Document overview
Digital Workshop Manual documentation for model DEUTZ FAHR 5100 DF → ZKDLU702W0TD50001 from the Series 5 DF (FARMOTION STAGE 5) family. Language: English; 1,105 pages.
The corresponding English table of contents contains 49 sections and 434 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 DF (FARMOTION STAGE 5)
- Model: 5100 DF
- Starting serial number: ZKDLU702W0TD50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,105
- File size: 435.22 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5100 DF → ZKDLU702W0TD50001.
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 and exhaust gas after-treatment systems – KF stage 5 engine
- Technical data, rockers – tappets
- Technical data and dimensions: valves – valve springs
- Technical data and dimensions: heads – valve guides – valve seats
- Technical data: counter-rotating masses
- Technical data: timing system gears
- Camshaft technical data
- Technical data: Connecting rods
- Technical data: pistons – piston rings
- Technical data: crankshaft
- Technical data: cylinder block
Engine accessories
- Starter motor
- Compensation tank
- Fuel tank with front PTO
- Fuel tank – version without PTO
- Fuel filter
- Fuel prefilter
- Air filter
- Coolant radiator
- Intercooler
- Fuel radiator
- Oil radiator
- Oil radiator thermostat valve
- Fuel tank
- AdBlue tank
- AdBlue solenoid valve
- AdBlue injector
- AdBlue pump
- AdBlue float sensor
- Exhaust silencer – Catalytic converter (DOC)
- DPF and SCR catalytic converter
Transmission
- Gearbox and shuttle assembly
- Dual clutch unit
- HML unit
- Gearbox assembly with HML
- Hydraulic reverse power shuttle
Rear axle
- Rear differential
- Rear axle
Front axle
- Pinion, differential and differential lock
- Differential unit
Bodywork – Cab – Platform
- Internal views of ROPS
- External views of the tractor
- Access to the driver seat
- Instrument panel
- Right hand console
- Dashboard
- Left hand console
Hydraulic system
- STEERING/TRANSMISSION pump (11 cm³)
- LIFT/REMOTE VALVES pump (14+11 cm³)
- STEERING/TRANSMISSION pump (16 cm³)
- LIFT/REMOTE VALVES pump (22.5 cm³)
- Electronic lift control valve
- 6-way remote control valve
- Base hydraulic circuit diagram
- Optional hydraulic circuit 1
- Optional hydraulic circuit 2
- Base hydraulic circuit, GS transmission
- Optional hydraulic circuit 3, GS
- Optional hydraulic circuit 4, LS
- Optional hydraulic circuit 5, GS
- Optional hydraulic circuit 6, LS
- Optional hydraulic circuit 7, GS
- Optional hydraulic circuit 8, LS
Calibrations and electronic diagnosis
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- Cluster configuration
- Optionals
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- On-board instruments (Cluster/Display) flashing
Method of intervention
B0 – Engine
- Front timing cover
- Alternator, water pump and A/C compressor belt
- Installing automatic belt tensioner
- Counter-rotating masses
- Crankshaft pulley
- Disassembling pistons and connecting rods
- Oil sump
- Oil pump
- Coolant manifold
- Engine coolant pump
- Oil heat exchanger
- A/C compressor belt
- Aligning water pump and crankshaft pulleys
- Adjusting oil pump gear backlash
- Tightening procedure for engine components
- Adjusting oil pump gear backlash
- Aligning water pump and crankshaft pulleys
- Adjusting PTO gear backlash
- Test of the thermostat valve
- Engine block-gearbox connector flange
- Cooling jets
- Engine flywheel
- Belt tensioner mounting plate.
