Document overview
Workshop Manual PDF for DEUTZ FAHR 5090.4 G → ZKDFE10200TD50001, Series 5 G (STAGE 3B) family. Document language: English; 2,141 pages.
The corresponding English table of contents contains 52 sections and 582 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: DEUTZ FAHR
- Family: Series 5 G (STAGE 3B)
- Model: 5090.4 G
- Starting serial number: ZKDFE10200TD50001
- Document type: Workshop Manual
- Language: English
- Pages: 2,141
- File size: 498.16 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5090.4 G → ZKDFE10200TD50001.
Complete table of contents
Introduction
- Tightening torques
- Pump tightening torques
- Wheel nut/screw tightening torques
- Tightening torques for nuts and bolts of electrical connections
- 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
- Technical data: cylinder block
- Technical data: crankshaft
- Technical data: pistons – piston rings
- Technical data: rockers
- Camshaft technical data
- Technical data: timing system gears
- Technical data: counter-rotating masses
- Technical data and dimensions: valves – valve springs
- Technical data and dimensions: heads – valve guides – valve seats
- Technical data, rockers – tappets
Engine accessories
- Starter motor
Transmission
- Transmission
- Transmission
- Transmission
- Four-wheel drive electrohydraulical engagement and parking brake assembly
- Hydraulic reverse power shuttle
- HI-LO unit
- HML unit
- Rear PTO
- Rear Power Take Off
- Views of transmission
Rear axle
- Rear axle
- Rear differential
Front axle
- Front axle 4 WD
- Front axle 2WD
- Pinion, differential and differential lock
- Final drive
Bodywork – Cab – Platform
- Air conditioning system – Version with Standard Roof
- Air conditioning system – High Visibility Version
Hydraulic system
- Braking valve (logic block)
- Trailer braking valve
- Power steering 125 cc
- SDD power steering
- Delivery line filter
- Hydraulic pumps unit
- Power steering pump
- Transfer pump
- Suction pump filter
- 60 l/min. ECO AUX block
- Distributor unit
- Reverse shuttle control valve block
- Pressure regulator valve unit
- Service valve unit
- HML control block
- Rear PTO
Electrical equipment
- FARMotion engine sensors and components
Front PTO
- Front PTO
- PTO delivery pump
- PTO control solenoid valve assy
- Front PTO
Front lift
- Damper assembly
- Front lift
Rear lift
- Mechanical rear lift
Calibrations and electronic diagnosis
- ECUs
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
SDF Analyser
- SDF SUITE
Commissioning and calibrating the tractor
- 4^ gear
- Draft Bar
ECU alarms
- SDF Severity of alarms
- ECU ALARMS (Electronic SAC)
- ECU ALARMS (Mechanical SAC)
Software management
- ECUs firmware update
- Download Dataset FARMotion & Flash ECU
Method of intervention
- Workshop tools for disassembly and reassembly
- Workshop tools for disassembly and reassembly
- Workshop tools for engine removal and reassembly
- Tightening procedure for engine components
- Tightening procedure for engine components
B0 – Engine
- Complete engine
- Engine- Separation from the transmission
- Engine flywheel
- Engine flywheel
- Engine block-gearbox connector flange
- Blow-by oil vapour recovery pipe
- Turbocharger oil pipes
- Turbocharger
- EGR exhaust gas recirculation pipe
- Exhaust manifold
- Thermostat valve
- EGR exhaust gas cooling pipes
- EGR manifold
- Disassembly of the EGR manifold
- EGR valve
- Blow-by filter
- Coolant manifold
- Intake manifold
- Oil filter
- Oil heat exchanger
- Engine coolant pump
- Electro-injectors and common rail
- Cylinder head covers
- Blow-by oil vapour pipe
- Pushrods
- Cylinder heads
- Crankshaft pulley and tone wheel
- Crankshaft pulley
- Power take off drive
- Front timing cover
- Rear flange
- Oil sump
- Oil pump
- Counter-rotating masses
- Overhauling counter-rotating masses
