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Same Explorer 75T 85T 95T service workshop repair manual
75T and 75TB
85T and 85TB
95T and 95TB
language:English
number of pages: 518 (full digital copy)
Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................. 1
INTRODUCTION....................................................................... 1
DESCRIPTION.......................................................................... 2
1.1 CLUTCH HOUSING............................................................ 3
1.2 HI-LO Unit .......................................................................... 4
1.3 GEARBOX AND SHUTTLE ASSEMBLY
(HI-LO version) ............................................................... 5
1.4 GEARBOX AND SHUTTLE ASSEMBLY
(VERSION WITHOUT HI-LO) .......................................... 6
1.5 BEVEL PINION AND RANGE GEARBOX ASSEMBLY ....... 8
1.6 FOUR-WHEEL DRIVE ENGAGEMENT
AND PARKING BRAKE ASSEMBLY .............................. 9
1.7 DIFFERENTIAL ASSEMBLY ............................................. 10
1.8 BRAKES AND REAR AXLE ASSEMBLY
(VERSION 85T - 95T).................................................... 11
1.9 BRAKES AND REAR AXLE ASSEMBLY
(VERSION 75T - 75TB - 85TB - 95TB) ........................ 12
2. REAR PTO......................................................................... 13
DESCRIPTION........................................................................ 13
2.1 PTO CLUTCH ASSEMBLY
(VERSION 85T - 95T - 95TB)....................................... 14
2.2 PTO CLUTCH ASSEMBLY
(VERSION 85T - 95T - 95TB)........................................ 15
2.3 PTO CLUTCH ASSEMBLY
(VERSION 75T - 75T - 85TB)....................................... 18
2.4 PTO CLUTCH ASSEMBLY
(VERSION 75T - 75T - 85TB)........................................ 19
2.5 2-SPEED PTO AND GROUNDSPEED PTO...................... 23
2.6 4-SPEED PTO AND GROUNDSPEED PTO...................... 24
3. FRONT AXLE..................................................................... 25
3.1 FINAL DRIVE (VERSION 75T - 75TB - 85TB)....................26
3.2 FINL DRIVE (VERSION 85T - 95T - 95TB).........................27
3.3 PINION, DIFFERENTIAL
AND DIFFERENTIAL LOCK...........................................28
4. HYDRAULIC SYSTEM.................................................... 29
DESCRIPTION.........................................................................29
4.1 HYDRAULIC DIAGRAM (VERSION 75T - 75TB - 85TB) ...30
4.2 HYDRAULIC DIAGRAM (VERSION 85T - 95T - 95TB)......34
4.3 STEERING CIRCUIT GEAR PUMP....................................39
4.4 LIFT CIRCUIT GEAR PUMP ..............................................40
4.5 POWER STEERING...........................................................41
4.6 PRESSURE CONTROL VALVE .........................................42
4.7 AUXILIARY SERVICES CONTROL VALVE........................43
4.8 LIFT CONTROL VALVE
(VERSION 75T - 75TB - 85TB) .....................................45
4.9 LIFT CONTROL VALVE
VERSION 85T - 95T - 95TB) .........................................51
5. BRAKING SYSTEM........................................................... 57
DESCRIPTION.........................................................................57
5.1 SEPARATE-BRAKES VALVE..........................................58
5.2 TRAILER BRAKING VALVE ...............................................63
ENGINE HOOD AND SIDE PANELS............. 1
Removal...................................................................... 1
Refitting ...................................................................... 2
RADIATOR..................................................... 3
Removal...................................................................... 3
Refitting ...................................................................... 6
STARTER MOTOR ........................................ 7
Removal...................................................................... 7
Refitting ...................................................................... 8
WHEELS......................................................... 9
FRONT WHEELS (4WD Version) ...................................9
Removal...................................................................... 9
Refitting ...................................................................... 9
FRONT WHEELS (2WD version)..................................10
Removal.................................................................... 10
Refitting .................................................................... 10
REAR WHEELS.............................................................11
Removal.................................................................... 11
Refitting .................................................................... 11
FRONT AXLE DRIVE SHAFT ...................... 12
Removal.................................................................... 12
Refitting .................................................................... 12
FRONT SUPPORT....................................... 13
Removal.................................................................... 13
Refitting .................................................................... 15
FRONT AXLE............................................... 16
COMPLETE AXLE ASSEMBLY....................................16
Removal.................................................................... 16
Refitting .................................................................... 18
Adjusting of the front axle end float ......................... 19
STEERING CYLINDER .................................................22
Removal.................................................................... 22
Refitting .................................................................... 23
Disassembly ............................................................. 24
Assembly .................................................................. 24
EPICYCLIC REDUCTION UNIT....................................25
Removal.................................................................... 25
Refitting .................................................................... 26
Disassembly (Version 75T - 85T - 95T) .................... 27
Assembly .................................................................. 30
Disassembly (TB version) ......................................... 33
Assembly .................................................................. 35
STEERING KNUCKLE HOUSING AND HALFSHAFT .37
Removal.................................................................... 37
Refitting .................................................................... 41
Adjusting the bearings preload................................. 43
PINION-DIFFERENTIAL ASSEMBLY ..........................46
Removal.................................................................... 46
Refitting .................................................................... 47
DIFFERENTIAL LOCK ..................................................48
Removal.................................................................... 48
Refitting .................................................................... 50
Adjustment ............................................................... 51
BEVEL GEAR PAIR.......................................................55
Disassembly ............................................................. 55
Adjustment of the differential preload ...................... 65
