Document overview
Workshop Manual for SAME EXPLORER 90 → ZKDDJ10200TS10001 from the EXPLORER (FARMOTION STAGE 4) family. Digital PDF in English with 1,678 pages.
The corresponding English table of contents contains 51 sections and 501 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 4)
- Model: EXPLORER 90
- Starting serial number: ZKDDJ10200TS10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,678
- File size: 455.68 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME EXPLORER 90 → ZKDDJ10200TS10001.
Complete table of contents
Introduction
- Tightening Torques
- Pump tightening torques
- Wheel rim to hub screws and nuts 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
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
Transmission
- Transmission
- Mechanical clutch assembly
- Four-wheel drive electrohydraulical engagement and parking brake assembly
- Rear PTO
- Views of transmission
Rear axle
- Rear differential
- Rear axle
- Rear axle
Front axle
- Front axle, 4WD – 4-planet gear differential
- Front axle, 4WD – size 1.5
- Front axle 2WD
- Steering angle sensor (version with SDD)
Bodywork – Cab – Platform
- Air conditioning system – Version with Standard Roof
- Air conditioning system – High Visibility Version
Hydraulic system
- Introduction to hydraulic circuit diagrams
- Transmission hydraulic circuits
- Auxiliary utility hydraulic circuits
- Hydraulic pumps unit
- Transfer pump
- 60 l/min. ECO AUX block
- Suction pump filter
- Delivery line filter
- Power steering 160 cc
- SDD power steering
- Distributor unit
- Braking system
- Master cylinder
- Separate-Brakes valve
- Bistable valve block
- Brake logic block
- Trailer braking valve
- Priority valve
- Three-stage module control block (HML)
- Pressure regulator valve unit
- Service valve unit
- Shuttle control unit
- Rear PTO
Electrical equipment
- FARMotion engine sensors and components
- FARMotion engine sensors and components
- FARMotion engine sensors and components
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Mechanical rear lift
- Electronic rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- ECUs
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- ECU Reset
- Set vehicle model
- Cluster configuration
- Measurement unit
- Power Shuttle
- Range
- 4^ gear
- Speed matching
- Four-Wheel Drive (4WD)
- Front Power Take-Off (PTO)
- ISO 11786
- Pneumatic trailer brake
- Hydraulic trailer brake
- Steering Double Displacement (SDD)
- Clutch pedal calibration
- Rear hitch position calibration
- PowerShuttle calibration
- PowerShuttle acceleration
- PowerShuttle balance
- PowerShuttle readiness
- PowerShuttle pedal
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
B0 – Engine
- Workshop tools for engine removal and reassembly
- Tightening procedure for engine components
- Complete engine
- Engine- separation from the transmission
- Preliminary operations before removing engine from vehicle
- Engine flywheel
- 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
- 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
- Cylinder head covers
- Aligning water pump and crankshaft pulleys
- Exhaust gas recirculation valve (EGR)
- A/C compressor belt
C0 – Engine accessories
- High pressure fuel pump
- Mounting brackets
- Power take off gear backlash adjustment
- Replacing the coolant
- Engine air intake fan
- Coolant radiator
- Complete radiator-heat exchanger pack
- Disassembling the radiator assembly
- Compensation tank
- Intercooler, gearbox oil and fuel heat exchangers
- Air filter
- Rigid air filter pipe
- Fuel filter
- Fuel pre-filter
- Bleeding the fuel circuit
- Manual fuel pump
- Fuel tank
- Electric starter motor
- Exhaust silencer
- Return line
- Intake throttle valve (TVA)
- AdBlue pump module
- AdBlue metering module
- AdBlue tank
- 2-way AdBlue solenoid valve
D0 – Transmission
- Draining and filling the transmission oil
- Gearbox/HML assembly
- Gearbox and HI-LO unit
- Separating connector flange from rear gearbox housing
- Clutch plate
- Clutch thrust bearing
- Disassembly of HI-LO unit output shaft
- Disassembling the reverse shuttle shaft
- Primary shaft
- Disassembly of the main shaft
- Secondary shaft – Version with HI-LO
- Disassembly of secondary shaft – Version with HI-LO
- Output shaft – Version with 3-stage module (HML)
- Disassembling the secondary shaft – Version with HI-LO or HML
- Adjustment of the differential – Bevel gear set
- PTO input shaft – 2 speed version
- Disassembling the PTO input shaft – 2 speed version
- PTO input shaft 4 speed version
- Disassembling the PTO input shaft 4 speed version
- PTO output shaft – 4 speed version
- Groundspeed PTO shaft
- DT shaft in transmission