- Intermediate gear and timing
- Disassembling pistons and connecting rods
- Crankshaft
- Cooling jets
- Cylinder sleeves
- Adjusting oil pump gear backlash
- Replacing the automatic tensioner
- Installing automatic belt tensioner
- Disassembling the cylinder heads
- Checking the thermostat valve
- Aligning water pump and crankshaft pulleys
- Exhaust gas recirculation valve (EGR)
- A/C compressor belt
C0 – Engine accessories
- High pressure fuel pump
- Mounting brackets
- Power take off gear backlash adjustment
- Air compressor for utilities
- Disassembling the utilities air compressor
- Replacing the coolant
- Engine air intake fan
- Coolant radiator
- Complete radiator-heat exchanger pack
- Disassembling the radiator assembly
- Compensation tank
- Intercooler, gearbox oil and fuel heat exchangers
- Air filter
- Rigid air filter pipe
- Fuel filter
- Fuel pre-filter
- Bleeding air from the fuel circuit
- Manual fuel pump
- Fuel tank
- Electric starter motor
- Exhaust pipe
- Exhaust silencer – (DOC catalytic converter)
D0 – Transmission
- Draining and filling the transmission oil
- Engine torsional spring plate
- Hydraulic reverse shuttle unit
- 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
- Gearbox internal cover
- Separating connector flange from rear gearbox housing
- Connector housing
- Gear selector assembly
- Main gear lever
- Gear selector rod
- Range selector assembly
- Disassembling the range selector assembly
- Gearbox assembly
- HI-LO unit
- Disassembling the HI range clutch housing
- Disassembling the HI-LO planetary reduction gearbox
- Gearbox and HI-LO unit
- HML unit
- Disassembling the HML unit
- Disassembling the H clutch
- Disassembling M-L clutches
- Replacing the L clutch
- Gearbox/HML assembly
- Disassembly of the HML planetary reduction gearbox
- Outer HML casing
- Disassembly of the gearbox and shuttle assembly – Version with HI-LO
- Secondary shaft – Version with (4 gears)
- Secondary shaft – Version with HI-LO
- Output shaft – Version with 3-stage module (HML)
- Primary shaft
- Primary shaft (4 gears)
- Disassembling the reverse shuttle 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
- Disassembling the secondary shaft – Version with HI-LO or HML
- 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 control clutch
- Disassembling PTO engagement clutch
- Pump drive PTO – External gear
- Pump drive PTO – Internal gear
- Disassembling the PTO output flange shaft – 2 speed version
- Disassembling PTO final flange shaft – 4 speed version
- Groundspeed PTO shaft
- Disassembling the ground speed PTO output shaft
- Disassembling the ground speed PTO clutch engage mechanism
- Removing the rear pinion – 2-range version
- Removing the rear pinion – 4-range version
- Adjustment of the differential – Bevel gear set
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- 4WD engagement device – Easyshift
- Removing dual traction output shaft 2-range version
- Removing dual traction output shaft – 4-range version
- Adjusting the parking brake lever
- Parking brake disc sectors – Versions with hydraulically engaged four wheel drive
- Parking brake disc sectors
E0 – Rear axle
- Right-hand rear axle
- Left-hand rear axle
- Removing right/left hand rear axle
- LH brake carrier
- RH brake carrier
- Disassembly of the brake carrier
- Differential lock selector fork
- Rear differential
- Removing rear differential
- Bleeding the braking system
F0 – Front axle
- Front axle (4WD)
- Carrier with front axle (4WD)
- 4WD shaft
- Front axle adjusting endfloat
- Steering bar/tie-rod
- Steering knuckle housing and half-shaft
- Adjustment of steering knuckle housing and axle shaft
- Differential assembly
- Disassembling the differential assembly
- Disassembly of the differential
- Differential assembly adjustment
- Steering cylinders
