Document overview
Workshop Manual for SAME IRON 115 DCR → ZKDT680200TS10001 from the IRON (STAGE 3A) family. Digital PDF in English with 1,543 pages.
The corresponding English table of contents contains 51 sections and 458 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 (STAGE 3A)
- Model: IRON 115 DCR
- Starting serial number: ZKDT680200TS10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,543
- File size: 198.08 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME IRON 115 DCR → ZKDT680200TS10001.
Complete table of contents
Introduction
- Tightening Torques
- Tightening torques for nuts and bolts of electrical connections
- Wheel rim to hub screws and nuts tightening torques
- Pump tightening torques
- 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
- Components of the TCD 2012 L04/L06 2V DCR engine
- Test and adjustment data (L3)
- Tightening requirements TCD 2012 L04/L06 2V DCR engine
Transmission
- Transmission
- Transmission detachment points
- Rear PTO
Rear axle
- Rear axle
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)
Hydraulic system
- Hydraulic system
- Medium hydraulic system
- Hydraulic pump
- Gear pump for services and steering
- Gear pump for ZF 7100 gearbox
- Power steering valve
- Hydraulic front axle suspension
- Front suspension assembly / INTEGRALL
- Remote control valve
- Braking system
- Hydraulic trailer braking system – Italy version
- Hydraulic trailer braking system – Export version
- Air trailer braking system – Italy version
- Air trailer braking system – Export version
- Trailer air braking valve (2-way)
- Trailer air braking valve (1-way)
- Compressor, antifreeze pump, pressure limiting valve
- Pressure test points on the electro-hydraulic shift control module
- Pressure test points on the electro-hydraulic shift control module
Calibrations and electronic diagnosis
Diagnostic tools
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket connection
Serdia 2000
- SERDIA 2000 level III” software
- SERDIA – Diagnostic socket connection
- Connecting the computer with Serdia software to the engine control unit
Diagnostic tool screens
- Position of control units and diagnostic instruments
- ECU interrogation
- Electronic system
- CANBUS System
- Automatic A/C system
- Engine ECU
- Engine ECU
- HLHP Control unit
- Transmission control unit
- Instrument panel
- Monitor screens for ART/PC Tester
- Calibration screens for ART/PC Tester
- Test screens for ART/PC Tester
- Alarm list screens for ART/PC Tester
- Cancellation of all alarms
Commissioning and calibrating the tractor
- Introduction to commissioning the tractor
- Renewal of the engine control unit – Introduction
- Renewal of the engine control unit – Reading and saving DATASET
- Renewal of the engine control unit – Programming the control unit with DATASET
- HLHP control unit – Calibration of the accelerator pedal
- HLHP control unit – Calibration of the hand throttle lever
- Renewal of the transmission control unit – Introduction
- Renewal of the transmission control unit – Transmission type configuration
- Renewal of the transmission control unit – Tyres type configuration
- Renewal of the transmission control unit – Configuration of the wheel circumference (using the ART)
- Renewal of the transmission control unit – Configuration of the wheel circumference (without using the ART)
- Renewal of the transmission control unit – Configuration of the maximum travel speed
- Renewal of the transmission control unit – Calibration of the clutch pedal
- Renewal of the transmission control unit – Calibration of the main clutch
- Renewal of the transmission control unit – Calibration of the FIELD/ROAD sensor
- Renewal of the HLHP control unit – Introduction
- Renewal of the HLHP control unit – Initialization of the HLHP control unit
- Renewal of the HLHP control unit – Configuration of the tractor model
- Renewal of the HLHP control unit – Configure the system for presence of front PTO
- Renewal of the HLHP control unit – SBA / ASM system enable
- Renewal of the HLHP control unit – Calibration the steering angle sensor
- Renewal of the HLHP control unit – Configuration for presence of the RADAR
- Renewal of the HLHP control unit – Calibrating low and high positions of the lift
- Renewal of the HLHP control unit – Front axle suspension system enable
- Renewal of the HLHP control unit – Setting the instrument control panel display language
