Same Solaris 30 40 50 Workshop Service Repair Manual PDF Download

It is workshop manual for Same tractors. Models included: 30 40 50 language:english number of pages: 430 (full digital version) Main sections: Introduction Safety sections 1. TRANSMISSION ................................................................ 1 1.1 INTRODUCTION ......................................................1 1.2 DESCRIPTION..........................................................2 1.2.1 DRIVE TRANSMISSION..................................3 1.3 CLUTCH HOUSING .................................................4 1.4 GEARBOX AND SHUTTLE ASSEMBLY...................5 1.5 4WD RANGE GEARS ASSEMBLY...........................6 1.6 PINION AND DIFFERENTIAL ASSEMBLY ...............7 1.7 BRAKES AND REAR AXLE ASSEMBLY ..................8 1.8 REAR PTO AND MID PTO .......................................9 1.8.1 COMPONENTS...............................................9 1.8.2 MAIN COMPONENTS...................................10 2. FRONT AXLE.................................................................... 11 2.1 STEERING CYLINDER...........................................12 2.2 DIFFERENTIAL- PINION - FINAL DRIVE UNIT.......13 3. CONTROLS ...................................................................... 14 3.1 RIGHT-HAND SIDE VIEW ......................................14 3.2 LEFT-HAND SIDE VIEW.........................................15 3.3 TOP VIEW ..............................................................16 4. HYDRAULIC SYSTEM..................................................... 17 4.1 DESCRIPTION .......................................................17 4.2 HYDRAULIC DIAGRAM.........................................18 4.3 STEERING CIRCUIT ..............................................19 4.3.1 FUNCTION....................................................19 4.3.2 OPERATION..................................................19 4.3.3 GEAR PUMP.................................................20 4.3.4 POWER STEERING ......................................21 4.3.5 DIFFERENTIAL LOCK CONTROL ASSEMBLY...................................................23 4.3.6 AUXILIARY SERVICES CONTROL VALVE (4 WAYS).......................................................25 4.3.7 POWER LIFT CONTROL VALVE...................26 ENGINE HOOD ..................................................... 1 Removal...................................................................... 1 Refitting ...................................................................... 1 SAFETY ROLL BAR.............................................. 2 Removal...................................................................... 2 Refitting ...................................................................... 2 SILENCER............................................................. 3 Removal...................................................................... 3 Refitting ...................................................................... 4 RADIATOR ............................................................ 5 Removal...................................................................... 5 Refitting ...................................................................... 7 FRONT SUPPORT ................................................ 8 Removal...................................................................... 8 Refitting .................................................................... 10 WHEELS.............................................................. 11 FRONT WHEELS...........................................................11 Removal.................................................................... 11 Refitting .................................................................... 11 REAR WHEELS.............................................................12 Removal.................................................................... 12 Refitting .................................................................... 12 INSTRUMENT PANEL........................................ 13 Removal.................................................................... 13 Refitting .................................................................... 14 CONSOLE SHROUDS ........................................ 15 Removal.................................................................... 15 Refitting .................................................................... 16 POWER STEERING ............................................ 17 Removal.................................................................... 17 Refitting .................................................................... 18 FUEL TANK......................................................... 19 Removal.................................................................... 19 Refitting .................................................................... 20 PLATFORM......................................................... 21 Removal.................................................................... 21 Refitting .................................................................... 23 STARTER MOTOR.............................................. 24 Removal.................................................................... 24 Refitting .................................................................... 26 HYDRAULIC PUMP............................................ 27 Removal.................................................................... 27 Refitting .................................................................... 27 ALTERNATOR..................................................... 28 Removal.................................................................... 28 Refitting .................................................................... 29 Tensioning the drivebelt ........................................... 29 ENGINE ............................................................... 31 Separating the engine from the transmission........... 31 Reconnecting the engine to the transmission .......... 36 Removal.................................................................... 37 Refitting .................................................................... 41 CLUTCH ASSEMBLY ......................................... 42 PTO CLUTCH................................................................42 Removal and renewal of the PTO clutch plate ......... 42 Check PTO clutch plate wear................................... 42 Refitting the PTO clutch plate .................................. 42 Adjustment of the clutch levers ................................ 43 PTO DRIVE SHAFT OIL SEAL......................................44 Renewal .................................................................... 44 CLUTCH RELEASE BEARINGS...................................45 Removal.................................................................... 45 Refitting .................................................................... 47 LIFT ..................................................................... 48 COMPLETE ASSEMBLY..............................................48 Removal.................................................................... 