Document overview
Workshop Manual for HURLIMANN XL.K 135 V-DRIVE → ZKDGZ50200TH50001 from the XL.K V-DRIVE (STAGE 5) family. Digital PDF in English with 1,742 pages.
The corresponding English table of contents contains 49 sections and 577 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 V-DRIVE (STAGE 5)
- Model: XL.K 135 V-DRIVE
- Starting serial number: ZKDGZ50200TH50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,742
- File size: 451.18 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XL.K 135 V-DRIVE → ZKDGZ50200TH50001.
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
- 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
- Continuously variable transmission
- Mechanical variable ratio transmission
- Cross section of transmission
- “Input” clutch
- Variable ratio transmission unit
- Shuttle unit
- Range change
- Pump carrier
Rear axle
- Rear wheel carrier
- Park brake unit
- Rear differential
Front axle
- Front axle 4 WD
- Disc type front differential lock (ASM)
- Planetary reduction gearbox
Hydraulic system
- Base hydraulic circuit gear pump
- Full house hydraulic circuit
- Base hydraulic circuit with LS pump
- Optional hydraulic circuit – 1
- Optional hydraulic circuit – 2
- Optional hydraulic circuit
- Transmission hydraulic circuit, base version
- Transmission hydraulic circuit, optional version
- Location of hydraulic system components
- Location of hydraulic accumulators
- 45 cc variable displacement pump
- Fixed gear pump (32 cc)
- Fixed gear pump (16 cc)
- Fixed gear pump (11 cc)
- Oil delivery line filter
- Transmission oil radiator
- Bypass thermostat valve
- Braking system
- Park Brake system
- Park Brake valve
- Power steering 80 -160cc
- APS 115-240cc hydraulic steering pump
- 70-170 cc LSRM hydraulic steering unit
- Mechanical spools valve
- Front axle suspension
- Electrohydraulic gear control unit
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Rear lift
- Rear 3-point linkage
Calibrations and electronic diagnosis
- ECUs
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- Reset ECU (MVCU + GTECU + SVCU)
- Distributor configuration
- Maximum vehicle speed
- Tyre type
- Language
- Units of measurement
- Rapid steer system (SDD)
- Front power take-off (PTO)
- PTOSyncro
- Automatic A/C system
- Engine brake (HEB)
- eVISCO
- Agrosky
- 4WD
- ISO 11786
- Pneumatic trailer brake
- Hydraulic trailer braking
- Iso 11783
- iMonitor
- Stoll
- ASM (Automatic Steering Management)
- Mechanical diverter
- Setting the distributors to neutral position
- eTCV parameters configuration
- Hand brake position calibration
- Rear hitch position calibration
- Steering angle calibration
- Front suspension calibration
- IMU calibration
- PTO calibration
- Work reverse clutch calibration
- Hydrostatic unit calibration
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- Aggiornamento software iMonitor 4
Method of intervention
B0 – Engine
- 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
- 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
- Removing and fitting belt tensioner (ribbed V belt)
- Separating engine / transmission
C0 – Engine accessories
- Replacing the coolant
- Bleeding the fuel circuit
- 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
- Diesel fuel tank
- AdBlue tank
- AdBlue pump
D0 – Transmission
- Special tools
- Draining and filling the transmission oil
- Applying sealant
- Front gearbox from its rear part
- Separating the gearbox housing from the rear gearbox housing
- Centre gearbox housing (CVT unit)
- Connector housing
- INPUT clutch disc replacement
- INPUT unit
- INPUT unit disassembly
- Front gearbox casing cover
- Hydrostatic unit
- Hydrostatic unit pipes
- Front section of dual traction shaft (in clutch housing)
- Disassembling the front section of the dual traction shaft
