Document overview
Workshop Manual for SAME EXPLORER 90 SPECIAL → ZKDT510200TS10001 from the EXPLORER SPECIAL family. Digital PDF in English with 782 pages.
The corresponding English table of contents contains 37 sections and 258 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: SAME
- Family: EXPLORER SPECIAL
- Model: EXPLORER 90 SPECIAL
- Starting serial number: ZKDT510200TS10001
- Document type: Workshop Manual
- Language: English
- Pages: 782
- File size: 215.37 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER 90 SPECIAL → ZKDT510200TS10001.
Complete table of contents
Introduction
- Tightening Torques
- Tightening torques for nuts and bolts of electrical connections
- Installation of solenoid valves and cartridge valves
- Installation of quick couplers
- Units of measurement and conversion factors
- Fixing the steering wheel
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
- Engine block technical data – cylinders
- Crankshaft technical data
- Piston technical data – Piston rings
- Connecting rod technical data
- Camshaft technical data – static advance of 13°
- Camshaft technical data – static advance of 16°
- Timing gears technical data
- Counter-rotating weights technical data
- Technical data and dimensions of valves – valve springs
- Technical data and dimensions of cylinder heads – valve guides – valve seats
- Technical data and dimensions of rocker arms – rocker shafts – tappets
- Engine injector technical data (aspirated versions)
- Engine injector technical data (with turbocharger)
- Hydraulic tappets diagram
Transmission
- Transmission
- Rear power take off (PTO)
Rear axle
- Rear axle
Front axle
- Front axle
Hydraulic system
- Gear pump (22.5 cm³)
- Gear pump (16 cm³)
- Power steering 80 cm³/rev.
- Power steering 125 cm³/rev.
- Ancillary utility distributor 4-way version
- Remote control valve – 6-way version
- Hydraulic lift control valve
- Braking system (without ‘Separate Brake’ valve)
- Braking system (with ‘Separate Brake’ valve)
- Separate-Brakes valve
- Trailer braking valve
Method of intervention
B0 – Engine
- Complete engine
- Separating engine / transmission
- Preliminary and final operations
- Final engine checks
- Checking engine block
- Crankshaft
- Crankshaft checks
- Flywheel checks
- Renewal of crankshaft rear oil seal
- Pistons and cylinder liners
- Pistons and rings check
- Cylinder liners check
- Check connecting rods – gudgeon pins – rod cap screws
- Camshaft
- Camshaft checks
- Timing gear checks
- Adjusting timing gears backlash
- Valve timing
- Counter-rotating weights
- Overhaul of counter-rotating weights assembly
- Counter-rotating weight checks
- Valves check
- Valve seats check
- Valves sealing check
- Valves adjustment
- Valve guides check and replacement
- Inspecting the rocker arms and rocker shafts
- Cylinder heads
- Heat exchanger removal
- Valve springs check
- Disassembly of the heat exchanger
- Lubrication pump
- Lubrication pump disassembly
- Oil sump
- INJECTION PUMPS, GOVERNOR AND FUEL SUPPLY
- Synchronising injection pumps
- Injectors assembly
- Injectors check
- Checking injectors protrusion – Renewal of copper bushes
- Injection pumps control rod
- Injection pump control rod
- Overhaul of the mechanical governor (standard and with LDA valve)
- Overhaul of the mechanical governor gear
- Electronic governor adjustment
- Installation of mechanical governor drive unit and electronic governor support
- Installation of electronic governor support
- Engine coolant pump
- Thermostatic valve
- Checking the thermostat valve
- Cooling and intake ducts
C0 – Engine accessories
- Replacing the coolant
- Fan
- Coolant radiator
- Expansion tank
- Air filter
- Air filter elements
- Air filter mount
- Fuel tank
- Starter motor
- Exhaust pipe
- Intermediate exhaust manifold
D0 – Transmission
- Changing the transmission oil
- Gearbox and shuttle assembly – Complete assembly
- Gearbox and shuttle assembly – 5-speed version
- Removing the gearbox and shuttle assembly – Complete assembly
- Shuttle shaft
- Disassembly of the main shaft
- Disassembly of the secondary shaft
- Gearbox mount and gear selector rods
- Secondary shaft – 5-speed version
- Removing dual traction output shaft – 4-range version
- Removing dual traction output shaft – 3-range version
- Separating the gearbox housing from the rear gearbox housing
- Clutch plate
- Clutch thrust bearing
- Primary shaft – Version without Hi-Lo
- Removing pinion – 4-range version
- Removing pinion – 3-range version
- Adjustment of the differential – Bevel gear set
- Pump drive PTO – Outer gear
- Pump drive PTO – Inner gear
- PTO output shaft – 2-speed versions
- Groundspeed PTO flange shaft
- P.T.O. Synchro engagement device
- 4WD engagement device
- Adjusting the parking brake lever
- PTO clutch
- Disassembly of the PTO clutch
- Parking brake
E0 – Rear axle
- Bleeding the braking system
- Removing right/left hand rear axle
- Rear axle brake discs
- Differential
- Removing rear differential
- Right hand rear axle
- Left hand rear axle
- Planet gear carrier
- Brake housing
- Rear axle brake piston
F0 – Front axle
- 4WD shaft
- Support with front axle
- Front axle
- Front axle (4WD)
- Adjusting front axle endfloat
- Steering cylinders
- Removing steering cylinders
- PINION-DIFFERENTIAL ASSEMBLY
- Removing bevel gear set
- Differential lock
- Differential locking device adjustment
- Disassembly of the differential
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Steering knuckle housing and half-shaft
- Adjustment of steering knuckle housing and axle shaft
- Front brake discs
- Front axle brake piston
G0 – Bodywork – Cab – Platform
- Access ladder
- Engine hood and front hood panels
- Lower hood guard
- Rear mudguard
- Footboards
- Instrument cluster
- Instrument cluster
- Lower instrument cluster
- Seat
- Steering wheel
- Steering column
- Brake master cylinders
- Clutch pump
- Clutch piston
- Parking brake lever
- Main gear lever
- Disassembling the reverse shuttle control lever
- Clutch pedal
- Auxiliary hydraulic distributor controls
- Disassembling the auxiliary hydraulic distributor controls
- Brake pedals
- Bleeding the clutch circuit
H0 – Hydraulic system
- Ancillary pump
- Power steering pump
- Hydrostatic steering (orbitrol)
- Power steering disassembly
- Rear ancillary distributor
L0 – Electrical system
- Battery
- Alternator
R0 – Rear lift
- Rear lift
- 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 – 2WD version
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Drawbar
Wiring diagrams
Components
- 2.8519.071.0/30 – Preheat 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)
- H – Manual electrical controls (steering column stalk)
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices, Flasher units and Timers
- O – Resistors and rheostats
- P – Various services
Systems
- S001 – Activation and charging
- S002 – Lights (for 75 HP versions)
- S002 – Lights (for 85 -95 HP versions)
- S003 – Instrument cluster (for 75 HP versions)
- S003 – Instrument cluster (for 85 -95 HP versions)
Wiring harnesses
- 0.009.6475.4/30 – Rear (85-95 HP)
- 0.009.9906.4/40 – Rear (75 HP)
- 0.021.7369.4/30 – Central – front – battery – instrument panel (75 HP)
- 0.021.7367.4/40 – Central – front – battery – instrument panel (85 -95 HP)
- 0.011.7840.4 – Rotating beacon
- 0.012.4375.4/10 – Front – rear lights
- 0.255.8454.3/20 – License plate light
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
- Flushing the lubrication circuit
- Deutz AG engine oil specifications
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- 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
- L0 – ELECTRIC AL SYSTEM
