Document overview
Workshop Manual PDF for DEUTZ FAHR 5090 KF → ZKDEJ21500TD10001, Series 5 K (FARMOTION STAGE 3B) family. Document language: English; 791 pages.
The corresponding English table of contents contains 35 sections and 319 individual topics.
Main sections included
- Introduction
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: DEUTZ FAHR
- Family: Series 5 K (FARMOTION STAGE 3B)
- Model: 5090 KF
- Starting serial number: ZKDEJ21500TD10001
- Document type: Workshop Manual
- Language: English
- Pages: 791
- File size: 318.33 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5090 KF → ZKDEJ21500TD10001.
Complete table of contents
Introduction
- Introduction
- Tightening Torques
- Pump tightening torques
- Tightening torques for nuts and bolts of electrical connections
- Solenoid valves and cartridge valves
- Installation of quick couplers
Technical characteristics
Engine
- Technical data: cylinder block
- Technical data: crankshaft
- 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
- Automatic tensioner
Engine accessories
- Starter motor
- Compensation tank
- Exhaust gas recirculation valve (EGR)
- Manual fuel pump
- Heater
- Fuel filter
- Fuel pre-filter
- Air filter
- Coolant radiator
- Intercooler
- Fuel radiator
- Gearbox oil radiator
- Viscostatic fan
- Exhaust silencer – Catalytic converter (DOC)
- Fuel tanks
Transmission
- Clutch
- Transmission
- Transmission diagram
- Rear power take off
- Hydraulic rear PTO clutch
- Rear power take off
Rear axle
- Rear axle
- Rear brakes
Bodywork – Cab – Platform
- External view of the tractor with folding ROPS
- External view of the tractor with fixed ROPS
- Main technical data
- Dimensions and weights of the tractor
- Internal views of the tractor with roll over protection frame
- Dashboard
- Instrument cluster
- Left hand console
- Right-hand console
Hydraulic system
- Auxiliary hydraulic circuit, base version
- Auxiliary hydraulic circuit, optional version
- Transmission hydraulic circuit
- Hydraulic pumps
- Steering control valve
- Hydrostatic steering pump
- Auxiliary control valve
Electrical equipment
- Battery
- Alternator
- Alternator
- FARMotion engine sensors and components
- Rear lift
Crawler undercarriage
- Steering clutch
Ballast – Towing hitches
- Rear drawbar
- Ballasting
Calibrations and electronic diagnosis
- ECUs
Diagnostic instrument
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- ECU Reset
- Set vehicle model
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- Download Dataset FARMotion & Flash ECU
Method of intervention
B0 – Engine
- Preliminary operations before removing engine from vehicle
- Complete engine
- Engine- separation from the transmission
- Engine- separation from the transmission
- Cylinder sleeves
- Engine-transmission mating flange
- Crankshaft pulley and tone wheel
- Crankshaft pulley
- Ancillary utility belt
- Rear flange
- Exhaust manifold
- Blow-by oil vapour recovery pipe
- Turbocharger oil pipes
- Turbocharger
- EGR exhaust gas recirculation pipe
- Thermostat valve
- Crankshaft
- Installing automatic belt tensioner
- Disassembling pistons and connecting rods
- Front timing cover
- Pushrods
- Power take off drive
- Intermediate gear and timing
- Cylinder head covers
- Cylinder heads
- Disassembling the cylinder heads
- Blow-by filter
- Blow-by oil vapour pipe
- Cooling jets
- Oil filter
- Oil sump
- Adjusting oil pump gear backlash
- Oil pump
- Electro-injectors and common rail
- Oil heat exchanger
- Aligning water pump and crankshaft pulleys
- EGR exhaust gas cooling pipes
- Coolant manifold
- Engine coolant pump
- Checking the thermostat valve
- EGR manifold
- Disassembly of the EGR manifold
- EGR valve
- Intake manifold
C0 – Engine accessories
- Replacing the coolant
- Coolant radiator
- Complete radiator-heat exchanger pack
- Compensation tank
- Engine air intake fan
- Intercooler
- Air filter
- Intercooler, oil and fuel exchangers
- Rigid air filter pipe
- High pressure fuel pump
- Fuel prefilter
- Fuel filter
- Left hand fuel tank float sensor
- Right hand fuel tank
- Left hand fuel tank
- Manual fuel pump
- Fuel radiator
- Starter motor
- Mounting brackets
- Exhaust silencer – DOC catalytic converter
- Exhaust pipe
- Power take off gear backlash adjustment
- Bleeding the fuel circuit
D0 – Transmission
- Checking the transmission oil level
- Changing the transmission oil
- Main clutch controls
- Engine clutch mount and thrust bearing
- Connector housing
- Gearbox input shaft and the oil seal
- Gearbox input shaft shoe adjustment
- Torsionally flexible coupling and flywheel
- Creeper or underdrive gear
- Primary shaft
- Complete transmission
- Internal gear controls
- Internal reverse shuttle controls
- Gear selector rod cover
- Internal creeper or underdrive controls
- Rear pinion (secondary shaft)
- Disassembling the secondary shaft (rear pinion)
- Adjustment of the bevel gear pair
- PTO hydraulic clutch adjustment
- PTO hydraulic clutch
- Disassembling the rear PTO hydraulic clutch
