Document overview
Workshop Manual PDF for SAME IRON 115 DCR 4V CONTINUO → WSXS310200LS10010, IRON CONTINUO (STAGE 3A) family. Document language: English; 1,752 pages.
The corresponding English table of contents contains 49 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: IRON CONTINUO (STAGE 3A)
- Model: IRON 115 DCR 4V CONTINUO
- Starting serial number: WSXS310200LS10010
- Document type: Workshop Manual
- Language: English
- Pages: 1,752
- File size: 184.35 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME IRON 115 DCR 4V CONTINUO → WSXS310200LS10010.
Complete table of contents
Introduction
- Tightening torques for nuts and bolts of Deutz engines
- Tightening torques for nuts and bolts of electrical connections
- Pump tightening torques
- Installation of solenoid valves and cartridge valves
- Installation of quick couplers
- Units of measurement and conversion factors
- Wheel nut/screw tightening torques
- Tightening torques
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
- Components of the TCD 2012 L04/L06 4V DCR engine
- Technical data of Engine TCD 2012 4V
- Tightening requirements TCD 2012 L04/L06 4V DCR (Lv.2) engine
- Tightening requirements TCD 2012 L04/L06 4V DCR (Lv.3) engine
Engine accessories
- “E-ViscoFan”
Transmission
- Transmission
Front axle
- Front axle – Version with suspension (with electrohydraulic differential lock and ASM/SBA)
- Front axle – Version without suspension (with electrohydraulic differential lock)
- Front axle – Version without suspension (with self-locking differential)
Bodywork – Cab – Platform
- Air conditioning system
Hydraulic system
- Hydraulic system
- Main hydraulic components
- Variable displacement pump
- Load pump
- Operation of the variable displacement pump
- Load sensing valve, pressure cut-off valve
- Power steering valve
- Hydraulic front axle suspension
- Hydraulic trailer braking system – Italy version
- Hydraulic trailer braking system – Export version
- Servo-brake valve for front axle
- Steering gear pump
- Braking system
- Master cylinder
- Brake assembly
- Remote control valve – 8-way version
- Remote control valve – 10-way version
- Remote control valve – 8-way version with hydraulic trailer braking
- Remote control valve – 10-way version with hydraulic trailer braking
- Lift control section
- Trailer air braking system – ITALY version
- Trailer air braking system – Export version
- Compressor
- Pressure limiting valve
- Trailer air braking valve (1-way)
- Trailer air braking valve (2-way)
Calibrations and electronic diagnosis
Diagnostic tools
- Position of ECUs and diagnostic instruments
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket connection
Serdia 2000
- Serdia
- SERDIA 2000 level III” software
- SERDIA – Diagnostic socket connection
Diagnostic tool screens
- ECU interrogation
Commissioning and calibrating the tractor
- Commissioning – Introduction (HLHP software version SC0127AB)
- Putting into service – Model configuration
- Putting into service – HLHP
- Putting into service – Calibration
- Putting into service – P.T.O.
- Putting into service – ASM
- Putting into service – Lift
- Putting into service – Suspension
- Putting into service – System
- Putting into service – Distributors
- Putting into service – Engine
- Putting into service – Air conditioning
- Putting into service – Agrosky
- Putting into service – Semiactive cabine
- Calibration screens for ART/PC Tester
- Alarm list screens for ART/PC Tester
ECU alarms
- Key to the “ECU alarms” tables
- FMI code
Engine alarms
- Engine ECU alarms – Serdia codes
- Engine ECU alarms – ART codes
Transmission alarms
- Transmission control unit alarms – Introduction
- Transmission control unit alarms – Definition of the system reaction
- Transmission control unit alarms
Armrest alarms
- Armrest ECU alarms
HLHP alarms
- HLHP ECU alarms
Electrohydraulic control valve alarms
- Electrohydraulic control valve alarms
Method of intervention
- Tools for engine disassembly and reassembly
