Document overview
Workshop Manual for SAME EXPLORER 115.4 → ZKDCK00200TS20001 from the EXPLORER (FARMOTION STAGE 3B) family. Digital PDF in English with 1,555 pages.
The corresponding English table of contents contains 54 sections and 444 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: EXPLORER (FARMOTION STAGE 3B)
- Model: EXPLORER 115.4
- Starting serial number: ZKDCK00200TS20001
- Document type: Workshop Manual
- Language: English
- Pages: 1,555
- File size: 547.58 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER 115.4 → ZKDCK00200TS20001.
Complete table of contents
Introduction
- Introduction – Engines
- Tightening torques
- 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
- Technical data: cylinder block
- Technical data: crankshaft
- Technical data: pistons – piston rings
- Technical data: rockers
- Camshaft technical data
- Technical data: timing system gears
- Technical data: counter-rotating masses
- Technical data and dimensions: valves – valve springs
- Technical data and dimensions: heads – valve guides – valve seats
- Technical data, rockers – tappets
Engine accessories
- FARMotion engine sensors and components
- EGR system
Transmission
- Transmission
- Four-wheel drive electrohydraulical engagement and parking brake assembly
- Hydraulic reverse power shuttle
- HI-LO unit
- Rear PTO
- Views of transmission
Rear axle
- Rear differential
- Rear axle
Front axle
- Front axle 4 WD
Hydraulic system
- Hydraulic distributor circuit
- Transmission hydraulic circuits
- Braking system
- Separate-Brakes valve
- Trailer braking valve
- Power steering 125 cc
- Transfer pump
- Hydraulic pumps unit
- Power steering pump
- Suction pump filter
- Delivery line filter
- 60 l/min. ECO AUX block
- Distributor unit
- Pressure regulator valve unit
- Service valve unit
- Shuttle control unit
- Rear PTO
Electrical equipment
- FARMotion engine sensors and components
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Mechanical rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- D-TECH App
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket connection
ECUSpace
- ECUSpace HANDBOOK
Diagnostic tool screens
- Position of ECUs and diagnostic instruments
- ECU interrogation
- Instrument Cluster Diagnostics – “Monitor”/Monitor screens for ART/PC Tester (SP286AD)
- Instrument Cluster Diagnostics – “Tests”/Test screens for ART/PC Tester (SP286AD)
- Instrument Cluster Diagnostics – “Alarms”/Alarms screens for ART/PC Tester (SP286AD)
- HLHP2 (TS176AA) ECU diagnostics – “Monitor”/Monitor screens for ART/PC Tester
- HLHP2 (TS176AA) ECU diagnostics – “Tests”/Test screens for ART/PC Tester
- HLHP2 (TS176AA) ECU diagnostics – “Alarms”/Alarms screens for ART/PC Tester
Commissioning and calibrating the tractor
- Calibrating the Digital Instrument Cluster (939569/40)
- Wheel constants (939569/40)
- Commissioning (939600) – Basic procedure
- Commissioning (939600) – Eeprom re-initialisation
- Commissioning (939600) – Line end programming of the tractor
- Commissioning (939600) – Clutch pedal calibration
- Commissioning (939600) – Options selection
- Commissioning (939600) – Hitch calibration
- Transmission calibration (939623) – Calibration of the shuttle clutches
- Transmission calibration (939623) – Calibrating the Stop&Go function
ECU alarms
- SDF Severity of alarms
- ECU ALARMS (Electronic SAC)
- ECU ALARMS (Mechanical SAC)
Software management
- Download Dataset FARMotion & Flash ECU
- ECUs firmware update
Method of intervention
- Workshop tools for disassembly and reassembly
- Workshop tools for engine removal and reassembly
- Engine components removal/refitting sequence
- Tightening procedure for engine components
B0 – Engine
- Preliminary operations before removing engine from vehicle
- Separating engine from transmission
- Engine flywheel