- Renewal of the HLHP control unit – Configuration for presence of the automatic A/C
- Renewal of the HLHP control unit – Configuring the quantity of auxiliary services
- Renewal of the HLHP control unit – Rear control valves identification
- Renewal of the armrest control unit – Introduction
- Renewal of the armrest control unit – Calibration of control valves n°3 and n°4 joystick
- Replacing the automatic A/C ECU – Introduction
- Replacing the automatic A/C ECU – Calibrating the heating circuit valve
- Replacing the automatic A/C ECU – Calibrating the air recirculation motors
ECU alarms
- Key to the “ECU alarms” tables
- FMI code
Engine alarms
- Engine control unit alarms – SERDIA codes
- Engine control unit alarms – ART codes
Transmission alarms
- Transmission alarms
Armrest alarms
- Armrest control unit alarms
HLHP alarms
- HLHP control unit alarms
- HLHP control unit 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
- Air conditioning compressor drive belt
- Tension adjustment of the fan and air conditioning compressor drive belt
- Alternator, fuel pump and water pump drive belt
- Tension adjustment of the alternator, fuel pump and water pump drive belt
- Check the compression value (L3)
- Assembly and disassembly of the engine on the assembly stand (L3)
- Valve clearance adjustment (with the exhaust gas recirculation module absent or removed) (L3)
- Valve clearance adjustment (with the exhaust gas recirculation module installed) (L3)
- Disassembly and assembly of the rocker and support (L3)
- Disassemble and complete the rocker and support, check
- Disassembly and assembly of the cylinder head (L3)
- Valve assembly and disassembly (L3)
- Valve check (L3)
- Check the valve guide (L3)
- Check the valve residual (L3)
- Crankshaft check (L3)
- Replace the crankshaft O-ring (flywheel end) (L3)
- Replace the crankshaft O-ring (opposite end to flywheel) (L3)
- Connecting rod drum check (L3)
- Assembly and disassembly of the crankshaft (L3)
- Disassembly and assembly of the piston and connecting rod drum (L3)
- Check the piston (L3)
- Check the piston rings and piston grooves (L3)
- Assembly and disassembly of the piston cooling nozzles (L3)
- Removing and fitting crankcase breather (L3)
- Checking cylinder (L3)
- Removal and refitting of the front cover (opposite end to flywheel) (L3)
- Disassembly and assembly of the connector box (L3)
- Disassembly and assembly of the gear case cover (L3)
- Assembly and disassembly of the camshaft (L3)
- Check the camshaft (L3)
- Disassembly and assembly of the turbocharger (L3)
- Disassembly and assembly of the turbocharging air duct (L3)
- Fitting and removing the exhaust gas recovery module (L3)
- Removing and fitting the fuel delivery pump (driven by ribbed V-belt) (L3)
- Removing and fitting the fuel control unit (L3)
- Removing and fitting high pressure pump (installation position A) (L3)
- Removing and fitting high pressure pump (installation position B) (L3)
- Removing and fitting the common rail system (L3)
- Removing and fitting injector (L3)
- Removing and fitting the pressure cut-off valve (L3)
- Removing and fitting the fuel pressure transducer (L3)
- Assembly and disassembly of the oil intake pipe (L3)
- Disassembly and assembly of the lubricant oil sump (L3)
- Disassembly and assembly of the oil radiator (L3)
- Removing and fitting the lubricant oil cooler housing (L3)
- Removing and fitting the lubricant oil filter (L3)
- Removing and fitting the oil pressure switch (L3)
- Removing and fitting reservoir (L3)
- Removing and fitting the coolant pump (driven by ribbed V-belt) (L3)
- Removing and refitting fan motor (L3)
- Removing and fitting fan motor (L3)
- Removing and fitting fan mount (L3)
- Disassembly and assembly of the torsional vibration damper (L3)
- Removing and fitting belt tensioner (ribbed V-belt) (L3)
- Assembly and disassembly of the flywheel (L3)
C0 – Engine accessories
- Starter motor
- Removal and refitting the engine block
- Fitting and removing thermostat (L3)
- Testing the thermostat (after removal)
- Removal and refitting of the crankshaft speed sensor (L3)
- Removal and refitting of the camshaft speed sensor (L3)
- Removing and refitting the exhaust manifold (L3)
- Fitting and removing the solenoid valve (exhaust gas recovery module) (L3)
- Removing and fitting the fuel filter mount (L3)
