Document overview
Workshop Manual PDF for SAME IRON 190 CONTINUO DCR → WSXJ990200LS10010, IRON CONTINUO (STAGE 3A) family. Document language: English; 1,675 pages.
The corresponding English table of contents contains 50 sections and 431 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 190 CONTINUO DCR
- Starting serial number: WSXJ990200LS10010
- Document type: Workshop Manual
- Language: English
- Pages: 1,675
- File size: 148.63 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME IRON 190 CONTINUO DCR → WSXJ990200LS10010.
Complete table of contents
Introduction
- Tightening torques for nuts and bolts of electrical connections
- Wheel rim to hub screws and nuts tightening torques
- 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 of Engine TCD 2012 4V
- Components of the TCD 2012 L04/L06 4V DCR engine
- Tightening requirements TCD 2012 L04/L06 4V DCR (Lv.2) engine
- Tightening requirements TCD 2012 L04/L06 4V DCR (Lv.3) engine
Transmission
- Transmission
- Transmission
- Hydrostatic unit- ZF 2097 004 005 – ZF 2097 004 010 – ZF 2097 004 009
- Hydrostatic unit – ZF 2097 004 001
- Rear PTO
Rear axle
- Rear axle
- Adjustment of the braking device
Front axle
- Front axle
Bodywork – Cab – Platform
- General introduction to the A/C system
- Air conditioning system
- Changes of the state of matter
- Compressor
- Condenser
- Filter-dryer
- Expansion valve
- Air conditioning system – Diagnostics
Hydraulic system
- Variable displacement pump
- Hydraulic pump
- Load sensing valve, pressure cut-off valve
- Priority valve
- Power steering
- Hydraulic front axle suspension
- Hydraulic trailer braking system – Italy version
- Hydraulic trailer braking system – Export version
- Hydraulic system
- Steering gear pump
- Remote control valve – 8-way version
- Remote control valve – 12-way version
- Remote control valve – 14-way version
- Air trailer braking system – Italy version
- Air trailer braking system – Export version
- Compressor
- Trailer air braking valve (2-way)
- Trailer air braking valve (1-way)
- Pilot solenoid valve for 1-way trailer air braking valve
Calibrations and electronic diagnosis
Diagnostic tools
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
- Engine control unit – Deutz EMR3
Commissioning and calibrating the tractor
- Renewal of HLHP ECU: Configuration of tractor model
- Renewal of HLHP ECU: Transmission Calibration
- Renewal of HLHP ECU: PTO Calibration
- Renewal of HLHP ECU: ASM Calibration
- Renewal of HLHP ECU: Lift Calibration
- Renewal of HLHP ECU: Suspension Calibration
- Renewal of HLHP ECU: System Calibration
- Renewal of HLHP ECU: Distributors Calibration
- Renewal of HLHP ECU: Engine Calibration
- Renewal of HLHP ECU: A/C Calibration
- Renewal of HLHP ECU: Agrosky Calibration
- Renewal of HLHP ECU: MR-D Cab Calibration
ECU alarms
- Key to the “ECU alarms” tables
- Alarms – List of semi-active cab alarms (MR-D)
Engine alarms
- Engine control unit alarms
Transmission alarms
- Transmission control unit alarms – SGR
- Transmission control unit alarms – FMGR
Armrest alarms
- Armrest control unit alarms
HLHP alarms
- HLHP control unit alarms
Electrohydraulic control valve alarms
- Remote valve control unit alarms
Method of intervention
- Tools for engine disassembly and reassembly
- Workshop tools for engine disassembly and reassembly
- Index Repair instructions
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)
- Removal and refitting of the camshaft speed sensor
- Removal and refitting of the exhaust manifold
- Removal and refitting of the fuel filter head.