- Removing steering cylinders
- Front axle brake discs
- Front axle brake piston
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Removing bevel gear set
- Adjustment of the bevel gear set
- Steering angle adjustment
- Steering sensor actuator plate orientation
G0 – Bodywork – Cab – Platform
- Cab
- Cab access steps
- Engine hood and front hood panels
- Lower hood cover
- Battery mount
- Front mudguards
- Cab mat
- Right hand console
- Left hand side cab trim
- Right hand side cab trim
- Cab pillar covers
- Instrument cluster
- Instrument cluster
- Sun blind
- Roof panel
- Screen wash liquid reservoir
- Windscreen wiper motor
- Roof hatch
- Rear screen
- Cab door
- Disassembling the door handle
- Anti-pollen filter
- External rear-view mirrors
- Driver seat
- Empty and charge the air conditioning system
- Complete air conditioner unit
- Disassembling the air conditioning unit
- Air conditioner control unit
- Air conditioning compressor
- Air conditioning condenser
- Dehydrator filter
- Replacing the evaporator
- Heating radiator – Version with air conditioning
- Motor with fans
- Expansion valve
- Anti-icing sensor
- Electronic foot throttle
- Disassembling the electronic throttle control
- Brake pedals
- Clutch pedal
- Steering column
- Steering wheel
- Brake master cylinders
- Replacing the Bowden cable of the parking brake
H0 – Hydraulic system
- Power steering pump
- ECO supplementary pump
- Disassembling the ECO auxiliary pump PTO
- Lift and ancillary utility distributor circuit pump
- HML solenoid valve block
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Oil filter
- Resonator
- Hydrostatic steering unit (Orbitrol) – Versions with rapid steering system (SDD)
- Rear auxiliary utility distributors
- Trailer air braking valve and air tank
- Air tanks
- Compressed air pressure gauge
- Brake block
- Brake control valve
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
L0 – Electrical system
- Battery
- Alternator
- Electronic engine control unit (ECU)
- Ancillary utility control unit (MLHP)
- Clutch pedal potentiometer
- Start enable switch
- Engine air temperature sensor
- Reverse shuttle speed sensor
- Replacing the steering angle sensor (SBA)
- Throttle pedal position sensor
- Shuttle control oil pressure switch
- HML speed sensor
- Hydraulic system inlet pressure switch
- Solenoid valve block and utility pressure switch
- Rear lift position sensor
- Wheel speed sensor
- Instrument panel
- Ignition switch barrel
- Battery master switch
- Trailer socket
- Steering column stalk
- Disassembling the steering column stalk
- Cab interior lights
- Engine wiring loom
- Charge pressure and air temperature sensor
- Electro-injector wiring loom
- Coolant temperature sensor
- Crankshaft speed sensor
- Preheat relay
- Camshaft timing sensor
- Engine oil pressure switch
- Engine oil temperature sensor
- Fuel pressure and temperature sensor
- Fuel pressure sensor
- Water in fuel sensor
- Air filter clogged sensor
- Trailer air braking pressure switch
- Angle sensor ± 45°
- Hydraulic trailer braking pressure sensor
- Engine speed sensor (pickup)
- Ambient Temperature Sensor
- Pressure and temperature sensor
- Oil pressure switch
- Timing sensor
- Fuel pressure sensor
- Coolant temperature sensor
- Pressure switch 0.4 – 0.7 bar
- Temperature sensor
M0 – Front PTO
- Front PTO
- Disassembling the front PTO
- Disassembling the front PTO control clutch
- Solenoid valve block
- Front PTO drive shaft
N0 – Front lift
- Front lift
- Lower front lift carrier
- Front lift arms
- Front lift hydraulic system valve
- Front lift cylinder
R0 – Rear lift
- Complete rear lift (SAC)
- Disassembling the complete rear lift (SAC)
- SAC disassembly – Automatic control station (mechanical distributor)
- Lift bushes
- Rear lift control distributor
- Auxiliary lift cylinders
