Document overview
Workshop Manual for HURLIMANN XS 90.4 → ZKDBN50200TH10001 from the XS (FARMOTION STAGE 3B) family. Digital PDF in English with 1,390 pages.
The corresponding English table of contents contains 49 sections and 474 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: XS (FARMOTION STAGE 3B)
- Model: XS 90.4
- Starting serial number: ZKDBN50200TH10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,390
- File size: 435.19 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XS 90.4 → ZKDBN50200TH10001.
Complete table of contents
Introduction
- Tightening Torques
- Pump tightening torques
- 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 accessories
- Technical data: cylinder block
- Technical data: crankshaft
- Technical data: pistons – piston rings
- Technical data: rockers
- Camshaft technical data
- Technical data: timing system gears
- Technical data: counter-rotating masses
- Technical data and dimensions: valves – valve springs
- Technical data and dimensions: heads – valve guides – valve seats
- Technical data, rockers – tappets
- Starter motor
Transmission
- Transmission
- Mechanical reverse shuttle kinematic scheme
- Hydraulic reverse shuttle unit
- HML assembly
- Gearbox assembly with HML
- Gearbox assembly with underdrive
- Range and parking brake assembly
- Range control rod and parking brake lever
- Four-wheel drive engagement assembly
Rear axle
- Brakes and rear axle assembly
- Differential unit
Front axle
- ActiveDrive system
- Front axle
- Pinion, differential and differential lock
- Final drive
Bodywork – Cab – Platform
- Changes of the state of matter
- General introduction to the A/C system
- Charging the A/C system
- Air conditioning system – Diagnostics
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
- Mechanical lift control valve
- Trailer braking valve (ITALY version)
- Trailer braking valve – (Export Version)
- Services solenoid valve assembly
- Power steering valve
Electrical equipment
- FARMotion engine sensors and components
Front PTO
- Front power take-off
- PTO delivery pump
- PTO clutch
- PTO control solenoid valve assy
Calibrations and electronic diagnosis
Diagnostic tools
- D-TECH App
- D-Tech and diagnostic ports
- SDF SUITE
Commissioning and calibrating the tractor
- MIS – Basic procedure
- Commissioning – Purpose of the document
- MIS – Procedure description
- MIS – Basic procedure
- Commissioning – Eeprom re-initialisation
- Commissioning – Tractor Configuration
- Front distributors calibration
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs firmware update
- Download Dataset FARMotion & Flash ECU
Method of intervention
- Workshop tools for disassembly and reassembly
B0 – Engine
- Workshop tools for engine removal and reassembly
- Tightening procedure for engine components
- Preliminary operations before removing engine from vehicle
- Engine flywheel
- Engine block-gearbox connector flange
- Blow-by oil vapour recovery pipe
- Turbocharger oil pipes
- Turbocharger
- Exhaust manifold
- Thermostat valve
- Checking the thermostat valve
- EGR exhaust gas recirculation pipe
- EGR exhaust gas cooling pipes
- EGR manifold
- Disassembly of the EGR manifold
- EGR valve
- Blow-by filter
- Coolant manifold
- Intake manifold
- Oil filter
- Oil heat exchanger
- Engine coolant pump
- Electro-injectors and common rail
- Electro-injectors and common rail
- Cylinder head covers
- Blow-by oil vapour pipe
- Pushrods
- Cylinder heads
- Disassembling the cylinder heads
- Crankshaft pulley and tone wheel
- Crankshaft pulley
- Power take off drive
- Front timing cover
- Rear flange
- Oil sump
- Oil pump
- Counter-rotating masses
- Overhauling counter-rotating masses
- Intermediate gear and timing