- Engine
- Alternator, water pump and A/C compressor belt
- Engine block-gearbox connector flange
- Blow-by oil vapour recovery pipe
- Turbocharger oil pipes
- Turbocharger
- EGR exhaust gas recirculation pipe
- Exhaust manifold
- Thermostat valve
- Checking the thermostat valve
- EGR exhaust gas cooling pipes
- EGR manifold
- Disassembly of the EGR manifold
- EGR valve
- Blow-by filter
- Coolant manifold
- Intake manifold
- Intake manifold
- Oil filter
- Oil heat exchanger
- Engine coolant pump
- Electro-injectors and common rail
- Cylinder head covers
- Blow-by oil vapour pipe
- Pushrods
- Cylinder heads
- Disassembling the cylinder heads
- Crankshaft pulley and tone wheel
- Crankshaft pulley
- Power take off drive
- Front timing cover
- Rear flange
- Oil sump
- Oil pump
- Counter-rotating masses
- Overhauling counter-rotating masses
- Intermediate gear and timing
- Disassembling pistons and connecting rods
- Crankshaft
- Cooling jets
- Cylinder sleeves
- Adjusting oil pump gear backlash
- Installing automatic belt tensioner
- Aligning water pump and crankshaft pulleys
C0 – Engine accessories
- Intercooler
- Catalytic converter
- Diesel radiator
- Fuel tank
- Exhaust pipe
- Viscostatic fan
- Air filter container
- Radiator assembly
- Disassembling the radiator assembly
- Expansion tank
- Engine coolant replacement
- High pressure fuel pump
- Mounting brackets
- Power take off gear backlash adjustment
D0 – Transmission
- Changing the transmission oil
- Engine torsional spring plate
- Shuttle unit – Complete assembly
- Disassembling the shuttle unit
- Removing the forward drive clutch unit
- Disassembling the reverse drive clutch unit
- Input shaft assembly and tone wheel
- DT shaft in transmission
- Clutch housing – separation from transmission
- Range selector assembly
- Disassembling the range selector assembly
- Gearbox internal cover
- HI-LO unit
- Disassembling the HI range clutch housing
- Disassembling the HI-LO planetary reduction gearbox
- Gearbox and HI-LO unit
- Secondary shaft – Version with HI-LO
- Secondary shaft – Version with (4 gears)
- Primary shaft
- Primary shaft (4 gears)
- Disassembling the gearbox input shaft
- Disassembly of secondary shaft – Version with HI-LO
- Disassembly of the main shaft
- Primary shaft disassembly (4 gears)
- Disassembly of HI-LO unit output shaft
- PTO output shaft – 2 speed version
- PTO output shaft – 4 speed version
- Removing the PTO output shaft – 2 speed version
- Removing the PTO output shaft – 4 speed version
- PTO engagement clutch
- Disassembling PTO engagement clutch
- Pump drive PTO – External gear with 60 l ECO pump
- Pump drive PTO – External gear without 60 l ECO pump
- Pump drive PTO – Internal gear
- Disassembling the PTO final flange shaft – 2 speed version
- Disassembling PTO final flange shaft – 4 speed version
- Disassembling the ground speed PTO output shaft
- Disassembling the ground speed PTO clutch engage mechanism
- Removing the rear pinion – 2-range version
- Removing the rear pinion – 4-range version
- Adjustment of the differential – Bevel gear set
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- Removing dual traction output shaft 2-range version
- Removing dual traction output shaft – 4-range version
- Parking brake disc sectors – Versions with hydraulically engaged four wheel drive
- Parking brake disc sectors
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
E0 – Rear axle
- Rear axle
- RH wheel mount
- LH wheel mount
- Removing right/left hand rear axle
- Brake carrier
- Disassembly of the brake carrier
- Rear differential
- Removing rear differential
F0 – Front axle
- DT dual traction shaft
- Front mount
- Separating front carrier from engine
- Front axle 4WD
- Steering cylinders
- Removing steering cylinders
- Differential unit
