Document overview
Digital Workshop Manual documentation for model DEUTZ FAHR 5100 G → ZKDDM00200TD10001 from the Series 5 G (FARMOTION STAGE 4) family. Language: English; 1,699 pages.
The corresponding English table of contents contains 51 sections and 503 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 (FARMOTION STAGE 4)
- Model: 5100 G
- Starting serial number: ZKDDM00200TD10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,699
- File size: 451.07 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5100 G → ZKDDM00200TD10001.
Complete table of contents
Introduction
- Tightening Torques
- Pump tightening torques
- Wheel rim to hub screws and nuts 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
Transmission
- Transmission
- Mechanical clutch assembly
- Four-wheel drive electrohydraulical engagement and parking brake assembly
- Rear PTO
- Views of transmission
Rear axle
- Rear differential
- Rear axle
- Rear axle
Front axle
- Front axle, 4WD – 4-planet gear differential
- Front axle, 4WD – size 1.5
- Front axle 2WD
- Steering angle sensor (version with SDD)
Bodywork – Cab – Platform
- Air conditioning system – Version with Standard Roof
- Air conditioning system – High Visibility Version
Hydraulic system
- Introduction to hydraulic circuit diagrams
- Transmission hydraulic circuits
- Auxiliary utility hydraulic circuits
- Hydraulic pumps unit
- Transfer pump
- 60 l/min. ECO AUX block
- Suction pump filter
- Delivery line filter
- Power steering 160 cc
- SDD power steering
- Distributor unit
- Braking system
- Master cylinder
- Separate-Brakes valve
- Bistable valve block
- Brake logic block
- Trailer braking valve
- Priority valve
- Three-stage module control block (HML)
- Pressure regulator valve unit
- Service valve unit
- Shuttle control unit
- Rear PTO
Electrical equipment
- FARMotion engine sensors and components
- FARMotion engine sensors and components
- FARMotion engine sensors and components
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Mechanical rear lift
- Electronic rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- ECUs
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- ECU Reset
- Set vehicle model
- Cluster configuration
- Measurement unit
- Power Shuttle
- Range
- 4^ gear
- Speed matching
- Four-Wheel Drive (4WD)
- Front Power Take-Off (PTO)
- ISO 11786
- Pneumatic trailer brake
- Hydraulic trailer brake
- Steering Double Displacement (SDD)
- Clutch pedal calibration
- Rear hitch position calibration
- PowerShuttle calibration
- PowerShuttle acceleration
- PowerShuttle balance
- PowerShuttle readiness
- PowerShuttle pedal
ECU alarms
- SDF Severity of alarms
- ECU ALARMS (Electronic SAC)
- ECU ALARMS (Mechanical SAC)
Software management
- Download Dataset FARMotion & Flash ECU
- ECUs firmware update
Method of intervention
B0 – Engine
- Workshop tools for engine removal and reassembly
- Tightening procedure for engine components
- Complete engine
- Engine- separation from the transmission
- Preliminary operations before removing engine from vehicle
- 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
- Checking the 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
- Blow-by oil vapour pipe
- Pushrods
- Cylinder heads
- Disassembling the 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
- Adjusting oil pump gear backlash
- Cooling jets
- Cylinder sleeves
- Installing automatic belt tensioner
- Cylinder head covers
- 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
- 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 the fuel circuit
- Manual fuel pump
- Fuel tank
- Electric starter motor
- Exhaust silencer
- Return line
- Intake throttle valve (TVA)
- AdBlue pump module
- AdBlue metering module
- AdBlue tank
- 2-way AdBlue solenoid valve
D0 – Transmission
- Draining and filling the transmission oil
- Gearbox/HML assembly
- Gearbox and HI-LO unit
- Separating connector flange from rear gearbox housing
- Clutch plate
- Clutch thrust bearing
- Disassembly of HI-LO unit output shaft
- Disassembling the reverse shuttle shaft
- Primary shaft
- Disassembly of the main shaft
- Secondary shaft – Version with HI-LO
- Disassembly of secondary shaft – Version with HI-LO
- Output shaft – Version with 3-stage module (HML)
- Disassembling the secondary shaft – Version with HI-LO or HML
- Adjustment of the differential – Bevel gear set
- PTO input shaft – 2 speed version
- Disassembling the PTO input shaft – 2 speed version
- PTO input shaft 4 speed version
- Disassembling the PTO input shaft 4 speed version
- PTO output shaft – 4 speed version
- Groundspeed PTO shaft
- DT shaft in transmission
- Disassembly of dual traction clutch – Easyshift with mechanical park brake
