Document overview
Workshop Manual for HURLIMANN XA 80 → ZKDR4402W0TH015001 from the XA (STAGE 3A) family. Digital PDF in English with 1,557 pages.
The corresponding English table of contents contains 55 sections and 471 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 (STAGE 3A)
- Model: XA 80
- Starting serial number: ZKDR4402W0TH015001
- Document type: Workshop Manual
- Language: English
- Pages: 1,557
- File size: 242.85 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XA 80 → ZKDR4402W0TH015001.
Complete table of contents
Introduction
- Introduction – Engines
- Identification of the engine type and serial number position, Europe version
- Identification of the engine type and serial number position, EPA version
- Identification of the injection pump type
- Identification of the injector type
- Injector type identification
- 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
- Engine block technical data
- Crankshaft technical data
- Technical data for pistons – Piston rings
- Connecting rod technical data
- Camshaft technical data – static advance of 12°
- Timing gears technical data
- Technical data and dimensions of valves – valve springs
- Technical data and dimensions of cylinder heads – valve guide – valve seats
- Technical data and dimensions of rocker arms – rocker shafts – tappets
- Engine injectors technical data
- Hydraulic tappets diagram
Engine accessories
- Starter motor
Transmission
- Transmission
- Shuttle
- Hydraulic reverse power shuttle
- Range selector unit (HML)
- Gearbox assembly
- Underdrive control rod
- Gear selector rod
- Range gearbox and parking brake assembly
- Range control rod and parking brake lever
- Range and parking brake assembly
Rear axle
- Brakes and rear axle assembly
- Differential unit
Front axle
- Dual traction front axle (4WD)
- Dual traction front axle differential (4WD)
- Final drive
- Front brakes
Bodywork – Cab – Platform
- Master cylinder
Hydraulic system
- ANCILLARY/SAC circuit, optional version
- STEERING/TRANSMISSION circuit, base version
- STEERING/TRANSMISSION circuit, full house version
- STEERING/TRANSMISSION circuit, optional version
- ANCILLARY/SAC circuit, optional version
- STEERING/TRANSMISSION circuit, optional version 1
- Hydraulic lift control valve
- Remote control valve
- Power steering valve
- Introduction to hydraulic circuit diagrams
- STEERING/TRANSMISSION pump (16 cm³)
- STEERING/TRANSMISSION pump (19 cm³)
- LIFT/REMOTE VALVES pump (22.5 cm³)
- Front lift
- Front PTO
- Trailer braking valve
Front PTO
- Front power take-off
- PTO delivery pump
- PTO control solenoid valve assy
- PTO clutch
Front lift
- Front lift
- Damper assembly
Rear lift
- Rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- Positions of ECUs and diagnostic instruments
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket
Diagnostic tool screens
- ECU interrogation
- PC Tester Screens – Smart Lever – Purpose of this document
- PC Tester Screens – Smart Lever – Home Menu
- PC Tester Screens – Smart Lever – Main Menu
- PC Tester Screens – Smart Lever – Monitor Menu
- PC Tester Screens – Smart Lever – Parameters Menu
- PC Tester Screens – Smart Lever – Calibration Menu
- PC Tester Screens – Smart Lever – Alarms Menu
- PC Tester Screens – Smart Lever – Test Menu
Commissioning and calibrating the tractor
- Digital Instrument Calibration
- Wheels constants
- Commissioning – Index
- Commissioning – Purpose of the document
- Commissioning – Instruments and information required
- Commissioning – Description of procedure
- Commissioning – Basic procedure
- Commissioning – Eeprom re-initialisation
- Commissioning – Tractor Configuration
- Commissioning – Calibration of the shuttle clutches
- Commissioning – Calibrating Stop&Go function
- Shuttle calibration – Purpose of this document
- Reverse shuttle calibration – Clutch calibration
- Reverse shuttle calibration – Stop&Go calibration
- Reverse shuttle calibration – Instruments and information required for calibration
- Shuttle calibration – Clutch calibration procedure
- Reverse shuttle calibration – Stop&Go calibration procedure
- Commissioning – Engine ECU – Presentation screen
- Commissioning – Engine ECU – Structure
- Commissioning – Engine ECU – Main menu
- Commissioning – Engine ECU – Configuration
- Commissioning – Engine ECU – Engine menu
- Commissioning – Engine ECU – HML menu
- Commissioning – Engine ECU – Preheating menu
- Commissioning – Engine ECU – Alarms Menu
- Commissioning – Engine ECU – Wheel Calibration Menu
- Commissioning – Engine ECU – Wheels menu
- Commissioning – Engine ECU – HRT Menu
- Commissioning – Engine ECU – DERATING Menu
- Commissioning – Engine ECU – Engine type config.
