANGE PARAMETER
SETTINGS DURING MANUAL
CALIBRATION........................................................ 41
4.3.9 AUTOMATIC CALIBRATION OF THE
SHUTTLE CLUTCHES ........................................... 41
4.3.10 MANUAL CALIBRATION OF THE
SHUTTLE CLUTCHES ........................................... 44
4.4 RENEWAL OF THE INSTRUMENT PANEL ........................48
4.4.1 PROGRAMMING THE TYPE OF TRACTOR .......... 48
4.4.2 ENTERING THE WHEELS CONSTANT ................. 50
4.4.3 SETTING THE SPEED CONVERSION FACTORS.. 52
4.5 RENEWAL OF THE LIFT ECU ...........................................54
4.5.1 CALIBRATION OF MAXIMUM
LIFT HEIGHT......................................................... 54
5. ALARMS .......................................................................... 57
5.1 ENGINE ECU ALARMS
(code 2.8519.054.0/60) 57
5.1.1 LIST OF ALARMS DISPLAYED ON THE
INSTRUMENT PANEL............................................ 57
5.1.2 LIST OF ALARMS DISPLAYED ON THE
INSTRUMENT PANEL (PRE-HEATING INDICATOR
LIGHT).................................................................... 57
5.1.3 LIST OF ALARMS DISPLAYED ON THE ART........ 58
5.2 SHUTTLE ECU ALARMS
(code 2.8519.030.0/60) ....................................................81
5.2.1 LIST OF ALARMS DISPLAYED ON THE
INSTRUMENT PANEL........................................... 81
5.2.2 LIST OF ALARMS DISPLAYED ON THE ART........ 85
5.3 INSTRUMENT PANEL ALARMS (code 2.8339.248.0) ....135
5.3.1 LIST OF ALARMS SIGNALLED ON THE ALARM
LAMP................................................................... 135
5.3.2 LIST OF ALARMS DISPLAYED ON THE ART...... 136
5.4 LIFT ECU ALARMS
(code 0.011.2992.4/30) ..................................................141
5.4.1 LIST OF ALARMS BY
FLASH SEQUENCE ON LIFT CONTROL BUTTON....
141
5.4.2 LIST OF ALARMS DISPLAYED ON THE ART...... 142
FRONT HOOD AND SIDE PANELS.............. 1
Removal...................................................................... 1
Installation .................................................................. 2
WHEELS......................................................... 3
FRONT WHEELS.............................................................3
Removal...................................................................... 3
Installation .................................................................. 3
REAR WHEELS...............................................................4
Removal...................................................................... 4
Installation .................................................................. 4
SAFETY ROLL BAR....................................... 5
Removal...................................................................... 5
Installation .................................................................. 5
FUEL TANK.................................................... 6
MAIN TANK.....................................................................6
Removal...................................................................... 6
Installation .................................................................. 8
SUPPLEMENTARY FUEL TANK....................................9
Draining ...................................................................... 9
Removal.................................................................... 10
Installation ................................................................ 11
RADIATOR................................................... 12
Removal.................................................................... 12
Installation ................................................................ 13
FRONT SUPPORT....................................... 14
Removal.................................................................... 14
Installation ................................................................ 16
FRONT AXLE (4WD version) ...................... 17
COMPLETE AXLE ASSEMBLY....................................17
Removal.................................................................... 17
Installation ................................................................ 19
STEERING CYLINDER .................................................20
Removal.................................................................... 20
Installation ................................................................ 22
STEERING KNUCKLE HOUSING AND HALFSHAFT .23
Removal.................................................................... 23
Installation ................................................................ 27
Adjusting the bearings preload ................................ 28
EPICYCLIC REDUCTION UNIT....................................31
Removal.................................................................... 31
Installation ................................................................ 32
Disassembly ............................................................. 33
Assembly.................................................................. 36
PINION-DIFFERENTIAL ASSEMBLY ..........................37
Removal.................................................................... 37
Installation ................................................................ 37
DIFFERENTIAL LOCK ENGAGEMENT DEVICE.........38
Removal.................................................................... 38
Installation ................................................................ 40
Adjustment ............................................................... 41
BEVEL GEAR PAIR.......................................................44
Disassembly ............................................................. 44
Adjustment of the pinion position and bearing
preloading................................................................. 48
Adjustment of the differential bearings preload ....... 53
Adjustment of the pinion and crown wheel .............. 57
Completion of assembly........................................... 57
DIFFERENTIAL .............................................................59
Disassembly ............................................................. 59
Assembly .................................................................. 60
PLATFORM ..................................................61
Removal.................................................................... 61
Installation ................................................................ 68
CAB...............................................................69
Removal.................................................................... 69
Installation ................................................................ 77
FRONT AXLE DRIVE SHAFT.......................78
Removal.................................................................... 78
Installation ................................................................ 78
ENGINE.........................................................79
Preparation before separating the engine from the
transmission ............................................................. 79
Preparation for removal ............................................ 79
Separation or removal .............................................. 80
Installation ................................................................ 82
STARTER MOTOR.......................................83