Adjustment of the pinion and crown wheel
backlash ................................................................... 69
Completion of assembly........................................... 69
DIFFERENTIAL .............................................................71
Disassembly ............................................................. 71
Assembly .................................................................. 72
EXHAUST PIPE ............................................73
Removal.................................................................... 73
Refitting .................................................................... 73
ENGINE.........................................................74
Separating the engine from the transmission........... 74
Removal.................................................................... 81
Refitting .................................................................... 86
CLUTCH ASSEMBLY...................................87
CLUTCH........................................................................87
Removal.................................................................... 87
.................................................................................. 88
Checking clutch plate wear ...................................... 88
CLUTCH RELEASE BEARING .....................................89
Renewal .................................................................... 89
CLUTCH MASTER CYLINDER ....................................90
Removal.................................................................... 90
Refitting .................................................................... 90
CLUTCH PISTON..........................................................91
Removal.................................................................... 91
Refitting .................................................................... 91
CLUTCH CONTROL CIRCUIT .....................................92
Bleeding.................................................................... 92
4-PILLAR ROPS FRAME............................. 93
ROPS FRAME............................................................... 93
Removal ....................................................................93
Refitting .....................................................................94
ROPS SUPPORT.......................................................... 95
Removal ....................................................................95
Refitting .....................................................................97
FOLDING SAFETY ROLL BAR ................... 98
COMPLETE ASSEMBLY.............................................. 98
Removal ....................................................................98
Refitting .....................................................................99
FENDER..................................................... 100
Removal ..................................................................100
Refitting ...................................................................101
SEAT SUPPORT........................................ 102
Refitting ...................................................................105
HYDRAULIC TRAILER BRAKING VALVE 106
VERSION 85T - 95T - 95TB ....................................... 106
Removal ..................................................................106
Refitting ...................................................................107
AUXILIARY SERVICES CONTROL VALVE -
VERSION 85T - 95T - 95TB....................... 108
Removal ..................................................................108
Refitting ...................................................................109
LIFT (VERSION 85T - 95T - 95TB)............ 110
COMPLETE ASSEMBLY............................................ 110
Removal ..................................................................110
Refitting ...................................................................113
Disassembly ............................................................114
Assembly ................................................................117
LIFT CYLINDER ......................................................... 119
Disassembly ............................................................119
Assembly.................................................................119
BUSHES...................................................................... 121
Renewal...................................................................121
LIFT CONTROL VALVE.............................................. 122
Disassembly ............................................................122
Assembly.................................................................125
CONTROL LEVERS.................................................... 128
Adjustment ..............................................................128
MECHANICAL DRAFT SENSOR............................... 133
Removal ..................................................................133
Refitting ...................................................................133
Disassembly ............................................................134
Assembly.................................................................135
LIFT (VERSION 75T-75TB-85TB) ............. 136
COMPLETE ASSEMBLY............................................ 136
Removal ..................................................................136
Refitting ...................................................................139
Disassembly ............................................................140
Assemblaggio..........................................................143
HYDRAULIC LIFT CONTROL VALVE ....................... 145
Removal ..................................................................145
Refitting ...................................................................145
Disassembly ........................................................... 146
Assembly................................................................ 149
CONTROL LEVERS ................................................... 152
Adjustment ............................................................. 152
3-POINT LINKAGE.....................................155
Removal ................................................................. 155
Refitting .................................................................. 156
BRAKES .....................................................157
REAR AXLE BRAKE DISCS ...................................... 157
Renewal.................................................................. 157
REAR AXLE BRAKE PISTON (VERSION 85T - 95T) 158
Disassembly ........................................................... 158
Assembly................................................................ 158
REAR AXLE BRAKE PISTON
(VERSION 75T - 75TB - 85TB - 95TB)160
Disassembly ........................................................... 160
Assembly................................................................ 160
FRONT AXLE BRAKE DISCS.................................... 162
Removal ................................................................. 162
Refitting .................................................................. 162
FRONT AXLE BRAKE PISTON.................................. 163
Disassembly ........................................................... 163