48 Refitting .................................................................... 49 POWER LIFT CONTROL VALVE..................................50 Removal.................................................................... 50 Refitting .................................................................... 51 Disassembly ............................................................. 52 Assembly .................................................................. 55 CYLINDER ....................................................................57 Disassembly ............................................................. 57 Assembly .................................................................. 58 LIFT ARM OIL SEAL.....................................................59 Removal.................................................................... 59 Refitting .................................................................... 61 BUSHES ........................................................................62 Renewal .................................................................... 62 INTERNAL LINKAGE....................................................63 Removal.................................................................... 63 Refitting .................................................................... 64 HYDRAULIC LEVER LIMIT.......................................... 65 Adjustment ................................................................65 LIFT CONTROL VALVE................................................ 66 Disassembly ..............................................................66 Assembly...................................................................67 AUXILIARY SERVICES CONTROL VALVE (4 WAYS) ............................................................. 68 AUXILIARY SERVICES CONTROL VALVE................. 68 Removal ....................................................................68 Refitting .....................................................................68 CONTROL RODS ......................................................... 69 Disassembly ..............................................................69 Assembly...................................................................69 DOUBLE/ SINGLE ACTING CONVERTER.................. 70 Overhaul ....................................................................70 CLUTCH HOUSING............................................ 71 Separation from the transmission .............................71 Reconnection to the transmission ............................76 GEARBOX AND SHUTTLE ASSEMBLY............ 77 COMPLETE ASSEMBLY.............................................. 77 Removal ....................................................................77 Refitting .....................................................................78 Disassembly ..............................................................79 Assembly...................................................................81 INPUT SHAFT............................................................... 83 Disassembly ..............................................................83 Assembly...................................................................84 PRIMARY SHAFT......................................................... 85 Disassembly ..............................................................85 Assembly...................................................................85 SECONDARY SHAFT................................................... 86 Disassembly ..............................................................86 Assembly...................................................................89 GEAR SELECTOR FORKS........................................... 90 Check flatness...........................................................90 REAR AXLE AND BRAKES................................ 91 REAR AXLE .................................................................. 91 Removal ....................................................................91 Refitting .....................................................................92 Disassembly ..............................................................93 Assembly...................................................................95 BRAKE.......................................................................... 99 Renewal of the braking discs ....................................99 REAR PTO ........................................................ 101 Disassembly ............................................................101 Assembly.................................................................104 RANGE GEARBOX AND REAR DIFFERENTIAL ASSEMBLY....................................................... 105 RANGE GEARBOX INPUT SHAFT ............................ 105 Disassembly ............................................................105 Assembly.................................................................106 DIFFERENTIAL........................................................... 107 Removal ................................................................. 107 Refitting .................................................................. 108 Disassembly ........................................................... 109 Assembly................................................................ 110 BEVEL GEAR PAIR .................................................... 111 Disassembly ........................................................... 111 Preparation for installation ..................................... 113 Adjustment of the differential preload .................... 114 Adjustment of the pinion position .......................... 115 Adjustment of the pinion and crown wheel............ 118 Final assembly........................................................ 119 4WD AND GROUND SPEED PTO OUTPUT SHAFT 120 Disassembly ........................................................... 120 Assembly................................................................ 121 PEDALS AND CONTROL LEVERS.................. 122 BRAKE PEDALS ........................................................ 122 Adjustment ............................................................. 122 PARKING BRAKE LEVER.......................................... 122 Adjustment ............................................................. 122 CLUTCH PEDAL ........................................................ 123 Adjustment ............................................................. 123 PTO SPEED SELECTOR LEVER............................... 123 Adjustment ............................................................. 123 PTO ENGAGEMENT LEVER...................................... 123 Adjustment ............................................................. 123 RANGE GEAR LEVER................................................ 123 Adjustment ............................................................. 123 MAIN GEAR LEVER ................................................... 124 Adjustment ............................................................. 124 FRONT AXLE.................................................... 125 COMPLETE AXLE ASSEMBLY................................. 125 Removal ................................................................. 