- Rear section of 4WD shaft (in clutch housing) and tone sleeve
- Removing the tone sleeve
- Replacing the variator input shaft bearings
- Replacing the WORK and TRANSPORT clutch assemblies (with the intermediate casing installed)
- Variator unit input gear assembly
- Disassembling the variator input gear unit
- WORK and TRANSPORT clutch-planetary reduction gearbox assembly
- Planetary reduction gearbox for the WORK and TRANSPORT clutches
- Disassembling the WORK and TRANSPORT planetary reduction gearbox
- Disassembling the WORK and TRANSPORT clutches
- REVERSE clutch-planetary reduction unit
- Disassembling the REVERSE planetary reduction unit
- Hydraulic pump drive
- Disassembling the hydraulic pump drive unit
- Speed range gear shafts
- Electrohydraulic range gearbox
- Disassembling the electrohydraulic range gearbox
- Electrohydraulic range gearbox position sensor and relative mount
- Disassembling the electrohydraulic range gearbox position sensor mount
- Disassembling the idler gear
- PTO engagement clutch
- Disassembling PTO engagement clutch
- PTO casing
- Disassembling the PTO casing
- PTO drive shaft
- PTO speed selection lever
- PTO driven shaft
- Disassembling the PTO driven shaft
- Removing the groundspeed PTO cover
- Differential pinion
- Disassembling the differential pinion
- Disassembling the HD (Heavy Duty) range gear
- Dual traction output shaft
- Disassembling the dual traction output shaft
- Dual traction output shaft transfer idler gear
- Dual traction clutch
- Disassembling the dual traction clutch
- Centre section of dual traction shaft (in variable transmission unit)
- Disassembling the centre section of the dual traction shaft
- Gearbox input shaft
- Assembling and adjusting gearbox
- Adjusting the range shaft
- Assembling the range selector assembly
- Disassembly of the internal range reduction gear controls
- 4WD engagement device
- Disassembly of the 4WD engagement device
- Disassembling the rear PTO output flange shaft
- Positioning and shimming of rear bevel gear set and differential
E0 – Rear axle
- Bleeding the braking system
- Rear axle – Wheel carrier
- Wheel mount disassembly
- Park brake unit
- Disassembling the park brake unit
- Rear differential
- Rear differential crown wheel
- Disassembling the rear differential case
- Controlling and adjusting the clearance of the teeth on the pinion and the differential crown wheel
F0 – Front axle
- Dual traction shaft (DT)
- Support 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
- Cab
- Cab access steps
- Empty and charge the air conditioning system
- A/C unit
- Air conditioner evaporator
- Heating radiator – Version with air conditioning
- Motor with fans
- Expansion valve
- Anti-icing sensor
- Air conditioning compressor
- Air conditioning condenser
- Disassembling the air conditioning condenser
- Dehydrator filter
- Engine hood
- Lower hood guard
- Battery mount
- Front mudguards
- Cab mat
- Windscreen wiper motor
- Screenwash fluid reservoir
- Instrument panel
- Instrument cluster
- Anti-pollen filter
- External rear-view mirrors
- Seat
- Passenger seat
- Right hand console
- Left hand console
- Front pillar trim covers
- Hydraulic distributor controls
- Park brake control
- Roof panel
- Throttle pedal
- Brake pedals
- Clutch pedal
- Steering wheel
- Steering column
- Brake master cylinders
- Roof hatch
H0 – Hydraulic system
- Load Sensing (LS) ancillary pump
- Lubrication pump
- Disassembling the lubrication pump
- Power steering pump
- Supplementary pump
- Hydrostatic steering (orbitrol)
- Rear auxiliary utility distributors and rear lift
- Front axle suspension solenoid valve block
- Trailer braking valve
L0 – Electrical system
- Battery
- Instrument panel
- Steering column stalk and reverse shuttle control
- Brake lights switch
- Clutch sensor
- Clutch switch
- Brake pedals latched sensor