Assembly................................................................ 163
PARKING BRAKE ...................................................... 164
Disassembly ........................................................... 164
Assembly................................................................ 165
BRAKE CYLINDERS.................................................. 166
Removal ................................................................. 166
Refitting .................................................................. 167
BRAKING CIRCUIT.................................................... 168
Brake bleeding procedure...................................... 168
Bleeding the rear brakes circuit ............................. 168
REAR AXLE................................................170
ASSEMBLY (VERSION 85T - 95T - 95TB) ................ 170
Removal of the complete rear axle
(Version 85T - 95T) ................................................ 175
Refitting .................................................................. 176
Removal of the complete rear axle assembly
(Version 95TB) ....................................................... 177
Refitting .................................................................. 178
COMPLETE ASSEMBLY (VERSION 75T - 75TB - 85TB)
179
Removal of the complete rear axle......................... 182
Refitting .................................................................. 183
Disassembly ........................................................... 184
Assembly................................................................ 188
PLANET CARRIER ASSEMBLY................................ 190
Disassembly ........................................................... 190
Assembly................................................................ 191
PLATFORM ................................................192
Removal ................................................................. 192
Refitting .................................................................. 198
HYDRAULIC PUMPS ................................ 199
PUMP FOR HYDRAULIC LIFT AND AUXILIARY
SERVICES ...................................................................199
Removal.................................................................. 199
Refitting .................................................................. 199
POWER STEERING PUMP.........................................200
Removal.................................................................. 200
Refitting .................................................................. 201
CLUTCH HOUSING................................... 202
COMPLETE ASSEMBLY ............................................202
Separating the engine from the transmission......... 202
Reassembly ............................................................ 206
GEARBOX AND SHUTTLE ASSEMBLY
(Standard version) .................................... 207
COMPLETE ASSEMBLY ............................................207
Removal.................................................................. 207
Refitting .................................................................. 208
GEARBOX SUPPORT AND GEAR SELECTOR
RODS...........................................................................213
Disassembly ........................................................... 213
Assembly ................................................................ 214
SHUTTLE AND UNDERDRIVE SHAFT ......................216
Disassembly ........................................................... 216
Assembly ................................................................ 220
MAIN SHAFT...............................................................222
Disassembly ........................................................... 222
Assembly ................................................................ 223
SECONDARY SHAFT .................................................224
Disassembly ........................................................... 224
Assembly ................................................................ 227
HI-LO UNIT AND GEARBOX .................... 229
COMPLETE ASSEMBLY ............................................229
Removal.................................................................. 229
Refitting .................................................................. 230
HI-LO UNIT ................................................ 231
COMPLETE ASSEMBLY ............................................231
Removal.................................................................. 231
Refitting .................................................................. 234
Adjustment of the end float of the gears of the
epicyclic unit........................................................... 236
PLANET CARRIER ASSEMBLY.................................237
Disassembly ........................................................... 237
Assemblaggio......................................................... 238
LO RANGE CLUTCH DRUM ......................................239
Disassembly ........................................................... 239
Assembly ................................................................ 244
Adjusting the spring preload .................................. 249
COMPLETE GEARBOX ASSEMBLY
(Version with HI-LO) ................................. 251
COMPLETE ASSEMBLY ............................................251
Removal.................................................................. 251
Refitting .................................................................. 252
Disassembly ........................................................... 253
Assembly ................................................................ 256
SHUTTLE SHAFT........................................................257
Disassembly ........................................................... 257
Assembly ................................................................ 259
MAIN SHAFT...............................................................261
Disassembly ........................................................... 261
Assembly ................................................................ 261
SECONDARY SHAFT .................................................262
Disassembly ........................................................... 262
Assembly ................................................................ 265
HML UNIT OUTPUT SHAFT.......................................266
Disassembly ........................................................... 266
Assembly ................................................................ 267
RANGE GEARBOX AND REAR
DIFFERENTIAL ASSEMBLY......................268
COMPLETE ASSEMBLY ............................................268
Removal.................................................................. 268
Refitting .................................................................. 268
DIFFERENTIAL ...........................................................269
Removal.................................................................. 269
Refitting .................................................................. 271
Disassembly ........................................................... 272
Assembly ................................................................ 274
BEVEL PINION (VERSION 85T-95T-95TB)................275
Disassembly ........................................................... 275