- Assembly and disassembly of the temperature sender (L3)
- Removal and refitting of the supply air pressure/temperature sender (L3)
- Removing and fitting the alternator (driven by ribbed V-belt) (L3)
- Fitting and removing the rail pressure sensor (L3)
- Disassembly and assembly of the cable bundle (L3)
- Disassembly and assembly of the starter (L3)
- Fitting and removing the glow plugs (L3)
- Changing the coolant and flushing the circuit
D0 – Transmission
- Checking the transmission oil level
- Changing the transmission oil
- Changing the transmission oil filter
- Rear axle-powershift transmission detachment/attachment
- Electro-hydraulic road/field shift control unit
- Joining the POWERSHIFT transmission/clutch housing
- Main clutch
- Clutch housing
- Clutches A – B
- Adjustment of bearing clearance – clutch unit A/B
- Clutches C – D
- Adjustment of bearing clearance – clutch unit D/C
- Removal of the POWERSHIFT assembly
- Output shaft – POWERSHIFT transmission
- Adjustment of bearing clearance – output shaft
- Output shaft
- Torsional spring plate
- Main shaft
- dual gear shaft
- Adjustment of bearing clearance – clutches A/B/C/D and dual gear shaft
- Adjustment of bearing clearance – dual gear shaft
- Selector shaft
- Positioning and adjustment of selector rods and selector forks
- Adjustment of the PTO control
- Bevel pinion assembly
- Creeper
- Creeper unit cover
- Ground speed PTO
- Adjustment of bearing clearance: 0 – 0.15 mm
- Adjustment of end float
- PTO transmission
- Adjustment of the clutch shaft bearing
- Adjustment of flanged shaft bearing
- Four-wheel drive assembly
- Four-wheel drive
- Transmission shaft – 4WD shaft – Version without front axle suspension
- Transmission shaft – 4WD shaft – Version with front axle suspension
- Disassembly of the electro-hydraulic shift control module
- Proportional valve and speed sensor – main clutch
E0 – Rear axle
- Checking the oil level of the rear axle final drives
- Changing the rear axle final drives oil
- Final drive housing
- Adjustment of bearing preload of rear axle shaft support
- Adjustment of planet carrier end float
- Rear brakes
- Adjustment of the rear brake
- Rear differential
- Adjustment of the crown wheel
- Adjustment of the bearing preload
- Adjustment of the braking device
F0 – Front axle
- Troubleshooting
- Front support – Version without front axle suspension
- Front support – Version with front axle suspension
- Toe-in/steering angle/assembly tests
- Front axle and swinging support – Version with front axle suspension
- Front axle – Version without front axle suspension
- 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
- Cab – Version without pneumatic cab suspension
- Cab – Version without pneumatic cab suspension
- Cab – Version with pneumatic cab suspension
- Cab – Version with pneumatic cab suspension
- Hood and side panels
- Battery support
- Cab access steps
- Fixed front fenders
- Adjustable front fenders
- Cab door lock, cable
- Steering column switch
- Shuttle control selector
- RH console
- Top right interior cover flap
- Top LH flap – Version with automatic A/C
- Top inner LH flap – Version with automatic A/C
- Instrument panel
- Cab roof lining
- Floor mat
- Seat
- Multifunction armrest
- Heating and air conditioning assembly – Version with manual A/C
- Heating and air conditioning assembly – Version with automatic A/C
- Air conditioning system
- Air conditioning control panel
- Air conditioning compressor
- Condenser
- Receiver-drier
- Air-conditioning evaporator – Version with manual A/C
- Air-conditioning evaporator – antifreeze sensor – Version with automatic A/C
- Heating valve – Version with manual A/C
- Heating valve – Version with automatic A/C
- Heating radiator – Version with manual A/C
- Heating radiator – Version with automatic A/C
- A/C fan – Version with manual A/C
- A/C fan – Version with automatic A/C
- Antifreeze thermostat – Version with manual A/C
- Air recirculation motor
- Brake master cylinders
- Parking brake tie rod
- Parking brake tie rod – adjustment
- Steering wheel
- Gear lever, control cable
- Creeper gear lever – control cable
- Rear PTO lever, control cable
- Syncro PTO linkage
H0 – Hydraulic system
- Power steering pump
- Changing the hydraulic services oil
- Hydraulic services oil tank
- “Load Sensing” variable displacement pump
- Transmission circuit pump
- Compressed air circuit antifreeze pump
