Document overview
Workshop Manual PDF for SAME Virtus J 110 → ZKDY490200TS10001, VIRTUS J family. Document language: English; 1,557 pages.
The corresponding English table of contents contains 56 sections and 445 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: VIRTUS J
- Model: Virtus J 110
- Starting serial number: ZKDY490200TS10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,557
- File size: 508.70 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match SAME Virtus J 110 → ZKDY490200TS10001.
Complete table of contents
Introduction
- Introduction
- Tightening torques for nuts and bolts of electrical connections
- Wheel nut/screw tightening torques
- 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
- Motor description – construction type
- Engine description – Views of engine
- Engine description – Lubricant oil diagram
- Engine description – Fuel circuit diagram
- Engine description – Coolant diagram
- Engine description – Exhaust gas recovery
- Engine description – Exhaust gas after-treatment
- Engine description – Electrical/electronic system
- Usage – Starting procedure
- Use – exhaust gas after-treatment systems
- Use – Stop procedure
- Operating materials – lubricant oil
- Operating materials – Fuel
- Operating materials – Coolant
- Care and maintenance work – Fuel distribution system
- Care and maintenance work – Cooling system
- Care and maintenance work – Engine cleaning
- Care and maintenance work – Intake system
- Care and maintenance work – Electrical system
- Malfunctions – Malfunction table
- Faults – Engine management
- Transport and storage – Transport
- Transport and storage – Engine protection treatment
- Technical data – Tools
Transmission
- Transmission
- Hydraulic reverse power shuttle
- Rear PTO
- Views of transmission
- HI-LO unit
- HML unit
Rear axle
- Rear differential
- Rear axle
Front axle
- Front axle
Bodywork – Cab – Platform
- A/C system – Version with standard roof
- A/C system – High visibility version
Hydraulic system
- Distributor hydraulic circuits
- Transmission hydraulic circuits
- Power steering 160 cc
- Power steering SDD 125-250cc
- Rear PTO
- Shuttle control unit
- 60 l/min. ECO AUX block
- Park Brake
- Suction pump filter
- HYDAC delivery line filter
- Transfer pump
- Hydraulic pumps unit
- Power steering pump
- Distributor unit
- Pressure regulator valve unit
- Services command unit
- HML control block
- Braking system
Calibrations and electronic diagnosis
Diagnostic tools
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket connection
Serdia 2010
- Safety-Hints
- Common Hints
- Common Hints – Start and Communication
- Common Hints – Disposability
- Introduction
- Error Hints (FAQ)
- Connection establishment
- Software handling
- Software handling – Topper elements
- Global Programfunctionality – Dataset management
- Global Programfunctionality – Error memory
- Global Programfunctionality – Graphical display
- Global Programfunctionality – Program adjustments
- UseCases EMR4
- Engine settings
- Adjustments engine speed – acceleration pedal
- CRT – TIER4 interim
- DPF – Burner – TIER4 interim
- SCR – TIER4 interim
- SCR service routines
- DPF service routines
- Service Routines DPF (DOC/SCR)
- Service-Cases
- Other
- UseCases EMR3
- UseCases EMR2
- Programm options
Diagnostic tool screens
- Position of ECUs and diagnostic instruments
- ECU interrogation
- Instrument Cluster Diagnostics – “Monitor”/Monitor screens for ART/PC Tester (SP286AD)
- Instrument Cluster Diagnostics – “Tests”/Test screens for ART/PC Tester (SP286AD)
- Instrument Cluster Diagnostics – “Alarms”/Alarms screens for ART/PC Tester (SP286AD)
- HLHP2 ECU diagnostics (TS171AC) – “Monitors”/Monitor screens for ART/PC Tester