- Workshop tools for engine disassembly and reassembly
B0 – Engine
- Engine earth pin fixing
- A/C drive belt alignment and tension adjustment
- Removing and installing the crankcase bleeding
- Removing and installing torsional vibration damper
- Alternator, fuel pump, coolant pump and fan drivebelt
- Removing and installing the flywheel
- Removing and installing the belt tensioner (V-rib belt)
- Air conditioning compressor drivebelt
- Air conditioning compressor drivebelt tensioning
- Checking piston overhang
- Removing and installing the rocker arm housing
- Disassembling, assembling and checking the rocker arm and rocker arm bracket
- Checking and setting the valve clearance
- Changing the engine oil
- Checking that the radiator is clean
- Removing and installing the cooler (exhaust gas recirculation)
- Removing and installing the flutter valve (exhaust gas return)
- Checking the coolant thermostat when uninstalled
- Removing and installing the fan drive
- Removing and installing the actuator (exhaust gas return)
- Removing and installing the exhaust line
- Removing and installing the shutoff valve (exhaust gas recirculation)
- Setting the shut-off valve (exhaust return)
- Removing and installing the turbocharger
- Compression test
- Assembly and disassembly of the engine on the assembly stand
- Adjustment of valve clearance
- Fitting and removing rocker seat
- Removing and refitting rocker seat, checking
- Disassembly and assembly of the cylinder head
- Measuring piston protrusion
- Valve assembly and disassembly
- Valve check
- Check the valve guide
- Check the valve residual
- Test data and settings
- Check the endfloat of the crankshaft
- Check the crankshaft
- Replace the crankshaft O-ring (flywheel end)
- Replacing the crankshaft O-ring (opposite end to flywheel)
- Check the connecting rod drum
- Assembly and disassembly of the crankshaft
- Disassembly and assembly of the piston and connecting rod drum
- Check the piston
- Check the piston rings and piston grooves
- Assembly and disassembly of piston cooling nozzles
- Removal and refitting of the crankcase breather
- Check the cylinder
- Removal and refitting of the front cover (opposite end to flywheel)
- Disassembly and assembly of the gear case cover
- Assembly and disassembly of the camshaft
- Check the camshaft
- Removal and refitting of the rotation device
- Removal and refitting of the heater
- Removal and refitting of the turbocharger
- Removing and fitting the butterfly valve (exhaust gas recovery)
- Removing and fitting the cooler (exhaust gas recovery)
- Removing and fitting regulator unit (exhaust gas recovery)
- Removing and fitting the cutoff valve (exhaust gas recovery)
- Adjusting the cutoff valve (exhaust gas recovery)
- Removing and fitting the fuel delivery pump (driven by ribbed V-belt) (L3)
- Removal and refitting of the fuel control unit
- Removal and refitting of the high-pressure pump (installation position A)
- Removal and refitting of the high-pressure pump (installation position B)
- Removal and refitting of the common rail
- Removal and refitting of the injectors
- Removal and refitting of the pressure cut-off valve
- Removal and refitting of the oil sump pan.
- Removal and refitting of the oil pickup pipe
- Removal and refitting of the oil cooler
- Removal and refitting of the lube oil cooler housing
- Removal and refitting of the water pump
- Testing the thermostat (after removal)
- Removal and refitting of the fan drive system
- Removal and refitting of the fan drive system
- Removal and refitting of the torsional vibration damper
- Removing and fitting belt tensioner (ribbed V-belt)
- Removal and refitting of the flywheel
C0 – Engine accessories
- Disassembly and assembly of the speed indicator (crankshaft)
- Remove and install fuel filter console
- Removal and refitting of the camshaft speed sensor
- Removal and refitting of the exhaust manifold
- Removing and installing the fuel supply pump
- Removal and refitting of the fuel filter head.