- Commissioning – Engine ECU – Engine type config.
- Commissioning – Engine ECU – Functional diagram
- Commissioning – Engine ECU – Alarms List
- Electronic lift control unit
ECU alarms
Engine alarms
- Engine control unit alarms
Transmission alarms
- PTO and transmission ECU alarms
Instrument panel alarms
- Instrument cluster alarms
Lift alarms
- Electronic lift control unit alarms
Method of intervention
B0 – Engine
- Complete engine
- Engine- separation from the transmission
- Preliminary disassembly operations
- Checking engine block
- Crankshaft
- Crankshaft checks
- Flywheel checks
- Renewal of crankshaft rear oil seal
- Pistons and cylinder liners
- Pistons and rings check
- Cylinder liners check
- Check connecting rods – gudgeon pins – rod cap screws
- Camshaft checks
- Camshaft
- Valve timing
- Timing gear checks
- Adjusting timing gears backlash
- Valves check
- Valve seats check
- Valves sealing check
- Valve guides check and replacement
- Adjusting valve clearance
- Inspecting the rocker arms and rocker shafts
- Cylinder heads
- Determining correct head gasket thickness
- Valve springs check
- Heat exchanger removal
- Lubrication pump
- Lubrication pump disassembly
- Oil sump
- INJECTION PUMPS, GOVERNOR AND FUEL SUPPLY
- Synchronising injection pumps
- Injectors assembly
- Checking injectors protrusion – Renewal of copper bushes
- Injectors check
- Injection pump control rod
- Overhaul of the mechanical governor (standard and with LDA valve)
- Electronic governor adjustment
- Installation of electronic governor support
- Engine coolant pump
- Thermostatic valve
- Checking the thermostat valve
- Cooling and intake ducts
- Final engine checks
C0 – Engine accessories
- Changing the coolant and flushing the circuit
- Water radiator
- Complete radiator-heat exchanger pack
- Fuel tank
- Compensation tank
- Air filter
- Air filter mount
- Air shroud
- Intercooler, gearbox oil and fuel heat exchangers
- Exhaust silencer
- Return line
D0 – Transmission
- Changing the transmission circuit and cleaning the inlet circuit filter
- Hydraulic reverse shuttle unit
- Complete shuttle unit disassembly
- Disassembling cover assembly
- Disassembling the forward drive clutch unit
- Disassembling the reverse drive clutch unit
- Range selector unit (HML)
- Disassembling the clutch assembly
- Planet gear carrier unit – Range selector unit (HML)
- Gearbox input shaft (version with range selector unit – HML)
- Gearbox input shaft
- Torsional spring plate
- Primary shaft (version with range selector unit – HML)
- Primary shaft – Version without HML
- Disassembling secondary shaft – Version with range selector unit
- Secondary shaft (version with range selector unit – HML)
- Secondary shaft – Version without HML
- Tone wheel
- Front gearbox
- Rear gearbox
- Front gearbox housing from the rear
- Remove the gearbox shafts
- Pinion
- Rear PTO clutch
- Rear PTO output shaft
- Gear selector rods
- Range selector rod
- Underdrive control rod – Version with HML
- Differential – Bevel gear set
- Dual traction output shaft and ground speed PTO
- Disassembling PTO clutch
- Pump drive PTO – internal gear
- SYNCRO ground speed PTO drive shaft
- PTO output shaft
- PTO output flange shaft, 2 speed version
- Parking brake
- Disassembling the parking brake
- Dual traction engagement device – Version without HML
- Disassembly of the 4WD engagement device
E0 – Rear axle
- Rear axle
- Rear axle brake piston
- Differential
- Bleeding air from the hydraulic circuit of the front and rear brakes
- LH rear axle
- Removing right/left hand rear axle
- RH rear axle
- Planet gear carrier
- Removing rear differential
- Rear axle brake discs
F0 – Front axle
- Carrier with front axle (4WD)
- Front axle (4WD)
- Axial play adjustment
- Removing steering cylinders
- Steering knuckle housing and half-shaft
- Steering knuckle and axle shaft
- Pinion-differential assembly
- Differential locking device adjustment
- Differential lock
- Adjusting the bevel gear set
- Disassembly of the differential
- 4WD shaft
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Front axle brake discs
- Front axle brake piston
G0 – Bodywork – Cab – Platform
- Lower hood cover
- Engine hood
- Cab
- Cab access steps
- Front mudguards
- Instrument cluster
- Steering wheel and instruments
- Right hand console
- Driver’s seat
- Cab air conditioning system maintenance
