Zetor Major HS service schedule

Zetor Major · 2017 on (handbook edition 1/2017)

Covers the Zetor Major HS (Major HS 80).

Every maker's service job for the Zetor Major HS, counted in hours, with the oils, filters and parts each one needs. Add your tractor to Farmyard Workshop and it works out what's due from your hours and dates, and keeps the service history.

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Service intervals

Job	When
Lubrication (about 19 points)	every 50 hours
Engine oil and filter change	every 500 hours or every year
Fine fuel filter change	every 500 hours
Hydraulic suction and pressure filters	every 500 hours
Front PTO housing oil and strainer	every 500 hours
Cab heating filter	every 1,000 hours or every 2 years
Coarse fuel filter change	every 1,000 hours
Air cleaner main element change	every 1,000 hours
Front axle housing and reducer oil change	every 1,000 hours
Gearbox and final drive oil change	every 1,500 hours
Coolant change	every 2 years
Brake fluid change	every 2 years

Service jobs and parts

Lubrication (about 19 points)

Chassis · every 50 hours

The contents list a 50-hour service and the greasing plan. Points: front axle pivot pins (4), spigot shafts (2), cardan joint (2), rear semi-axle bearings (2), lifting rods (2), upper draw bar bracket (3) and the front hitch cylinder pins. Count is approximate, check your handbook. Grease only with the engine stopped.

Part	Qty	Notes	Part number
Grease	1	EP2 grease. Grease to ISO 6743/9 CCEB 2/3 (NLGI 2 type); check your handbook. Aztec Oils match: VOLCATEC LITHIUM EP 2	check your handbook

Step-by-step

Wipe each nipple, pump in grease until clean grease shows and wipe off the excess.

Tools: Grease gun, Rags

Engine oil and filter change

Engine · every 500 hours or every year

The schedule lists the engine oil and the oil filter element together at 500 hours. Table pairing read from the order of tasks and values; check your handbook.

Part	Qty	Notes	Part number
Engine oil	1	Deutz DQC III-10 LA, ≈8 L. The handbook gives no SAE grade, so check your handbook	check your handbook
Oil filter element	1	Check your handbook or dealer for the number	check your handbook

Step-by-step

Warm the engine, stop it and apply the parking brake.
Drain the oil from the sump plug and replace the filter, oiling its seal first.
Refit the plug, fill with about 8 L of the specified oil and run the engine to check for leaks.
Re-check the level on the dipstick.

Tools: Drain tray (12 L), Filter wrench, Socket set, Funnel, Gloves

Fine fuel filter change

Fuel · every 500 hours

The schedule lists the fine fuel filter element at 500 hours and the coarse (raw) fuel filter at 1,000 hours. Table pairing read from the order of tasks and values.

Part	Qty	Notes	Part number
Fine fuel filter element	1	Check your handbook or dealer for the number	check your handbook

Step-by-step

Clean around the housing, change the element and bleed the fuel system as in the handbook.

Tools: Container, Rags

Hydraulic suction and pressure filters

Transmission · every 500 hours

The schedule lists the hydraulic pump suction filter and the pressure filter element at 500 hours, more often than the oil.

Part	Qty	Notes	Part number
Suction filter and pressure filter elements	1	Check your handbook for the numbers	check your handbook

Step-by-step

Clean around the housings, change the elements, run the engine and check for leaks.

Tools: Filter wrench, Rags

Front PTO housing oil and strainer

Front axle · every 500 hours

The schedule lists the front PTO housing oil and cleaning its strainer at 500 hours.

Part	Qty	Notes	Part number
Front PTO gearbox oil	1	10W-30. Check your handbook for the grade. ≈2.7 L	check your handbook

Step-by-step

Drain, wash the strainer and refill to the level mark.

Tools: Drain tray, Funnel

Cab heating filter

Cab · every 1,000 hours or every 2 years

The schedule lists the heating filter element at 1,000 hours or 2 years.

Part	Qty	Notes	Part number
Cab heating filter element	1	Check your handbook for the number	check your handbook

Step-by-step

Open the cover and fit a new element.

Tools: Screwdriver

Coarse fuel filter change

Fuel · every 1,000 hours

See the fine filter task: the coarse (raw) fuel filter element is listed at 1,000 hours.