- Remove and install the heating flange
- Removal and refitting of the rail pressure sensor
- Removing and installing pressure sensor/temperature sensor (charge air)
- Removing and installing the generator (operating side)
- Removing and fitting the alternator (driven by ribbed V-belt) (L3)
- Removing and installing the starter
- Disassembly and assembly of the starter
- Removal and refitting of the supply air pressure/temperature sender
D0 – Transmission
- Pressure tests
- Pressure test points
- ECCOM 1.3 reference diagrams
- Separating of rear axle from transmission
- Removing the system control
- Removing the hydraulic control system
- Removing the pump drive gear
- Removing the speed transmitter and inductive sensor
- Removing the filter
- Removing the shaft ring seals
- Separation of flywheel housing from clutch housing
- Removing of double gear and intermediate gear
- Removing drive shaft
- Removing spur gear
- Removing tube
- Removing hydrostatic unit
- Separation of clutch housing from intermediate housing
- Removing KV/KR Clutch
- Disassembly double gear
- Disassembly KR clutch
- Disassembly KV clutch
- Removing central shaft
- Removing front-wheel-drive
- Disassembly pinion shaft
- Disassembly multi-disk brake (BG)
- Disassembly shifting drum (planetary transmission)
- Disassembly P4/BG ring gear
- Disassembly K3/K4 clutch
- Disassembly P4 planetary drive
- Disassembly central shaft
- Disassembly K1/K2 clutch
- Disassembly P3 planetary drive
- Disassembly P2 planetary drive
- Disassembly P1 planetary drive
- Disassembly spur gear
- Removing wiring harness
- Fitting wiring harness
- Reassembly spur gear
- Reassembly P1 planetary drive
- Reassembly P2 planetary drive
- Reassembly P3 planetary drive
- Reassembly K1/K2 clutch
- Reassembly central shaft
- Reassembly P4 planetary drive
- Reassembly K3/K4 clutch
- Reassembly multi-disk brake (BG)
- Reassembly pinion shaft
- Reassembly front-wheel-drive
- Reassembly central shaft
- Reassembly hollow shaft/disk carrier
- Reassembly KR clutch
- Reassembly double gear
- Fitting of intermediate housing to clutch housing
- Fitting hydrostatic unit
- Fitting tube
- Fitting spur gear
- Fitting drive shaft
- Fitting double gear and intermediate gear
- Mounting of flywheel housing to the clutch housing
- Fitting the shaft seal rings
- Fitting the filter
- Fitting the inductive sensor and speed transmitter
- Fitting the pump drive gear
- Fitting the hydraulic control system
- Fitting the system control unit
- Fitting of transmission to rear axle
E0 – Rear axle
- Adjustment of the braking device
- Removing the axle housing
- Removing the differential
- Removing the PTO
- Removing brakes
- Removing the deviator, lifter and brake shaft
- Fitting the deviator, lifter and brake shaft
- Fitting the PTO transmission
- Fitting the differential
- Fitting brakes
- Fitting the axle housing
F0 – Front axle
- Fitting the speed sensor
- Troubleshooting
- Toe-in/steering angle/assembly tests
- Steering cylinders assembly
- Checking the bevel gear pair
- ML differential carrier assembly
- Differential disassembly – ML version
- LS Differential carrier assembly
- Differential disassembly – LS version
- Flange assembly
- Front axle bevel pinion assembly
- Planetary reduction gear assembly
- Wheel hub assembly
- Toe-in – steering angle – post-assembly checks
G0 – Bodywork – Cab – Platform
- Fixing the steering wheel
H0 – Hydraulic system
- Spool valves
- Hydraulic pump
- LS variable displacement pump filter
- Installation of the hydraulic oil filter sensor
L0 – Electrical system
- Steering position sensor assembly
V1 – AFTERMARKET KITS
- Installation of the air conditioning kit
- Installing supplementary fuse box kit
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 – Earths
- D – Intermediate connections
- E – On-board instruments and visual and audible indicators
- F – External lights
- G – Interior lights
- H – Electrical and manual controls
- 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, rheostats, diodes and diode boards
- P – Various services
- Q – Safety devices
- R – Diagnostics
- 04214367 – Engine ECU
- 2.8519.127.0 – HLHP ECU
- 2.8519.102.0 – Transmission ECU
Systems
- S001 – Starting and preheating
- S002 – Electrical engine governor
- S003 – Transmission
- S004 – Instrument panel
- S005 – Steering column lights switch – Version without front lift
- S006 – Steering column switch unit lights – Version with front lift
- S007 – Steering column switch
- S008 – Worklights – Version without front lift
- S009 – Worklights – Version with front lift
- S010 – Manual air conditioner
- S011 – Power supply (+30)
- S012 – Power supply (+15)
- S013 – Negatives
- S014 – Can Bus
- S015 – PTO – Version without front PTO
- S016 – PTO – Version with front PTO
- S017 – Brakes
- S018 – Hydraulic control valves
- S019 – Front and rear lifts
- SO20 – Front axle suspension
- S021 – Windscreen wipers
- S022 – Radio
- S023 – Monitor, camera, radio – Version with amplifier
- S024 – Monitor, camera, radio – Version without amplifier
- S025 – Diagnostics – accessories
- S026 – ISO 11783
- S027 – ISO 11786
- S028 – Accessories
- S029 – Starting and preheating (U.S.A.)
- S030 – Transmission (U.S.A.)
- S031 – Instrument panel (U.S.A.)
- S032 – Steering column lights switch – Version without front lift (U.S.A.)
