Document overview
Workshop Manual PDF for DEUTZ FAHR 5100.4 D TTV → ZKDEU80200TD50001, Series 5 D TTV (FARMOTION STAGE 3B) family. Document language: English; 1,628 pages.
The corresponding English table of contents contains 52 sections and 563 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 D TTV (FARMOTION STAGE 3B)
- Model: 5100.4 D TTV
- Starting serial number: ZKDEU80200TD50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,628
- File size: 632.66 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5100.4 D TTV → ZKDEU80200TD50001.
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
- Automatic tensioner
Engine accessories
- Starter motor
- Compensation tank
- Exhaust gas recirculation valve (EGR)
- Alternator
- Manual fuel pump
- Heater
- Fuel filter
- Fuel prefilter
- Air filter
- Coolant radiator
- Intercooler
- Fuel radiator
- Oil radiator
- Oil radiator thermostat valve
- Auxiliary fuel tank
- Fuel tank with front PTO
- Fuel tank – version without PTO
- Exhaust silencer – Catalytic converter (DOC)
Transmission
- CVT transmission
- Hydrostatic unit
Rear axle
- Rear axle FL
- Rear axle
Front axle
- Dual traction front axle (4WD)
- Dual traction front axle differential (4WD)
- Final drive
- Front brakes
Bodywork – Cab – Platform
- Air conditioning system
- Air conditioning system – Recharging
- Cab air conditioning system
- Air conditioning system compressor
Hydraulic system
- Steering, transmission and brake circuit, base version
- Auxiliary circuit, base version
- Steering, transmission and brake circuit
- Steering, transmission and brake circuit, with PTO
- Auxiliary circuit
- Auxiliary circuit, optional version
- Optional auxiliary circuit
- Full house hydraulic circuit
- Auxiliary hydraulic circuit, with OC pump
- Variable displacement pump LS 45 cc
- Trailer hydraulic braking valve
- Parking brake valve
Electrical equipment
- FARMotion engine sensors and components
- Engine intake air temperature sensor
- Air filter clogging pressure switch
- Speed sensor (pick-up)
- EGR valve
- Fuel level sensor
- Hall effect speed sensor
- Angle sensor ± 45°
- 11 Bar sensor
- Steering angle sensor
- Engine speed sensor (pickup)
- Pressure switch 0.4 – 0.7 bar
- Ambient Temperature Sensor
- Draft sensor (25 KN)
- Air filter clogged sensor
- Hall effect speed sensor
- Pressure sensor (40 bar)
- Angle sensor ± 60° (Active Drive)
- Angle sensor ± 60°
- Pressure and temperature sensor
- Oil pressure switch
- Timing sensor
- Fuel pressure sensor
- Coolant temperature sensor
- Pressure switch (15 Bar)
- Temperature sensor
- Filter clogging sensor 2.75 bar
- Single axis accelerometer
Rear lift
- Rear lift
- Rear lift distributor
Calibrations and electronic diagnosis
- ECUs
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- ECU Reset
- Vehicle model selection
- Distributors configuration
- Maximum vehicle speed
- Tyre type
- Measurement unit
- Language
- Front Power Take-Off (PTO)
- Hydraulic trailer brake
- ActiveDrive
- Cylinders
- Agrosky
- Steering Double Displacement (SDD)
- Isobus
- iMonitor
- ISO 11786
- eVisco fan
- PTO Syncro
- ASM
- Armrest
- CAT4 (air conditioning)
- Distributors command calibration neutral
- Clutch pedal calibration
- Slope sensor calibration
- Rear hitch position calibration
- Steering angle calibration
- ActiveDrive calibration
- Front suspension calibration
- Wheel Angle Sensor calibration
- Rear Power Take-Off (PTO) calibration
- Work reverse clutch calibration
- Hydrostatic unit calibration
- Reinitialising LOGIC BOX CAT4
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- Download Dataset FARMotion & Flash ECU
Method of intervention
B0 – Engine
- Tightening procedure for engine components
- Complete engine
- Separating engine from transmission
- Preliminary operations before removing engine from vehicle
- Engine flywheel
- Engine block-gearbox connector flange
- Torsionally flexible coupling
- EGR exhaust gas recirculation pipe
- Exhaust manifold
- Thermostat valve