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- 4WD engagement device – Easyshift
- Parking brake disc sectors
- Gearbox internal cover
- HI-LO unit
- Disassembling the LO range clutch housing
- Disassembling the HI-LO planetary reduction gearbox
- HML unit
- Disassembling the HML unit
- Disassembling the H clutch
- Disassembling M-L clutches
- Replacing the L clutch
- Disassembly of the HML planetary reduction gearbox
- Outer HML casing
- Gear selector assembly
- Gear selector rod
- Range selector assembly
- Disassembling the range selector assembly
- Range reduction gear shaft – 2 range version
- Range reduction gear shaft – 4 range version
- Rear pinion – 2-range version
- Rear pinion – 4-range version
- PTO engagement clutch
- Disassembling PTO engagement clutch
- Hydraulic pump drive
- Pump drive PTO – External gear
- Pump drive PTO – internal gear
E0 – Rear axle
- Bleeding the braking system
- Rear differential
- Removing rear differential
- Right-hand rear axle
- Left-hand rear axle
- Rear axle crown wheel
- Removing right/left hand rear axle
- Park Brake assembly
- Park Brake unit disassembly
- Brake carrier
- Disassembly of the brake carrier
F0 – Front axle
- Front axle (4WD)
- 4WD shaft
- Steering bar/tie-rod
- Differential assembly
- Disassembling the differential assembly
- Disassembly of the differential
- Differential assembly adjustment
- Steering cylinders
- Removing steering cylinders
- Adjustment of the bevel gear set
G0 – Bodywork – Cab – Platform
- Cab
- Cab access steps
- Engine hood and front hood panels
- Lower hood cover
- Battery mount
- Mudguard
- Cab mat
- Right hand console
- Left hand side cab trim
- Right hand side cab trim
- Disassembling the hydraulic distributors levers
- Registration of the hydraulic distributors bowden cable
- Instrument cluster
- Instrument cluster
- Roof panel
- Screen wash liquid reservoir
- Windscreen wiper motor
- Roof hatch
- Door frame
- Cab roof
- Anti-pollen filter
- External rear view mirrors
- Seat
- Empty and charge the air conditioning system
- A/C unit
- Air conditioner control unit
- Air conditioning compressor
- Air conditioning condenser
- Dehydrator filter
- Air conditioner evaporator
- Heating radiator – Version with air conditioning
- Motor with fans
- Expansion valve
- Anti-icing sensor
- Throttle pedal
- Disassembling the electronic throttle control
- Brake pedals
- Steering column
- Steering wheel
- Brake master cylinders
- Replacing the Bowden cable of the parking brake
H0 – Hydraulic system
- Lift pump
- Power steering pump
- HML solenoid valve block
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Oil filter
- Resonator
- Hydrostatic steering (orbitrol)
- 6-rear way ancillary utility distributor
- Brake system flow regulator valve
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
L0 – Electrical system
- Battery
- Alternator
- Electronic engine control unit (ECU)
- HLHP Ancillary utility electronic control unit
- Urea electronic control unit (DCU)
- Clutch pedal potentiometer
- Start enable switch
- Reverse shuttle speed sensor
- Throttle pedal position sensor
- Shuttle control oil pressure switch
- HML speed sensor
- Hydraulic system inlet pressure switch
- Solenoid valve block and utility pressure switch
- Rear lift position sensor
- Wheel speed sensor
- Instrument cluster
- Button panels
- Ignition switch barrel
- Battery master switch
- Steering column stalk
- Cab interior lights
- 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
- Headlights
- Work lights
M0 – Front PTO
- Front power take-off
- Disassembling the front PTO
- Disassembling the front PTO control clutch
- Solenoid valve block
- Front PTO input shaft
N0 – Front lift
- Front lift
- Front lift hydraulic system valve
- Front lift hydraulic cylinders
R0 – Rear lift
- Complete rear lift (SAC)
- Disassembling the complete rear lift (SAC)
- Lift bushes
- Rear lift control distributor
- Lift cylinders
- 3-point linkage
- Mechanical draft sensor
- 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
- Electronic rear lift troubleshooting
- Checking and testing the mechanical rear lift
- Adjusting mechanical rear lift controls
- Rear lift draft rod replacement
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook
V1 – AFTERMARKET KITS
- Pneumatic brake kit – P/N 9.DK589.90.0
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 – Grounds
- D – Wiring connectors
- E – On-board instruments
- F – External lights (rotating beacon)
- G – Interior lights
- H – Electrical controls
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices
- N – Electric motors and actuators
- O – Resistors and diodes
- P – Various services
- R – Diagnostics
Systems
- S001A – Electronic engine throttle (version for mechanical rear lift)