Assembly ................................................................ 279
BEVEL PINION (Version 75T-75TB-85TB) ................281
Disassembly ........................................................... 281
Assembly ................................................................ 285
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL...287
Disassembly ........................................................... 287
Assembly ................................................................ 289
4WD OUTPUT SHAFT AND PARKING
BRAKE........................................................290
Disassembly ........................................................... 290
Assembly ................................................................ 293
BEVEL GEAR PAIR.....................................................294
Preparation for adjustments ................................... 295
Adjusting the differential bearings preload............. 297
Adjustment of the pinion position........................... 299
Adjustment of the pinion and crown wheel ............ 303
PUMP DRIVE PTO .....................................304
OUTER GEAR .............................................................304
Disassembly ........................................................... 304
Assembly ................................................................ 305
INTERNAL GEAR........................................................306
Disassembly ........................................................... 306
Assembly ................................................................ 307
REAR PTO..................................................308
PTO INPUT SHAFT (4-speed versions) ....................308
Removal.................................................................. 308
Refitting .................................................................. 310
Disassembly ........................................................... 311
Assembly ................................................................ 313
PTO OUTPUT SHAFT (4-speed version) ..................314
Disassembly ........................................................... 314
Assembly ................................................................ 317
REAR PTO ................................................. 318
PTO INPUT SHAFT (2-speed version)...................... 318
Removal ..................................................................318
Refitting ...................................................................320
PTO CLUTCH CONTROL .......................................... 322
Removal ..................................................................322
Refitting ...................................................................325
Disassembly (Version 75T-75TB-85TB) ..................327
Assembly.................................................................333
Disassembly (Version 85T-95T-95TB).....................334
Assembly.................................................................339
GROUNDSPEED PTO OUTPUT SHAFT ................... 340
Disassembly ............................................................340
Assembly.................................................................342
GROUNDSPEED PTO ENGAGEMENT DEVICE....... 343
Disassembly ............................................................343
Assembly.................................................................343
INSTRUMENT PANEL............................... 344
Removal ..................................................................344
Refitting ...................................................................346
POWER STEERING VALVE....................... 347
Removal ..................................................................347
Refitting ...................................................................348
Pressure relief valve setting ....................................349
Disassembly ............................................................350
Assembly.................................................................356
THE STRUCTURE OF THE UNIT ...................................1
HOW TO CONSULT THE UNIT ......................................2
1. INTRODUCTION .........................................................3
1.1 LIST OF WIRING LOOMS........................................................3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ..................3
1.3 GENERAL RULES....................................................................4
1.3.1 MODIFICATION OF THE TRACTOR'S
ELECTRICAL/ELECTRONIC CIRCUITS..................... 4
1.3.2 MAIN WIRING FAULTS.............................................. 4
1.3.3 REMOVAL, REFITTING AND DRYING
OF CONNECTORS AND WIRING .............................. 5
1.4 DIAGNOSTIC INSTRUMENTS.................................................6
1.5 WIRE COLOUR CODES...........................................................6
2. INDICES ......................................................................7
2.1 INDEX BY PART DESCRIPTION..............................................7
2.2 INDEX BY PART CODE ...........................................................9
2.3 INDEX BY CONNECTOR.......................................................11
3. COMPONENTS .........................................................14
3.1 COMPONENT TECHNICAL DATA.........................................14
3.2 DESCRIPTION OF THE PREHEATING SYSTEM...................17
3.2.1 OPERATION............................................................. 17
3.2.2 TABLE OF PREHEATING CONTROL
UNIT ALARMS ......................................................... 18
3.2.3 PREHEATING CONTROL UNIT PINOUT................. 18
4. SYSTEMS ................................................................. 19
4.1 EARTHING POINTS............................................................19
4.2 STARTING AND PREHEATING ..........................................20
4.3 LIGHTS - LIGHT SELECTOR SWITCH...............................21
4.4 INSTRUMENT PANEL ........................................................22
4.5 BRAKES..............................................................................23
4.6 TRANSMISSION.................................................................24
4.7 PTO.....................................................................................25
5. WIRING LOOMS ...................................................... 27
BATTERY WIRING.......................................................................27
FRONT WIRING (1/2) ..................................................................28
FRONT WIRING (2/2) ..................................................................29
CENTRAL WIRING (1/2) ..............................................................39
CENTRAL WIRING (2/2) ..............................................................40
REAR WIRING (1/2) ....................................................................45
REAR WIRING (2/2) ....................................................................46
PTO-FILTER2 WIRING.................................................................47
TRAILER BRAKE WIRING............................................................48
FRONT LIGHT WIRING................................................................53
REAR LIGHTS WIRING (VERSION TB) .......................................54
REAR LIGHTS WIRING (VERSION T) .........................................55
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