Document overview
Digital Workshop Manual documentation for model SAME EXPLORER 90 → ZKDBG30200TS20001 from the EXPLORER (FARMOTION STAGE 3B) family. Language: English; 1,553 pages.
The corresponding English table of contents contains 54 sections and 441 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
- Starting serial number: ZKDBG30200TS20001
- Document type: Workshop Manual
- Language: English
- Pages: 1,553
- File size: 544.79 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER 90 → ZKDBG30200TS20001.
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 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
- Tightening procedure for engine components
- Engine components removal/refitting sequence
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
- 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
- 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)
- 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
- 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
- 0.019.7336.4/40 – Engine
- 0.019.7337.4/10 – 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)
- 0.021.2724.4/40 – Cable for alternator (with front hitch)
- 0.021.3183.4 – Console (with electronic rear hitch)
- 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
- 0.021.5363.4 – Front lights / horn
- 0.021.5387.4/10 – Cables for battery (+) (without front lift)
- 0.021.5388.4/10 – Cables for battery (+) (with front lift)
- 0.021.6690.4 – Front wiring loom
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
- Belt Tensioner FarMotion Engine
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
- Loosed air compressor pulley
- 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
