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Same Silver 80 90 100.4 100.6 service workshop repair manual
About this manual
It is workshop manual for Same tractors. Models included:
80
90
100.4
100.6
language:english
number of pages: 470 (full digital version)
Main sections:
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
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
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
80
90
100.4
100.6
language:english
number of pages: 470 (full digital version)
Main sections:
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
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
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
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