125 Refitting .................................................................. 127 BEVEL GEAR PAIR .................................................... 128 Disassembly ........................................................... 128 Assembly................................................................ 133 FINAL DRIVE REDUCTION UNITS ........................... 139 Removal ................................................................. 139 Refitting .................................................................. 139 OUTPUT FLANGE...................................................... 141 Disassembly ........................................................... 141 Assembly................................................................ 143 STEERING JOINT ...................................................... 144 Disassembly ........................................................... 144 Preparation For Assembly...................................... 146 Final assembly........................................................ 148 STEERING CYLINDER............................................... 149 Disassembly ........................................................... 149 Assembly................................................................ 152 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 ..................................................... 13 3.1 COMPONENT TECHNICAL DATA................................... 13 3.2 PREHEATING SYSTEM................................................... 16 3.3 ENGINE STOP SYSTEM.................................................. 16 4. SYSTEMS ............................................................... 17 4.1 EARTHING POINTS .........................................................17 4.2 STARTING........................................................................18 4.3 FRONT AXLE DIFFERENTIAL LOCK ...............................19 4.4 LIGHTS-SWITCH UNIT-BRAKES.....................................20 4.5 INSTRUMENT PANEL......................................................21 5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS, CONNECTOR POSITIONS .................................... 23 FRONT WIRING (1/2) ................................................................23 FRONT WIRING (2/2) ................................................................24 CENTRAL WIRING (1/2) ............................................................31 CENTRAL WIRING (2/2) ............................................................32 REAR WIRING (1/2)...................................................................43 REAR WIRING (2/2)...................................................................44 INTRODUCTION........................................................... 1 How to use this manual.............................................. 2 GENERAL INFORMATION Model identification and serial number location ........ 5 Component positions - naturally aspirated engine (S4L/S4L2).................................................................. 6 Component positions - turbo engine (S4L-T/S4L2-T) ........................................................... 7 Specifications ............................................................. 8 OVERHAUL INSTRUCTIONS Determining when to overhaul the engine.................. 9 Compression pressure measurement ...................... 10 Troubleshooting........................................................ 11 Basic precautions for disassembly and assembly ... 19 DISASSEMBLY Preparation for disassembly..................................... 21 Electrical system ...................................................... 22 Cooling system......................................................... 27 Fuel system .............................................................. 28 Lubrication system. .................................................. 30 Air inlet system and exhaust system........................ 31 Cylinder head and valve mechanism........................ 32 Timing gears and flywheel........................................ 36 Cylinder block, crankshaft, pistons and oil pan ....... 41 INSPECTION Cylinder head and valve mechanism........................ 47 Timing gears and flywheel........................................ 55 Cylinder block, crankshaft, pistons and oil pan ....... 59 ASSEMBLY Cylinder block, crankshaft, pistons and oil pan ....... 68 Timing gears and flywheel........................................ 77 Cylinder head and valve mechanism........................ 84 Air inlet system and exhaust system........................ 89 Fuel system .............................................................. 90 Lubrication system ................................................... 92 Cooling system......................................................... 93 Electrical system ...................................................... 95 ELECTRICAL SYSTEM General ..................................................................... 97 Starter ..................................................................... 101 Alternator ................................................................ 109 Key shutoff system................................................. 115 Automatic glow plug system .................................. 117 COOLING SYSTEM General ................................................................... 120 Inspection ............................................................... 121 LUBRICATION SYSTEM General ................................................................... 125 Inspection ............................................................... 126 FUEL SYSTEM General ................................................................... 129 Fuel injection nozzle ............................................... 130 Fuel injection pump ................................................ 133 Governor................................................................. 140 Fuel pump............................................................... 143 Fuel filter ................................................................. 143 AIR INLET SYSTEM AND EXHAUST SYSTEM General ................................................................... 146 Inspection ............................................................... 147 MAINTENANCE Lubrications a maintenance chart .......................... 149 Engine oil and oil filter ............................................ 150 Valve clearance....................................................... 152 Fuel injection timing................................................ 154 Fuel filter ................................................................. 157 Fuel system priming ............................................... 159 Fuel injection nozzle ............................................... 160 Fan belt................................................................... 161 SERVICE DATA Specifications ......................................................... 163 Tightening torques.................................................. 167 Sealants .................................................................. 169 Special tools ........................................................... 170