- Removal and refitting of the rail pressure sensor
- Remove and install the heating flange
- Removing and fitting the alternator (driven by ribbed V-belt) (L3)
- Disassembly and assembly of the starter
- Removal and refitting of the supply air pressure/temperature sender
D0 – Transmission
- Separating rear axle from transmission
- Attaching rear axle to gearbox
- PTO Transmission – Disassembly
- Fitting the PTO transmission
- Removal of cartridge
- Disassembly of shifting drum
- Disassembly of P1 ring gear carrier
- Disassembly of P1/P2 Planetary drive
- Disassembly of P5/P6 Planetary drive
- Disassembly of KV clutch
- Disassembly of K1 clutch
- Disassembly of K3/K4 clutch and P3/P4 planetary drive
- Disassembly of K3/K4 clutch
- Disassembly of P3/P4 planetary drive
- Disassembly of KR clutch
- Disassembly of K2 clutch
- Disassembly of hydrostatic unit
- Disassembly of control (TCU)
- Disassembly of pump
- Disassembly of suction filter
- Disassembly of filter head
- Disassembly of pressure relief valves
- Disassembly of control unit
- Disassembly of valves, pressure sensor, inductive sensors
- Disassembly of wiring harness, valve block and plate
- Disassembly of valve block (filter head, pressure relief valves, thermocouple)
- Disassembly of valve block (all-wheel-drive / park lock)
- Disassembly of valve block (hydraulic control)
- Disassembly of valve block (pressure reducing valve)
- Disassembly of wiring harnesses and control unit
- Disassembly of inductive sensors
- Disassembly of plug-in module
- Disassembly of clutch (all-wheel-drive)
- Disassembly of spur gear
- Disassembly of pinion
- Disassembly of park lock
- Disassembly of output shaft
- Disassembly of intermediate housing
- Disassembly of drive shaft
- Preassembly of transmission housing
- Reassembly of drive shaft
- Reassembly of intermediate housing
- Reassembly of pinion
- Reassembly of park lock
- Reassembly of clutch (all-wheel-drIve)
- Reassembly of spur gear
- Reinstallation of plug-in module
- Reassembly of output shaft
- Preassembly of housing lid
- Reassembly of plate
- Reassembly of valve block
- Reassembly of wiring harnesses
- Reassembly of inductive sensors, pressure sensors, valves
- Reassembly of control unit (hydrostatic unit)
- Reassembly of pressure relief valves (PRV)
- Reassembly of filter head
- Disassembly of wiring harnesses and control unit
- Reassembly of wiring harnesses and control unit
- Reassembly of valve block (pressure reducing valve)
- Reassembly of valve block (hydraulic control)
- Reassembly of valve block (all wheel-drive / park lock)
- Reassembly of valve block (filter head, pressure relief valves, thermocouple)
- Reassembly of pump
- Reassembly of control
- Reassembly of hydrostatic unit
- Reassembly of suction filter
- Reassembly of K2 Clutch
- Reassembly of KR clutch
- Reassembly of P3/P4 planetary drive
- Reassembly of K3/K4 clutch
- Reassembly of K1 Clutch
- Reassembly of KV Clutch
- Reassembly of P5/P6 planetary drive
- Reassembly of P1/P2 planetary drive
- Reassembly of P1 Ring gear carrier
- Reinstallation of cartridge
E0 – Rear axle
- Axle Stub – Disassembly
- Axle Stub – Assembly
- Brake Disassembly
- Brake Assembly
- Differential – Disassembly
- Fitting the differential
- Oil Supply – Disassembly
- Oil Supply – Assembly
- Rear Axle Housing – Preassembly
- Procedure for checking EPB travel
F0 – Front axle
- Toe-in/steering angle/assembly tests
- Steering cylinders assembly
- Axle shaft assembly
- Flange assembly
- Differential assembly – carrier
- Checking the bevel gear pair
- Differential disassembly
- Axle pivot bearings assembly
- Bevel pinion assembly
- Planetary reduction gear assembly
- Wheel hub assembly
- Brake assembly
L0 – Electrical system
- Steering position sensor assembly
R0 – Rear lift
- Lifting Unit – Disassembly
- Lifting Unit – Assembly
V0 – Ballast – towing hitches
- Tightening Torques for Tow Hitches
- Standard fastener hardware: Tightening torque/Tension forces
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 – Valves and fuses box
- 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
- R – Diagnostics
- 04214367 – Engine control unit
- 2.8519.085.0/10 – Transmission control unit
Systems
- S001 – Engine
- S002 – Transmission
- SO03 – Front axle suspension
- S004 – Instrument panel
- S005 – Lights – Version without front lift
- S005a – Direction indicators – Version without front lift
- S006 – Lights – Version with front lift
- S006a – Direction indicators – Version with front lift
- S007 – Worklights – Version without front lift
- S008 – Worklights – Version with front lift
- S009 – Semi-active cab suspension
- S010 – Air conditioning
- S011 – Positives
- S011a – Positive +30
- S012 – Negatives
- S013 – CAN BUS – Standard version
- S013a – CAN BUS – Version with I-Monitor
- S013a – CAN BUS – Version with I-Monitor
- S013b – CAN BUS – Version with ISO 11783
- S014 – PTO
- S015 – Front and rear lifts
- S016 – Brakes
- S017 – Trailer air braking
- S018 – Hydraulic control valves
- S019 – Windscreen wipers
- S020 – Radio
- S021 – Accessories
- S022 – Diagnostics
- S023 – Monitor – Camera – Radio
- S023a – Monitor – Camera – Radio – Version with amplifier
- S024 – Positives (U.S.A.)