- Disassembling pistons and connecting rods
- Disassembling pistons and connecting rods
- Crankshaft
- Cooling jets
- Cylinder sleeves
- Adjusting oil pump gear backlash
- Installing automatic belt tensioner
- Aligning water pump and crankshaft pulleys
- Complete engine
- Engine- separation from the transmission
- A/C compressor belt
C0 – Engine accessories
- Replacing the coolant
- Engine fan
- High pressure fuel pump
- Coolant radiator
- Complete heat exchanger assembly
- Mounting brackets
- Power take off gear backlash adjustment
- Compensation tank
- Intercooler, gearbox oil and fuel heat exchangers
- Air filter
- Air filter elements
- Rigid air filter pipe
- Fuel filter
- Bleeding the fuel circuit
- Fuel prefilter
- Fuel gauge
- Main fuel tank
- Auxiliary fuel pump
- Auxiliary fuel tank
- Starter motor
- Return line
- DOC catalytic converter
D0 – Transmission
- Changing the transmission oil and cleaning the intake circuit filter
- Complete gearbox assembly
- Front gearbox from its rear part
- Front gearbox housing
- Clutch plates
- Thrust plate assembly
- Clutch plate wear check
- Primary shaft (version with range selector unit)
- Primary shaft – Version without HML
- Adjusting endfloat of the secondary shaft gears
- Disassembling secondary shaft – Version with range selector unit
- Secondary shaft – Version without HML
- Range reduction gearbox rod
- Range selector rod
- Gearbox support and gear selector rods
- Dual traction output shaft and groundspeed PTO
- Sprocket
- Differential – Bevel gear set
- Pump drive PTO – internal gear
- PTO input shaft
- PTO output shaft
- PTO output shaft (2 speed + ground speed)
- PTO output flange shaft, 2 speed version
- Ground speed P.T.O. control shaft
- Disassembly of the 4WD engagement device
- 4WD engagement device
- Disassembling the parking brake lever
- Adjusting the parking brake lever
- HML unit
- Planet gear support unit – HML unit
- Clutch assembly
- Rear PTO control clutch
- Disassembling PTO control clutch
- Parking brake
E0 – Rear axle
- Bleeding the braking system
- Disassembling rear axle
- Rear differential
- Removing rear differential
- Right-hand rear axle
- Left-hand rear axle
- Planet gear carrier
- Brake housing
- Rear axle brake piston
F0 – Front axle
- 4WD shaft
- Support with rear axle
- Front axle (4WD)
- Axial play adjustment
- Steering cylinder
- Steering cylinders disassembly
- Pinion-differential assembly
- Differential lock device
- Differential lock device
- Bevel gear pair
- Differential
- Adjustment of the pinion position and bearing preloading
- Planetary reduction gearbox
- Disassembly of the planetary reduction gearbox
- Complete steering knuckle housing
- Adjusting bearing preload
- Front axle brake discs
- Front axle brake piston
- 4WD shaft (Active Drive)
- Separating engine from front axle carrier (Active Drive)
- Front axle (Active Drive)
- Complete knuckle assembly (Active Drive)
- Steering angle sensor (Active Drive)
- Disassembling the knuckle assembly (Active Drive)
- Steering tie-rod (Active Drive)
- Damper (Active Drive)
- Adjusting end float (Active Drive)
- Steering cylinder (Active Drive)
- Steering knuckle housing and half-shaft (Active Drive)
- Checking free play of upper head (Active Drive)
- Checking free play of lower head (Active Drive)
- Replacing the elastic gaiters (Active Drive)
- Wheel side universal joint (Active Drive)
- Differential side universal joint (Active Drive)
- Cylinder protection (Active Drive)
- Pinion-differential assembly (Active Drive)
- Differential lock (Active Drive)
- Disassembling the front axle differential (Active Drive)
- Adjusting differential (Active Drive)
- Adjusting pinion/crown wheel backlash (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Front axle brake discs (Active Drive)