- Engine Control Unit (ECU)
- Engine control unit (PCB)
- 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
R0 – Rear lift
- Complete rear lift
- Disassembling the lift assembly (SAC)
- Rear lift cylinder
- Rear lift draft sensor
- Bushes
- 3-point linkage
S0 – Wheels
- Front Wheels
- Rear wheel
V0 – Ballast – towing hitches
- Rear tow hitch
V1 – AFTERMARKET KITS
- 9.GW738.10.0
Wiring diagrams
- W-TECH – ELECTRICAL SECTION
Components
- Location of ECUs
- SVCU Control Unit
- PFCU Control Unit
- MVCU Control unit
- Deutz Engine Control unit
- KF Engine Control Unit
- CTM/AM55 Control Unit
- ETCV – ECU
- A – Starting and charging
- B – Fuses
- C – Grounds
- D – Intermediate connections
- E – On-board instruments
- F – External lights (rotating beacon)
- G – Interior lights
- 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
- S001A – Electronic engine governor (125- 135 HP DEUTZ engine)
- S001B – Electronic engine governor (125 – 135 HP KF engine)
- S002A – Preheat (125 – 135 HP DEUTZ engine)
- S002B – Preheat (125 – 135 HP KF engine)
- S003A – Engine start (125- 135 HP DEUTZ engine)
- S003B – Engine start (125 – 135 HP KF engine)
- S004 – Lift (125- 135 HP)
- S005 – Road lights (125 – 135 HP)
- S006 – Work lights (125 – 135 HP)
- S007 – Wipers (125 – 135 HP)
- S008 – Instrument panel
- S009 – Radio system (125- 135 HP)
- S010 – Air conditioning system (125 – 135 HP)
- S011 – Transmission (125 – 135 HP)
- S012 – PTO (125-135 HP)
- S013 – Accessories (125 – 135 HP)
- S014 – CAN network (125 – 135 HP DEUTZ engine)
- S015 – Engine CAN line (125 – 135 HP)
- S016 – Braking system (125 – 135 HP)
- S017 – Trailer brake (125 – 135 HP)
- S019A – Emissions control (125 – 135 HP)
- S019B – Emissions control (125- 135 HP)
- S020 – Front loader (125 – 135 HP)
- S021 – SDD (125 – 135 HP)
- S022 – Battery master switch (125 – 135 HP)
- S023 – Smart Lever (125 – 135 HP)
- S024 – Agrosky (125 – 135 HP)
- S025 – Isobus
- S026 – Front axle and reverse shuttle (125 – 135 HP)
- S027 – Armrest
- S028 – Console controls
Wiring harnesses
- 0.012.2756.3 – Front PTO solenoid valve
- 0.014.1567.4/20 – Front wiper motor – opening windscreen version
- 0.014.8453.4 – Windscreen wiper (version with fixed windscreen)
- 0.016.8489.4 – Trailer parking brake solenoid valve (version with pneumatic braking)
- 0.017.0496.410A – H9 left hand lower rear work lights
- 0.017.0496.410B – Right hand H9 lower rear work lights
- 0.017.8425.4/10 – Trailer socket, EU
- 0.018.5346.4 – Distributor 7-8
- 0.019.5702.4/10 – ISO 11786
- 0.019.8827.4 – SDD (rapid steer system)
- 0.020.9462.4/10 – Flashing beacon cable
- 0.021.0490.4/10 – ABS socket for trailer
- 0.021.5509.4 – Rear screen defrost adapter
- 0.023.1282.4/10 – Injectors (4 cylinder version)
- 0.024.8482.4/10 – Mechanically engaged front loader 1
- 0.025.1281.4/20 – Front loader lever_HML
- 0.025.5561.4AH – Left hand H9 front lights
- 0.025.5561.4AL – Left hand LED front lights
- 0.025.5561.4BH – Right hand H9 front lights
- 0.025.5561.4BL – Right hand LED front lights
- 0.026.1301.4 – Mechanically engaged front loader 2
- 0.026.4756.4A – Electrically adjustable and heated rear view mirrors, left hand side
- 0.026.4756.4B – Electrically adjustable and heated rear view mirrors (right hand side)
- 0.026.5702.4_10 – Fuel pre-filter pump
- 0.026.6049.4 – Cowl
- 0.026.6240.4_10 – Hydrostatic unit
- 0.026.6377.4 – SBA ASM WAS adapter
- 0.027.2444.4 – Wiring loom for MR pneumatic trailer braking system
- 0.028.1208.4 – Ground wiring loom (AIR PREX)
- 0.030.6480.4/10 – Engine (4 cylinder version)
- 0.032.5469.4/10 – Glowplugs (4 cylinder version)
- 0.032.8553.4 – Provision for ISO 11783 socket
- 0.033.0899.4 – AGI2 antenna cable
- 0.033.8944.4_20B – LED TOP lights adapter
- 0.028.1208.4 – Ground wiring loom (AIR PREX)
- 0.036.3073.4/10 – DPF sensor