- Differential disassembly
- Bevel gear pair
- Disassembly of the differential
- Adjustment of the bevel gear set
- Differential assembly adjustment
- Front axle – Adjusting endfloat
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Steering knuckle housing and axle shaft
- Adjustment of steering knuckle housing and axle shaft
- Front brake discs
- Front axle brake piston
G0 – Bodywork – Cab – Platform
- Empty and charge the air conditioning system
- Cab
- Cab mat
- Engine cowl
- Battery mount
- Battery mount – Version without front PTO
- Cab access steps
- Right hand console
- Right hand side cab trim
- Driver seat
- Heater unit
- A/C unit
- A/C system ECU
- Condenser
- Disassembling the condenser
- Dehydrator filter
- Air conditioner evaporator
- Heater radiator – Version with air conditioner
- Motor with fans
- Expansion valve
- Anti-icing sensor
- Steering wheel
- Steering column with universal joint
- Complete steering column
- Front mudguards
- Brake master cylinders
- Hand brake bowden cable replacement
H0 – Hydraulic system
- Disassembling the complete pump assembly
- Power steering valve
- Transmission oil radiator
- Rear ancillary utility distributor
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
- 60L ECO 8-way distributor solenoid valve
- Disassembling the 60L ECO 8-way distributor solenoid valve
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Bleeding the braking circuit
- 4-rear way ancillary utility distributor
- 6-rear way ancillary utility distributor
- Replacing positioning for automatic release
L0 – Electrical system
- Engine control unit
- Transmission control unit
- Clutch pedal potentiometer
- SHUTTLE OUTPUT SPEED SENSOR
- External air temperature sensor
- Instrument cluster
- Cab interior lights
- Battery master switch
- Steering column stalk
- Button panels
- Engine wiring loom
- Charge pressure and air temperature sensor
- Electro-injector wiring loom
- Coolant temperature sensor
- Crankshaft speed sensor
- Preheat relay
- Camshaft timing sensor
- Engine oil pressure switch
- Engine oil temperature sensor
- Fuel pressure and temperature sensor
- Fuel pressure sensor
- Water in fuel sensor
M0 – Front PTO
- Front PTO
- Disassembling front PTO
- Front PTO input shaft
- Pump assembly
- Front PTO clutch-brake assembly
- Disassembling the front PTO clutch-brake assembly
- Solenoid valve block
R0 – Rear lift
- S.A.C. – Automatic control station
- S.A.C. – Automatic control station disassembly
- Auxiliary hitch cylinders
- Disassembling the rear lift control distributor
- Mechanical draft sensor
- 3-point linkage
- Connecting the Bowden cable to the position and draft control lever (mechanical lift)
- Adjusting mechanical rear lift controls
- Checking and testing the mechanical rear lift
- Mechanical rear lift adjustments
- Mechanical rear lift troubleshooting
- Rear lift draft rod replacement
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook sled
V1 – AFTERMARKET KITS
- Installation of passenger seat kit
- Stabilizers connecting brackets
- 9.Y3654.90.0 and 9.Y4054.90.0 kit installation
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
- Location of main ECUs (electronic rear hitch)
- Location of main ECUs (mechanical rear hitch)
- 2.8519.151.0 – Farmotion engine ECU
- 2.8519.176.0/30 – HLHP2 ECU
- 0.019.7293.4 – Hydraulic reverse shuttle lever
- 2.8339.286.0/30 – Digital Instrument (Cluster) with mechanical lift
- 2.8339.286.0/30 – Digital Instrument (Cluster) with electronic lift
- 2.8519.181.0 – 60 Lt./ECO ECU
- 2.8519.178.0 – Rear PTO ECU
- 2.8519.148.0 – ISO 11786 ECU
- A – Starting and charging
- B – FUSES
- C – Grounds
- D – Intermediate connections
- E – On-board instruments and visual and audible indicators
- F – External lights (rotating beacon)
- G – Interior lights