Removal.................................................................... 83
Installation ................................................................ 85
TORSIONAL SPRING PLATE......................86
Removal.................................................................... 86
Installation ................................................................ 86
REVERSE SHUTTLE UNIT ..........................87
COMPLETE ASSEMBLY..............................................87
Removal.................................................................... 87
Installation ................................................................ 89
Disassembly ............................................................. 90
CONTENTS
30-ii
Assembly...................................................................91
COVER ASSEMBLY..................................................... 93
Disassembly ..............................................................93
Assembly...................................................................93
FORWARD DRIVE CLUTCH ASSEMBLY................... 94
Disassembly ..............................................................95
Assembly...................................................................97
REVERSE DRIVE CLUTCH ASSEMBLY..................... 99
Disassembly ............................................................100
Assembly.................................................................103
HML UNIT .................................................. 106
COMPLETE ASSEMBLY............................................ 106
Removal ..................................................................106
Installation ...............................................................110
Checking the reduction unit end float .....................111
CLUTCH UNITS.......................................................... 112
Disassembly ............................................................112
Assembly.................................................................119
PLANET CARRIER ASSEMBLY ................................ 125
Disassembly ............................................................125
Assembly.................................................................127
GEARBOX AND SHUTTLE ASSEMBLY... 129
COMPLETE ASSEMBLY (Version without HML)..... 129
Removal ..................................................................129
Installation ...............................................................134
COMPLETE ASSEMBLY (Version with HML) .......... 135
Removal ..................................................................135
Reassembly.............................................................138
Disassembly ............................................................139
GEARBOX INPUT SHAFT.......................................... 142
Disassembly ............................................................142
Assembly.................................................................145
PRIMARY SHAFT....................................................... 146
Disassembly ............................................................146
Assembly.................................................................147
SECONDARY SHAFT
(Version with HML)..................................................148
Disassembly ............................................................148
Assembly.................................................................154
SECONDARY SHAFT (Version without HML).......... 160
Assembly.................................................................165
GEAR SELECTOR ROD............................................. 170
Disassembly ............................................................170
Assembly.................................................................170
UNDERDRIVE CONTROL ROD................................. 171
Disassembly ............................................................171
Assembly.................................................................171
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL... 172
Removal ..................................................................172
Installation ...............................................................172
Disassembly ............................................................173
Assembly.................................................................174
HYDRAULIC PUMPS ................................ 175
STEERING PUMP
AND SOLENOID VALVES .......................................... 175
Removal ..................................................................175
Installation .............................................................. 178
PUMP FOR HYDRAULIC LIFT AND AUXILIARY
SERVICES .................................................................. 179
Removal ................................................................. 179
Installation .............................................................. 181
SERVICE VALVES ASSEMBLY .................182
Removal ................................................................. 182
Installation .............................................................. 185
Disassembly ........................................................... 186
Assembly................................................................ 188
HYDRAULIC TRAILER
BRAKING VALVE ......................................189
Removal ................................................................. 189
Installation .............................................................. 190
LIFT
(VERSION WITH MECHANICAL
GOVERNOR)
....................................................................191
COMPLETE ASSEMBLY ........................................... 191
Removal ................................................................. 191
Installation .............................................................. 194
Disassembly ........................................................... 195
Assembly................................................................ 201
BUSHES ..................................................................... 202
Renewal.................................................................. 202
LIFT CONTROL VALVE ............................................. 203
Removal ................................................................. 203
Installation .............................................................. 204
Disassembly ........................................................... 205
Assembly................................................................ 208
LIFT CYLINDER ......................................................... 210
Disassembly ........................................................... 210
Assembly................................................................ 211
MECHANICAL DRAFT SENSOR............................... 213
Removal ................................................................. 213
Installation .............................................................. 213
Disassembly ........................................................... 214
Assembly................................................................ 215
LIFT CONTROL LEVERS........................................... 217
Adjustments ........................................................... 217
AUXILIARY SERVICES CONTROL VALVE.....
