SAME Dorado 66, 76 & 86 Power Shuttle Tractor Workshop Manual

Description

Same Dorado 66 76 86 Power Shuttle Tractor Workshop Manual is the factory technical publication for the Dorado 66, Dorado 76 and Dorado 86 tractors equipped with the hydraulic Power Shuttle transmission. Produced for authorised dealer technicians and service centres, it provides the repair procedures, operating descriptions, diagnostic information, inspection data, tightening torques and adjustment specifications required for professional tractor servicing.

This is a substantial chassis, transmission, hydraulic and electrical workshop manual. It explains the correct methods for removing, dismantling, checking, adjusting and refitting the tractor assemblies covered by the publication. Technical illustrations, sectional drawings, hydraulic diagrams and electrical circuit diagrams support the written procedures, making the manual suitable for fault diagnosis as well as planned overhaul work.

The manual is particularly useful to agricultural engineers, independent tractor specialists, fleet workshops and experienced owners undertaking repairs beyond routine maintenance. Coverage includes the Power Shuttle and HML transmission units, gearbox, rear axle, rear PTO, hydraulic lift, steering, brakes, front axle, electronic controls, cab components and electrical system. Detailed internal engine overhaul instructions are not included; the publication refers technicians to the separate SAME 1000/3/4/6 engine workshop manual.

GENERAL WORKSHOP INFORMATION

The introductory section establishes the approved workshop practices to be followed before work begins. It includes guidance for safely supporting the tractor, lifting major assemblies, protecting open hydraulic lines and completing repairs without contaminating components or damaging wiring and connectors.

General workshop information includes:

• Safety rules for inspection, diagnosis, dismantling and overhaul
• Precautions for removing and refitting mechanical assemblies
• Hydraulic pressure release and fluid-handling procedures
• Correct use of lifting equipment, wire ropes and polyester slings
• Component support and tractor blocking instructions
• Standard tightening torques for screws, nuts and hydraulic fittings
• Threadlocking compounds, sealants, adhesives and lubricating products
• Electrical connector, wiring loom and battery precautions
• Unit conversion tables and technical symbols
• Final checks following hydraulic or cooling-system repairs

POWER SHUTTLE AND TRANSMISSION

A major part of the manual is devoted to the hydraulic Power Shuttle transmission and associated HML speed-change system. Operating descriptions and hydraulic information are combined with removal, dismantling, inspection and assembly procedures. This allows technicians to trace faults through the controls and hydraulic circuits before disturbing the mechanical assemblies.

Transmission subjects include:

• Power Shuttle operating principles and hydraulic control
• Forward and reverse shuttle clutch assemblies
• Shuttle solenoid valves and modulation controls
• HML high, medium and low clutch unit
• HML planetary gears and internal transmission components
• Main gearbox removal, dismantling and reassembly
• Gearbox input shaft and associated bearings
• Underdrive unit and speed-selection mechanisms
• Gear-selector rods, forks and transmission adjustments
• Range gearbox and parking-brake assembly

REAR AXLE, DIFFERENTIAL AND BRAKES

The rear transmission casing and axle assemblies are covered with workshop procedures for internal inspection and repair. The manual identifies the correct dismantling sequence, dimensional checks, adjustments and tightening requirements needed when servicing the differential, final-drive components and braking system.

Coverage includes:

• Rear axle removal and internal component servicing
• Range gearing and rear differential assembly
• Differential-lock components and controls
• Service-brake assemblies and friction discs
• Brake control and service-valve assemblies
• Parking-brake mechanism and adjustment
• Shaft, gear and bearing inspection
• Seal, O-ring, circlip and locking-device replacement
• Assembly clearances and mechanical adjustment data

POWER TAKE-OFF AND LINKAGE

The manual provides repair information for the rear power take-off and the tractor’s three-point linkage equipment. Procedures cover the mechanical assemblies and related hydraulic or electrohydraulic controls, with diagrams and adjustment information for workshop diagnosis.

Covered subjects include:

• Rear PTO removal and dismantling
• 540, economy and 1000 rpm PTO arrangements where fitted
• Groundspeed PTO components
• PTO shafts, gears, bearings and engagement parts
• Electrohydraulic PTO engagement controls
• Three-point linkage components
• Linkage mounting and mechanical inspection
• Towing hitch installation and related components

HYDRAULIC SYSTEM AND REAR LIFT

Mechanical descriptions and hydraulic diagrams explain the operation of the steering, rear-lift, auxiliary-services and trailer-braking circuits. The manual supports pressure testing and fault isolation as well as the overhaul of pumps, valves and lift components.

Hydraulic-system coverage includes:

• Steering-circuit and lift-circuit gear pumps
• Hydraulic oil flow and circuit operating descriptions
• Rear lift with mechanical governor
• Lift control valve removal and servicing
• Auxiliary-services control valve
• Remote hydraulic service circuits
• Trailer-braking valve and hydraulic connections
• Pressure switches, filters and circuit protection
• Hydraulic diagrams for applicable equipment configurations
• Pressure, flow and adjustment specifications

FRONT AXLE AND STEERING

The front chassis and steering sections provide the procedures required when repairing the driven front axle, steering controls and related support components. Instructions cover safe removal of heavy assemblies, inspection of shafts and pivots, and lubrication following reassembly.