- 4WD engagement device – Easyshift
- Parking brake disc sectors
- Gearbox internal cover
- HI-LO unit
- Disassembling the LO range clutch housing
- Disassembling the HI-LO planetary reduction gearbox
- HML unit
- Disassembling the HML unit
- Disassembling the H clutch
- Disassembling M-L clutches
- Replacing the L clutch
- Disassembly of the HML planetary reduction gearbox
- Outer HML casing
- Gear selector assembly
- Gear selector rod
- Range selector assembly
- Disassembling the range selector assembly
- Range reduction gear shaft – 2 range version
- Range reduction gear shaft – 4 range version
- Rear pinion – 2-range version
- Rear pinion – 4-range version
- PTO engagement clutch
- Disassembling PTO engagement clutch
- Hydraulic pump drive
- Pump drive PTO – External gear
- Pump drive PTO – internal gear
E0 – Rear axle
- Bleeding the braking system
- Rear differential
- Removing rear differential
- Right-hand rear axle
- Left-hand rear axle
- Rear axle crown wheel
- Removing right/left hand rear axle
- Park Brake assembly
- Park Brake unit disassembly
- Brake carrier
- Disassembly of the brake carrier
F0 – Front axle
- Front axle (4WD)
- 4WD shaft
- Steering bar/tie-rod
- Differential assembly
- Disassembling the differential assembly
- Disassembly of the differential
- Differential assembly adjustment
- Steering cylinders
- Removing steering cylinders
- Adjustment of the bevel gear set
G0 – Bodywork – Cab – Platform
- Cab
- Cab access steps
- Engine hood and front hood panels
- Lower hood cover
- Battery mount
- Mudguard
- Cab mat
- Right hand console
- Left hand side cab trim
- Right hand side cab trim
- Disassembling the hydraulic distributors levers
- Registration of the hydraulic distributors bowden cable
- Instrument cluster
- Instrument cluster
- Roof panel
- Screen wash liquid reservoir
- Windscreen wiper motor
- Roof hatch
- Door frame
- Cab roof
- Anti-pollen filter
- External rear view mirrors
- Seat
- Empty and charge the air conditioning system
- A/C unit
- Air conditioner control unit
- Air conditioning compressor
- Air conditioning condenser
- Dehydrator filter
- Air conditioner evaporator
- Heating radiator – Version with air conditioning
- Motor with fans
- Expansion valve
- Anti-icing sensor
- Throttle pedal
- Disassembling the electronic throttle control
- Brake pedals
- Steering column
- Steering wheel
- Brake master cylinders
- Replacing the Bowden cable of the parking brake
H0 – Hydraulic system
- Lift pump
- Power steering pump
- HML solenoid valve block
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Oil filter
- Resonator
- Hydrostatic steering (orbitrol)
- 6-rear way ancillary utility distributor
- Brake system flow regulator valve
- Services solenoid valve assembly
- Disassembling the ancillary solenoid valve block
L0 – Electrical system
- Battery
- Alternator
- Electronic engine control unit (ECU)
- HLHP Ancillary utility electronic control unit
- Urea electronic control unit (DCU)
- Clutch pedal potentiometer
- Start enable switch
- Reverse shuttle speed sensor
- 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 cluster
- Button panels
- Ignition switch barrel
- Battery master switch
- 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
- Headlights
- Work lights
M0 – Front PTO
- Front power take-off
- Disassembling the front PTO
- Disassembling the front PTO control clutch
- Solenoid valve block
- Front PTO input shaft
N0 – Front lift
- Front lift
- Front lift hydraulic system valve
- Front lift hydraulic cylinders
R0 – Rear lift
- Complete rear lift (SAC)
- Disassembling the complete rear lift (SAC)
- Lift bushes
- Rear lift control distributor
- 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
- Mechanical rear lift troubleshooting
- Electronic rear lift troubleshooting
- Checking and testing the mechanical rear lift
- Adjusting mechanical rear lift controls
- Rear lift draft rod replacement
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook
V1 – AFTERMARKET KITS
- Pneumatic brake kit – P/N 9.DK589.91.0
Wiring diagrams
Introduction
- Introduction
- Basic electronics for mechanics (1/2)
- Basic electronics for mechanics (2/2)
- Electrical and electronic components (1/2)
- Electrical and electronic components (2/2)
Components
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Wiring connectors
- E – On-board instruments
- F – External lights (rotating beacon)
- G – Interior lights
- H – Electrical controls
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices
- N – Electric motors and actuators
- O – Resistors and diodes
- P – Various services
- R – Diagnostics
Systems
- S001A – Electronic engine throttle (version for mechanical rear lift)
