Document overview
Digital Workshop Manual documentation for model SAME EXPLORER³ 110 → ZKDL8002W0TS1001 from the EXPLORER³ (STAGE 3A) family. Language: English; 1,632 pages.
The corresponding English table of contents contains 50 sections and 403 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: SAME
- Family: EXPLORER³ (STAGE 3A)
- Model: EXPLORER³ 110
- Starting serial number: ZKDL8002W0TS1001
- Document type: Workshop Manual
- Language: English
- Pages: 1,632
- File size: 186.02 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER³ 110 → ZKDL8002W0TS1001.
Complete table of contents
Introduction
- Introduction – Engines
- Tightening torques
- Tightening torques for nuts and bolts of electrical connections
- Wheel nut/screw tightening torques
- Installation of solenoid valves and cartridge valves
- Installation of quick couplers
- Units of measurement and conversion factors
Safety
Preface
- Important notes concerning safety
Important safety information
- Recognising hazards
- Indications for persons in contact with the tractor
Safety rules
- Risks during tractor preparation
- Risks during maintenance
- Work on machine systems
- Special disassembly/assembly/inspection procedures
Safety pictograms
- Replacing safety pictograms
Environmental risks
- Hazards associated with the operating environment
Technical characteristics
Engine
- Components of the 2012 2V UPS engine
- Test data and settings
- Tightening requirements 2012 2V UPS engine
Transmission
- Transmission
- Rear PTO
- 2 and 4-speed PTO and Syncro PTO
- Hydraulic reverse power shuttle
Front axle
- Front axle
Hydraulic system
- Hydraulic system
- Steering circuit pump – lift circuit pump
- Power steering valve
- Remote control valve – 6-way version
- Hydraulic lift control valve
- Braking system
- Trailer braking valve
- Park Brake system
- Park Brake valve
- Services solenoid valves assembly – Pressure holding valves
- Shuttle solenoid valves assembly
Calibrations and electronic diagnosis
Diagnostic tools
- Position of ECUs and diagnostic instruments
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket
Serdia 2000
- SERDIA 2000 level III” software
Diagnostic tool screens
- ECU interrogation
Commissioning and calibrating the tractor
- Digital instrument calibration
- Renewal of the shuttle ECU – Introduction
- Renewal of the shuttle ECU – Initialisation of the ECU
- Renewal of the shuttle ECU – Line end programming
- Renewal of the shuttle ECU – Introductory notes
- Renewal of the shuttle ECU – Automatic calibration
- Renewal of the shuttle ECU – Manual calibration
- Renewal of the shuttle ECU – Editing the comfort parameters
- Renewal of the shuttle ECU – Calibration of the clutch pedal
- Renewal of the engine ECU – Introduction
- Renewal of the engine ECU – Calibration of the accelerator pedal
- Renewal of the engine ECU – Calibration of the hand throttle lever
ECU alarms
- Key to the “ECU alarms” tables
- FMI code
Engine alarms
- Alarms – Engine alarms list
Transmission alarms
- Alarms – Transmission alarms list
Instrument panel alarms
- Alarms – Instrument panel alarms list
- P.T.O. selfdiagnosis indicator light.
