Document overview
Digital Workshop Manual documentation for model HURLIMANN XL.K 125 → ZKDNB40200TH50001 from the XL.K (STAGE 5) family. Language: English; 1,130 pages.
The corresponding English table of contents contains 44 sections and 388 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: XL.K (STAGE 5)
- Model: XL.K 125
- Starting serial number: ZKDNB40200TH50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,130
- File size: 382.92 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XL.K 125 → ZKDNB40200TH50001.
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
- 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
- Complete cooling pack
- Coolant radiator
- Expansion tank
- Intercooler
- Air filter
- Diesel fuel tank
- Diesel radiator
- Starter motor
- DOC catalytic converter
- AdBlue® technical characteristics
- AdBlue pump
- AdBlue injector
- AdBlue valve
- AdBlue tank
- AdBlue float
- Exhaust pipe
- Air compressor
Transmission
- Transmission
- Hydraulic reverse shuttle
- Continuously variable transmission
Rear axle
- Rear power take off
- Rear wheel carrier
- Park brake unit
- Rear differential
Front axle
- Front axle 4 WD
- Disc type front differential lock (ASM)
- Planetary reduction gearbox
Bodywork – Cab – Platform
- External views of the tractor
- Viste interni cabina
- Front console and cab pillars
- Right hand console
- Left hand console
- Roof panel
- Instrument panel
- Main technical data
- Dimensions and weights of the tractor
Hydraulic system
- Transmission hydraulic circuit, base version
- Transmission hydraulic circuit, full house version
- General introduction to the A/C system
- Air conditioning system
- A/C system – Version with standard roof
- Air conditioning system controls – High-visibility roof system
- Air conditioning system – Diagnostics
- Air conditioning compressor
- Hydraulic pump unit
- 45 cc variable displacement pump
- Gear pump
- Suction pump filter
- Delivery line filter
- Braking system
- Park Brake system
- Park Brake valve
- Hydraulic Engine Brake
- Power steering 80 -160cc
- Power steering SDD 125-250cc
- Power steering SDD 115-240cc
- Front axle suspension
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
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Bushes
- Rear lift
- Rear 3-point linkage
Calibrations and electronic diagnosis
Diagnostic tools
- ECUs
- D-Tech and diagnostic ports
Software management
- ECUs firmware update
- Aggiornamento software iMonitor 4
Method of intervention
- Special tools
B0 – Engine
- Complete engine
- Engine- Separation from the transmission
- Tightening procedure for engine components
- Overhauling counter-rotating masses
- Adjusting oil pump gear backlash
- Aligning water pump and crankshaft pulleys
- Power take off gear backlash adjustment
- Test of the thermostat valve
- Engine block-gearbox connector flange
- Cooling jets
- Engine flywheel
- Belt tensioner mounting plate.
- Automatic belt tensioner
- A/C compressor belt
- Ancillary utility belt
- Crankshaft pulley and tone wheel
- Crankshaft pulley complete with tone wheel
- Counter-rotating masses
- 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 valves
- 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
C0 – Engine accessories
- Replacing the coolant
- Water radiator
- Expansion tank
- Fan
- Air filter
- Intercooler
- Oil radiator
- Diesel radiator
- Diesel fuel tank
- Fuel and filter and prefilter
- Manual fuel pump
- DOC exhaust silencer
- AdBlue tank
- Drain pipe
- AdBlue pump
- Air compressor
- 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
- DOC outlet side exhaust flange
- DOC inlet side exhaust flange
- Bleeding the fuel circuit
D0 – Transmission
- Draining and filling the transmission oil
- Separating the gearbox housing from the rear gearbox housing
- Shuttle unit – Complete assembly
- Disassembly of the shuttle unit
- Disassembly of the cover unit
- Clutch assembly: Forward Drive
- Clutch assembly: Reverse
- Disassembly of the forward drive clutch assembly
- Disassembly of the reverse drive clutch assembly
- Shimming HML Shaft – Assembly standard: 939177
- Gearbox assembly with HML
- Disassembling the Low range clutch – Version with HML
- Disassembling the HML unit
- Refitting and adjusting HML unit
- Disassembling the outer HML housing
- Disassembling the HML planetary gear carrier
- Gearbox input shaft
- Gearbox input shaft – Version with HML
- Primary shaft disassembly – Version with HML
- Secondary shaft disassembly – Version with HML
- Shimming Secondary Shaft Bearing – Assembly standard: 939177
- Complete gearbox assembly – Version with HML
- HML unit assembly procedure – Assembly standard: 939177
- Assembling and adjusting gearbox
- Adjusting the range shaft