- Automatic belt tensioner
- Air compressor belt
- Ancillary utility belt
- Crankshaft pulley and tone wheel
- Crankshaft pulley complete with tone wheel
- Crankshaft
- Disassembling pistons and connecting rods
- Cylinder sleeves
- Power take off drive
- Front timing cover
- Rear flange
- Cylinder head covers
- Pushrods
- Cylinder heads
- Intermediate gear and timing
- Disassembling the cylinder heads
- Engine oil and filter
- Turbocharger oil pipes
- Blow-by filter
- Blow-by oil vapour pipe
- Oil sump
- Oil pump
- Oil vapour pipe
- Electro-injectors and common rail
- Thermostat valve
- Coolant manifold
- Oil heat exchanger
- Engine coolant pump
- EGR exhaust gas recirculation pipe
- EGR exhaust gas cooling pipe
- EGR manifold
- Disassembly of the EGR manifold
- Exhaust gas pressure line
- Exhaust manifold
- Intake manifold
- Turbocharger
- Mass air flow sensor
- EGR valve
- AdBlue injector
- NOx sensor
- DOC outlet side exhaust temperature sensor
- DOC inlet side exhaust temperature sensor
- Exhaust gas pressure sensor
- Throttle valve actuator
- Alternator
- Boost pressure sensor and air temperature sensor
- Mass air flow sensor
- Crankshaft speed sensor
- Camshaft timing sensor
- Engine oil pressure switch
- Coolant temperature sensor
- Engine oil temperature sensor
- Fuel pressure sensor
- Water in fuel sensor
- Engine – separation from the transmission
C0 – Engine accessories
- Engine fan
- High pressure fuel pump
- Electric starter motor
- DOC catalytic converter
- Air filter
- Diesel fuel tank
- AdBlue tank
- Drain pipe
- SCR
- Alternator mount
- Transverse plate
- Mounting brackets
- Fuel pump
- Fuel prefilter
- Fuel filter
- Filter mounting plate
- High pressure fuel pump
- Glow plug
- Preheat relay
- Starter motor
- Exhaust pipe
- DOC outlet side exhaust flange
- DOC inlet side exhaust flange
- DOC exhaust silencer
- Air compressor
- Replacing the coolant
- Compensation tank
- Bleeding the fuel circuit
D0 – Transmission
- Planet gear support unit – HML unit
- Complete gearbox assembly
- Disassembly of the main shaft
- Disassembling the secondary shaft
- Disassembling the gearbox input shaft
- Adjusting differential – bevel gear set
- Rear pinion casing
- Rear pinion
- Sprocket
- Adjusting the bevel gear set
- Differential – Bevel gear set
- PTO output shaft (2 speed version and groundspeed version)
- PTO input shaft
- PTO input shaft disassembly
- SYNCRO ground speed PTO drive shaft
- Rear PTO drive shaft
- Disassembling the rear PTO drive shaft
- PTO input shaft
- PTO output shaft (2 speed + ground speed)
- PTO output flange shaft, 2 speed version
- PTO output shaft
- Ground speed P.T.O. control shaft
- PTO output shaft
- Reverse shuttle and range control cover.
- Hydraulic reverse shuttle
- Disassembly of shuttle assembly
- Assembly of the gearbox forks
- Assembly of the HI-LO unit in the front gearbox housing
- Assembly of PTO output shaft ring nut
- HML unit assembly in the front gearbox
- 4WD shaft
- Changing the transmission oil
- Separating the clutch housing from the transmission
- PTO control clutch
E0 – Rear axle
- Rear axle
- Removing right/left hand rear axle
- Disassembling rear axle
- Right-hand rear axle
- Left-hand rear axle
- Disassembling the planetary gear unit
- Planet gear carrier
- Removing the rear differential
- Differential lock selector fork
- Rear differential
- Rear axle brake piston
- Brake carriers
- Replacing the friction shoes
- Rear axle brake discs
- Bleeding air from the hydraulic brake system
- Rear axle (version with wheel bolts)
F0 – Front axle
- Support with rear axle
- Axial play adjustment
- Pinion-differential assembly
- Disassembly of the differential
- Bevel gear pair
- Adjustment of the pinion position and bearing preloading
- Steering cylinders
- Complete steering knuckle housing
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Disassembling the bevel gear set
- Front axle (4WD)
- Adjusting bearing preload
- Front axle brake discs
- Front axle brake piston
- Front axle (Active Drive)
- Complete front carrier (Active Drive)
- Damper (Active Drive)
- Lower oscillating suspension arm (Active Drive)
- Upper oscillating suspension arm (Active Drive)
- Front steering tie-rod (Active Drive)
- Complete knuckle assembly (Active Drive)
- Differential lock (Active Drive)
- 4WD shaft (Active Drive)
- Steering cylinder (Active Drive)
- Planetary reduction gearbox (Active Drive)
- Steering knuckle housing and half-shaft (Active Drive)
- Front axle brake discs (Active Drive)