- 3-point linkage
- Mechanical draft sensor
- Connecting the Bowden cable to the position and draft control lever (mechanical lift)
- Adjusting mechanical rear lift controls
- Checking and testing the mechanical rear lift
- Mechanical rear lift adjustments
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Rear towing hitch
V1 – AFTERMARKET KITS
- Pneumatic brake kit – P/N 9.DK589.91.0
Wiring diagrams
Components
- 22.8519.261.0 – HLHP control unit, with electronically controlled lift
- 2.8519.151.0 – Engine ECU
- 2.8519.148.0 – ECU ISO 11786
- MLHP Control Unit
- O.C.U. – Control unit
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments
- F – External lights (rotating beacon)
- G – Interior lights
- H – Manual electrical controls (steering column stalk)
- 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
- R – Diagnostics
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments
- F – External lights (rotating beacon)
- G – Interior lights
- H – Manual electrical controls (steering column stalk)
- 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
- R – Diagnostics
Systems
- S001A – Electronic engine throttle (mechanical rear lift)
- S001B – Electronic engine throttle (electronically controlled rear lifter)
- S002A – Preheat, mechanical rear lift
- S002B – Preheat (electronically controlled rear lift)
- S003A – Starting (mechanical rear lift)
- S003B – Starting (electronic rear lift)
- S004 – Lift
- S005A – Lights (mechanically controlled rear lift)
- S005B – Lights (electronic rear lift)
- S006 – Work lights
- S007 – Windscreen wipers (electronic rear lift)
- S008A – Instrument cluster (mechanical rear lift)
- S008B – Instrument cluster (electronic rear lift)
- S009 – Radio system
- S010 – Air conditioning system
- S011A – Transmission (mechanically controlled rear lift)
- S011B – Transmission (electronically controlled rear lift)
- S012A – PTO (mechanical rear lift)
- S012B – PTO (electronically controlled rear lift)
- S013A – Accessories (mechanically controlled rear lift)
- S013B – Accessories (electronically controlled rear lift)
- S014A – Can network (mechanical rear lift)
- S014B – Can network (electronic rear lift)
- S015A – Engine Can line (mechanical rear lift)
- S015B – Engine Can line (electronic rear lift)
- S016A – Braking system (mechanically controlled rear lift)
- S016B – Braking system (electronically controlled rear lift)
- S017A – Trailer brake (mechanical rear lift)
- S017B – Trailer brake (electronic rear lift)
- S018A – Eco Saving (mechanical rear lift)
- S018B – Eco Saving (electronic rear lift)
- S021A – SDD (mechanically controlled rear lift)
- S021B – SDD (electronically controlled rear lift)
- S022A – Battery master switch (mechanically controlled rear lift)
- S022B – Battery disconnector (electronically controlled rear lift)
- S001A – Electronic engine throttle (mechanical rear lift)
- S001B – Electronic engine throttle (electronically controlled rear lifter)
- S002A – Preheat, mechanical rear lift
- S002B – Preheat (electronically controlled rear lift)
- S003A – Starting (mechanical rear lift)
- S003B – Starting (electronic rear lift)
- S004 – Lift
- S005A – Lights (mechanically controlled rear lift)
- S005B – Lights (electronic rear lift)
- S006 – Work lights
- S007 – Windscreen wipers
- S008A – Instrument cluster (mechanical rear lift)
- S008B – Instrument cluster (electronic rear lift)
- S009 – Radio system
- S010 – Air conditioning system
- S011A – Transmission (mechanically controlled rear lift)
- S011B – Transmission (electronically controlled rear lift)
- S012A – PTO (mechanical rear lift)
- S012B – PTO (electronically controlled rear lift)
- S013A – Accessories (mechanically controlled rear lift)
- S013B – Accessories (electronically controlled rear lift)
- S014A – Can network (mechanical rear lift)