Method of intervention
- Tools for engine disassembly and reassembly
- Workshop tools for engine disassembly and reassembly
B0 – Engine
- Air conditioning compressor drive belt
- Tension adjustment of the fan and air conditioning compressor drive belt
- Alternator, fuel pump and water pump drive belt
- Tension adjustment of the alternator, fuel pump and water pump drive belt
- Compression test
- Assembly and disassembly of the engine on the assembly stand
- Adjustment of valve clearance
- Removal and refitting of the rocker arms and pedestals
- Disassemble and complete the rocker and support, check
- Disassembly and assembly of the cylinder head
- Grinding the cylinder head seal surface
- Measuring piston protrusion
- Valve assembly and disassembly
- Valve check
- Check the valve guide
- Replacing the valve guide (oversized – cast)
- Check the valve residual
- Replacing the lined valve seat (oversized)
- Check the endfloat of the crankshaft
- Check the crankshaft
- Replace the crankshaft O-ring (flywheel end)
- Replacing the crankshaft O-ring (opposite end to flywheel)
- Check the connecting rod drum
- Fitting and removing piston pin bush
- Assembly and disassembly of the crankshaft
- Fitting and removing counterweight shafts, checking
- Disassembly and assembly of the piston and connecting rod drum
- Check the piston
- Check the piston rings and piston grooves
- Assembly and disassembly of piston cooling nozzles
- Removal and refitting of the crankcase breather
- Check the cylinder
- Removal and refitting of the front cover (opposite end to flywheel)
- Disassembly and assembly of the connector box
- Fitting and removing the camshaft bearings, checking
- Disassembly and assembly of the gear case cover
- Assembly and disassembly of the camshaft
- Check the camshaft
- Removal and refitting of the rotation device
- Removing and fitting the V-belt pulley
- Fitting, removing, checking and setting adjuster rod
- Removal and refitting of the heater
- Removal and refitting of the turbocharger
- Removal and refitting of the charge air duct
- Fitting and removing injection pump
- Determine the thickness of the shim (engine without injection advance variator)
- Determine the thickness of the shim (engine with injection advance variator)
- Determination of the overall dimensions of the injection pump (engine without the injection advance variator)
- Determination of the overall dimensions of the injection pump (engine with the injection advance variator)
- Fitting and removing injection valves
- Checking the injection valves
- Removal and refitting of the fuel lift pump
- Removal and refitting of the oil pickup pipe
- Removing and fitting the lubricant oil sump pan (cast iron lubricant oil sump)
- Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate)
- Removal and refitting of the oil cooler
- Disassembly and assembly of the oil radiator housing
- Removal and refitting of the oil pressure switch
- Removal and refitting of the water pump
- Testing the thermostat (after removal)
- Removal and refitting of the thermostat
- Removal and assembly of the fan support
- Removal and refitting of the fan support
- Removal and refitting of the flywheel
- Replacing the starter motor ring gear on the flywheel
C0 – Engine accessories
- Starter motor
- Removing and fitting the engine governor
- Removal and refitting of the exhaust manifold
- Removal and refitting of the fuel filter head.
- Assembly and disassembly of the temperature sender
- Removal and refitting the engine block
- Removal and refitting of the alternator (with drivebelt)
- Disassembly and assembly of the starter
D0 – Transmission
- Changing the transmission oil
- Range selector assembly
- Disassembly of the range selector
- Separation of housing from transmission
- Shuttle assembly – complete unit
- Disassembly of the shuttle unit
- Disassembly of the cover unit
- Disassembly of the forward drive clutch assembly
- Disassembly of the reverse drive clutch assembly
- Gearbox and Hi-Lo assembly
- Disassembly of the Hi-Lo unit
- Disassembly of the planet carrier
- Disassembly of the Hi range clutch housing
- Hi-Lo unit output shaft disassembly procedure
- Disassembly of the gearbox input shaft
- Torsional spring plate
- Disassembly of the primary shaft – Version with Hi-Lo
- Secondary shaft – Version with Hi-Lo
- Disassembly of the secondary shaft – Version with Hi-Lo
- Range gearbox and differential assembly – complete assembly
- Complete gearbox assembly – Version with Hi-Lo
- Adjustment of the differential – Bevel gear pair
- Disassembly of the rear pinion
- Disassembly of the 4WD output shaft
- PTO clutch.
