Document overview
Workshop Manual for HURLIMANN XB 90 → ZKDW7802W0TH20001 from the XB (STAGE 3A) family. Digital PDF in English with 1,225 pages.
The corresponding English table of contents contains 39 sections and 292 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: XB (STAGE 3A)
- Model: XB 90
- Starting serial number: ZKDW7802W0TH20001
- Document type: Workshop Manual
- Language: English
- Pages: 1,225
- File size: 116.93 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XB 90 → ZKDW7802W0TH20001.
Complete table of contents
Introduction
- Introduction – Engines
- Tightening torques
- 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
- 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
- Counter-rotating weights 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
Transmission
- Transmission
- Rear P.T.O.
- 2 and 4-speed PTO and Groundspeed PTO
- Hydraulic reverse power shuttle
Front axle
- Front axle
Rear lift
- Rear lift distributor
Calibrations and electronic diagnosis
Diagnostic tools
- ECU interrogation
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket
Diagnostic tool screens
- 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
- PC Tester Screens – Engine ECU – Structure
Commissioning and calibrating the tractor
- Check Panel Calibration
- Wheel constants
- Commissioning – Document purpose
- Commissioning – Instruments and information required
- MIS – Procedure description
- Commissioning – Basic procedure
- Commissioning – Eeprom re-initialisation
- MIS – Tractor configuration
- Commissioning – Calibration of the shuttle clutches
- Commissioning – Calibrating Stop&Go function
- Hydraulic reverse 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 – Alarms List
- 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
ECU alarms
- Key to the “ECU alarms” tables
- FMI code
Engine alarms
- Alarms – SLH engine alarm code list
Transmission alarms
- Alarms – Transmission alarms list
Instrument panel alarms
- Alarms – Instrument alarms list
Electrohydraulic control valve alarms
- Alarms – Services alarms list
Method of intervention
B0 – Engine
- 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
- Counter-rotating weights
- Counter-rotating weight checks
- Overhaul of counter-rotating weights assembly
- Valves check
- Valve seats check
- Valves sealing check
- Adjusting valve clearance
- Valve guides check and replacement
- 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
- 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
- Engine coolant pump
- Thermostatic valve
- Checking the thermostat valve
- Cooling and intake ducts
- Final engine checks
- Final refitting operations
- Pulley hub fixing (for types without front PTO)
- Pulley hub fixing (for types with front PTO)
D0 – Transmission
- Transmission – Adjusting endfloat of planetary reduction unit gears
- Transmission – Adjusting spring preload
- Transmission – Adjusting secondary shaft (part No. 927798)
- Transmission – Adjusting differential bearing preload
- Transmission – Adjusting pinion position
- Adjusting mounts – Assembly
- Shuttle – Removing shuttle unit
- Shuttle- Removing/installing forward drive clutch
- Shuttle – Removing/installing reverse drive clutch
- Gearbox internal cover
F0 – Front axle
- Front axle – Adjusting differential
R0 – Rear lift
- ADJUSTING LIFT
Wiring diagrams
Components
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments and visual and audible indicators
- F – External lights (rotating beacon)
- G – Interior lights
- H – Manual electrical controls (steering column switch)
- 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
- Q – Safety devices
- R – Diagnostics
Systems
- S001 – Cab engine start – ITA
- S001 – Cab engine start – USA
- S001 – Cab engine start – ITA
- S001 – Engine start, platform version – USA
- S002 – Heating, standard cab (heater and air conditioning) – ITA
- S002 – Heating, standard cab (heater and air conditioning) – USA
- S003 – Air conditioning, standard cab
- S003 – Air conditioning, cab with high visibility roof
- S003 – Air conditioning, standard cab – USA
- S003 – Air conditioning, cab with high visibility roof – USA