- Assembling the range selector assembly
- Internal range reduction gear controls
- Disassembly of the internal range reduction gear controls
- Disassembling the gear selector lever
- Adjusting differential – bevel gear set
- Adjustment of pinion and crown wheel backlash
- Disassembly of the 4WD engagement device
- Removing the rear pinion
- 4WD engagement device
- Disassembly of dual traction output shaft
- Range gearbox and Creeper gears
- Disassembling the supercreeper gear shaft
- Rear PTO control clutch
- Disassembly of the PTO clutch
- Pump drive PTO – external gear
- Pump drive PTO – internal gear
- PTO output shaft
- Disassembling the PTO output shaft – 4 speed version
- Disassembling the rear PTO output flange shaft
- Disassembling the ground speed PTO output flange shaft
- INPUT unit
- INPUT unit disassembly
- Hydrostatic unit
- Replacing the WORK and TRANSPORT clutch assemblies (with the intermediate casing installed)
- WORK and TRANSPORT clutch-planetary reduction gearbox assembly
- REVERSE clutch-planetary reduction unit
- Speed range gear shafts
- Disassembling the PTO casing
- PTO drive shaft
- Differential pinion
- Disassembling the lift assembly (SAC)
- Disassembling the HML unit
- Disassembling the WORK and TRANSPORT clutches
E0 – Rear axle
- Bleeding the braking system
- Rear axle
- Removing right/left hand rear axle
- Brake flange
- Park brake unit
- Disassembling the park brake unit
- Rear differential
- Disassembling the rear differential case
F0 – Front axle
- Dual traction shaft (DT)
- Carrier with front axle
- Adjusting front carrier – engine alignment
- Steering bar/tie-rod
- Front axle
- Front axle adjusting endfloat
- Steering cylinders
- Removing steering cylinders
- Suspended axle pivot bracket
- Differential assembly
- Disassembly of the differential locking device
- Disassembling the differential assembly – pinion
- Adjusting differential preload and pinion-crown wheel backlash
- Pinion positioning and preload adjustment
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Steering knuckle casing and axle shaft
- Adjustment of steering knuckle casing and axle shaft
- Front axle brake discs
G0 – Bodywork – Cab – Platform
- Empty and charge the air conditioning system
- Engine hood and front hood panels
- Battery mount
- Lower hood guard
- Cab
- Cab access steps
- Front mudguard
- Cab mat
- Screenwash fluid reservoir
- Windscreen wiper motor
- Right hand console
- Instrument cluster
- Instrument panel
- Front pillar trim covers
- Left hand side cab trim
- External rear-view mirrors
- Anti-pollen filter
- Roof hatch
- Seat
- Passenger seat
- Air conditioning condenser
- Disassembling the air conditioning condenser
- Dehydrator filter
- A/C unit
- Air conditioner evaporator
- Heating radiator – Version with air conditioning
- Expansion valve
- Anti-icing sensor
- Air conditioning compressor
- Brake pedals
- Clutch pedal
- Park brake control
- Throttle pedal
- Steering wheel
- Steering column
- Gear lever
- Gear lever Bowden cable
- Range shift lever
- Hydraulic distributor controls
H0 – Hydraulic system
- Load Sensing (LS) ancillary pump
- Lubrication pump
- Disassembling the lubrication pump
- Disassembling the hydraulic pump drive unit
- Hydraulic steering pump (16 cc)
- Left hydraulic pump (32 cc)
- Right hydraulic pump (14 cc)
- Supplementary pump
- Hydrostatic steering (orbitrol)
- Rear auxiliary utility distributors
- Suspended axle accumulator block
- HML valve unit
- Shuttle solenoid valves assembly
- Services solenoid valve assembly
- Brake logic block
- Front braking valve
- Trailer air braking valve and air tank
- Air tanks
- Testing operation of pneumatic trailer braking system (eTCV)
- Pneumatic trailer braking system (eTCV)
- Trailer braking electronic control unit (WABCO)
- Brake master cylinders
L0 – Electrical system
- Battery
- Engine control unit
- Fuse box
- Alternator
N0 – Front lift
- Front top link
- Front lift
R0 – Rear lift
- Rear lift cylinder
- Complete rear lift
- Disassembling the lift assembly (SAC)
- Rear lift draft sensor
- 3-point linkage
- Top link
- Bushes
S0 – Wheels
- Rear wheel
- Front Wheels
V0 – Ballast – towing hitches
- Rear tow hitch
Wiring diagrams
Wiring harnesses
- Wiring looms
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
C0 – ENGINE ACCESSORIES
- SERVICE NEWS – DEF Unit – Wrong level indication
- Diagnostic protocol – AdBlue – Float level unit
F0 – FRONT AXLE
- Bevel gear set loosing screws
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- SERVICE NEWS – Front suspension malfunction
- 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)
V1 – AFTERMARKET KITS
- SERVICE NEWS – Antenna Predisposition
- Check correct installation of braking KIT
- Instructions for kit aftersales