- Disassembly of the PTO clutch
- Pump drive PTO – Outer gear
- Pump drive PTO – Inner gear
- PTO output shaft – 4 speed version
- Disassembly of the PTO output shaft – 4 speed version
- Disassembly of the Groundspeed PTO output shaft
- Disassembly of the Groundspeed PTO engagement device
- Disassembly of the 4WD engagement device – Easyshift
E0 – Rear axle
- Right-hand rear axle
- Disassembly of LH/RH rear axle
- Left-hand rear axle
- Disassembly of the planet carrier
- Rear differential
- Disassembly of the rear differential
- Park Brake assembly
- Park Brake unit disassembly
F0 – Front axle
- Separation of front support from engine
- Front support
- 4WD front axle
- Adjusting the front axle end float
- Steering cylinders
- Steering cylinders disassembly
- Steering knuckle housing and half-shaft
- Adjustment of steering knuckle housing and axle shaft
- Differential unit
- Differential disassembly
- Differential unit adjustment
- Bevel gear pair
- Adjustment of the bevel gear pair
- Disassembly of the differential
- 4WD shaft
- Planetary reduction gear
- Disassembly of the planetary reduction gearbox
- Front brake discs
- Front axle brake piston
G0 – Bodywork – Cab – Platform
- Cab
- Front hood and side panels
- Battery support
- Cab access steps
- Fenders
- Right-hand console
- Left-hand console
- Front instrument panel
- Roof lining – Version with high visibility cab
- Heating fan – Version with high visibility cab
- Air conditioning system controls – High-visibility roof system
- A/C system – Version with standard roof
- Heating and air conditioning unit – Version with high visibility cab
- Heating control cable
- Condenser – Version with high-visibility roof
- Receiver drier – Version with high visibility roof
- Conditioner evaporator – Version with standard roof
- Air-conditioning evaporator – Version with high-visibility roof
- Heating valve – Version with high visibility cab
- Heater matrix – Version with high-visibility roof
- Heating radiator – Version with standard roof
- Heating and air conditioning unit fan – Version with standard roof
- Expansion valve – Version with high visibility roof
- Expansion valve – Version with standard roof
- Antifreeze sensor – Version with high visibility roof
- Condenser cooling fans – Version with high-visibility roof
- Condenser fan control pressure switch – Version with high visibility roof
- Air conditioning temperature control thermostat – Version with standard roof
- Remote valve control cables
- Adjustment of the control levers
H0 – Hydraulic system
- Pump for hydraulic lift and auxiliary services
- Power steering valve
- Power steering disassembly
- Pressure relief valve setting
- Power steering pump
- GEARBOX OIL COOLER
- Rear remote control valve
- Bleeding the braking circuit
- Parking brake control valve
- Braking distributor valve
- Services solenoid valve assembly
- Pressure reduction and holding valve disassembly
- Shuttle solenoid valves assembly
L0 – Electrical system
- Lateral battery
- Alternator
- Clutch pedal potentiometer
- Shuttle output speed sensor
- Accelerator pedal position sensor
- Hand throttle position sensor
- Steering column switch
- Shuttle ECU and forward/reverse selector
M0 – Front PTO
- Front PTO
- PTO assembly.
- Pump assembly
- Front PTO oil cooler
- Clutch-brake assembly
- Solenoid valve assembly
N0 – Front lift
- Front lift
- Disassembly of front lift cylinders
R0 – Rear lift
- Lift – Complete assembly
- Disassembly of the lift- complete assembly
- Lift cylinder
- Bushes
- Auxiliary lift cylinders
- Disassembly of the lift control valve
- Mechanical draft sensor
- Mechanical draft sensor disassembly
- 3-point linkage
S0 – Wheels
- Front wheels
- Rear wheels
V0 – Ballast – towing hitches
- Towing hitch slide
Wiring diagrams
Introduction
- Introduction
- Basic electronics for mechanics (1/2)
- Basic electronics for mechanics (2/2)
- Electrical and electronic components (1/2)
- Electrical and electronic components (2/2)
Components
- A – Starting and charging
- B – Fuses
- C – Earths
- D – Intermediate connections
- E – On-board instruments and visual and audible indicators
- F – External lights
- G – Interior lights
- H – Electrical and manual controls
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices, flasher units and timers
- N – Electric motors and actuators
- O – Resistors and rheostats
- P – Various services
- R – Diagnostics
- T – Power supply points (+15 o +30)
Systems
- S001 – Starting and preheating
- S002 – Electronic engine governor
- S003 – Diagnostics and accessories – Version with standard cab
- S004 – Diagnostics and accessories – Version with high-visibility cab
- S005 – Instrument panel
- S006 – Work lights – Version with standard cab without front lift
- S007 – Work lights – Version with standard cab with front lift
- Work lights – Version with high-visibility cab without front lift
- S009 – Work lights – Version with high-visibility cab with front lift
- S010 – Heating – Version with standard cab
- S011 – Heating – Version with high-visibility cab
- S012 – Manual climate control – Version with standard cab
- S013 – Manual climate control – Version with standard cab
- S014 – Manual climate control – Version with high-visibility cab
- S015 – Steering column lights switch – Version with cab without front lift
- S016 – Steering column lights switch – Version with cab with front lift
- S017 – +30 Positives
- S018 – +15 Positives
- S019 – Windscreen wipers – Version with standard cab
- S020 – Windscreen wipers – Version with high-visibility cab
- S021 – Transmission
- S022 – PTO
- S023 – Can Bus
- S024 – Brakes
- S025 – Negatives
- S026 – Steering column lights switch – Version with cab without front lift (U.S.A.)
