Document overview
Workshop Manual for HURLIMANN XA 100 SPIRIT → ZKDKF90200BH50001 from the XA SPIRIT (STAGE 5) family. Digital PDF in English with 919 pages.
The corresponding English table of contents contains 45 sections and 377 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: HURLIMANN
- Family: XA SPIRIT (STAGE 5)
- Model: XA 100 SPIRIT
- Starting serial number: ZKDKF90200BH50001
- Document type: Workshop Manual
- Language: English
- Pages: 919
- File size: 352.48 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XA 100 SPIRIT → ZKDKF90200BH50001.
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
Engine accessories
- Starter motor
Transmission
- Transmission
- Four-wheel drive electrohydraulical engagement and parking brake assembly
- Hydraulic reverse shuttle
- HI-LO unit
- Rear PTO
- Hydraulic reverse power shuttle
Rear axle
- Brakes and rear axle assembly
- Differential unit
Front axle
- Front axle
- Pinion and Differential
- Final drive
Bodywork – Cab – Platform
- Main technical data
- Dimensions and weights of the tractor
- Air conditioning vents
- Roof panel
- Instrument panel
- Viste interni cabina
- Dashboard
- Right hand console
- Left hand console
- External views of the tractor
- Openable roof hatch
Hydraulic system
- Trailer braking valve
- Power steering 125 cc
- Hydraulic pumps unit
- Power steering pump
- Transfer pump
- Base hydraulic circuit
- Full house hydraulic circuit
- Optional hydraulic circuit
- Base hydraulic circuit 2
- Full House hydraulic circuit 2
Electrical equipment
- 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
Rear lift
- Mechanical rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
- ECUs
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- On-board instruments (Cluster/Display) flashing
Method of intervention
B0 – Engine
- Separating the engine from the transmission
- Complete engine
- 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
- 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
- Oil filter
- Preliminary operations before removing engine from vehicle
- Power take off gear backlash adjustment
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
- Exhaust pipe (Lateral)
- DOC outlet side exhaust flange
- DOC inlet side exhaust flange
- DOC exhaust silencer
- Air compressor
- Compensation tank
- Fan
- Air filter
- Water radiator
- Intercooler
- Fuel radiator
- Fuel tank
- Complete radiator-heat exchanger pack
- Power take off gear backlash adjustment
- Replacing the coolant
- Bleeding the fuel circuit
- DPF
D0 – Transmission
- Draining and filling the transmission oil
- Separating front gearbox housing from rear gearbox housing
- Hydraulic reverse shuttle unit
- Forward drive clutch unit
- Reverse drive clutch unit
- HML unit
- Assembly of the HI-LO unit in the front gearbox housing
- Planet gear support unit – HML unit
- Gearbox input shaft (version with range selector unit – HML)
- Torsional spring plate
- Internal PTO drive shaft
- Disassembly of the main shaft
- Adjusting endfloat of the secondary shaft gears
- Disassembling the secondary shaft
- Complete gearbox assembly
- Gear lever
- Range selector rod cover
- Disassembling the gear selector rod
- Bevel gear adjustments
- Pinion
- Range reduction gearbox shaft
- PTO clutch
- Assembly of PTO output shaft ring nut
- Ground speed PTO shaft
- PTO output shaft
- PTO input shaft
- PTO input shaft disassembly
- Parking brake disc sectors
- Disassembling the parking brake lever
- 4WD output shaft in transmission.