- Front axle lower ball joint assembly (Active Drive)
- Assembly and adjustment of front differential (Active Drive)
G0 – Bodywork – Cab – Platform
- Cab
- Cab access steps
- Engine hood
- Right hand side member
- Left hand side member
- Battery mount
- Battery cover
- Cab mat
- Control console
- Dashboard
- Roof panel trim
- Rear windscreen wiper motor
- Door handle
- Door lock
- Door window
- Internal cab anti-pollen filter
- External cab anti-pollen filter
- External rear view mirrors
- Driver seat
- Complete air conditioner unit
- Heater – air conditioner control button panel
- Air conditioning compressor
- Empty and charge the air conditioning system
- Air-conditioning system condenser
- Dehydrator filter – standard version
- Air-conditioning system evaporator
- Cab heating heat exchanger
- Air conditioning system fans
- Condenser fans
- Expansion valve – standard version
- 3-level pressure switch
- Throttle pedal
- Clutch pedal
- Steering wheel
- Brake master cylinders
H0 – Hydraulic system
- Ancillary pump
- Power steering pump
- Oil filter
- Auxiliary utility circuit oil tank
- Power steering
- Power steering disassembly
- Front hydraulic distributor
- Front hydraulic couplers
- Ancillary utility distributor
- Flow regulator for front-mounted hydraulic couplers
- Hydraulic trailer braking unit
- Disassembling the ancillary solenoid valves
- Services solenoid valve assembly
L0 – Electrical system
- Battery
- Alternator
- Engine control unit
- Starter enable switch
- Parking brake switch
- Gearbox input shaft speed sensor
- Air filter clogging pressure switch
- Trailer brake pressure switch
- Engine wiring loom
- Engine wiring loom
- Charge pressure and air temperature sensor
- Electro-injector wiring loom
- Electro-injector wiring loom
- Coolant temperature sensor
- Crankshaft speed sensor
- Preheat relay
- Camshaft timing sensor
- Engine oil pressure switch
- Engine oil temperature sensor
- Fuel pressure and temperature sensor
- Fuel pressure sensor
- Water in fuel sensor
- Camshaft speed sensor
- Engine air temperature sensor
- Oil temperature sensor
- Clutch switch and sensor
- Speed sensor
- Instrument cluster
- Ignition switch barrel
- Battery master switch button
- Internal cab light
M0 – Front PTO
- Front power take-off
- Front PTO housing, guard
- Disassembling PTO clutch
N0 – Front lift
- Front lift
R0 – Rear lift
- Lift – Complete unit – Version with mechanical lift
- Lift – Complete unit – Version with electronic lift
- Lift disassembly – Complete unit – Version with electronic lift
- Lift disassembly – complete unit – Version with mechanical lift
- Lift cylinder – Version with mechanical lift
- Replacing bushes
- Lift control distributor – Version with electronic lift
- Lift control distributor – Version with mechanical lift
- Disassembling the lift control cylinder – Version with mechanical lift
- Position sensor
- Mechanical draft sensor – Version with mechanical lift
- Mechanical draft sensor disassembly – Version with mechanical lift
- 3-point linkage
S0 – Wheels
- Front Wheels
- Rear wheels
- Steering angle adjustment
V0 – Ballast – towing hitches
- Tow hook sled
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
- 2.8519.151.0 – Engine ECU
- PTO ECU
- Rear lift control unit
- Front 4-way auxiliary distributor and automatic four wheel drive control unit
- HLHP suspended axle ECU
- 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 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 – Activation and charging
- S004 – Lights
- S005 – Cab lights
- S006 – Air conditioner
- S007 – Windscreen wipers
- S008 – Radio
- S009 – Rear lift
- S010 – 3-point linkage electronic control