- HLHP2 ECU diagnostics (TS171AC) – “Tests”/Test screens for ART/PC Tester
- HLHP2 ECU diagnostics (TS171AC) – “Alarms”/Alarms screens for ART/PC Tester
Commissioning and calibrating the tractor
- Digital Instrument Calibration
- Wheels constants
- Commissioning (939571) – Basic procedure
- Commissioning (939571) – Eeprom re-initialisation
- Commissioning (939571) – Line end programming of the tractor
- Commissioning (939571) – Accelerators calibration
- Commissioning (939571) – Clutch pedal calibration
- Commissioning (939571) – Options selection
- Commissioning (939571) – Hicth calibration
- Commissioning (939571) – Steering sensor calibration (SDD)
- Transmission calibration (939570) – Calibration of the shuttle clutches
- Transmission calibration (939570) – Calibrating HML clutches
- Transmission calibration (939570) – Calibrating the Stop&Go function
ECU alarms
Engine alarms
- Engine ECU Alarms: SPN 000016-000175
- Engine ECU Alarms: SPN 000190-001188
- Engine ECU Alarms: SPN 001231-003520
- Engine ECU Alarms: SPN 003532-005763
- Engine ECU Alarms: SPN 520521-523632
- Engine ECU Alarms: SPN 523633-523918
- Engine ECU Alarms: SPN 523919-524030
- Engine ECU Alarms: SPN 524031-524108
- Engine ECU Alarms: SPN 524109-524267
Transmission alarms
- Transmission alarms
Instrument panel alarms
- Alarms – Instrument alarms list
HLHP alarms
- HLHP2 Service ECU alarms “User Control”
AC system alarms
- Manual Air Conditioner Alarms
Lift alarms
- Lift E.C.U. Alarms
Software management
- Engine dataset upgrade
Method of intervention
- Tools for engine disassembly and reassembly
- Workshop tools for engine disassembly and reassembly (Lv.2)
- Workshop tools for engine disassembly and reassembly (Lv.3)
- Workshop tools for disassembly and reassembly
B0 – Engine
- Separating engine from transmission
- Replace the crankshaft O-ring (flywheel end)
- Fitting and removing seal seat
- Fitting and removing transition pipe
- Line
- Removal and refitting of the oil sump pan.
- Closing components
- Topping up with oil
- Removal and refitting of the flywheel (fixing elements)
- Removal and refitting of the cylinder head cover
- Support
- Intermediate gear
- Removal and refitting of the oil cooler
- Lubricating oil filter console
- Disassembling and assembling the oil suction pipe
- Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger)
- Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger)
- Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger)
- Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger)
- Fitting and removing the high pressure pump
- Removing and fitting the injector
- Removing and fitting the rail
- Removing and fitting the charge air duct
- Removal and refitting of the charge air manifold
- Intake manifold (turbocharger)
- Charge air manifold
- Charge air duct
- V-belt pulley
- Actuating elements
- V-belt pulley
- Disassembling and assembling the thermostat
- Checking the thermostat (after removal)
- Line
- Line
- Line
- Connection (crankcase, exhaust gas recovery, coolant pipe)
- Removing and fitting the compensation pipe (exhaust gas recirculation system)
- Pipe (thermostat housing, exhaust gas recovery, coolant pipe)
- Removal and refitting of the turbocharger
- Removal and refitting of the turbocharger
- Exhaust manifold (turbocharger)
- Exhaust manifold (turbocharger)
- Exhaust manifold (turbocharger)
- Removing and fitting the belt tensioner (ribbed V-belt)
- Removing and fitting the console (ribbed V-belt)
- Engine mounting
- Engine mounting
- Engine mounting
- Disassembly and assembly of the connector box
- Disassembly and assembly of the connector box
- Disassembly and assembly of the connector box