- Checking the thermostat valve
- Turbocharger
- Turbocharger oil pipes
- 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
- Disassembling the cylinder heads
- Crankshaft pulley and tone wheel
- Crankshaft pulley
- 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
- Installing automatic belt tensioner
- Aligning water pump and crankshaft pulleys
- A/C compressor belt
C0 – Engine accessories
- High pressure fuel pump
- Mounting brackets
- Power take off gear backlash adjustment
- Replacing the coolant
- Fan
- Engine coolant radiator
- Complete exchanger assembly
- Compensation tank
- Intercooler and gearbox oil and fuel heat exchangers
- Air filter
- Rigid air filter pipe
- Fuel filter
- Fuel prefilter
- Bleeding the fuel circuit
- Diesel fuel tank
- Auxiliary fuel tank
- Starter motor
- Exhaust pipe
- DOC catalytic converter
D0 – Transmission
- Draining and filling the transmission oil
- Front gearbox from its rear part
- Front gearbox casing
- Separating the gearbox casing from the rear gearbox casing
- Centre gearbox casing
- Gearbox input unit
- Disassembling the gearbox input unit
- Hydrostatic unit
- 4WD shaft (in front gearbox casing)
- Disassembling the 4WD shaft (in front gearbox casing)
- WORK and TRANSPORT clutch-planetary reduction gearbox assembly
- Disassembling the variator input gear unit
- Disassembling the WORK and TRANSPORT planetary reduction gearbox
- Disassembling the WORK and TRANSPORT clutches
- Assembling variable transmission-reverse shuttle unit and determining correct shim thickness
- REVERSE planetary gear unit – cover and shaft
- REVERSE planetary gear unit cover – clutches and reduction gear unit
- Disassembling the REVERSE planetary gear unit – Cover and shaft
- Disassembling the REVERSE planetary reduction unit
- Hydraulic pump drive
- Determining correct shim thickness for pump drive tapered roller bearings and installing shims
- 4WD clutch and 4WD shaft in centre gearbox casing
- Disassembling 4WD shaft in centre gearbox casing
- Rear pinion casing
- Disassembling the rear pinion casing
- Positioning and shimming of rear bevel gear set and differential
- Rear PTO clutch
- Disassembling PTO engagement clutch
- Front PTO casing
- Disassembling the PTO casing
- Rear PTO drive shaft
- Rear PTO driven shaft
- Disassembling the PTO driven shaft
- Rear PTO selector lever
E0 – Rear axle
- Rear axle
- Park brake piston
- Right hand park brake unit
- Left hand park brake unit
- Disassembling the park brake unit
- Installing the park brake unit with pressurised system
- Rear differential lock control fork
- Rear differential
- Removing rear differential
- Bleeding the braking system
F0 – Front axle
- 4WD shaft (ACTIVE DRIVE)
- Carrier with front axle (Active Drive)
- Planetary reduction gearbox (Active Drive)
- Front axle (Active Drive)
- Complete knuckle assembly (Active Drive)
- Front steering tie-rod (Active Drive)
- Checking free play of front steering tie-rod (Active Drive)
- Damper (Active Drive)
- Adjusting end float (Active Drive)
- Steering cylinder (Active Drive)
- Steering knuckle housing and half-shaft (Active Drive)
- Replacing the elastic gaiters (Active Drive)
- Pinion-differential assembly (Active Drive)
- Differential lock (Active Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Front axle brake discs (Active Drive)
- Lower oscillating suspension arm (Active Drive)
- Checking free play of lower suspension knuckle (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Front axle lower ball joint assembly (Active Drive)
- Assembly and adjustment of front differential (Active Drive)
- Upper oscillating suspension arm (Active Drive)
- Complete front carrier
- Front axle
- Axial play adjustment
- Steering cylinders
- Disassembling the steering cylinder
- Complete steering knuckle housing
- Adjusting bearing preload
- Pinion-differential assembly
- Differential lock
- Differential locking device adjustment
- Disassembling the bevel gear set