Part	Qty	Notes	Part number
Coarse fuel filter element	1	Check your handbook or dealer for the number	check your handbook

Step-by-step

Change the element, then bleed the system as in the handbook.

Tools: Container, Rags

Air cleaner main element change

Engine · every 1,000 hours

The schedule lists the air filter element at 1,000 hours and the safety element at 2,000 hours. Service the air cleaner earlier if the indicator shows.

Part	Qty	Notes	Part number
Air cleaner main element	1	Check your handbook or dealer for the number	check your handbook
Air cleaner safety element (every 2,000 h)	1	Check your handbook or dealer for the number	check your handbook

Step-by-step

Remove the cover, replace the main element (and the safety element every 2,000 h) and close up.

Tools: Gloves, Clean cloth

Front axle housing and reducer oil change

Front axle · every 1,000 hours

The schedule lists the front drive axle housing oil and the reducers' oil at 1,000 hours.

Part	Qty	Notes	Part number
Front axle oil	1	Zetor LS 80W (SAE 80W, 80W-90 or 10W-30 with limited-slip additives). ≈5.5 L housing, 2 x 0.6 L reducers. Aztec Oils match: TRANSMATEC EP-4 80W-90	check your handbook

Step-by-step

Drain the housing and reducers, refit the plugs and fill to the level plugs.

Tools: Drain tray, Socket set, Funnel

Gearbox and final drive oil change

Transmission · every 1,500 hours

The schedule lists the gearbox and final drive oil at 1,500 hours. Change the suction and pressure filters (every 500 hours) at the same time.

Part	Qty	Notes	Part number
Gearbox and hydraulic oil	1	10W-30 STOU, API GL-4 (Zetor Extra 10W-30 STOU), ≈35 L. Aztec Oils match: AGRITEC UTTO	check your handbook
Hydraulic pump suction filter and pressure filter elements	1	Check your handbook for the numbers	check your handbook

Step-by-step

Warm the oil, stop the engine and put a large tray under the drain plug.
Drain, change the filters and refit the plug.
Refill to the dipstick, run the hydraulics and re-check the level.

Tools: Drain tray (45 L), Socket set, Funnel, Gloves

Coolant change

Cooling · every 2 years

The schedule lists the coolant, brake fluid and one other item every 2 years. Table pairing read from the order of values.

Part	Qty	Notes	Part number
Coolant	1	Check your handbook for the antifreeze type. ≈12 L	check your handbook

Step-by-step

Let the engine cool, drain, flush and refill, then bleed and top up after a warm-up run.

Tools: Drain tray, Funnel

Brake fluid change

Brakes · every 2 years

Brake fluid takes in water, so the schedule lists it every 2 years. Table pairing read from the order of values.

Part	Qty	Notes	Part number
Brake fluid	1	Check your handbook for the DOT grade. ≈0.5 L. Aztec Oils match: HYDRATEC DOT 4 BF	check your handbook

Step-by-step

Bleed each brake until clean fluid shows, keeping the reservoir topped up.

Tools: Bleed kit, Spanner

Oils, fluids and capacities

System	Oil or spec	Capacity
Engine	Deutz TCD 2.9 L4: 2,925 cc four-cylinder turbocharged diesel, 55.4 kW, with oxidation catalyst
Engine oil	Engine oil to Deutz DQC III-10 LA (the handbook gives the specification, not an SAE grade)	8 L
Coolant	12 L. Check your handbook for the antifreeze type
Valve clearances	Check your handbook
Engine oil	Deutz DQC III-10 LA	8 L
Gearbox and final drive housing	10W-30 STOU, API GL-4 (Zetor Extra 10W-30 STOU)	35 L; add 4-8 L for slope work or heavy outside hydraulic use
Front driving axle housing	Zetor LS 80W; SAE 80W, 80W-90 or 10W-30 with limited-slip additives	5.5 L
Front axle planetary reducers	Same as the front axle housing	2 x 0.6 L
Front PTO gearbox	Check your handbook	2.7 L
Brake fluid	Check your handbook for the DOT grade	0.5 L
Coolant	Check your handbook	12 L
Fuel	Diesel	80 L

Specifications


Power	55.4 kW (Major HS 80)
Torque	300 Nm at 1,600 rpm
Weight	3,350 to 3,500 kg depending on equipment
Idle speed	900 rpm

Known problems

Beyond 500 hours

The handbook lists replacing the accessories drive belt and tensioning roller, checking front wheel toe-in and replacing hydrostatic hoses outside the 500-hour list. The interval could not be read, so check your handbook.