- S032 – Steering column lights switch – Version with front hitch (U.S.A.)
- S034 – Steering column switch (U.S.A.)
- S035 – Worklights – Version without front lift (U.S.A.)
- S036 – Worklights – Version with front lift (U.S.A.)
- S037 – Power supply (+30) (U.S.A)
- S038 – Power supply (+15) (U.S.A.)
- S039 – CAN BUS (U.S.A.)
- S040 – PTO – Version without front PTO (U.S.A.)
- S041- PTO – Version with front PTO (U.S.A.)
- S042 – PTO – Brakes (U.S.A)
- S043 – Diagnostics – Accessories (U.S.A.)
- S044 – ISO 11783 (U.S.A.)
- S045 – Accessories (U.S.A.)
Wiring harnesses
- 0.012.2018.4/20 – RH number plate light – Wide fenders version
- 0.012.2018.4/20 – LH number plate light – Wide fenders version
- 0.014.0007.4/10 – Steering column switch
- 0.014.9570.4/10 – ISO 11786
- 0.015.3974.4/10 – Front axle suspension
- 0.015.5429.4/20 – Front lift control
- 0.016.0642.4/20 – LH rear lower worklight (Xenon)
- 0.016.0642.4/20 – RH lower rear worklight (Xenon)
- 0.016.0650.4/10 – RH supplementary worklight on arm (Xenon)
- 0.016.0650.4/10 – LH supplementary worklight on arm (Xenon)
- 0.016.9118.4/20 – Preheating relay power supply
- 0.016.9178.4/10 – Preheating
- 0.017.0052.4/10 – Roof
- 0.017.0053.4/20 – LH fender – Wide fenders version
- 0.017.0053.4/20 – RH fender – Wide fenders version
- 0.017.0164.4 – Rear video camera
- 0.017.0382.4/10 – On-board monitor
- 0.017.0383.4/10 – Audio
- 0.017.0496.4/10 – RH supplementary worklight on arm
- 0.017.0496.4/10 – LH supplementary worklight on arm
- 0.017.0497.4/20 – RH rear lower worklight
- 0.017.0497.4/20 – LH rear lower worklight
- 0.017.0789.4/10 – LH fender – Wide fenders version (U.S.A.)
- 0.017.0789.4/10 – RH fender – Wide fenders version (U.S.A.)
- 0.017.5028.4/30 – Fuses and relays
- 0.017.5884.4/20 – ISO 11783 – Cab line
- 0.017.5885.4/20 – ISO11783 – Rear line
- 0.017.7184.4/10 – RH fender – Version with extensions
- 0.017.7184.4/10 – LH fender – Version with extensions
- 0.017.7187.4 – Hood lights
- 0.017.7650.4/50 – Front instrument panel
- 0.017.8887.4/10 – ISO11783 – Front line
- 0.017.9756.4/20 – Right-hand transmission
- 0.017.9896.4/20 – Front instrument panel (U.S.A.)
- 0.017.9904.4/30 – Front instrument panel (U.S.A.)
- 0.018.0017.4/10 – LH fender – Version with extensions (U.S.A.)
- 0.018.0017.4/10 – RH fender – Version with extensions (U.S.A.)
- 0.018.0173.4/20 – LH transmission
- 0.018.0281.4 – Battery negative
- 0.018.1021.4 – Amplifier
- 0.018.2800.4 – Hydraulic braking
- 0.018.2837.4/10 – LH transmission (U.S.A.)
- 0.018.3622.4/20 – Side console wiring
- 0.900.0816.0 – Front PTO
- 0.900.1582.4 – Air conditioning
- 04214409 – Engine injectors
- 04216173 -Engine
- 04411923.4 – Lower RH headlight
- 04411923.4 – Lower LH headlight
- 04412045 – Windscreen wiper motor
- 04414114 – RH number plate light – Version fender extensions
- 04414114 – LH number plate light – Version fender extensions
- 04422156/20 – Battery positive
- 04436707 – Flashing 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
- New function: Download PDF manuals
- 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
- SDF Parts and SDF Service DVDs 03/2013 version 24
B0 – ENGINE
- Flushing the lubrication circuit
- Deutz AG engine oil specifications
- SerDia 2010 updating license file
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Additive for diesel fuel
- Expansion tank failure
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- Air conditioning system filter-drier
- 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
- Heat exchanger
- Spool valve malfunction
- L0 – ELECTRIC AL SYSTEM