- 0.036.4523.4 – NOx sensor
- 0.036.4581.4_10 – Under-hood
- 0.036.6318.4 – Hydraulic trailer braking (dual mode)
- 0.036.6782.4A – H9 roof lights
- 0.036.6782.4B – H9 roof lights
- 0.036.7358.4A – LED roof lights
- 0.036.7358.4B – LED roof lights
- 0.036.7414.4/10 – License plate light
- 0.036.7712.4 – DAB antenna
- 0.036.7766.4 – FM antenna
- 0.036.7926.4A – Left hand LED turn indicator adapter cable
- 0.036.7926.4B – Right turn LED turn indicator adapter cable
- 0.036.9474.4 – Alternator – Preheat (3 cylinder version)
- 0.036.9659.4/30 – Cab
- 0.036.9660.4_20 – PT454 roof
- 0.017.8425.4/10 – Trailer socket, EU
- 0.036.9664.4 – Agrosky SGR1 antenna PT454
- 0.036.9665.4/10 – AGI 2 antenna
- 0.036.9667.4 – CTM control unit PT 454
- 0.036.9669.4 – iMonitor X25
- 0.036.9670.4_10 – Centre ISOBUS wiring loom PT454
- 0.036.9671. 4_10 – SVCU control unit
- 0.036.9672.4 – Instrument cluster wiring loom, EU
- 0.036.9677.4 10 – Rear braking adapter PT 454
- 0.036.9681.4_10 – Rear Body wiring loom, PT454, VST_TTV
- 0.036.9682. 4_10 – NOx sensor
- 0.036.9683.4 – Rear ISOBUS wiring loom PT454
- 0.036.9684.4 – Junction terminal board
- 0.036.9685.4 – Suspended front axle wiring loom
- 0.036.9686.4_20 – Front
- 0.036.9687.4_10 – Front Engine ECU KF PT454
- 0.036.9688.4/10 – Deutz power cables
- 0.036.9689. 4_10 – Power cables KF PT 454
- 0.037.8098.4 – CLS steering unit
- 0.039.6688.4 – Loader wiring loom
- 0.040.0815.4/20 – Distributor 1_2_3_4 wiring loom
- 0.040.1839.4 – Hydraulic trailer braking, MR PT454
- 0.040.2174.4 – Right hand console, VST_TTV, Full distributor config.
- 0.040.3799.4 – Right hand console, VST_TTV, Mix distributor config.
- 0.040.3800.4/10 – Armrest
- 0.040.5327.4 – Wabco pneumatic trailer braking system
- 0.040.8629.4 – E-Visco prex
- 04422324.4_10 – ISO 11786 socket
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- SERVICE NEWS – TTV SERIES – CRUISE CONTROL BEHAVIOUR
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
- Diagnostics 2023 subscription
- Diagnostics 2024 subscription
- Diagnostics 2022 subscription
- After-sales 2024 subscription
- After-sales 2023 subscription
- After-sales 2022 subscription
B0 – ENGINE
- Error code SPN 2659 FMI1
- TURBOCHARGER VGT MALFUNCTION
C0 – ENGINE ACCESSORIES
- SERVICE NEWS – DEF Unit – Wrong level indication
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
D0 – TRANSMISSION
- Wrong dimension on RPTO stub shaft 21 splines 1-3/8″
- PINION NUT LOOSENING
- G1 – G2 gears failure on SDF CVT transmission 6C TTV-RVSHIFT Stage 5 (PT454) – 6.4 TTV-RVSHIFT Stage 5 (PT504)
F0 – FRONT AXLE
- 4WD CARDAN SHAFT WEAR
- Bevel gear set loosing screws
- Missing lubrification point of front axle
G0 – BODYWORK – CAB
- Interference between rear tyres and rear fenders screws
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Pneumatic trailer brake system vibration
- SERVICE NEWS – Front suspension malfunction
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Leakage from power beyond pipe fitting 6C PS-TTV-RVSHIFT Stage 5 (PT454)
- Leakage from brake valve and distributor pipe
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
- FAS SENSOR BRACKET BENT
- MAF sensor malfunction on VGT FarMotion engine Error code SPN 132 FMI15 (M28)
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- Front Loader Joystick controllability 6C/6.4 TTV-RVSHIFT stage 5
- SerDia4.0
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- Regeneration start issue
- ERROR CODE SPN 624 FMI 3
- M709-520375 FMI15 error code on TCD 3.6 Stage 5 (6C, 6C TTV, 6C RVSHIFT stage 5)
- M83 error code on TCD 3.6 Stage 5 (6C, 6C TTV, 6C RVSHIFT stage 5)
- Lost connection diagnostic tools
- PTO switch not working
V1 – AFTERMARKET KITS
- SERVICE NEWS – Antenna Predisposition
- Check correct installation of braking KIT
- Instructions for kit aftersales