- Hydraulic pump drive
- Disassembling the power steering pump and ancillary pump carrier
- Adjusting power steering pump and ancillary pump carrier gear free play
- Rear PTO output shaft
- Rear PTO gears
E0 – Rear axle
- Draining oil from the rear crawler track final drive units
- Crawler track final drive unit cover
- Disassembling the crawler track final drive unit
- Crawler track final drive unit pinion
- Rear differential
- Disassembling the crawler track drive clutch
- Right hand crawler track final drive unit
- Left hand crawler track final drive unit
- Crawler track drive clutch
- Adjusting the brake band
- Disassembling the brake drum and brake band
- Disassembling the steering clutch piston
- Crawler track drive clutch – Clutch piston
- Brake actuator piston
- Disassembling the brake actuator piston
F0 – Front axle
- Front mount
G0 – Bodywork – Cab – Platform
- Engine hood and front hood panels
- Battery mount
- Lower hood guard
- Engine hood frame
- Engine hood mount
- Left hand mudguard
- Right hand mudguard
- Centre footboard
- Disassembling the platform
- Access steps
- Left hand console
- Right hand console
- Instrument cluster
- External rear view mirror
- Seat
- Clutch pedal
- Brake pedal
- Procedure for brake pedals adjustment
- Parking brake lever
- Grab rail
- Creeper or underdrive external controls
- Roll bar
H0 – Hydraulic system
- Auxiliary utilities hydraulic pump
- Disassembling the hydraulic ancillary pump
- Power steering pump
- Steering pumps
- Disassembling the steering pump
- Transmission oil filter
- Hydraulic circuit pressure holding valve
- Calibrating the hydraulic circuit pressure holding valve
- Hydraulic circuit pressure holding valve disassembly
- Transmission oil radiator
- Ancillary utility distributors
- Rigid ancillary utility pipes
- Removing the rigid ancillary utility pipes
- Utilities solenoid valve block
- Utilities solenoid valve block
- Steering levers
L0 – Electrical system
- Battery
- Alternator
- Engine wiring loom
- Electro-injector wiring loom
- Electro-injector wiring loom
- Preheat relay
- Engine ECU
- Charge pressure and air temperature sensor
- Coolant temperature sensor
- Crankshaft speed sensor
- Camshaft timing sensor
- Engine oil pressure switch
- Engine oil temperature sensor
- Fuel pressure and temperature sensor
- Fuel pressure sensor
- Water in fuel sensor
- Hydraulic utilities pressure switch
- Instrument panel
R0 – Rear lift
- Complete rear lift
- Disassembling the lift and the relative components
- Lift control valve
- Disassembling the lift distributor
- Rear lift cylinders
- Replacing the lift cylinder gaskets
- 3-point linkage
T0 – Tracks
- Front suspension (leaf spring)
- Driving sprocket
- Front idler wheel
- Crawler track carrier roller
- Idler wheels
- Track tensioner cylinder
- Track tensioner spring
- Undercarriage covers
- Opening/closing the track chain
- Complete undercarriage
- Track roller frame alignment
- Setting track chain tension
- Setting the tension of the rubber crawler tracks
V0 – Ballast – towing hitches
- Drawbar
- Front ballast
Wiring diagrams
Components
- Engine control unit
- MLHP Control Unit
- Seat safety ECU
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments
- F – External lights (rotating beacon)
- 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 – Engine governor system (4-cylinder version)
- S001B – Engine governor system (3-cylinder version)
- S002 – Preheating
- S003 – Activation and charging
- S004 – Lights
- S005 – Work lights
- S006 – Power take off (PTO)
- S007 – CAN line and diagnostics
- S008 – Instrument panel
- S009 – Distributors
Wiring harnesses
- 0.010.4795.3/10 – Distributor
- 0.011.7840.4 – Rotating beacon
- 0.021.1217.4 – Heater
- 0.023.1279.4/20 – Engine (3 cylinder version)
- 0.023.1280.4/20 – Engine – 4 cylinder version
- 0.023.1281.4 – Injectors (3 cylinder version)
- 0.023.1282.4 – Injectors – 4 cylinder version
- 0.024.2826.4/10 – Alternator – preheat
- 0.028.1600.4 – Battery negative
- 0.028.1601.4 – Control unit power supply
- 0.028.1605.4/10 – Battery – 3 cylinder version power supply
- 0.028.1604.4/20 – Front 4 cylinder version
- 0.028.1606.4/10 – Battery – 4 cylinder version power supply
- 0.028.1609.4/20 – Central wiring loom
- 0.028.1603.4/20 – Front, 3 cylinder version
- 0.028.1614.4 – Cowl lights
- 0.028.1615.4/20 – Rear wiring loom
- 0.028.1616.4 – H9 work lights
- 0.028.1617.4 – Led work lights
- 0.028.1619.4/20 – Roof
- 0.030.0561.4 – Power feed for platform, version without cab
- 0.030.0562.4 – Power feed for platform, version with cab
- 0.030.0563.4 – Bottom work lights fuse (2-pillar version)
- 0.030.0564.4 – Bottom work lights fuse (4-pillar version)
- 0.030.0567.4 – Cab roof lights controls
Service Info
D0 – TRANSMISSION
- PTO collar breakage
- Underdrive ball bearing breakage
T0 – CRAWLER TRACKS
- SERVICE NEWS – Front crosspiece p.n. 0.029.4843.2 – Improvement
- Oil leakage from crawler idler wheel
- Rubber track tensioning check
