Document overview
Workshop Manual for SAME IRON³ 190 DCR → ZKDU0502W0LS10010 from the IRON³ (STAGE 3A) family. Digital PDF in English with 1,191 pages.
The corresponding English table of contents contains 53 sections and 392 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: IRON³ (STAGE 3A)
- Model: IRON³ 190 DCR
- Starting serial number: ZKDU0502W0LS10010
- Document type: Workshop Manual
- Language: English
- Pages: 1,191
- File size: 175.31 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME IRON³ 190 DCR → ZKDU0502W0LS10010.
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
- Installation of solenoid valves and cartridge valves
- Pump tightening torques
- 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
- Engine 2013 components
- Technical data
Transmission
- POWER SHIFT Transmission
- H-M-L unit
- Intermediate gearbox
- Rear gearbox
Rear axle
- Rear axle
- Rear PTO
Front axle
- Front axle
Hydraulic system
- Hydraulic circuit diagram
- Variable displacement pump
- Steering gear pump
- Oil level maintenance gear pump
- Oil level maintenance pump
- Remote control valve – 8-way version
- Remote control valve – 8 rear ways and 4 front ways version
- Remote control valve – Version with 10 rear ways
- Remote control valve – 10 rear ways and 4 front ways version
- Shuttle control valve
- Power Shift control valve
- Services control valve
- Range gearbox control valve
- Power steering
- 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)
- Pilot solenoid valve for 1-way trailer air braking valve
- Master cylinder
- Compressor
- Pressure cut-off valve
- Servo-brake valve for front axle
Rear lift
- Rear lift
- Lift control section (LS)
Calibrations and electronic diagnosis
Diagnostic tools
- Position of ECUs and diagnostic instruments
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket
- SDF Analyser – Armrest connection
Serdia 2000
- Serdia
- SERDIA – Diagnostic socket connection
- SERDIA 2000 level III” software
Diagnostic tool screens
- ECU interrogation
- ART/PC TESTER Transmission screen pages – Introduction
- ART/PC TESTER Transmission screen pages – Main menu
- ART/PC TESTER Transmission screen pages – Monitor screen pages
- ART/PC TESTER Transmission screen pages – Configuration screen pages
- ART/PC TESTER Transmission screen pages – Test screen pages
- ART/PC TESTER Transmission screen pages – Alarm list screens
- ART/PC TESTER Services screen pages – Introduction
- ART/PC TESTER Services screen pages – Main menu
- ART/PC TESTER Services screen pages – Monitor screen pages
- ART/PC TESTER Services screen pages – Calibration screen pages
- ART/PC TESTER Services screen pages – Test screen pages
- ART/PC TESTER Services screen pages – Alarm list screens
- ART/PC TESTER Armrest screen pages – Main menu
- ART/PC TESTER Armrest screen pages – Monitor screen pages
- ART/PC TESTER Armrest screen pages – Test screen pages
- ART/PC TESTER Armrest screen pages – Settings screen pages
- ART/PC TESTER Armrest screen pages – Alarm list screens
Commissioning and calibrating the tractor
- Putting into service – Introduction
- Putting into service – Common operations
- Putting into service of Transmission ECU – Introduction (Software vers. SP0110AD)
- Putting into service of Transmission ECU – EEPROM reset
- Putting into service of Transmission ECU – Model selection and configuration
- Putting into service of Transmission ECU – Clutch pedal calibration
- Putting into service of Transmission ECU – Slope sensor calibration
- Putting into service of Transmission ECU – Range position sensor calibration
- Putting into service of Transmission ECU – Auto calibration of PowerShift clutches
- Putting into service of Transmission ECU – Auto calibration of PowerShuttle cluthes
- Putting into service of Transmission ECU – Alarms erase
- Putting into service of Transmission ECU – Appendix A – Manual calibration of PowerShift clutches
- Putting into service of Transmission ECU – Appendix B – Manual calibration of PowerShuttle clutches
- Putting into service of Service ECU – Introduction (Software vers. SP0111AC)
- Putting into service of Service ECU – EEPROM reset
- Putting into service of Service ECU – Model configuration
- Putting into service of Service ECU – Calibration of pedal gas and hand gas
- Putting into service of Service ECU – Front PTO configuration
- Putting into service of Service ECU – Suspension configuration
- Putting into service of Service ECU – System configuration
- Putting into service of Service ECU – Electrohydraulic distributors configurations
- Putting into service of Service ECU – ASM sensor configuration
- Putting into service of Service ECU – Rear lift configuration and calibration
- Putting into service of Service ECU – Proportional PTOs calibration