- S001B – Electronic engine throttle (version for electronic rear lift)
- S002A – Preheat, mechanical rear lift
- S002B – Preheat (electronically controlled rear lift)
- S003A – Starting (electronically controlled rear lift)
- S003B – Starting (mechanically controlled rear lift)
- S004 – Lift
- S005A – Lights (mechanically controlled rear lift)
- S005B – Lights (version for electronic rear lift)
- S006A – Work lights (version for electronically controlled lift)
- S006B – Work lights (version for mechanically controlled lift)
- S007A Wipers (version for electronically controlled rear lift)
- S007B – Wipers (version for mechanically controlled rear lift)
- S008A – Instrument cluster (electronically controlled rear lift)
- S008B – Instrument cluster (mechanically controlled rear lift)
- S009 – Radio system
- S010 – Air conditioning system
- S011A – Transmission (version for electronically controlled rear lift)
- S011B – Transmission (version for mechanically controlled rear lift)
- S012A – PTO (version for electronically controlled lift)
- S012B – PTO (version for mechanically controlled lift)
- S013A – Accessories (mechanically controlled rear lift)
- S013B – Accessories (version for electronically controlled rear lift)
- S014A – CAN network (version with mechanical lift)
- S014B – CAN relay (version with electronically controlled rear lift)
- S015 – Engine CAN line
- S016A Braking system (version for electronic rear lift)
- S016B – Braking system (version for mechanical rear lift)
- S017A – Trailer brake (version for mechanical rear lift)
- S017B – Trailer brake (version for electronic rear lift)
- S018A – Eco Saving (version with electronic lift)
- S018B – Eco saving (version with mechanical lift)
- S019 – Emissions
- S020A – Front loader (version for mechanically controlled lift)
- S020B – Front loader (version for electronically controlled lift)
- S021A – SDD (version for electronic lift)
- S021B – SDD (version for mechanical lift)
- S022A – Battery master switch (version for mechanical rear lift)
- S022B – Battery master switch (version for electronic rear lift)
Wiring harnesses
- Wire colour reference table
- 0.011.3797.3 – SBA sensors
- 0.012.2756.3 – Front PTO
- 0.014.1567.4/20 – Front wiper motor – opening windscreen version
- 0.014.1645.4/10 – Hydraulic trailer braking pressure switch wiring
- 0.014.8453.4 – Front wiper motor – fixed windscreen version
- 0.016.1001.4/20 – Hydraulic trailer braking
- 0.021.1196.4/10 – Low work lights
- 0.018.5346.4 – Distributor 7-8
- 0.019.5702.4/10 – ISO port kit
- 0.019.8827.4 – SDD
- 0.020.6706.4/40 – Roof panel
- 0.020.8203.4/10 – Cab roof work lights
- 0.020.9462.4/10 – Flashing beacon cable
- 0.021.1217.4 – relay – heater
- Front lights and horn
- 0.021.4309.4 PTO
- 0.021.4310.4 – PTO “Mushroom”
- 0.021.4505.4 – PTO 540/750 wiring loom
- 0.023.1279.4/20 – Engine – 3 cylinder version
- 0.023.1280.4/20 – Engine
- 0.023.1281.4 – Injectors – 3 cylinder version
- 0.023.1282.4 – Injectors
- 0.023.3110.4/10 – DCU metering module
- 0.023.3353.4/10 – Front wiring loom
- 0.023.3418.4 – Front, 3 cylinders
- 0.024.1788.4/10 – Power cables
- 0.024.2826.4 – Alternator – preheat
- 0.024.3458.4 – Right hand console
- 0.024.3509.4/10 – OCU control unit
- 0.024.3753.410 – Rear, for mechanical reverse shuttle and electronically controlled lift
- 0.024.4167.4/10 – Rear, for version with mechanical reverse shuttle and mechanically controlled lift
- 0.024.4172.4 – Cab, for mechanical reverse shuttle and mechanically controlled lift
- 0.024.8482.4.10 – Front loader
- 0.025.1281.4 – Wiring loom for front loader
- 0.025.3466.4 – RH headlight, Europe
- 0.025.3467.4 – LH headlight, EUROPE
- 04422324.410 – ISO 11786
- 2.7659.368.0/30 – Battery isolator switch
- 2.8059.562.0 – LH headlight, USA
- 2.8059.563.0 – RH headlight, USA
- 0.026.1301.4 – Wiring loom for front loader
- 0.026.4751.4 – Override button wiring loom
- 0.024.3750.4 – Cab, for mechanical reverse shuttle and electronically controlled lift
- 0.027.8546.4_20 – Cab, for hydraulic reverse shuttle and electronically controlled lift
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
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Deutz AG engine oil specifications
- Engine sealing ring leakage
- Belt Tensioner FarMotion Engine
C0 – ENGINE ACCESSORIES
- SERVICE NEWS – DEF Unit – Wrong level indication
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- AdBlue Float level unit
- Farmotion high pressure pipe replacement
- SCR AREA DAMAGED SENSORS
- ERROR M426 – SCR system efficiency
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Front axle final reduction shims
- 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