- S024a – Positive +30 (U.S.A.)
- S025 – Transmission (U.S.A.)
- S026 – Lights – Version without front lift (U.S.A.)
- S027 – Lights – Version with front lift (U.S.A.)
- S028 – Direction indicators (U.S.A.)
- S029 – Worklights – Version without front lift (U.S.A.)
- S030 – Worklights – Version with front lift (U.S.A.)
- S031 – PTO (U.S.A.)
- S032 – Brakes (U.S.A.)
- S033 – Trailer air braking (U.S.A.)
- S034 – ISO 11783
Wiring harnesses
- 0.012.2018.4/20 – Number plate light
- 0.014.0007.4/10 – Lights selector switch
- 0.014.4992.4/10 – Agrosky
- 04422156/20 – Battery positive – Version with 1 tank
- 0.014.5132.4/10 – Battery positive – Version with 2 tanks
- 0.014.5144.4/10 – Battery negative
- 0.015.3974.4/10 – Front axle suspension
- 0.015.5429.4/20 – Front lift control
- 0.015.7505.4 – Front screen washer pump
- 0.015.7505.4 – Rear screen washer pump
- 0.016.0234.4/30 – Semi-active cab suspension
- 0.016.0642.4/20 – Rear RH lower worklights on cab (Xenon)
- 0.016.0642.4/20 – Rear lower worklights on cab (Xenon)
- 0.016.0650.4/10 – Front RH lower worklights on cab (Xenon)
- 0.016.0650.4/10 – Front LH lower worklights on cab (Xenon)
- 0.016.0867.4/80 – Side console
- 0.016.0868.4/40 – LH transmission
- 0.016.0869.4/70 – RH transmission
- 0.016.0871.4/30 – Front console
- 0.016.3980.4/30 – Front console (U.S.A.)
- 0.016.3987.4/80 – Side console (U.S.A.)
- 0.016.3997.4/30 – LH transmission (U.S.A.)
- 0.016.6244.4/10 – Power supplies
- 0.016.7898.4 – Engine hood
- 0.017.0052.4/10 – Roof
- 0.017.0053.4/20 -RH fender
- 0.017.0053.4/20 – LH fender
- 0.017.0164.4 – Rear camera
- 0.017.0382.4/10 – I-Monitor
- 0.017.0382.4/20 – I-Monitor
- 0.017.0383.4/10 – Audio
- 0.017.0496.4/10 – Supplementary RH worklight on arm
- 0.017.0496.4/10 – Supplementary LH worklight on arm
- 0.017.0789.4/10 – LH fender (U.S.A.)
- 0.017.0789.4/10 -RH fender (U.S.A.)
- 0.017.5493.4 – Worklights control relay
- 0.017.5884.4/20 – ISO 11783 – Cab line
- 0.017.5885.4/20 – ISO 11783 – Rear line
- 0.017.8887.4/10 – ISO 11783 – Front line
- 0.018.1021.4 – Amplifier
- 0.900.1421.0 – Air conditioning
- 04214410 – Fuel injectors
- 04216076 – Engine
- 04411923.4 – Front LH lower worklights on cab
- 04411923.4 – Front RH lower worklights on cab
- 04412045 – Windscreen wiper motor
- 04428092.4 – Front LH sidelight and direction indicator
- 04428092.4 – Front RH sidelight and direction indicator
- 04436707 – Rotating beacon
- 04437355.4/10 – Air braking pressure switch
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
- Technical Documentation DVD 06/2009
- SDF LUBRICANTS: Lubricant oils and coolant fluids
- 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
- Technical Documentation DVD 03/2010
- 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
D0 – TRANSMISSION
- Rear pinion support flange
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
- Resonator failure
- Assembly instructions for solenoid valves and cartridge valves
- Pressure line from variable displacement pump
- L0 – ELECTRIC AL SYSTEM
