Document overview
Workshop Manual for HURLIMANN XF 90 → ZKDLK202W0TH50001 from the XF (FARMOTION STAGE 5) family. Digital PDF in English with 933 pages.
The corresponding English table of contents contains 44 sections and 352 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: XF (FARMOTION STAGE 5)
- Model: XF 90
- Starting serial number: ZKDLK202W0TH50001
- Document type: Workshop Manual
- Language: English
- Pages: 933
- File size: 376.42 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XF 90 → ZKDLK202W0TH50001.
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
- 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
Front axle
- Pinion, differential and differential lock
- Differential unit
Hydraulic system
- STEERING/TRANSMISSION pump (11 cm³)
- LIFT/REMOTE VALVES pump (14+11 cm³)
- STEERING/TRANSMISSION pump (16 cm³)
- LIFT/REMOTE VALVES pump (22.5 cm³)
- Electronic lift control valve
- 6-way remote control valve
- Basic auxiliary hydraulic circuit, LS and GS
- Auxiliary hydraulic circuit, optional version 1, LS and GS
- Auxiliary hydraulic circuit, optional version 2, LS and GS
- Basic hydraulic transmission circuit, GS
- Optional hydraulic transmission circuit 1, GS
- Optional hydraulic circuit
- Optional hydraulic transmission circuit 2, GS
- Optional hydraulic transmission circuit 2, LS
- Optional hydraulic transmission circuit 3, GS
- Optional hydraulic transmission circuit 3, LS
Calibrations and electronic diagnosis
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
- ECUs
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- Cluster configuration
- Optionals
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
Method of intervention
B0 – Engine
- Front timing cover
- Alternator, water pump and A/C compressor belt
- Installing automatic belt tensioner
- Counter-rotating masses
- Crankshaft pulley
- Disassembling pistons and connecting rods
- Oil sump
- Oil pump
- Coolant manifold
- Engine coolant pump
- Oil heat exchanger
- A/C compressor belt
- Aligning water pump and crankshaft pulleys
- Adjusting oil pump gear backlash
- 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
- 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
- Complete engine
- Separating the engine from the transmission
C0 – Engine accessories
- Engine fan
- High pressure fuel pump
- Electric starter motor
- DOC catalytic converter
- Air filter
- Diesel fuel tank
- AdBlue tank
- Drain pipe
- SCR
- 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
D0 – Transmission
- Planet gear support unit – HML unit
- Complete gearbox assembly
- Disassembling the secondary shaft
- Disassembling the gearbox input shaft
- Adjusting differential – bevel gear set
- Rear pinion casing
- Rear pinion
- Sprocket
- Adjusting the bevel gear set
- Differential – Bevel gear set
- PTO output shaft (2 speed version and groundspeed version)
- PTO input shaft
- PTO input shaft disassembly
- SYNCRO ground speed PTO drive shaft
- Rear PTO drive shaft
- Disassembling the rear PTO drive shaft
- PTO input shaft
- PTO output shaft (2 speed + ground speed)
- PTO output flange shaft, 2 speed version
- PTO output shaft
- Ground speed P.T.O. control shaft
- PTO output shaft
- Reverse shuttle and range control cover.