- Power steering valve
- Checking and adjustment of the power steering calibration
- Power steering disassembly
- GEARBOX OIL COOLER
- Front axle with suspension cylinders
- Auxiliary services control valve – Complete assembly
- LH directional control valves
- RH control valves – Version with front lift
- Circuit bleeding procedure
- Hydraulic trailer braking valve
- 2-way trailer air braking valve
- Air reservoir for air braking
- Pressure reducer valve for the cab suspension
- Compressed air circuit supply pressure control valve
- Remote control
- Lubrication pressure control valve
- Electro-hydraulic shift control module
- Electro-hydraulic road/field shift control module
L0 – Electrical system
- Battery
- Alternator
- Clutch pedal potentiometer
- Clutch pedal proximity sensor
- Accelerator potentiometer
- Front suspension position sensor
- Front axle suspension position sensor
- Front suspension solenoid valves assy
- Steering position sensor assembly
- Speed sensor/road speed
- Temperature sensor
- Fan speed resistor – Version with manual A/C
- Ventilation unit air temperature sensor – Version with automatic A/C
M0 – Front PTO
- 1000E rpm
- Front PTO flexible coupling
N0 – Front lift
- Front lift – version with front PTO
- Front lift cylinders
R0 – Rear lift
- Rear lift
- Bush
- Lift control valve
- Draft sensor
- Position sensor
- Checking and calibrating the position sensor
S0 – Wheels
- Front wheels
- Rear wheels
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 (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 interval timers
- N – Electric motors and actuators
- O – Resistors and rheostats
- P – Various services
- R – Diagnostics
Systems
- S001 – Starting
- S002 – Preheating
- S003 – Electronic engine governor
- S004 – Diagnostics and accessories
- S005 – Instrument panel
- S006 – Work lights
- S007 – Air conditioning
- S008 – Radio
- S009 – Lights (version without front lift)
- S010 – Lights (version with front lift)
- S011 – Windscreen wipers
- S012 – Transmission
- S013 – PTO
- S014 – Can Bus
- S015 – Distributors
- S016 – Braking system
- S017 – Front axle suspension
- S018 – ASM – 4WD – Differential
- S019 – Rear lift
Wiring harnesses
- 0.011.3824.4/10 – Rotating beacon wiring
- 0.013.0663.4/30 – Engine hood wiring
- 0.013.4085.4/20 – Hood front worklights wiring loom
- 0.013.9304.4/70 – Cab roof wiring loom
- 0.013.9309.4/30 – Fenders wiring loom
- 0.013.9327.4/50 – Front axle suspension wiring
- 0.014.0002.4 – Supplementary arm worklights wiring loom – Version with front lift
- 0.014.0732.4/10 – Arm worklights wiring loom
- 0.014.1874.4/20 – Arm worklight controls wiring loom – Version without front lift
- 0.014.1875.4/10 – Arm worklight controls wiring loom – Version with front lift
- 0.014.5144.4/10 – Battery negative wiring loom
- 0.014.8351.4 – Cab earth wiring loom
- 0.015.5452.4 – Comfort package wiring loom
- 0.015.7461.4/20 – Braking and front lift interface wiring
- 0.015.9792.4 – Cab roof front and rear worklights wiring loom
- 04437355.4/10 – Trailer brake wiring loom (Germany)
- 04437356.4/10 – Trailer brake wiring loom (Italy)
- 0.014.5132.4/10 – Battery positive wiring loom
- 0.014.1564.4 – Power wiring loom (2/2)
- 0.015.8055.4/50 – Central wiring loom
- 0.014.1567.4/10 – Front wipers wiring loom
- 0.014.3649.4/70 – Instrument panel wiring loom
- 0.014.1617.4/20 – Remote valves wiring loom
- 0.015.8060.4/20 – Right-hand transmission wiring loom
- 0.015.8061.4/10 – Engine wiring loom
- 0.015.8057.4/30 – Left-hand transmission wiring loom
- 0.014.8453.4 – Front wiper motor wiring loom – fixed windscreen version
- 0.014.2647.4/50 – Remote valves wiring loom
- 0.014.3658.4/20 – Power supply wiring loom (1/2)
- 016.4784.4 – Remote valves wiring loom
- 0.015.9371.4/20 – Shuttle central wiring loom (USA Export version)
- 0.017.3486.4 – Condenser pressure switch wiring loom
- 0.015.9470.4/20 – LH transmission wiring loom (USA Export version)
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
- POSSIBLE LEAKAGE OF FUEL INTO THE ENGINE SUMP (LEVEL RISE)
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Exhaust clamp
- 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
- Gear lever control Bowden cable
- Gear lever control Bowden cable
- Air conditioning system filter-drier
- Water and dust infiltration into cab via the doors
- 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