- Disassembly of dual traction output shaft
- Parking brake unit assembly
- Disassembling the gearbox input shaft
E0 – Rear axle
- Rear axle
- Left-hand rear axle
- Disassembling rear axle
- Planet gear carrier
- Disassembling the planetary gear unit
- Rear differential
- Removing the rear differential
- Rear differential lock control fork
- Adjusting the bevel gear set and the rear differential
- Bleeding air from the hydraulic brake system
- Rear brake discs
- Brake housing
F0 – Front axle
- 4WD shaft
- Front axle 4WD
- Steering cylinders
- Disassembling the steering cylinder
- Disassembling the bevel gear set
- Disassembling the front axle differential – Complete assembly
- Disassembly of the planetary reduction gearbox
- Front brake discs
- Differential lock
- Pinion-differential assembly
- Front axle brake piston
- Adjusting bearing preload
- Differential locking device adjustment
- Axial play adjustment
- Adjusting pinion/crown wheel backlash
- Adjusting pinion position
- Adjusting pinion bearing preload
- Planetary reduction gearbox
- Adjustment of the differential preload
- Disassembly of the planetary reduction gearbox
- Complete steering knuckle housing
- Steering knuckle housing and half-shaft
- Support with front axle
G0 – Bodywork – Cab – Platform
- Hand throttle
- Cab
- Battery mount – Version without front PTO
- Engine hood
- Air conditioning compressor
- Air conditioning system condenser (version on machine)
- Right hand console
- Left hand console
- Pillars
- Hood frame
- Instrument panel
- Instrument cluster
- Dehydrator filter
- Complete air conditioner unit
- Parking brake lever
- Shuttle lever
- Rear distributor control levers
- Rear side window
- Rear screen
- Front mudguards
- Rear mudguards
- Brake pedals
- Steering column
- Brake master cylinders
- Cab door
- Lower hood guard
- Left hand cab access steps
- Seat
- Second driver seat
- Screen wash liquid reservoir
- Roof panel
- External rear-view mirrors
- Internal rear view mirror
- Empty and charge the air conditioning system
- Cab mat
- Roof
- Brake fluid reservoir
- Steering wheel
- Clutch pedal
- Disassembling the lift control lever (SAC)
- Rear lift control lever (SAC)
- Cab carriers
- Rear PTO speed selector lever
H0 – Hydraulic system
- Rear auxiliary utility distributors
- Oil filter
- Shuttle solenoid valves assembly
- Hydrostatic steering (orbitrol)
- Disassembling the power steering pump and ancillary pump carrier
- Adjusting power steering pump and ancillary pump carrier gear free play
- Disassembling the rear ancillary utility distributor
- Disassembling shuttle solenoid valve block
- Disassembling the ancillary solenoid valve block
- Trailer braking valve – Italy version
- Trailer socket
- Power steering pump
- Ancillary pump
L0 – Electrical system
- 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
- Hydraulic system inlet pressure switch
- Solenoid valve block and utility pressure switch
- Rear lift position sensor
- Wheel speed sensor
- 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
- Engine control unit
R0 – Rear lift
- 3-point linkage
- Lift bushes
- Disassembling the lift cylinder
- Adjusting mechanical rear lift controls
- Checking and testing the mechanical rear lift
- Complete rear lift
- Rear lift – Complete assembly
- Hitch control distributor
- Disassembling the lift control distributor
- Mechanical draft sensor disassembly
- Distributor for mechanical SAC
- Adjusting the SAC, low range 50 HP version
- Mechanical draft sensor
S0 – Wheels
- Front wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook
Wiring diagrams
Wiring harnesses
- Wiring looms
- W-TECH – ELECTRICAL SECTION
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
- Diagnostics 2024 subscription
- After-sales 2024 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- MISSING IDLER ON BELT DRIVE SYSTEM WITH A/C
- FARMotion seal ring leakage
- 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
D0 – TRANSMISSION
- HYDRAUILC PUMP SUPPORT BREAKAGE
F0 – FRONT AXLE
- SERVICE NEWS – FRONT AXLE FINAL REDUCERS NIPPLE GREASER
- Bevel gear set loosing screws
- Front Axle Bearing damage on slope condition
G0 – BODYWORK – CAB
- SERVICE NEWS – REAR WIPER MOTOR STUCK
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Oil leakage from easy-lift cylinder 0.036.2115.4
- PTO gear self disengagement
- Windscreen washer pump
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)
- SERVICE NEWS – Software package release 2026-02
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- SerDia4.0
- PTO switch not working
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