- Putting into service of Service ECU – Alarms erase
- Workshop Procedure for EPB Calibration
- Data Monitor – Introduction
- Data Monitor – Description
- Data Monitor – Programming
- Data Monitor – Programming the vehicle parameters
ECU alarms
Engine alarms
- FMI code
- Engine ECU alarms – Serdia codes
- Engine ECU alarms – ART codes
Transmission alarms
- Alarms of HLHP Transmission ECU
Armrest alarms
- Armrest control unit alarms
HLHP alarms
- Alarms of HLHP Service ECU
EPB Alarms
- EPB control unit alarms – Introduction
- EPB control unit alarms – Description of user interface
- EPB control unit alarms – Alarm signalling
- EPB control unit alarms – Park Brake internal system lockup alarm
- EPB control unit alarms – Power supply batteries alarm
- EPB control unit alarms – Park Brake overheating alarm
- EPB control unit alarms – Park Brake improper use alarm
- EPB control unit alarms – Control lever alarm
- EPB control unit alarms – Excessive brake wear alarm
- EPB control unit alarms -Trailer brake relay alarm
- EPB control unit alarms – Brakes pressure switch alarm
- EPB control unit alarms – Temporary system lockup alarm
- EPB control unit alarms – Generic internal alarm
- EPB control unit alarms – Initialisation procedure
- EPB control unit alarms – List
Electrohydraulic control valve alarms
- Remote valve control unit alarms
Software management
- Transmission firmware update
Method of intervention
B0 – Engine
- Engine earth pin fixing
- A/C drive belt alignment and tension adjustment
- Engine-gearbox fasteners
- Removal and refitting of the crankcase breather
- Renewal of the front crankshaft oil seal (opposite end to flywheel)
- Installation/removal of the front crankshaft wear sleeve (opposite end to flywheel)
- Removal and refitting of the front cover (opposite end to flywheel)
- Removal and refitting of the oil sump pan.
- Removal and refitting of the V-belt and pulley
- Removal and refitting of the torsional vibration damper
- Removal and refitting of the flywheel
- Compression test
- Removal and refitting of the cylinder head cover
- Renewal of the rear crankshaft oil seal (flywheel end)
- Valve clearance adjustment (with the exhaust gas recirculation module installed).
- Valve clearance adjustment (with the exhaust gas recirculation module absent or removed).
- Removal and refitting of the rocker arms and pedestals
- Removal and refitting of the oil cooler
- Removal and refitting of the lube oil cooler housing
- Removal and refitting of the oil pickup pipe
- 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 injectors
- Removal and refitting of the fuel lift pump
- Removal and refitting of the common rail
- Removal and refitting of the pressure limiting valve
- Removal and refitting of the rail pressure sensor
- Removal and refitting of the charge air duct
- Removal and refitting of the water pump
- Removal and refitting of the fuel pressure sensor
- Removal and refitting of the belt tensioner
- Removal and refitting of the fan drive system
- Removal and refitting of the fan support (fan driven by ribbed V-belt)
- Removal and refitting of the exhaust manifold
- Removal and refitting of the turbocharger
C0 – Engine accessories
- Removal and refitting of the fuel filter head.
- Removal and refitting of the thermostat
- Testing the thermostat (after removal)
- Removal and refitting of the thermostat housing
- Removal and refitting of the alternator (with drivebelt)
- Removal and refitting of the starter motor
- Removal and refitting of the engine wiring loom
- Removal and refitting of the camshaft speed sensor
- Removal and refitting of the crankshaft speed sensor
- Removal and refitting of the intake air pressure/temperature sender
- Removal and refitting of the oil pressure switch
- Removal and refitting of the coolant temperature sender
- Removal and refitting of the rotation device
- Removal and refitting of the torsional vibration damper
- Removal and refitting of the heater
- Removal and refitting of the glowplugs
D0 – Transmission
- Changing the transmission oil
- Complete hydraulic shuttle assembly
- Shuttle and HML assembly
- Clutch control assembly
- Disassembly of the clutch control assembly
- Installation of the forward drive clutch assembly
- Forward drive clutch shim adjustment
- H clutch assembly
- Disassembly of the H clutch assembly
- Slow-medium gear clutch pack
- Slow/medium epicyclic gear unit
- Powershift control valve
- Disassembly of powershift control valve
- Primary shaft
- Secondary shaft
- Bearing preload adjustment – Secondary shaft
- Rear PTO drive shaft and pumps assembly
- Front gearbox
- View of front gearbox from rear
- Rear gearbox removal
- Front gearbox cover
- Range gear control cover
- Lower gearbox cover
