Document overview
Workshop Manual PDF for DEUTZ FAHR 5100 → ZKDHZ40200TD50001, Series 5 (STAGE 5) family. Document language: English; 1,679 pages.
The corresponding English table of contents contains 46 sections and 565 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 (STAGE 5)
- Model: 5100
- Starting serial number: ZKDHZ40200TD50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,679
- File size: 763.88 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match DEUTZ FAHR 5100 → ZKDHZ40200TD50001.
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
- Introduction – Engines
- Cold start system (preheat glow plugs)
- Engine cooling system
- Engine intake system
- Engine injection system – low pressure circuit
- Exhaust backpressure, engine oil temperature
- Fuel injection system – Common Rail System
- Engine air intake system
- Turbocharging system
- Exhaust gas recirculation system (EGR)
- Exhaust aftertreatment system
- 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
Transmission
- Transmission
- Hydraulic reverse power shuttle
- HML unit
- Rear PTO
- Views of transmission
- PTO configurations
Rear axle
- Rear differential
- Rear axle
Front axle
- Front axle, 4WD – 4-planet gear differential
- Front axle, 4WD – size 2
- Steering cylinders
- Planetary reduction gearbox
Bodywork – Cab – Platform
- Main technical data
- Dimensions and weights of the tractor
- External views of the tractor
- Air conditioning system – Charging
- Viste interni cabina
- Front console and pillars (hydraulic reverse shuttle)
- Front console and pillars (mechanical reverse shuttle)
- Left hand console
- Right hand console (with mechanically controlled rear lift)
- Right hand console (with electronically controlled rear lift)
- Instrument panel
- Roof panel
- Ballast technical data
- Tow hitch carrier
- Drawbar
Hydraulic system
- Introduction to hydraulic circuit diagrams
- Hydraulic pumps unit
- 60 l/min. ECO AUX block
- Suction pump filter
- Power steering 160 cc
- SDD power steering
- Transfer pump
- 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
- Hydraulic distributor configurations
Front lift
- Front lift
Rear lift
- Mechanical rear lift
- Electronic rear lift
- Rear lift
- Rear 3-point linkage
Calibrations and electronic diagnosis
- ECUs
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
Diagnostic tool screens
- 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
- ECU ALARMS (Electronic SAC)
- SDF Severity of alarms
- ECU ALARMS (Mechanical SAC)
Software management
- ECUs firmware update
- Download Dataset FARMotion & Flash ECU
Method of intervention
B0 – Engine
- Complete engine
- Separating engine / transmission
- Tightening procedure for engine components
- Overhauling counter-rotating masses
- Adjusting oil pump gear backlash
- 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
- Turbocharger exhaust outlet flange
- 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
- Ancillary drive belt (version on machine)
C0 – Engine accessories
- 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
- Complete radiator-heat exchanger pack
- Compensation tank
- Fan
- Air filter
- Water radiator
- Intercooler
- Oil radiator
- Fuel radiator
- Intercooler, oil and fuel heat exchangers
- Fuel tank
- Fuel filter and prefilter (version on machine)
- Fuel filter and prefilter mounting bracket (version on machine)
- Starter motor (version on machine)
- Exhaust pipe (version on machine)
- Intermediate manifold (version on machine)
- AdBlue tank
- AdBlue pump
- Exhaust pipe mounting bracket
- Bleeding the fuel circuit
D0 – Transmission
- Draining and filling the transmission oil
- Separating front gearbox housing from rear gearbox housing
- Connector housing
- Gearbox/HML assembly
- Gearbox and HI-LO unit
- Input shaft assembly and tone wheel
- Engine torsional spring plate
- Disassembly of HI-LO unit output 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
- Hydraulic reverse shuttle unit
- Disassembling the shuttle unit
- Disassembling cover assembly
- Removing the forward drive clutch unit
- Disassembling the reverse drive clutch unit
- 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
- Disassembling the LO range clutch housing
- Disassembling the HI-LO planetary reduction gearbox
- 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 pumps
- Pump drive – External gear
- Pump drive PTO – internal gear
E0 – Rear axle
- Right-hand rear axle
- Bleeding the braking system
- Brake housing
- Disassembling the brake carrier (versions without Park Brake)
- Rear differential
- Removing rear differential
- Disassembling rear axle
F0 – Front axle
- Front axle
- Steering cylinders
- Disassembling the steering cylinder
- Front axle adjusting endfloat
- Support with front axle
- Steering bar/tie-rod
- Steering knuckle housing and half-shaft
- Adjustment of steering knuckle housing and axle shaft
- 4WD shaft
- Differential assembly
- Disassembling the differential assembly
- Differential assembly adjustment
- 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
- Disassembly of the planetary reduction gearbox
G0 – Bodywork – Cab – Platform
- Cab
- Engine hood and front hood panels
- Lower hood guard
- Battery mount
- Cab access steps
- Rear mudguard
- Roof panel
- Sunroof
- Cab filters
- Rear view mirrors
- Front turn indicator mount
- Cab mat
- Right hand console
- Front turn indicators
- Empty and charge the air conditioning system
- Dehydrator filter
- A/C unit
- Brake fluid reservoir
- Instrument cluster
- Instrument cluster