- S001B – Electronic engine throttle (version for electronic rear lift)
- S002A – Preheat, mechanical rear lift
- S002B – Preheat (electronically controlled rear lift)
- S003A – Starting (electronically controlled rear lift)
- S003B – Starting (mechanically controlled rear lift)
- S004 – Lift
- S005A – Lights (mechanically controlled rear lift)
- S005B – Lights (version for electronic rear lift)
- S006A – Work lights (version for electronically controlled lift)
- S006B – Work lights (version for mechanically controlled lift)
- S007A Wipers (version for electronically controlled rear lift)
- S007B – Wipers (version for mechanically controlled rear lift)
- S008A – Instrument cluster (electronically controlled rear lift)
- S008B – Instrument cluster (mechanically controlled rear lift)
- S009 – Radio system
- S010 – Air conditioning system
- S011A – Transmission (version for electronically controlled rear lift)
- S011B – Transmission (version for mechanically controlled rear lift)
- S012A – PTO (version for electronically controlled lift)
- S012B – PTO (version for mechanically controlled lift)
- S013A – Accessories (mechanically controlled rear lift)
- S013B – Accessories (version for electronically controlled rear lift)
- S014A – CAN network (version with mechanical lift)
- S014B – CAN relay (version with electronically controlled rear lift)
- S015 – Engine CAN line
- S016A Braking system (version for electronic rear lift)
- S016B – Braking system (version for mechanical rear lift)
- S017A – Trailer brake (version for mechanical rear lift)
- S017B – Trailer brake (version for electronic rear lift)
- S018A – Eco Saving (version with electronic lift)
- S018B – Eco saving (version with mechanical lift)
- S019 – Emissions
- S020A – Front loader (version for mechanically controlled lift)
- S020B – Front loader (version for electronically controlled lift)
- S021A – SDD (version for electronic lift)
- S021B – SDD (version for mechanical lift)
- S022A – Battery master switch (version for mechanical rear lift)
- S022B – Battery master switch (version for electronic rear lift)
Wiring harnesses
- Wire colour reference table
- 0.011.3797.3 – SBA sensors
- 0.012.2756.3 – Front PTO
- 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 – Front wiper motor – fixed windscreen version
- 0.016.1001.4/20 – Hydraulic trailer braking
- 0.021.1196.4/10 – Low work lights
- 0.018.5346.4 – Distributor 7-8
- 0.019.5702.4/10 – ISO port kit
- 0.019.8827.4 – SDD
- 0.020.6706.4/40 – Roof panel
- 0.020.8203.4/10 – Cab roof work lights
- 0.020.9462.4/10 – Flashing beacon cable
- 0.021.1217.4 – relay – heater
- Front lights and horn
- 0.021.4309.4 PTO
- 0.021.4310.4 – PTO “Mushroom”
- 0.021.4505.4 – PTO 540/750 wiring loom
- 0.023.1279.4/20 – Engine – 3 cylinder version
- 0.023.1280.4/20 – Engine
- 0.023.1281.4 – Injectors – 3 cylinder version
- 0.023.1282.4 – Injectors
- 0.023.3110.4/10 – DCU metering module
- 0.023.3353.4/10 – Front wiring loom
- 0.023.3418.4 – Front, 3 cylinders
- 0.024.1788.4/10 – Power cables
- 0.024.2826.4 – Alternator – preheat
- 0.024.3458.4 – Right hand console
- 0.024.3509.4/10 – OCU control unit
- 0.024.3753.410 – Rear, for mechanical reverse shuttle and electronically controlled lift
- 0.024.4167.4/10 – Rear, for version with mechanical reverse shuttle and mechanically controlled lift
- 0.024.4172.4 – Cab, for mechanical reverse shuttle and mechanically controlled lift
- 0.024.8482.4.10 – Front loader
- 0.025.1281.4 – Wiring loom for front loader
- 0.025.3466.4 – RH headlight, Europe
- 0.025.3467.4 – LH headlight, EUROPE
- 04422324.410 – ISO 11786
- 2.7659.368.0/30 – Battery isolator switch
- 2.8059.562.0 – LH headlight, USA
- 2.8059.563.0 – RH headlight, USA
- 0.026.1301.4 – Wiring loom for front loader
- 0.026.4751.4 – Override button wiring loom
- 0.024.3750.4 – Cab, for mechanical reverse shuttle and electronically controlled lift
- 0.027.8546.4_20 – Cab, for hydraulic reverse shuttle and electronically controlled lift
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
- After-sales – 2018 subscription
B0 – ENGINE
- FARMotion seal ring leakage
- Deutz AG engine oil specifications
- Engine sealing ring leakage
C0 – ENGINE ACCESSORIES
- SERVICE NEWS – DEF Unit – Wrong level indication
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Alarm M352 or DEF level unit does not indicate the correct DEF level (No EPA)
- AdBlue Float level unit
- Farmotion high pressure pipe replacement
- SCR AREA DAMAGED SENSORS
- ERROR M426 – SCR system efficiency
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
- Mechanical rear lift control levers
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