- Checking free play of front steering tie-rod (Active Drive)
- Checking free play of lower suspension knuckle (Active Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Replacing the elastic gaiters (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Adjusting end float (Active Drive)
- Front axle lower ball joint assembly (Active Drive)
- Assembly and adjustment of front differential (Active Drive)
- Carrier with front axle (Active Drive)
G0 – Bodywork – Cab – Platform
- External rear view mirrors
- Driver seat
- Hand throttle control lever
- Throttle pedal
- Engine hood and front hood panels
- Platform
- Access ladders
- Mudguard
- Right hand console
- Gear lever control
- Roll bar
- Roll bar
- Dashboard
- Steering wheel
- Battery
- Shuttle lever
- Side panels
- Mudguards
- Electrohydraulic distributor lever
H0 – Hydraulic system
- Oil filter
- Hydrostatic steering (orbitrol)
- Brake control valve
- Hydraulic braking solenoid valve
- Electrohydraulic distributor
- Mechanical distributor
- Hydraulic steering pump (11 cc, LH)
- Load Sensing oil pump filter
L0 – Electrical system
- Battery
- Alternator
- Speed sensor
- FARMotion engine sensors
- Sensors and components of the FARMotion engine exhaust system
- FARMotion engine components
- Engine wiring loom
- Electro-injector wiring loom
- Preheat glow plug wiring loom
M0 – Front PTO
- Front power take-off
- Disassembling PTO clutch
N0 – Front lift
- Front lift
R0 – Rear lift
- Hitch control distributor
- Disassembling the lift control distributor
- 3-point linkage
- Complete rear lift
S0 – Wheels
- Front Wheels
- Rear wheel
- Rear wheel (version with bolts)
V0 – Ballast – towing hitches
- Tow hook sled
- Drawbar
- Rear tow hitch
Wiring diagrams
- W-TECH – ELECTRICAL SECTION
Components
- Location of ECUs
- Engine Control unit
- AD-BLUE SUPPLY MODULE
- Rear lift control unit
- MVCU 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
- S001 – Electronic engine throttle
- S002 – Preheating
- S003 – Starter
- S004 – Lights
- S006 – Transmission
- S007 – PTO
- S008 – CAN line and diagnostics
- S009 – Engine CAN line
- S010 – Braking system
- S011 – Trailer brake
- S012 – Emissions control system
- S013 – Battery master switch
- S014 – Sockets and accessories
Wiring harnesses
- 0.011.7840.4 – Rotating beacon
- 0.013.6326.4 – ROPS rotating beacons
- 0.013.6327.4 – Rotating beacon socket
- 0.015.0070.4 – Solenoid valve
- 0.016.0314.4_10 – 4V PTO
- 0.016.0316.4_10 – 3V PTO
- 0.017.8425.4/10 – Trailer socket
- 0.021.0490.4/10 – TRAILER ABS
- 0.021.4505.4 – PTO 540_750 wiring loom
- 0.023.1281.4/10 – Injectors (3 cylinder version)
- 0.023.1282.4_10 – Injectors (4 cylinder version)
- 0.027.5538.4 – License plate light
- 0.027.7652.4/10 – Cowl
- 0.030.6479.4 – Engine, 3-cylinder version
- 0.030.6480.4/10 – Engine, 4-cylinder version
- 0.032.5468.4/10 – Glowplugs (3 cylinder version)
- 0.032.5469.4_10 – Glowplugs (4 cylinder version)
- 0.036.0966.4 – Junction terminal board
- 0.037.0995.4 – Preheating
- 0.046.2781.4/10 – Power cables
- 0.046.2782.4_10 – Platform power feed
- 0.046.2783.4/10 – Front wiring loom
- 0.046.2784.4/10 – Rear wiring loom, Basic version
- 0.046.2802.4 – Battery negative
- 0.046.2803.4/10 – Rear wiring loom, OPT version
- 0.046.2805.4 – Central wiring loom
- 0.046.2804.4 – Rear, GS
- 0.046.2806.4 – Power feed unit
- Wiring looms
- Wiring looms – EPA Version
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
- After-sales 2024 subscription
- After-sales 2023 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Belt Tensioner FarMotion Engine
C0 – ENGINE ACCESSORIES
- M339 error code on FarMotion Stage 5 models
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
- Oil Leakage From Active Drive
D0 – TRANSMISSION
- RANGE LEVER KNOB BREAKAGE
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Front Axle Bearing damage on slope condition
- Active Drive rubber boot breakage
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
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
- Possible streching or crushing of the front brake oil pipe assembly
L0 – ELECTRIC AL SYSTEM
- CTM MALFUNCTION ON FRUTTETO PLATFORM GS/LS STAGE V
- SERVICE NEWS – M334-M335-M430-M28-M427 New Engine SW release A09 (FarMotion Stage 5)
- SerDia4.0
- REAR LIFT SELF-LOCKING
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- Lost connection diagnostic tools
- PTO switch not working
R0 – REAR LIFT
- Dust from the transmission Breather on Frutteto Platform LS St.5 with Mechanical SAC
- 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
