Document overview
Workshop Manual for SAME EXPLORER 90.4 → ZKDAW30200TS10001 from the EXPLORER (FARMOTION STAGE 3B) family. Digital PDF in English with 1,505 pages.
The corresponding English table of contents contains 52 sections and 417 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 90.4
- Starting serial number: ZKDAW30200TS10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,505
- File size: 573.95 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER 90.4 → ZKDAW30200TS10001.
Complete table of contents
Introduction
- Introduction – Engines
- Tightening torques
- Tightening torques for nuts and bolts of electrical connections
- Wheel nut/screw 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
- Hydraulic reverse power shuttle
- HI-LO unit
- Rear PTO
- Views of transmission
Rear axle
- Rear differential
- Rear axle
Front axle
- Front axle
Bodywork – Cab – Platform
- A/C system – High visibility version
- A/C system – Version with standard roof
Hydraulic system
- Hydraulic distributor circuit
- Transmission hydraulic circuits
- Suction pump filter
- Delivery line filter
- Power steering SDD 125-250cc
- Power steering 160 cc
- Rear PTO
- Shuttle control unit
- 60 l/min. ECO AUX block
- Park Brake
- Transfer pump
- Distributor unit
- Pressure regulator valve unit
- Services command unit
- Braking system
- Hydraulic pumps unit
Electrical equipment
- FARMotion engine sensors and components
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) – Accelerators calibration
- Commissioning (939600) – Clutch pedal calibration
- Commissioning (939600) – Hitch calibration
- Commissioning (939600) – Options selection
- Commissioning (939600) – Steering sensor calibration (SDD)
- 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 engine removal and reassembly
- Workshop tools for disassembly and reassembly
- Tightening procedure for engine components
- Engine components removal/refitting sequence
B0 – Engine
- Separating engine from transmission
- Engine flywheel
- Engine
- Preliminary operations before removing engine from vehicle
- 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
- 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
- Engine speed sensor
- Camshaft timing sensor
- Temperature sensors
- Engine oil pressure switch
- 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
- Disassembling cover assembly
- Removing the forward drive clutch unit
- Disassembling the reverse drive clutch unit
- Input shaft assembly and tone wheel
- Range selector assembly
- Disassembling the range selector assembly
- DT shaft in transmission
- Clutch housing – separation from transmission
- 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
- Primary shaft – Version with HI-LO
- Disassembling the gearbox input shaft
- Disassembly of secondary shaft – Version with HI-LO
- Disassembly of the main shaft
- Disassembly of HI-LO unit output shaft
- PTO output shaft – 2 speed version
- PTO output shaft – 4 speed version
- Disassembling the PTO output shaft – 2-speed version
- Removing the PTO output shaft – 4 speed version
- PTO engagement clutch
- Disassembling PTO engagement clutch
- Removing the rear pinion – 2-range version
- Removing the rear pinion – 4-range version
- Disassembly of dual traction clutch – Easyshift
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- Disassembling the ground speed PTO output shaft
- Disassembling the ground speed PTO clutch engage mechanism
- Disassembling the PTO final flange shaft – 2 speed version
- Disassembling PTO final flange shaft – 4 speed version
- Pump drive PTO – External gear without 60 l ECO pump
- Pump drive PTO – External gear with 60 l ECO pump
- Pump drive PTO – Internal gear
- Adjustment of the differential – Bevel gear set
- 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
- Wheel carriers
- Wheel mount disassembly
- Brake carrier (versions without Park Brake)
- Disassembling the brake carrier (versions without Park Brake)
- Park Brake assembly
- Park Brake unit disassembly
- Rear differential
- Removing rear differential
F0 – Front axle
- Front axle 4WD
- Steering cylinders
- Removing steering cylinders
- Separating front carrier from engine
- Steering cylinders
- Front mount
- 4WD shaft
- Steering sensor actuator plate orientation
G0 – Bodywork – Cab – Platform
- Cab
- Engine cowl
- Battery mount
- Condenser
- Cab access steps
- Expansion valve
- Heater radiator – Version with air conditioner
- Air conditioner evaporator
- Motor with fans
- Steering wheel
- Heater unit
- A/C unit
- Disassembling the condenser
- Heater radiator – Version with heater
- Dehydrator filter
- Anti-icing sensor
- Hand brake bowden cable replacement
H0 – Hydraulic system
- Rear ancillary utility distributor
- 2-way distributor
- Disassembling the 2-way distributor
- Disassembling shuttle solenoid valve block
- Power steering valve
- 60L ECO 8-way distributor solenoid valve
- Disassembling the 60L ECO 8-way distributor solenoid valve
- Transmission oil radiator
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
- Disassembling the complete pump assembly
- Shuttle solenoid valves assembly
- 4-rear way ancillary utility distributor
- 6-rear way ancillary utility distributor
- Replacing positioning for automatic release
L0 – Electrical system
- Battery
- External air temperature sensor
- Engine control unit
- 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 clutch-brake assembly
- Disassembling the front PTO clutch-brake assembly
- Pump assembly
- Solenoid valve block
- Front PTO input shaft
R0 – Rear lift
- S.A.C. Automatic control station
- Disassembling the hitch assembly (SAC)
- Bushes
- Auxiliary hitch cylinders
- Disassembling the rear hitch control distributor
- Mechanical draft sensor
- 3-point linkage
- Checking and testing the mechanical rear lift
- Adjusting mechanical rear lift controls
- Rear lift draft rod replacement
S0 – Wheels
- Rear wheels
- Front Wheels
V0 – Ballast – towing hitches
- Tow hook sled
V1 – AFTERMARKET KITS
- Installation of passenger seat kit
- Head and pin kit assembly procedure for automatic hitch
- 9.Y3654.90.0 and 9.Y4054.90.0 kit installation
Wiring diagrams
Introduction
- Structure of the unit
- Introduction
- Basic electronics for mechanics (1/2)
- Electrical and electronic components (1/2)
- Basic electronics for mechanics (2/2)
- 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)
- 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 hitch)
- S001 – Electronic engine throttle (mechanical rear lift)
- S002 – Preheating
- S003 – Starter (electronic rear lift)
- S003 – Starter (mechanical rear lift)
- S004 – Hitch
- S005 – Lights (electronic rear hitch)
- S005 – Lights (mechanical rear hitch)
- S006 – Work lights (electronic rear hitch)
- S006 – Work lights (mechanical rear hitch)
- S007 – Windscreen wiper
- S008 – Instrument cluster (electronic rear lift)
- S008 – Instrument cluster (mechanical rear lift)
- S009 – Radio
- S010 – Manual air conditioner
- S011 – Transmission (electronic rear hitch)
- S011 – Transmission (mechanical rear hitch)
- S012 – PTO (electronic rear hitch)
- S012 – PTO (mechanical rear hitch)
- S013 – Accessories (electronic rear hitch)
- S013 – Accessories (mechanical rear hitch)
- S014 – Can bus (electronic rear hitch)
- S014 – Can bus (mechanical rear hitch)
- 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 hitch)
- S018 – ECO Saving (mechanical rear hitch)
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
- 0.017.9311.4/30 – Hydraulic reverse shuttle wiring loom – Stoll (GS only)
- 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
- SDF Parts and SDF Service DVDs 05/2014 version 25
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
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
- BRAKE PUMP INTERNAL LEAKAGE
- 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