Front axle and steering subjects include:

• Front axle drive shaft removal and installation
• Front support and axle mounting components
• Driven front axle removal and overhaul
• Stub-axle housings, pivots and steering joints
• Front wheel and hub-related service work
• Hydrostatic steering control valve
• Power-steering control valve and rotary spool
• Steering-cylinder and hydraulic connection checks
• Steering pressure tests and system adjustments

CHASSIS, CAB AND EXTERNAL COMPONENTS

Procedures are supplied for removing the external and structural components that must be cleared before access to major tractor assemblies. These instructions are useful during transmission splitting, clutch work, cooling-system repairs and cab-related electrical servicing.

Chassis and cab coverage includes:

• Wheels and associated installation checks
• Front bonnet, side panels and mudguards
• Radiator removal and refitting
• Fuel-tank removal and installation
• Engine removal and installation as a complete assembly
• Clutch assembly and torsional spring plate
• Cab removal and refitting
• Front instrument panel
• Side console and control mountings

ELECTRONIC DIAGNOSIS AND CONFIGURATION

A dedicated diagnostic section explains the service software and test equipment used to communicate with the tractor’s electronic control units. It includes connection instructions, configuration procedures, commissioning information and fault-code tables for the electronically controlled systems.

Diagnostic information includes:

• Connection of the diagnostic tester to control units
• Navigation of diagnostic software and service menus
• Tractor electronic-system identification
• Machine and control-unit configuration
• Commissioning procedures following repair or replacement
• Reading stored and active alarm codes
• Fault-code descriptions and operating consequences
• Clearing alarms and checking for recurring faults
• Power Shuttle and HML control diagnosis
• Lift, PTO and auxiliary-service control diagnosis

ELECTRICAL AND CONTROL SYSTEMS

The electrical section contains component locations, wiring-unit information, loom diagrams and circuit schematics. It supports continuity checks, power-supply diagnosis, connector inspection and systematic tracing of faults affecting the transmission, hydraulics, PTO, instruments and tractor services.

Electrical coverage includes:

• Structure and identification of the tractor wiring system
• Electrical component and connector indices
• Complete system circuit diagrams
• Main wiring looms and branch connections
• Power Shuttle solenoid-valve wiring
• HML solenoid-valve assemblies and circuits
• Hydraulic-services solenoid-valve assembly
• Electronic control units, sensors and switches
• Instrument-panel and operator-control circuits
• Battery, alternator and electrical safety procedures

TESTING AND ADJUSTMENT

The manual supplies the measured values and prescribed methods needed to confirm correct operation before and after repair. Technicians can use the operating descriptions, diagrams and specifications to check system pressures, mechanical settings and electronic functions rather than replacing components without diagnosis.

• Power Shuttle clutch-pressure and modulation checks
• Transmission, gearbox and selector adjustments
• Hydraulic lift and steering pressure tests
• Trailer-braking circuit pressure checks
• PTO control and engagement checks
• Brake and parking-brake adjustments
• Dimensional checks and visual inspection criteria
• Specified tightening torques for critical assemblies
• Electronic commissioning and control-unit configuration
• Post-repair fluid-level, leakage and operational checks

TROUBLESHOOTING AND REPAIR

Fault-code tables, hydraulic diagrams, electrical schematics and mechanical operating descriptions are brought together to assist with accurate diagnosis. The publication is suitable for investigating intermittent electronic faults as well as mechanical, hydraulic and electrical failures.

• Power Shuttle forward or reverse engagement faults
• HML speed-change and solenoid-control problems
• Gear selection and range-control faults
• Rear lift and auxiliary hydraulic malfunctions
• Power-steering pressure and control problems
• PTO engagement and control-unit alarms
• Brake and trailer-braking system faults
• Sensor, switch, connector and wiring failures
• Stored electronic alarms and diagnostic codes
• Checks following component renewal or tractor reassembly

MODELS COVERED

• SAME Dorado 66 Power Shuttle
• SAME Dorado 76 Power Shuttle
• SAME Dorado 86 Power Shuttle

MARKET VERSION

English-language workshop publication for SAME Dorado Power Shuttle tractors. No restricted national market or export specification is identified in the available manual information.

SERIAL NUMBERS COVERED

No individual tractor serial-number limits are stated on the supplied title or introductory pages. Applicability is identified by the exact Dorado 66, Dorado 76 and Dorado 86 Power Shuttle model designations.

MANUAL DETAILS

• Manufacturer: SAME
• Publication type: Factory workshop manual
• Publication number: 307.1131.3.0
• Language: English
• Publication date: April 2006
• Page count: 800 pages
• Engine overhaul coverage: Not included
• Referenced engine manual: SAME 1000/3/4/6, English publication 307.1103.3.5

This workshop manual provides the principal factory information required to maintain and repair the tractor systems surrounding the engine. Its detailed treatment of the Power Shuttle, HML unit, gearbox, hydraulics, electronic diagnosis and wiring makes it especially important when investigating faults that cross mechanical, hydraulic and electronic systems.

Use the manual for the stated Power Shuttle models rather than mechanically shuttled Dorado tractors or later Dorado generations. Always identify the tractor model and installed optional equipment before beginning work, and refer to the separate engine publication whenever internal engine dismantling, measurement or overhaul is required.