- S014B – Can network (electronic rear lift)
- S015A – Engine Can line (electronic rear lift)
- S015B – Engine Can line (mechanical rear lift)
- S016A – Braking system (mechanically controlled rear lift)
- S016B – Braking system (electronically controlled rear lift)
- S017A – Trailer brake (mechanical rear lift)
- S017B – Trailer brake (electronic rear lift)
- S018A – Eco Saving (mechanical rear lift)
- S018B – Eco Saving (electronic rear lift)
- S021A – SDD (mechanically controlled rear lift)
- S021B – SDD (electronically controlled rear lift)
- S022A – Battery disconnector (mechanically controlled rear lift)
- S022B – Battery disconnector (electronically controlled rear lift)
Wiring harnesses
- Wire colour reference table
- 0.011.3797.3 – SBA/ASM sensor
- 0.012.2756.3 – Front PTO solenoid valve
- 0.012.2756.3 – Hydraulic trailer braking solenoid valve
- 0.014.1567.4/20 – Front wiper motor – opening windscreen version
- 0.014.1645.4/10 – Hydraulic trailer braking pressure switch wiring
- 0.014.8453.4 – Windscreen wiper (version with fixed windscreen)
- 0.015.0070.4 – Solenoid valves
- 0.016.1001.4/20 – Trailer parking brake solenoid valve (version with hydraulic braking)
- 0.016.8489.4 – Trailer parking brake solenoid valve (version with pneumatic braking)
- 0.017.0496.4/10 – H9 lower front work lights
- 0.018.5346.4 – Distributor 7-8
- 0.019.5702.4/10 – ISO 11786
- 0.019.8827.4 – SDD (rapid steer system)
- 0.020.6706.4/50 – Roof panel
- 0.020.8203.4/10 – Cab roof work lights
- 0.020.9462.4/10 – Flashing beacon cable
- 0.021.1196.4/10 – Bottom work lights H9
- 0.021.1217.4 – Heater
- 0.021.4505.4 – PTO 540-750 wiring loom
- 0.021.5363.4/10 – Cowl
- 0.021.5364.4/10 – Cowl
- 0.021.5365.4/10 – Cowl
- 0.023.1279.4/20 – Engine (3 cylinder version)
- 0.023.1281.4 – Injectors (3 cylinder version)
- 0.023.3418.4/20 – Front wiring loom (3 cylinder version)
- 0.024.2826.4/10 – Alternator – preheat
- 0.024.3458.4/10 – Right hand console
- 0.024.3509.4/10 – OCU control unit
- 0.024.8482.4/10 – Mechanically engaged front loader 1
- 0.025.1281.4/10 – Gearbox
- 0.025.5561.4 – Front lights
- 0.026.1301.4 – Mechanically engaged front loader 2
- 0.026.4751.4 – Override button wiring loom
- 0.027.8546.4/10 – Cab, hydraulic reverse shuttle (with electronic rear lift)
- 0.027.9843.4/10 – Cab, mechanical reverse shuttle (with electronic rear lift)
- 0.028.0461.4/20 – Cab, hydraulic reverse shuttle (with mechanical rear lift)
- 0.028.1207.4/20 – Trailer air braking system, Mother Regulation version (MR)
- 0.028.1208.4 – Ground wiring loom (AIR PREX)
- 0.028.5242.4 – Rear, hydraulic reverse shuttle (with electronic rear lift)
- 0.028.5243.4 – Rear, mechanical reverse shuttle (with electronic rear lift)
- 0.028.7829.4 – Rear, hydraulic reverse shuttle (with mechanical rear lift)
- 0.028.7830.4 – Rear, mechanical reverse shuttle (with mechanical rear lift)
- 0.028.8182.4 – Power cables T2
- 0.028.8216.4/10 – Engine ECU power supply
- 0.029.6821.4/30 – Cab, mechanical reverse shuttle (with mechanical rear lift)
- 0.029.7828.4 – Ground wiring loom (AIR PREX)
- 04422324.4/10 – ISO 11786
- Front lights and horn
- 0.023.1280.4/20 – Engine – 4 cylinder version
- 0.023.1282.4 – Injectors – 4 cylinder version
- 0.023.3353.4/10 – Front wiring loom
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
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Deutz AG engine oil specifications
- Engine sealing ring leakage
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
- Doc outlet pipe & exhaust system alignment
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Front axle final reduction shims
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Air conditioning system recharging
- Distributors bowden cables damage
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