- Disassembly and assembly of the connector box
- Disassembly and assembly of the connector box
- Connector casing
- Console
- Removing and fitting hydraulic pump drive
- Engine flywheel
- Engine
- A/C compressor belt
- Alternator / water pump belt
- Check the connecting rod shank
- Removing and fitting pistons (L3)
- Check the piston
- Removing and fitting the piston rings
- Checking piston rings
- Disassembling and assembling the cylinder head (fasteners)
C0 – Engine accessories
- Intercooler
- Catalytic converter
- Coolant fluid radiator
- Fuel radiator
- Fuel tank
- Exhaust pipe
- Viscostatic fan
- Air filter container
- Radiator assembly
- Disassembling the radiator assembly
- Fuel prefilter
- Fuel filter
- Fuel line
- Fuel delivery pump
- Oil measuring device
- Removing and fitting the fuel pipes (injector, rail, high pressure pump)
- Blower fan
- Disassembling and assembling the exhaust manifold
- Removal and refitting of the exhaust manifold
- Removing and fitting the alternator (retainer bracket)
- Removing and fitting the alternator (fastener elements)
- Disassembly and assembly of the starter
- Disassembly and assembly of the starter
- Alternator
- Alternator
- Camshaft speed sensor
- Removal and refitting of the glowplugs
- Pressure transducer (L3)
- Pressure sensor (L3)
- Technical data – Speed indicator
D0 – Transmission
- Engine torsional spring plate
- Shuttle unit – Complete assembly
- Disassembling the shuttle unit
- Disassembling cover assembly
- Removing the forward drive clutch unit
- Disassembling the reverse drive clutch unit
- Input shaft assembly and tone wheel
- DT shaft in transmission
- Clutch housing – Separation from transmission
- Range selector assembly
- Disassembling the range selector assembly
- 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 M-L clutches
- Disassembling the H clutch
- Replacing the L clutch
- Disassembly of the HML planetary reduction gearbox
- Outer HML casing
- Gearbox and HI-LO unit
- Gearbox/HML assembly
- Secondary shaft – Version with HI-LO
- Secondary shaft – Version with HML
- Primary shaft
- Disassembling the gearbox input shaft
- Disassembly of secondary shaft – Version with HI-LO
- Disassembly of the main shaft
- Disassembly of HI-LO unit output shaft
- Disassembling the HML unit output shaft
- PTO output shaft – 2 speed version
- PTO output shaft – 4 speed version
- Disassembling the PTO output shaft – 2-speed version
- Removing the PTO output shaft – 4 speed version
- PTO engagement clutch
- Disassembling PTO engagement clutch
- Pump drive PTO – External gear
- Pump drive PTO – Internal gear
- Disassembling the PTO flange shaft – 2-speed version
- Disassembling PTO final flange shaft – 4 speed version
- Removing the rear pinion – 2-range version
- Removing the rear pinion – 4-range version
- Adjustment of the differential – Bevel gear set
- Disassembling the ground speed PTO flange output shaft
- Disassembling the ground speed PTO clutch engage mechanism
- Disassembly of dual traction output shaft
- Removing dual traction output shaft – 4-range version
- Disassembling EasyShift DT clutch system
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- Pump drive PTO – External gear without 60 l ECO pump
E0 – Rear axle
- Wheel carriers
- Wheel mount disassembly
- Park Brake assembly
- Park Brake unit disassembly
- Rear differential
- Removing rear differential
- Disassembling the brake carrier (versions without Park Brake)
- Brake carrier (versions without Park Brake)
F0 – Front axle
- Front axle
- Steering cylinders
- Removing steering cylinders
- 4WD shaft
- Separating front carrier from engine
- Front mount
- Steering sensor actuator plate orientation