- Charging the A/C system
- Roof lining – Version with high visibility cab
- Heating fan – Version with high visibility cab
- Heating and air conditioning unit – Version with high visibility cab
- Heating control cable
- Condenser – Version with high-visibility roof
- Receiver drier – Version with high visibility roof
- Conditioner evaporator – Version with standard roof
- Air-conditioning evaporator – Version with high-visibility roof
- Heating valve – Version with high visibility cab
- Heater matrix – Version with high-visibility roof
- Heating radiator – Version with standard roof
- Heating and air conditioning unit fan – Version with standard roof
- Expansion valve – Version with high visibility roof
- Expansion valve – Version with standard roof
- Antifreeze sensor – Version with high visibility roof
- Condenser cooling fans – Version with high-visibility roof
- Condenser fan control pressure switch – Version with high visibility roof
- Air conditioning temperature control thermostat – Version with standard roof
- Remote valve control cables
- Roof panel
- Brake master cylinders
- Lift control lever
- Air conditioning system controls – High-visibility roof system
- Air conditioning system – Standard roof version
H0 – Hydraulic system
- Lever mounting bracket
- Power steering pump
- Hydrostatic steering (orbitrol)
- Pressure relief valve setting
- Power steering disassembly
- Lift and ancillary utility distributor circuit pump
- Rear ancillary distributor
- Rear ancillary utility distributor (version with flow regulator)
- Disassembling the rear ancillary utility distributor
- Trailer braking valve
- Disassembling the ancillary solenoid valve block
- Services solenoid valve assembly
L0 – Electrical system
- Battery
M0 – Front PTO
- Front power take-off
- Front PTO housing, guard
- Disassembling PTO clutch
N0 – Front lift
- Front lift
R0 – Rear lift
- Mechanical rear hitch control
- Disassembling the mechanical rear lift
- Electronic rear hitch control
- Disassembling the electronic rear lift
- Disassembling the lift cylinder – Version with mechanical lift
- Bushes
- Disassembling the regulator distributor, with mechanical lift:
- Regulator distributor with electronically controlled rear lift
- Disassembling the regulator distributor, with electronically controlled lift:
- Mechanical draft sensor – Version with mechanical lift
- Mechanical draft sensor disassembly
- 3-point linkage
S0 – Wheels
- Front wheels
- Rear wheels
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
- Engine control unit
- Hydraulic reverse shuttle lever
- PTO ECU
- A – Starting and charging
- B – FUSES
- C – Grounds
- D – Intermediate junctions (1/3)
- D – Intermediate junctions (2/3)
- D – Intermediate junctions (3/3)
- E – On-board instruments and visual and audible indicators
- F – External lights
- G – Interior lights
- H – Electrical and manual controls
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electronic devices, Flasher units and Timers
- N – Electric motors and actuators
- O – Resistors and rheostats
- P – Various utilities
- R – Diagnostics
Systems
- S001A – Power feed for central wiring loom (0.016.6309.410)
- S001B – Power feed for central wiring loom (0.018.4443.410)
- S001C – Power feed for central wiring loom (0.016.6290.410)
- S001D – Power feed for central wiring loom (0.018.4442.4)
- S001E – Power feed for central wiring loom (0.018.4445.4)
- S001F – Power feed for central wiring loom (0.016.6299.410)
- S001G – Power feed for central wiring loom (0.016.6300.420)
- S001H – Power feed for central wiring loom (0.018.4444.4)
- S002A – +58 For Europe
- S002B – For USA with hydraulic reverse shuttle
- S002C – For USA with mechanical reverse shuttle
- S003A – Electronic governor (mechanical reverse shuttle)
- S003B – Electronic governor (hydraulic reverse shuttle)
- S004 – Preheating
- S005A – Starter system, for mechanical reverse shuttle (serial Nos. 0.018)
- S005B – Starter system, for hydraulic reverse shuttle
- S005C – Starter system, for mechanical reverse shuttle (serial Nos. 5000_ with vertical silencer)
- S006 – Lighting, Europe
- S006B – Lighting, USA, platform
- S006C – Lighting, USA, cab
- S007A – Cab lights, HV version
- S007B – Cab lights, High Visibility version
- S008A – Air conditioner, HV
- S008B – Air conditioner, standard cab roof