- Disassembly of the differential
- Adjustment of the differential preload
- Adjusting pinion position
- Adjusting pinion/crown wheel backlash
- Adjusting pinion bearing preload
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Shim for wheel hub bearings
- Front brake discs
- Front axle brake piston
- Steering sensor actuator plate orientation
G0 – Bodywork – Cab – Platform
- Cab
- Cab access steps
- Engine hood and front hood panels
- Battery mount
- Cab mat
- Right hand console
- Left hand console
- Rear cab pillar covers
- Front cab pillar covers
- Instrument cluster
- Instrument cluster
- Roof panel
- Screen wash reservoir
- Rear screen
- Rear windscreen wiper motor
- Windscreen wiper motor
- Right hand cab door
- Right hand external cab door handle
- Right hand internal cab door handle
- Right hand cab door lock
- Left hand cab door
- Left hand external cab door handle
- Left hand internal cab door handle
- Left hand cab door lock
- Toolbox
- External rear-view mirrors
- Seat
- Empty and charge the air conditioning system
- Roof
- CAT2 – CAT4 cab filters
- Air conditioning compressor
- Park brake control
- Electronic foot throttle
- Disassembling the electronic throttle control
- Brake pedals
- Clutch pedal
- Steering column
- Steering wheel
- Steering column stalk
- Brake master cylinders
- Brake fluid reservoir
- Mudguard
H0 – Hydraulic system
- Transmission oil pump (16cc, RH)
- Hydraulic steering pump (11 cc, LH)
- Transfer pump (22.5 cc, LH)
- Load Sensing pump (45cc, RH)
- Oil delivery line filter
- Load Sensing oil pump filter
- Hydraulic power steering unit (Orbitrol)
- Accumulator block
- Front lift hydraulic system
- Front lift valve block
- Rear ancillary distributor
- Disassembling the rear ancillary utility distributor
- Front auxiliary utility distributor
- Pressure holding valve
- Radiator bypass valve
- Rear PTO block
- Hydraulic steering drain block
- Front brake pipe
- Solenoid valve unit
- Services solenoid valve assembly
- Fitment sequence for hydraulic pipes.
- Flow regulator valve
L0 – Electrical system
- Battery
- Alternator
- Electronic engine control unit (ECU)
- PFCU control unit
- SVCU and MVCU electronic control units
- Air filter clogged sensor
- Planetary reduction gearbox speed sensor
- Rear PTO speed selector switch
- Rear pinion speed sensor
- EASY-SHIFT 4WD shaft sensor
- Pump speed sensor
- Instrument panel
- Electronic unit
- Multifunction armrest
- Multifunction armrest
- 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
M0 – Front PTO
- Front power take off
- Disassembling PTO clutch
- Differential lock solenoid valve and front PTO
- Oil filter
N0 – Front lift
- Front lift assembly
R0 – Rear lift
- Replacing bushes
- Complete rear lift
- Rear lift distributor
- Disassembling the regulator distributor, with electronically controlled lift:
- 3-point linkage
S0 – Wheels
- Front Wheels
- Steering angle adjustment
- Rear wheel
V0 – Ballast – towing hitches
- Tow hook
V1 – AFTERMARKET KITS
- Aftersales pneumatic braking kit
Wiring diagrams
Components
- Locations of main ECUs
- Engine control unit
- MVCU “Main Vehicle Control Unit”
- SVCU “Secondary Vehicle Control Unit”
- PFCU “Precision Farming 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
Systems
- S001 – Power
- S002 – Activation and charging
- S003 – Preheating
- S004 – Engine control system
- S005 – Front lights
- S006 – Turn indicators
- S007 – Work lights
- S008 – Internal illumination and rotating beacon
- S009 – Wipers and horn
- S010 – Rear view mirror adjustment
- S011 – Radio
- S012 – Air conditioning
- S013 – Power sockets and accessories
- S014 – Rear lift
- S015 – Braking system
- S016 – Agrosky
- S017 – Gearbox
- S018 – PTO, differential lock and 4WD
- S019 – Stabilisers
- S020 – Front axle (ActiveDrive)
- S021 – AUX CAN line (basic version)
- S021 – AUX CAN line (full version)
- S022 – VEHICLE CAN line (basic version)
- S022 – VEHICLE CAN line (full version)
- S023 – DISTRIBUTORS CAN line