- Range reduction unit control assembly
- Disassembly of the range reduction unit control assembly
- 2nd – 4th gear servo control
- Range gear and creeper selector assembly
- Adjustment of the differential – bevel gear pair
- Range driving gear
- Disassembly of the range driving gear
- Range driving gear
- Creeper planetary reduction unit
- Disassembly of the creeper planetary gear unit
- PTO clutch
- PTO output shaft
- PTO ring nut and waterproof seal
- PTO output shaft
- 4WD shaft and clutch
E0 – Rear axle
- Rear axle
- Disassembly of the rear axle
- Brake housing
- Disassembly of the planet carrier
- Rear differential
- Disassembly of the rear differential
- Rear axle brake assembly and brake discs
- Disassembly of the rear axle brake assembly
- Brake actuator
- Rear brakes
- Adjustment of rear half-shaft bearings
- EPB – Bowden Assembly Adjustment
F0 – Front axle
- Front axle or 4WD
- Bevel gear pair
- Front brake discs
- Disassembly of the front axle brake piston
- Disassembly of the differential locking device
- 4WD shaft for suspended front axle
- Steering knuckle housing and half-shaft
- Adjustment of pinion and crown wheel backlash
G0 – Bodywork – Cab – Platform
- Bleeding the brakes
- Fixing the steering wheel
- Electronic park brake mechanism
H0 – Hydraulic system
- Spool valves
- Complete pumps assembly
- Priority valve
- Brakes lubrication pump
- Powershift steering pump
- Transfer pump
- LS pump
L0 – Electrical system
- Front axle suspension position sensor
- Range gearbox output speed sensor
M0 – Front PTO
- Installation of the front PTO and shaft adjustment
- Front PTO flexible coupling
- Tightening the flange-pulley screws
- Front PTO
V1 – AFTERMARKET KITS
- Installation of the air conditioning kit
- Engine overheating
- Coolant radiator
- Installing heat shields
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 and rheostats
- P – Various services
- Q – Safety devices
- R – Diagnostics
- T – Power supply points
Systems
- S001 – Starting and preheating
- S002 – Electronic engine governor
- S003 – Transmission
- S004 – Instrument panel
- S005 – Lights – Version without front lift
- S006 – Lights – Version with front lift
- S007 – Direction indicators
- S008 – Worklights – Version without front lift
- S009 – Worklights – Version with front lift
- S010 – Air Conditioning
- S011 – +30 Positive
- S011 – +15 Positive
- S013 – CAN BUS – Standard version
- S014 – CAN BUS – Version with I-Monitor
- S015 – CAN BUS – Version with ISO 11783
- S016 – Front and rear lifts
- S017 – Brakes
- S018 – Hydraulic control valves
- S019 – Rear lift
- SO20 – Front axle suspension
- S021 – Windscreen wipers
- S022 – Radio
- S023 – Multimedia
- S024 – Multimedia with ISO 11783
- S025 – Diagnostics
- S026 – Accessories
Wiring harnesses
- 0.010.8707.4/10 – SBA sensors
- 0.011.6007.3 – Rear screen washer pump
- 0.011.6007.3 – Front screen washer pump
- 0.012.2756.3 – Front PTO LH solenoid valve
- 0.012.2756.3 – Front PTO RH solenoid valve
- 0.014.0007.4/10 – Lights selector switch
- 0.015.3974.4/10 – Front axle suspension
- 0.016.0650.4/10 – RH front supplementary worklight on arm (Xenon)
- 0.016.0650.4/10 – LH front supplementary worklight on arm (Xenon)
- 0.016.7898.4 – Engine hood
- 0.016.8489.4 – Air braking
- 0.016.9118.4/20 – Preheating relay power supply
- 0.016.9179.4/10 – Preheating
- 0.017.0052.4/10 – Roof
- 0.017.0164.4 – Rear camera
- 0.017.0382.4/20 – I-Monitor
- 0.017.0383.4/10 – Audio
- 0.017.0496.4/10 – Supplementary RH front worklight on arm
- 0.017.0496.4/10 – Supplementary LH front worklight on arm
- 0.017.5028.4/30 – Fuses and relays
- 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
- 0.018.0281.4 – Battery negative
- 0.018.1021.4 – Amplifier
- 0.018.2800.4 – Hydraulic braking
- 0.018.2841.4/40 – Side console wiring
- 0.018.2983.4/30 – LH transmission
- 0.018.2984.4/20 – RH transmission
- 0.018.3279.4/20 – Remote valves
- 0.018.5061.4/30 – Front console
- 0.018.5084.4 – LH rear lower worklight
- 0.018.5084.4 – RH rear lower worklight
- 0.018.5085.4 – RH rear lower worklight (Xenon)
- 0.018.5085.4 – LH rear lower worklight (Xenon)
- 0.018.5132.4 – RH fender
- 0.018.5132.4 – LH fender
- 0.900.1582.4 – Air conditioning
- 04214895 – Engine
- 04411923.4 – Front RH lower worklights on cab
- 04411923.4 – Front LH lower worklights on cab
- 04412045 – Windscreen wiper motor
- 04422156/20 – Battery positive
- 04428092.4 – Front RH sidelight and direction indicator
- 04428092.4 – Front LH sidelight and direction indicator
- 04436707 – Rotating beacon
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
D0 – TRANSMISSION
- Retainer circlip of 4WD drive engagement mechanism
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
- L0 – ELECTRIC AL SYSTEM