- Air conditioning condenser
- Air conditioning compressor
- Left hand side cab trim
- Right hand side cab trim
- Disassembling the hydraulic distributors levers
- Registration of the hydraulic distributors bowden cable
- Screen wash liquid reservoir
- Windscreen wiper motor
- Door frame
- Seat
- Air conditioner control unit
- 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
- Power steering pump
- Ancillaries and lift pump
- Supplementary pump
- Oil transfer pump
- Rear auxiliary utility distributor
- Disassembling the rear ancillary utility distributor
- Hydraulic trailer braking assembly
- AdBlue solenoid valve
- Hydrostatic steering (orbitrol)
- HML solenoid valve block
- Shuttle solenoid valves assembly
- Disassembling shuttle solenoid valve block
- Oil filter
- Resonator
- Brake system flow regulator valve
L0 – Electrical system
- Battery
- Alternator
- Work lights
- 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
- 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
- Charge pressure and air temperature sensor
- 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
R0 – Rear lift
- Complete rear lift
- Disassembling the lift cylinder
- Disassembling the rear lift
- Lift bushes
- Rear lift control distributor
- 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
- Checking and testing the mechanical rear lift
- Adjusting mechanical rear lift controls
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook
Wiring diagrams
Components
- OCU Control Unit
- 2.8519.301.0 – HLHP control unit, with electronically controlled lift
- 2.8519.148.0 – ECU ISO 11786
- 2.8519.302.0 – MLHP Control Unit
- CTM/AM55 Control Unit
- 2.8519.280.0 – Engine control unit
- Locations of main control units
- 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)
- S002 – Preheating
- S003A – Starting (mechanical rear lift)
- S003B – Starting (electronic rear lift)
- S004 – Lift
- S005 – Lights
- 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)
- S015 – Engine CAN line
- 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)
- S019 – Emissions
- S020A – Front loader (mechanically controlled rear lift)
- S020B – Front loader (electronically controlled rear lift)
- S021A – SDD (mechanically controlled rear lift)
- S021B – SDD (electronically controlled rear lift)
- S022 – Battery master switch
Wiring harnesses
- 0.011.3797.3 – SBA/ASM sensor
- 0.012.2756.3 – Front PTO solenoid valve
- 0.014.1567.4/20 – Front wiper motor – opening windscreen version
- 0.014.1645.4/10 – Pneumatic trailer braking pressure switch
- 0.014.1645.4/10 – Hydraulic trailer braking pressure switch wiring
- 0.014.8453.4 – Windscreen wiper (version with fixed windscreen)
- 0.015.1440.4 – Reverse shuttle wiring loom, 100 HP
- 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)
- 0.020.9462.4/10 – Flashing beacon cable
- 0.021.0490.4/10 – ABS socket for trailer
- Front lights and horn
- 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)
- 0.024.3509.4/10 – OCU control unit
- 0.024.8482.4/10 – Mechanically engaged front loader 1
- 0.025.1281.4/10 – HML front loader lever
- 0.025.5561.4 – Front lights
- 0.026.1301.4 – Mechanically engaged front loader 2
- 0.028.1207.4/20 – Pneumatic trailer braking system, Mother Regulation version (MR)
- 0.028.1208.4 – Ground wiring loom (AIR PREX)
- 0.029.7828.4 – Ground wiring loom (AIR PREX)
- 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)
- 0.033.8944.4/20 – LED TOP lights adapter
- 0.033.9905.4 – FM and DAB antenna
- 0.034.2047.4 – FM and DAB antenna amplifier
- 0.036.2342.4 – GS cab, electronically controlled rear lift
- 0.036.2437.4/10 – Front wiring loom (4 cylinder version)
- 0.036.2925.4 – Rear wiring loom, GS, electronically controlled rear lift
- 0.036.3073.4/10 – DPF sensor
- 0.036.3464.4 – Engine restart junction
- 0.036.4492.4 – Power cables (4 cylinder version)
- 0.036.4521.4 – Alternator – Preheat (4 cylinder version)
- 0.036.4523.4 – NOx sensor
- 0.036.4581.4 – Under-cowl sensors
- 0.036.4590.4 – Rear wiring loom, LS, electronically controlled rear lift
- 0.036.4593.4 – LS Cab, mechanically controlled rear lift
- 0.036.4594.4 – LS Cab, electronically controlled rear lift
- 0.036.4595.4 – GS cab, mechanically controlled rear lift
- 0.036.4596.4 – Rear wiring loom, GS, mechanically controlled rear lift
- 0.036.4597.4 – Rear wiring loom, LS, mechanically controlled rear lift
- 0.036.5978.4 – Right hand console (with electronic rear lift)
- 0.036.6318.4 – Hydraulic trailer braking (dual mode)
- 0.036.6400.4 – Hydraulic trailer braking pressure switch wiring
- 0.036.6401.4 – DM hydraulic trailer braking solenoid valve, Mother Regulation version (MR)
- 0.036.6533.4 – Roof
- 0.036.6567.4 – CTM antenna
- 0.036.6782.4 – H9 cab roof work lights
- 0.036.7358.4 – LED cab roof work lights
- 0.036.7414.4/10 – License plate light
- 0.036.7712.4 – DAB antenna
- 0.036.7766.4 – FM antenna
- 0.036.9463.4 – Front wiring loom (3 cylinder version)
- 0.036.9472.4 – Power cables (3 cylinder version)
- 0.036.9474.4 – Alternator – Preheat (3 cylinder version)
- 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
- Belt Tensioner FarMotion Engine
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- 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
L0 – ELECTRIC AL SYSTEM
- SERVICE NEWS – M334-M335-M430-M28-M427 New Engine SW release A09 (FarMotion Stage 5)
- 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
- Lost connection diagnostic tools
- PTO switch not working
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