- S024 – AUTOGUIDANCE CAN line
- S025 – ENGINE CAN line
- S026 – ISOBUS
- S027 – Instrument cluster
- S029 – Distributors (Power beyond)
- S030 – ABS
Wiring harnesses
- 0.007.7899.3 – Front PTO solenoid valve
- 0.007.7899.3 – Front differential locking solenoid valve
- 0.014.1567.4/30 – Front wiper motor – opening windscreen version
- 0.017.8425.4/10 – Trailer socket
- 0.018.2800.4 – Hydraulic trailer braking
- 0.018.4630.4/10 – SBA/ASM sensor
- 0.019.2571.4/10 – ISO 11786
- 0.019.8827.4 – SDD (rapid steer system)
- 0.020.9462.4/10 – Rotating beacon
- Video camera cables
- 0.021.0490.4/10 – Trailer ABS
- 0.021.1217.4 – Heater
- 0.023.1279.4/20 – Engine (3 cylinder version)
- 0.023.1280.4/20 – Engine (4 cylinder version)
- 0.023.1281.4/10 – Injectors (3 cylinder version)
- 0.023.1282.4/10 – Injectors (4 cylinder version)
- 0.023.2616.4/20 – Front axle solenoid valves (version with ActiveDrive)
- 0.024.2826.4/10 – Alternator – preheat
- 0.025.9259.0 – Pressure switch on delivery line filter
- 0.026.6240.4/10 – Hydrostatic unit
- 0.026.6605.4 – Electric steering system (Agrosky)
- 0.027.7652.4 – Cowl
- 0.028.5244.4/10 – Cab roof work lights
- 0.028.5246.4/40 – Roof
- 0.028.5305.4/10 – Battery cables (negative)
- 0.028.5306.4/30 – Battery cable (positive)
- 0.028.5334.4/20 – Front wiring loom
- 0.028.5352.4/10 – Front axle (version with ActiveDrive)
- 0.028.5380.4/30 – Rear wiring loom
- 0.028.5381.4/40 – LH
- 0.028.5382.4/30 – RH
- 0.028.5490.4 – Rear-view mirrors
- 0.028.6140.4/50 – Cab
- 0.028.8817.4/30 – “Plus”
- 0.028.8818.4/50 – “Full” Cab
- 0.028.8819.4/20 – Optional LH
- 0.029.1625.4 – Wiring harness for cab roof working lights (LED)
- 0.029.5346.4 – Electrohydraulic steering (Agrosky)
- 0.029.5651.4/30 – ISOBUS 11783
- 0.029.7644.4/20 – Agrosky SGR1 Aerial
- 0.029.7649.4/20 – iMonitor X25
- 0.029.8764.4 – “TOP” lights
- 0.030.2414.4/30 – RH optional (Power beyond)
- 0.030.3692.4 – Distributors 1-5
- 0.032.8846.4 – Shock-absorber sensors (version with ActiveDrive)
- 0.033.0001.4/10 – CTM + ETHERNET
- 0.033.0736.4 – AGI 2 antenna
- 0.033.0899.4 – AGI2 antenna cable
- 0.033.4620.4/10 – ASM 2 LT
- 0.033.4758.4/10 – ASM 1 RH
- 0.033.7176.4 – Armrest Ethernet wiring loom
- 0.033.8944.4 – TOP LED lights adapter
- 0.034.2417.4 – Provision for ABS
- 0.035.2304.4 – Rear road lights
- 0.035.2349.4/10 – License plate lights
- 04422324.4/10 – ISO 11786 socket
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
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Deutz AG engine oil specifications
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
- Oil Leakage From Active Drive
D0 – TRANSMISSION
- Wrong dimension on RPTO stub shaft 21 splines 1-3/8″
- PTO gearshift lever pin loosing
F0 – FRONT AXLE
- Active Drive Cylinder Malfunction and Cold Start issue
- Bevel gear set loosing screws
- Front Axle Bearing damage on slope condition
- Check the front axle steering knuckles for wear
- Active Drive rubber boot breakage
- Steering behavior check procedure
- Adjusting Active Drive front axle toe-in
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- BRAKE PUMP INTERNAL LEAKAGE
- 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
- Inaccurate steering during road driving
- Error Code SPN 629 FMI 12
- Possible streching or crushing of the front brake oil pipe assembly
- EHS1 control valve blocked
- Seal ring breakage
L0 – ELECTRIC AL SYSTEM
- SERVICE NEWS – Software package release 2026-02
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- SerDia4.0
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- Bad visualizazion of wiring diagram on technical documentaion
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- iMonitor software HORIZON 5.02
- Lost connection diagnostic tools
- iMonitor SW upgrade
- M10 & M11 check procedure
- PTO switch not working
R0 – REAR LIFT
- Hydraulic lateral stabilizer 0.007.3680.4/50 Stabilizer + 0.015.2791.3 Terminal
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