- S027 – Steering column lights switch – Version with cab with front lift (U.S.A.)
- S028 – PTO (U.S.A.)
- S029 – Brakes (U.S.A.)
Wiring harnesses
- 0.008.0913.3 – Front PTO
- 0.009.7853.3/20 – Air conditioning condenser fan – Version with standard cab
- 0.010.2147.2 – Heating – Version with standard cab
- 0.010.2153.2 – Air conditioning – Version with standard cab
- 0.010.4516.3 – Windscreen wiper – Version with standard cab
- 0.011.3597.3 – Windscreen wiper – Version with high-visibility cab
- 0.013.4909.4 – Rear lights (U.S.A.)
- 0.013.6327.4 – LH rotating beacon
- 0.013.6327.4 – RH rotating beacon
- 0.014.1645.4/10 – Compressed air pressure sensor
- 0.014.3927.4/40 – LH auxiliary work lights – Version with high-visibility cab
- 0.014.3927.4/40 – RH auxiliary work lights – Version with high-visibility cab
- 0.014.8107.4/30 – Hood lights
- 0.014.9195.4/20 – Preheating
- 0.015.1418.4/30 – Cab shuttle
- 0.015.1435.4/20 – RH auxiliary work lights – Version with standard cab
- 0.015.1435.4/20 – LH auxiliary work lights – Version with standard cab
- 0.015.1983.4/10 – Power supplies 1
- 0.015.1983.4/10 – Power supplies 2
- 0.015.1983.4/10 – Power supplies 3
- 0.015.1998.4/10 – Drivetrain shuttle
- 0.015.6123.4 – Rear wiper – Version with standard cab
- 0.015.6272.4/40 – Cab roof – Version with high-visibility cab
- 0.015.7021.4/70 – Central wiring
- 0.015.7023.4/50 – Drivetrain
- 0.015.7266.4/40 – Air conditioning condenser fan – Version with high-visibility cab
- 0.015.7266.4/40 – Air conditioning condenser fan – Version with standard cab
- 0.016.0373.4/30 – Cab power supply
- 0.016.0484.4/60 – Central (U.S.A.)
- 0.016.0664.4 – Front lights
- 0.016.0865.4/10 – Cab roof – Version with standard cab
- 0.016.0866.4/10 – Front-rear work lights – Version with standard cab
- 0.016.1001.4/20 – Hydraulic trailer braking valve
- 0.016.2000.4/20 – Engine – Version with front battery
- 0.016.2001.4/10 – Engine – Version with lateral battery
- 0.017.0473.4 – Battery negative
- 0.017.0474.4 – Battery positive
- 0.017.1063.4 – Cab earth
- 0.018.5825.4 – Cab roof – Version with standard cab
- 04215655 – Engine
- 04411923.4 – RH lower headlights
- 04411923.4 – LH lower headlights
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
- Diagnostics 2023 subscription
- Diagnostics 2024 subscription
- Diagnostics 2022 subscription
- Diagnostics 2021 subscription
- Technical Documentation DVD 06/2009
- Technical Documentation DVD 07/2008
- SDF LUBRICANTS: Lubricant oils and coolant fluids
- After-sales 2024 subscription
- After-sales 2023 subscription
- After-sales 2022 subscription
- After-sales 2021 subscription
- After-sales 2019 subscription
- SDF Parts and SDF Service DVV 04/2014, version 26
- Technical Documentation DVD 03/2010
- New function: Download PDF manuals
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
- Service and Spare Parts – 2017 Subscription
- SDF Parts and SDF Service DVDs 05/2014 version 25
- SDF Parts and SDF Service DVDs 03/2013 version 24
B0 – ENGINE
- Flushing the lubrication circuit
- Deutz AG engine oil specifications
- SerDia 2010 updating license file
- POSSIBLE LEAKAGE OF FUEL INTO THE ENGINE SUMP (LEVEL RISE)
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Additive for diesel fuel
D0 – TRANSMISSION
- Hydraulic shuttle central disc
- Wrong dimension on RPTO stub shaft 21 splines 1-3/8″
- Twisted parking brake lever
- Bushes on shuttle input shafts
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Clutch pedal potentiometer actuator pin
- Air conditioning system recharging
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Assembly instructions for solenoid valves and cartridge valves
- L0 – ELECTRIC AL SYSTEM