- S004 – Starting and preheating, cab
- S004 – Starting and preheating, cab – USA
- S004 – Starting and preheating, platform
- S004 – Starting and preheating, platform – USA
- S005 – PTO, cab version
- S005 – PTO, cab version – USA
- S005 – PTO, platform version
- S005 – PTO, platform version – USA
- S006 – Windscreen wipers, cab with high visibility roof
- S006 – Windscreen wipers, standard cab with heater and air conditioning
- S006 – Windscreen wipers, cab with high visibility roof – USA
- S006 – Windscreen wipers, standard cab with heater and air conditioning – USA
- S007 – Instrument panel, cab
- S007 – Instrument panel, platform
- S007 – Instrument panel, cab version – USA
- S007 – Instrument panel, platform version – USA
- S008 – Brakes, cab version – ITA
- S008 – Brakes, cab version – USA
- S008 – Brakes, platform version – ITA
- S008 – Brakes, platform version \- USA
- S009 – Cab lights – ITA
- S009 – Cab lights – USA
- S009 – Lights, platform version – ITA
- S009 – Lights, platform version – USA
- S010 – Work lights, standard cab – ITA
- S010 – Work lights, standard cab – USA
- S010 – Work lights, HV cab – ITA
- S010 – Work lights, HV cab – USA
- S010 – Work lights, platform version – ITA
- S010 – Work lights, platform version – USA
- S011 – Cab accessories – ITA
- S011 – Cab accessories – USA
- S011 – Platform accessories – ITA
- S011 – Platform accessories – USA
- S012 – Transmission, ITA cab version
- S012- Transmission, ITA platform version
- S012- Transmission, USA cab version
- S012- Transmission, USA platform version
- S013 – Distributors, cab version
- S013 – Distributors, cab version – USA
- S014 – CAN Bus, cab version
- S014 – Can Bus, platform version
Wiring harnesses
- 0.010.2147.2 – Heating
- 0.010.2153.2 – Air conditioning
- 0.010.4516.3 – Windscreen wiper, without high visibility cab
- 0.011.0729.4/10 – Loudspeakers
- 0.011.3597.3 – Windscreen wiper, with high visibility cab
- 0.012.2756.3 – Front PTO solenoid valve
- 0.013.4085.4/20 – Front work lights
- 0.013.4909.4 – Rear lights
- 0.013.4910.4 – Rear sidelights and turn indicators
- 0.013.6327.4 – Rotating beacon
- 0.014.1645.4/10 – Air-hydraulic braking pressure switch ITA/D
- 0.014.1645.4/10 – Air-hydraulic braking pressure switch ITA/D
- 0.014.8666.4/30 – Front lights and horn
- 0.014.9195.4/20 – Preheating
- 0.014.9281.4 – Work light and rotating beacon, platform
- 0.015.1418.4/30 – Hydraulic reverse shuttle in cab
- 0.015.1435.4/20 – Auxiliary work lights
- 0.015.1998.4/10 – Hydraulic reverse shuttle, drivetrain
- 0.015.4257.4/10 – PTO sensor – (USA EXPORT)
- 0.015.6123.4 – Rear screen wiper, without high visibility cab
- 0.015.6272.4/40 – Roof, with High Visibility cab
- 0.015.7266.4/40 – Air conditioning condenser fan
- 0.016.0373.4/30 – Cab power supply
- 0.016.0664.4 – Low rear work lights
- 0.016.0849.4 – Front sidelights and turn indicators
- 0.016.0866.4/10 – Work lights and windscreen wiper, without High Visibility cab
- 0.017.0474.4 – Battery positive terminal
- 0.017.1063.4 – Cab earth
- 0.017.8922.4/10 – Battery negative, version with lateral battery
- 0.017.9016.4/10 – Battery negative, version with front battery
- 0.018.5825.4 – Roof, standard cab with heater and air conditioning
- 0.019.1100.4/20 – Central wiring loom, cab
- 0.019.1176.4/10 – Rear wiring loom
- 0.019.1788.4/40 – Central wiring loom, cab – USA
- 0.019.1789.4/40 – Central wiring loom, platform
- 0.019.1790.4/20 – Central wiring loom, platform – USA
- 0.019.1817.4/10 – Cab power, front battery
- 0.019.1837.4/10 – Cab power, step battery
- 0.019.1914.4 – Front battery
- 0.019.1915.4 – Step battery
- 0.019.1936.4 – Step heater
- 0.019.5535.4 – Front work lights, with HV cab and FOPS roll cage.
- 0441.1923.4 – Lower front lights
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
- SDF Parts and SDF Service DVV 04/2014, version 26
- 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
- Deutz AG engine oil specifications
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
F0 – FRONT AXLE
- 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
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