- S008C – Air conditioner, heated cab
- S009A – Wiper and radio, HV cab roof
- S009B – Windscreen wiper and radio, standard cab roof
- S010A – PTO, mechanical reverse shuttle, USA
- S010B – PTO, hydraulic reverse shuttle, USA
- S010C – PTO, Europe versions
- S011 – Hydraulic reverse shuttle
- S012 – Gearbox, differential lock and ranges
- S013 – Electronic lift
- S014A – Diagnostics, mechanical reverse shuttle
- S014B – Diagnostics, hydraulic reverse shuttle
- S015 – Accessories
- S016 – Trailer brake
- S017 – Instrument cluster
Wiring harnesses
- Wire colour reference table
- 0.007.7899.3 – Front PTO solenoid valve
- 0.009.7853.3 – Air conditioner, for versions with standard cab roof
- 0.010.4516.3 – Front screen wiper – version with standard cab
- 0.010.6468.3 – Pneumatic seat
- 0.011.0729.4/10 – Loudspeakers
- 0.011.3597.3 – Front screen wiper – version with “High Visibility” cab
- 0.011.7074.3 – Ground cable
- 0.011.7711.3 – Oil pressure switch cable
- 0.011.7840.4 – Siren mount for folding roll bars
- 0.012.2103.3 – Trailer brake wiring loom
- 0.013.4544.4 – H-L lever cable
- 0.013.4909.4 – Rear work lights, for versions with cab
- 0.013.4910 – Front-rear lights, for platform
- 0.013.6327.4 – Rotating beacon
- 0.014.1647.4 – Battery
- 0.014.3927.4/40 – Work light on arm
- 0.014.9281.4 – Rear work lights – version with platform
- 0.015.6123.4 – Rear screen wiper – version with standard cab
- 0.015.6272.4/40 – Roof – version with “High Visibility” cab
- 0.015.7266.4/40 – Air conditioner
- 0.016.0314.410 – PTO, groundspeed
- 0.016.0316.410 – PTO, not groundspeed
- 0.016.0373.4/30 – Roof power feed
- 0.016.0664.4 – Front lights – version with cab
- 0.016.0849.4 – Front lights – version with platform
- 0.016.0865.4/10 – Roof – version with front screen wiper
- 0.016.0866.4/10 – Work lights, windscreen wipers and rotating beacon
- 0.016.6282.4 – Lift
- 0.016.6283.4 – Cab power feed, 4 cylinders
- 0.016.6287.4 – Front, 3 cylinders
- 0.016.6288.4 – Front, 4 cylinders
- 0.016.6289.410 – Rear work lights, for versions with fixed roll bar
- 0.016.6290.410 – Central, mechanical reverse shuttle, EU
- 0.016.6291.410 – Rear, mechanical reverse shuttle, EU
- 0.016.6292.4 – Adapter for lift
- 0.016.6294.410 – Front PTO, USA
- 0.016.6298.410 – Rear, mechanical reverse shuttle, USA
- 0.016.6299.420 – Central, mechanical reverse shuttle, USA
- 0.016.6300.420 – Central, hydraulic reverse shuttle, EU
- 0.016.6301.410 – Rear, hydraulic reverse shuttle, EU
- 0.016.6303.4 – Front lights, USA
- 0.016.6305.4 – Front lights, for versions with cab
- 0.016.6308.410 – Rear, hydraulic reverse shuttle, USA
- 0.016.6309.4/10 – Central, hydraulic reverse shuttle, USA
- 0.017.6979.4 – Battery negative
- 0.018.4442.4 – Central, mechanical reverse shuttle, EU
- 0.018.4443.410 – Central, mechanical reverse shuttle, USA
- 0.018.4444.4 – Central, hydraulic reverse shuttle, EU
- 0.018.4445.4 – Central, hydraulic reverse shuttle, USA
- 0.018.5825.4 – Roof – version with front and rear screen wipers
- 0.019.5535.4 – Work lights on roof – version with “High Visibility” cab
- 04411923.4 – Lower front lights
- Front lights and horn
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
- Technical Documentation DVD 06/2009
- SDF LUBRICANTS: Lubricant oils and coolant fluids
- After-sales 2024 subscription
- After-sales 2023 subscription
- After-sales 2022 subscription
- After-sales 2021 subscription
- After-sales 2019 subscription
- SDF Parts and SDF Service DVV 04/2014, version 26
- Technical Documentation DVD 03/2010
- New function: Download PDF manuals
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
- Service and Spare Parts – 2017 Subscription
- SDF Parts and SDF Service DVDs 05/2014 version 25
- SDF Parts and SDF Service DVDs 03/2013 version 24
B0 – ENGINE
- Flushing the lubrication circuit
- Engine fan belt
- Front crankshaft main bearing
- Deutz AG engine oil specifications
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
D0 – TRANSMISSION
- SERVICE NEWS – Forward Gear p.n. 0.013.1652.0 improvement
- Bushes on shuttle input shafts
F0 – FRONT AXLE
- Workshop manual update – Planetary reduction gearbox
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Clutch pedal potentiometer actuator pin
- 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
- Resonator failure
- L0 – ELECTRIC AL SYSTEM