Fault codes: SAE J1939 engine codes: how to read SPN and FMI

Any modern electronic diesel engine

Code	Meaning	What to do
SPN 91	Accelerator pedal position	Power may be limited. Check the pedal plug.
SPN 94	Fuel delivery (lift pump / filter) pressure	Check fuel level and filters; look for air in the fuel.
SPN 97	Water in fuel	Drain the water separator.
SPN 100	Engine oil pressure	FMI 1 means stop at once. Check the oil level.
SPN 102	Boost (turbo) pressure	Check air filter and intake for leaks.
SPN 105	Intake manifold (charge air) temperature	Clean the cooler and intake.
SPN 110	Engine coolant temperature	FMI 0 means overheating: stop and let it cool.
SPN 157	Common rail fuel pressure	Check fuel filters. Call your dealer.
SPN 168	Battery voltage	Check the battery, terminals and alternator.
SPN 174	Fuel temperature	Call your dealer if high or erratic.
SPN 190	Engine speed	Check the sensor plug if the rev counter misbehaves.
SPN 1136	Engine controller temperature	Let it cool; check engine bay ventilation.
SPN 3216	SCR catalyst conversion efficiency (exhaust AdBlue system)	Check DEF quality and level. Call your dealer.
SPN 3361	DEF (AdBlue) dosing unit	Check the DEF tank level; call your dealer.
SPN 4094	DEF (AdBlue) tank level	Fill the DEF tank. Power will be cut if it runs out.
FMI 0	Reading valid but well above normal (most severe)	Treat as a real problem: stop and check, for example temperature or pressure.
FMI 1	Reading valid but well below normal (most severe)	Treat as a real problem: for oil pressure, stop the engine at once.
FMI 2	Erratic, intermittent or wrong data	Check the plug and wiring at the sensor.
FMI 3	Voltage above normal or wiring shorted to supply	Sensor or wiring fault. Check the plug.
FMI 4	Voltage below normal or wiring shorted to ground	Sensor or wiring fault. Check the plug.
FMI 5	Current below normal or open circuit	A wire has come off or a part has failed. Check the plug.
FMI 6	Current above normal or grounded circuit	A short to ground. Check wiring for chafing.
FMI 7	Mechanical part not responding or out of adjustment	Not electrical: check the part moves freely.
FMI 8	Abnormal frequency or pulse width	Signal fault. Check the sensor and wiring.
FMI 9	Abnormal update rate (message arriving too slowly or too fast)	Often a network fault. Switch off and restart.
FMI 10	Abnormal rate of change	Reading changing too fast. Check the sensor.
FMI 11	Failure detected, exact cause not known	Call your dealer.
FMI 12	Controller or device faulty	Usually needs a replacement part: call your dealer.
FMI 13	Out of calibration	Call your dealer to recalibrate.
FMI 14	Special instructions: the maker has its own steps	Call your dealer.
FMI 15 / 16	Reading above normal: least severe / moderately severe	Warning stage. Ease off and check, for example coolant.
FMI 17 / 18	Reading below normal: least severe / moderately severe	Warning stage. Check the system named.
FMI 19	Data received over the network carries an error flag	Check the sensor plugged into the other controller.
FMI 20 / 21	Data drifted high / drifted low compared with other readings	Sensor may be failing. Call your dealer.
FMI 31	The condition named by the SPN exists (no more detail), or not available	Read the SPN name for what it means.

Repair guides

Weak or slow hydraulics: suction filter magnet and gearbox pressure filter (Moderate, 1 hour): Slow or weak lift, a whining hydraulic pump, or gearbox oil filter indicator showing full.
Accessories drive belt, tensioning roller and hydrostatic hoses (Major HS) (Moderate, 1–2 hours): Squealing or loose belt, charging fault, wandering steering, cracked or weeping steering hoses.

The full step-by-step guides are in Farmyard Workshop once you add your tractor.

Sources

Open Farmyard Workshop