220
Removal ................................................................. 220
Installation .............................................................. 222
REAR AXLE................................................223
RIGHT AND LEFT AXLES.......................................... 223
Preparation for removal of the right axle................ 223
Preparation for removal of the left axle .................. 225
Removal of the complete rear axle......................... 226
Installation .............................................................. 227
Disassembly (wide version) .................................... 228
Assembly................................................................ 231
Disassembly (narrow version)................................. 233
Assembly................................................................ 236
PLANET CARRIER ASSEMBLY................................ 238
CONTENTS
30-iii
Disassembly ........................................................... 238
Assembly................................................................ 238
BRAKES..................................................... 239
REAR AXLE BRAKES.................................................239
Renewal of the brake discs .................................... 239
BRAKING PISTON......................................................240
Disassembly ........................................................... 240
Assembly................................................................ 240
FRONT AXLE BRAKES...............................................242
Removal.................................................................. 242
Installation .............................................................. 243
Piston disassembly................................................. 244
Piston assembly ..................................................... 244
PARKING BRAKE.......................................................245
Removal of the friction shoes................................. 245
Refitting the friction shoes...................................... 247
Disassembly ........................................................... 249
Assembly................................................................ 249
BRAKE CYLINDERS...................................................250
Removal.................................................................. 250
Installation .............................................................. 251
3-POINT LINKAGE .................................... 252
Removal.................................................................. 252
Installation .............................................................. 254
TOWING HITCH......................................... 255
Removal.................................................................. 255
Installation .............................................................. 255
REAR PTO ................................................. 256
PTO INPUT SHAFT.....................................................256
Removal.................................................................. 256
Installation .............................................................. 257
PTO CONTROL CLUTCH...........................................258
Removal.................................................................. 258
Installation .............................................................. 259
Disassembly ........................................................... 260
Assembly................................................................ 264
PTO OUTPUT SHAFT
(2-SPEED + GROUNDSPEED VERSION) .................265
Disassembly ........................................................... 265
Assembly................................................................ 269
GROUNDSPEED PTO DRIVE SHAFT........................270
Disassembly ........................................................... 270
Assembly................................................................ 271
RANGE GEARBOX AND
REAR DIFFERENTIAL ASSEMBLY...........272
COMPLETE ASSEMBLY............................................272
Disassembly ........................................................... 272
Assembly ................................................................ 272
PUMP DRIVE PTO......................................................273
Disassembly ........................................................... 273
Assembly ................................................................ 275
DIFFERENTIAL ASSEMBLY ......................................276
Removal.................................................................. 276
Installation .............................................................. 278
Disassembly ........................................................... 279
Assembly ................................................................ 281
PINION ........................................................................282
Disassembly ........................................................... 282
Assembly ................................................................ 285
RANGE SELECTOR ROD...........................................286
Disassembly ........................................................... 286
Assembly ................................................................ 287
4WD AND GROUNDSPEED
PTO OUTPUT SHAFT................................................288
Disassembly ........................................................... 288
Assembly ................................................................ 292
BEVEL GEAR PAIR.....................................................293
Preparation for adjustments ................................... 293
Adjustment of the differential bearings preload ..... 295
Adjustment of the pinion position........................... 297
Adjustment of the pinion and crown wheel ............ 299
INSTRUMENT PANEL ...............................300
Removal.................................................................. 300
Installation .............................................................. 302
POWER STEERING....................................303
Removal.................................................................. 303
Installation .............................................................. 304
THE STRUCTURE OF THE UNIT....................................1
HOW TO CONSULT THE UNIT ......................................2
1. INTRODUCTION..........................................................3
1.1 LIST OF WIRING HARNESSES ............................................3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ...............4
1.3 GENERAL RULES.................................................................5
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/
ELECTRONIC CIRCUITS ........................................... 5
1.3.2 MAIN WIRING FAULTS.............................................. 5
1.3.3 REMOVAL, REFITTING AND DRYING OF
CONNECTORS AND WIRING.................................... 6
1.4 DIAGNOSTIC INSTRUMENTS..............................................7