- H – Manual electrical controls (steering column switch)
- 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
Systems
- Tractor schematic diagram (electronic rear hitch)
- Tractor schematic diagram (mechanical rear hitch)
- S001 – Electronic engine throttle (electronic rear lift)
- S001 – Electronic engine throttle (mechanical rear lift)
- S002 – Preheating
- S003 – Starter (electronic rear lift)
- S003 – Starter (mechanical rear lift)
- S004 – Lift
- S005 – Lights (mechanical rear hitch)
- S005 – Lights (electronic rear hitch)
- S006 – Work lights (mechanical rear hitch)
- S006 – Work lights (electronic rear hitch)
- S007 – Windscreen wiper (electronic rear lift)
- S007 – Windscreen wiper (mechanical rear lift)
- S008 – Instrument cluster (electronic rear lift)
- S008 – Instrument cluster (mechanical rear lift)
- S009 – Radio
- S010 – Manual air conditioner
- S011 – Transmission (electronic rear lift)
- S011 – Transmission (mechanical rear lift)
- S012 – PTO (electronic rear lift)
- S012 – PTO (mechanical rear lift)
- S013 – Accessories (mechanical rear lift)
- S013 – Accessories (electronic rear lift)
- S014 – Can bus (electronic rear lift)
- S014 – Can bus (mechanical rear lift)
- S015 – Can Bus – engine line
- S016 – Brakes (electronic rear hitch)
- S016 – Brakes (mechanical rear hitch)
- S017 – Trailer brake (electronic rear lift)
- S017 – Trailer brake (mechanical rear lift)
- S018 – ECO Saving (electronic rear lift)
- S018 – ECO Saving (mechanical rear lift)
Wiring harnesses
- 0.012.2756.3 – Front PTO solenoid valve
- 0.014.1567.4/20 – Front windscreen wiper
- 0.014.1645.4/10 – ITA-D Air braking pressure switch
- 0.014.8453.4 – Front wiper motor – fixed windscreen version
- 0.016.1001.4/20 – Hydraulic trailer braking valve
- 0.018.5346.4 – 2-ways electronic distributor
- 0.019.5702.4/10 – ISO 11786
- 0.019.7332.4/40 – Engine
- 0.019.7335.4/10 – Injectors
- 0.020.6706.4/30 – Roof
- 0.020.8203.4/10 – Cab roof work lights
- 0.020.9462.4/10 – Rotating beacon
- 0.021.1196.4 – Lower front work lights – H9
- 0.021.1217.4 – Heater
- 0.021.2292.4/20 – Cab (with electronic rear lift)
- 0.021.2294.4/20 – Central (with electronic rear hitch)
- 0.021.2295.4 – Cables for battery (+) (without front hitch)
- 0.021.2296.4 – Cables for battery (+) (with front hitch)
- 0.021.2297.4 – Supplementary relays (engine)
- 0.021.2298.4/40 – Front wiring loom
- 0.021.2724.4/40 – Cable for alternator (with front hitch)
- 0.021.2871.4/20 – Cables for battery (+) (without front hitch)
- 0.021.3066.4/20 – Cables for battery (+) (with front hitch)
- 0.021.3183.4 – Console (with electronic rear hitch)
- 0.021.3542.4 – Front lights / horn
- 0.021.3601.4/10 – Cold start /pre-heating
- 0.021.3867.4/30 – Cab (with mechanical rear hitch)
- 0.021.4080.4/20 – Central (with mechanical rear lift)
- 0.021.4119.4 – 60LT
- 0.021.4309.4 – Rear PTO ECU
- 0.021.4310.4 – Rear PTO (with mechanical rear hitch)
- 0.021.4505.4 – PTO 540 – 750
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
- 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
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
- Service and Spare Parts – 2017 Subscription
B0 – ENGINE
- FARMotion seal ring leakage
- Flushing the lubrication circuit
- FARMotion engine cylinder head leakages
- Coolant leakages on FARMotion engines
- Deutz AG engine oil specifications
- Engine sealing ring leakage
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Farmotion high pressure pipe replacement
- Doc outlet pipe & exhaust system alignment
- Fuel low pressure
D0 – TRANSMISSION
- Hydraulic shuttle central disc
- Hand brake lever greasing
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
- Air conditioning system recharging
- Mechanical rear lift control levers
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- L0 – ELECTRIC AL SYSTEM