- S011 – Transmission
- S012 – Front remote valves
- S012 – Front distributors (ActiveDrive)
- S013 – Dual traction and differential lock
- S013 – Dual traction and differential lock (ActiveDrive)
- S014 – Power take off (PTO)
- S015 – CAN line and diagnostics
- S015 – CAN line and diagnostics (ActiveDrive)
- S016 – Accessories
- S017 – Instrument cluster
- S018 – Front axle (ActiveDrive)
Wiring harnesses
- Wire colour reference table
- 0.007.7899.3 – Front PTO solenoid valve
- 0.011.2025.4/40 – Electronic rear lift
- 0.011.7711.3 – Oil regulator valve block pressure switch
- 0.011.7840.4 – Rotating beacon
- 0.011.9828.3 – Cab earth
- 0.012.0101.4 – Electro-hydraulically controlled 3-point linkage
- 0.012.2103.3 – Hydraulic trailer braking
- 0.013.6326.4 – ROPS rotating beacons
- 0.013.6327.4 – Rotating beacon socket
- 0.015.0070.4 – Solenoid valves
- 0.015.3160.4 – Platform ground
- 0.016.0328.4 – Battery master switch ground
- 0.016.0561.4 – Work light
- 0.016.0767.4/10 – Air conditioner
- 0.016.0771.4 – Headlights on cab
- 0.016.6292.4 – Adapter for position sensor
- 0.018.4623.4 – Manual dual traction controls (version with auxiliary distributors)
- 0.018.4624.4 – Automatic dual traction controls – version with auxiliary distributors
- 0.018.4625.4 – Automatic dual traction controls
- 0.018.4626.4 – Manual dual traction controls
- 0.018.4628.4 / 0.018.4629.4 / 0.018.4630.4 – Steering sensor
- 0.018.4638.4 – Work lights, windscreen wipers and rotating beacon
- 0.018.4639.4 – Loudspeakers
- 0.018.4640.4/20 – Roof
- 0.021.1217.4 – Heater
- 0.023.1279.4_20 – Engine – 3-cylinder version
- 0.023.1280.4/20 – Engine – 4 cylinder version
- 0.023.1281.4 – Injectors – 3 cylinder version
- 0.023.1282.4/10 – Injectors (4 cylinder version)
- 0.023.2612.4 – Distributor joystick (version with ActiveDrive)
- 0.023.2613.4/10 – Piston sensors (version with ActiveDrive)
- 0.023.2616.4/20 – Front axle solenoid valves (version with ActiveDrive)
- 0.023.9906.4/20 – Front – 3 cylinder version
- 0.023.9907.4/20 – Front – 4 cylinder version
- 0.023.9908.4/10 – Front
- 0.023.9910.4 – Front axle with ActiveDrive
- 0.023.9913.4 – Rear – EU market
- 0.023.9912.4 – Central wiring loom – EU market
- 0.023.9916.4 – Central wiring loom (version with ActiveDrive)
- 0.023.9918.4 – Front distributors
- 0.023.9919.4/10 – Engine ECU power supply
- 0.023.9920.4 – Throttle pedal
- 0.023.9921.4 – Power
- 0.023.9922.4 – Battery wiring
- 0.023.9924.4 – Roof + platform power feed
- 0.023.9925.4 – Platform power supply
- 0.023.9927.4 – Roof power feed
- 0.023.9934.4 – Front lights and horn
- 0.024.2826.4/10 – Alternator – preheat
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
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
B0 – ENGINE
- FARMotion seal ring leakage
- Deutz AG engine oil specifications
- Engine sealing ring leakage
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Fuel auxiliary pump breakage
- SCR AREA DAMAGED SENSORS
- Doc outlet pipe & exhaust system alignment
- Oil Leakage From Active Drive
D0 – TRANSMISSION
- SERVICE NEWS – Forward Gear p.n. 0.013.1652.0 improvement
F0 – FRONT AXLE
- Bevel gear set loosing screws
- Check the upper and lower steering knuckles of the front axle for wear
- Check the front axle steering knuckles for wear
- Active Drive rubber boot breakage
- Wear of the final drive reduction units, planetary gear
- Steering behavior check procedure
- Adjusting Active Drive front axle toe-in
- ActiveDrive sensor alarm – U43
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Air conditioning system recharging
- Hot air from bonnet – P/N 9.ER372.92.0
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- 4WD BLINKING LIGHT
- L0 – ELECTRIC AL SYSTEM