G0 – Bodywork – Cab – Platform
- Cab
- Condenser
- Disassembling the condenser
- Dehydrator filter
- A/C unit
- Heater unit
- Cab access steps
- Expansion valve
- Engine cowl
- Hand brake bowden cable replacement
H0 – Hydraulic system
- Rear ancillary utility distributor
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Power steering valve
- Disassembling the complete pump assembly
- Transmission oil radiator
- 60L ECO 8-way distributor solenoid valve
- Disassembling the 60L ECO 8-way distributor solenoid valve
- 2-way distributor
- Disassembling the 2-way distributor
- Pressure transducer / Temperature sender (intake air)
- 4-rear way ancillary utility distributor
- 6-rear way ancillary utility distributor
- Replacing positioning for automatic release
L0 – Electrical system
- Battery mount with wiring loom
M0 – Front PTO
- Disassembling front PTO
R0 – Rear lift
- S.A.C. Automatic control station
- Disassembling the hitch assembly (SAC)
- Bushes
- Auxiliary hitch cylinders
- Disassembling the rear hitch control distributor
- Mechanical draft sensor
- 3-point linkage
- Rear lift draft rod replacement
S0 – Wheels
- Rear wheels
- Front Wheels
V0 – Ballast – towing hitches
- Tow hook sled
V1 – AFTERMARKET KITS
- 9.Y3654.90.0 and 9.Y4054.90.0 kit installation
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 – 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 Timers
- O – Resistors and rheostats
- P – Various services
- R – Diagnostics
- 04217755 – Engine control unit
- 2.8519.171.0/20 – HLHP2 ECU
- 2.8339.285.0/30 – Digital instrument cluster (MTA 2.0)
- 2.8519.148.0 – ISO 11786 ECU
Systems
- S001 – Electronic engine throttle
- S002 – Preheating
- S004 – Lift
- S005 – Lights
- S006 – Work lights
- S007 – Windscreen wiper
- S008 – Instrument panel
- S009 – Radio
- S010 – Manual air conditioner
- S011 – Transmission
- S012 – PTO
- S013 – Accessories
- S014 – CAN BUS
- S015 – CAN BUS (Engine line)
- S018 – Diagnostics
- S003 – Starter
- S016 – Brakes
- S017 – Trailer brake
- S019 – Distributors
Wiring harnesses
- 0.019.3018.4/20 – Front wiring loom
- 0.020.6707.4/20 – Cab
- 0.020.2857.4/10 – Rear wiring loom
- 0.014.1567.4/20 – Front windscreen wiper
- 0.014.8453.4 – Front wiper motor – fixed windscreen version
- 0.020.6706.4/20 – Roof
- 0.020.7971.4/10 – Right hand console
- 0.019.3870.4/10 – Front light-horn – Low
- 0.020.8203.4 – Cab roof work lights
- 0.020.9462.4/10 – Rotating beacon
- 0.021.1196.4 – Lower front work lights wiring loom – H9
- 0.012.2756.3 – Front PTO solenoid valve
- 0.011.3797.3 – SBA-ASM (GS-LS 110 HP)
- 0.017.9311.4/30 – Hydraulic reverse shuttle wiring loom – Stoll (GS only)
- 0.015.1440 – Shuttle SV wiring loom, 100 HP (for GS 110/120 HP only)
- 0.014.1645.4/10 – ITA-D Air braking pressure switch
- 0.019.8827.4 – S.D.D
- 0.016.1001.4/20 – Hydraulic trailer braking valve
- 0.018.5346.4 – 2-way electronic distributor electrical system wiring loom
- 0.020.0726.4 – Fuel pre-filter
- 0.020.6714.4 – Battery wiring (-)
- 0.021.1202.4 – Battery wiring (+)
- 04219367 – Alternator fuse wiring loom (GS 100/110 HP – LS)
- 0.019.5702.4 – ISO 11786
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
B0 – ENGINE
- Flushing the lubrication circuit
- Engine pulley detachment
- Deutz AG engine oil specifications
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
D0 – TRANSMISSION
- Hydraulic shuttle central disc
- Hand brake lever greasing
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- BRAKE PUMP INTERNAL LEAKAGE
- Main gear lever
- 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
- SDD steering unit position sensor and solenoid valve replacement
- L0 – ELECTRIC AL SYSTEM