1.5 WIRE COLOUR CODES .......................................................7
2. INDICES.......................................................................8
2.1 INDEX BY PART DESCRIPTION...........................................8
2.2 INDEX BY PART CODE ......................................................12
2.3 INDEX BY CONNECTOR....................................................17
3. COMPONENTS .........................................................27
3.1 COMPONENT TECHNICAL DATA......................................27
3.2 PINOUTS AND DESCRIPTIONS OF
ELECTRONIC CONTROL UNITS.......................................36
3.2.1 ENGINE ECU (code 2.8519.054.0/60) ..................... 36
3.2.2 ELECTRONIC LIFT ECU
(code 0.011.2992.4/50) ........................................... 38
3.2.3 SHUTTLE ECU (code 2.8519.030.0/60)................... 39
3.2.4 INSTRUMENT PANEL (code 2.8339.248.0/20)........ 41
4. SYSTEMS ..................................................................43
4.1 EARTHING POINTS............................................................43
4.2 STARTING AND PREHEATING...........................................46
4.3 ELECTRONIC ENGINE CONTROL ....................................47
4.4 LIGHTS - STEERING COLUMN SWITCH...........................48
4.5 DIAGNOSTIC ACCESSORIES (CAB VERSION) .................49
4.6 DIAGNOSTIC ACCESSORIES (PLATFORM VERSION)......50
4.7 INSTRUMENT PANEL ........................................................51
4.8 WORKLIGHTS (CAB VERSION)..........................................52
4.9 WORKLIGHTS(PLATFORM VERSION) ...............................53
4.10 WINDSCREEN WIPERS......................................................54
4.11 HEATING ............................................................................55
4.12 AIR CONDITIONING ...........................................................56
4.13 BRAKES..............................................................................57
4.14 HML TRANSMISSION ........................................................58
4.15 ELECTRONIC LIFT .............................................................59
4.16 FRONT AND REAR PTO.....................................................60
4.17 FRONT CONTROL VALVE..................................................61
4.18 3-POINT LINKAGE..............................................................62
4.19 CAN BUS............................................................................63
5. WIRING ..................................................................... 65
BATTERY LEADS WIRING...........................................................65
BATTERY LEADS WIRING.......................................................... 67
CENTRAL WIRING (1/2)...............................................................69
CENTRAL WIRING (2/2)...............................................................70
SHUTTLE LEVER WIRING...........................................................71
CENTRAL WIRING...................................................................... 81
REAR WIRING (1/2) .....................................................................83
REAR WIRING (2/2) .....................................................................84
TRAILER BRAKE WIRING............................................................85
FILTER WIRING ...........................................................................86
INTERFERENCE SUPPRESSOR WIRING ...................................87
REAR WIRING - TRAILER BRAKING WIRING
.................................................................................................... 93
FILTER WIRING - INTERFERENCE SUPPRESSOR WIRING..... 93
ENGINE WIRING (3-CYLINDER VERSION) (1/2) .........................95
ENGINE WIRING (3-CYLINDER VERSION) (2/2) .........................96
ENGINE WIRING (4-CYLINDER VERSION) (1/2) .........................97
ENGINE WIRING (4-CYLINDER VERSION) (2/2) .........................98
ROTATING BEACON WIRING.....................................................99
CAB LIGHTS WIRING................................................................100
FRONT PTO WIRING.................................................................101
WIRING FOR ROLL BAR LIGHTS .............................................102
ENGINE WIRING - ROTATING BEACON WIRING -CAB LIGHTS
WIRING
109...................................................................................................
PRE-HEATING AND POWER SUPPLY WIRING
(3-CYLINDER VERSION WITH CAB) ........................................111
PRE-HEATING AND POWER SUPPLY WIRING
(4-CYLINDER VERSION WITH CAB) .........................................112
PRE-HEATING AND POWER SUPPLY WIRING
(3-CYLINDER VERSION WITH PLATFORM) .............................113
PRE-HEATING AND POWER SUPPLY WIRING
(4-CYLINDER VERSION WITH PLATFORM) .............................114
PRE-HEATING AND POWER SUPPLY WIRING....................... 117
ROOF LINE WIRING (1/2) ..........................................................119
ROOF LINE WIRING (2/2) ..........................................................120
CAB POWER SUPPLY WIRING ................................................121
WINDSCREEN WIPER WIRING.................................................122
ROOF LINE WIRING - CAB POWER SUPPLY WIRING
- WINDSCREEN WIPER WIRING ............................................ 125
HEATER WIRING.......................................................................127
HEATER WIRING...................................................................... 129
AIR CONDITIONING SYSTEM WIRING.....................................131
CONTENTS
40-ii
AIR CONDITIONING SYSTEM WIRING.................................... 133
AIR CONDITIONING
FAN WIRING (1/2).....................................................................135
AIR CONDITIONING
FAN WIRING (2/2) ......................................................................136
AIR CONDITIONING FAN WIRING .......................................... 137
WIRING FOR WORKLIGHTS, REAR WINDOW
WIPER AND FLASHING LIGHT (1/2) .........................................139
WIRING FOR WORKLIGHTS, REAR
WINDOW WIPER AND FLASHING LIGHT (2/2).........................140
EARTH WIRING .........................................................................141
WIRING FOR WORKLIGHTS, REAR WINDOW WIPER AND
FLASHING
LIGHT - EARTH WIRING .......................................................... 145
ELECTRONIC LIFT WIRING (1/2) ..............................................147
ELECTRONIC LIFT WIRING (2/2) ..............................................148
FRONT CONTROL VALVE WIRING(1/2)....................................149
FRONT CONTROL VALVE WIRING (2/2)...................................150
FRONT CONTROL VALVE SOLENOID VALVE WIRING
ANTERIORE...............................................................................151
3-POINT LINKAGE WIRING.......................................................153
3-POINT LINKAGE WIRING.......................................................154
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