- Separating the gearbox casing from the rear gearbox casing
E0 – Rear axle
- Rear axle
- Removing right/left hand rear axle
- Disassembling rear axle
- Right-hand rear axle
- Left-hand rear axle
- Disassembling the planetary gear unit
- Planet gear carrier
- Removing the rear differential
- Differential lock selector fork
- Rear differential
- Rear axle brake piston
- Brake carriers
- Replacing the friction shoes
- Rear axle brake discs
F0 – Front axle
- Support with rear axle
- Axial play adjustment
- Pinion-differential assembly
- Disassembly of the differential
- Bevel gear pair
- Adjustment of the pinion position and bearing preloading
- Steering cylinders
- Complete steering knuckle housing
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Disassembling the bevel gear set
- Front axle (4WD)
- Adjusting bearing preload
- Front axle brake discs
- Front axle brake piston
- Carrier with front axle (Active Drive)
G0 – Bodywork – Cab – Platform
- External rear view mirrors
- Driver seat
- Hand throttle control lever
- Throttle pedal
- Engine hood and front hood panels
- Platform
- Access ladders
- Mudguard
- Right hand console
- Gear lever control
- Roll bar
- Roll bar
- Side panels
- Mudguards
- Electrohydraulic distributor lever
H0 – Hydraulic system
- Oil filter
- Hydrostatic steering (orbitrol)
- Brake control valve
- Hydraulic braking solenoid valve
- Electrohydraulic distributor
- Mechanical distributor
- Front mid-mounted connectors
L0 – Electrical system
- Battery
- Alternator
- Speed sensor
- 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
M0 – Front PTO
- Front power take-off
- Disassembling PTO clutch
N0 – Front lift
- Front lift
R0 – Rear lift
- Hitch control distributor
- Disassembling the lift control distributor
- 3-point linkage
V0 – Ballast – towing hitches
- Tow hook sled
- Drawbar
- Rear tow hitch
Wiring diagrams
Components
- Location of ECUs
- Engine Control unit
- BDS ECU
- AD-BLUE SUPPLY MODULE
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments
- F – External lights (rotating beacon)
- 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
- S001 – Electronic engine throttle
- S002 – Preheating
- S003 – Starter
- S004 – Lights
- S006 – Transmission
- S007 – PTO
- S008 – CAN line and diagnostics
- S009 – Engine CAN line
- S010 – Braking system
- S011 – Trailer brake
- S012 – Emissions control system
- S013 – Battery master switch
- S014 – Sockets and accessories
Wiring harnesses
- 0.011.7840.4 – Rotating beacon
- 0.013.6326.4 – ROPS rotating beacons
- 0.013.6327.4 – Rotating beacon socket
- 0.015.0070.4 – Solenoid valve
- 0.016.0314.4_10 – 4V PTO
- 0.016.0316.4_10 – 3V PTO
- 0.017.8425.4/10 – Trailer socket
- 0.021.0490.4/10 – TRAILER ABS
- 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)
- 0.027.5538.4 – License plate light
- 0.027.7652.4/10 – Cowl
- 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)
- 0.036.0966.4 – Junction terminal board
- 0.037.0995.4 – Preheating
- 0.046.2781.4/10 – Power cables
- 0.046.2782.4_10 – Platform power feed
- 0.046.2783.4/10 – Front wiring loom
- 0.046.2784.4/10 – Rear wiring loom, Basic version
- 0.046.2785.4/10 – Central wiring loom
- 0.046.2802.4 – Battery negative
- 0.046.2803.4/10 – Rear wiring loom, OPT version
- 0.046.2806.4 – Power feed unit
- Wiring looms
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
- After-sales 2024 subscription
- After-sales 2023 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Belt Tensioner FarMotion Engine
C0 – ENGINE ACCESSORIES
- M339 error code on FarMotion Stage 5 models
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
D0 – TRANSMISSION
- RANGE LEVER KNOB BREAKAGE
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Front Axle Bearing damage on slope condition
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- MINI-REDUCER CONTROL LEVER STUCKED
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Possible streching or crushing of the front brake oil pipe assembly
L0 – ELECTRIC AL SYSTEM
- CTM MALFUNCTION ON FRUTTETO PLATFORM GS/LS STAGE V
- SERVICE NEWS – M334-M335-M430-M28-M427 New Engine SW release A09 (FarMotion Stage 5)
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- SerDia4.0
- REAR LIFT SELF-LOCKING
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- Lost connection diagnostic tools
- PTO switch not working
R0 – REAR LIFT
- Dust from the transmission Breather on Frutteto Platform LS St.5 with Mechanical SAC
- Hydraulic lateral stabilizer 0.007.3680.4/50 Stabilizer + 0.015.2791.3 Terminal
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
