Document overview
Workshop Manual for HURLIMANN XS 90 PRO → ZKDJD80200TH50001 from the XS PRO (FARMOTION STAGE 5) family. Digital PDF in English with 966 pages.
The corresponding English table of contents contains 45 sections and 351 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 PRO (FARMOTION STAGE 5)
- Model: XS 90 PRO
- Starting serial number: ZKDJD80200TH50001
- Document type: Workshop Manual
- Language: English
- Pages: 966
- File size: 444.97 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XS 90 PRO → ZKDJD80200TH50001.
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
- Technical data and exhaust gas after-treatment systems – KF stage 5 engine
- Camshaft technical data
- Technical data, rockers – tappets
- Technical data: crankshaft
- 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
- 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
Engine accessories
- Coolant radiator
- Compensation tank
- Air filter
- Intercooler
- Fuel radiator
- Gearbox oil radiator
- Fuel tank
- Fuel tank
- Fuel tank with front PTO
- Fuel tank – version without PTO
- Manual fuel pump
- Fuel filter
- Fuel prefilter
- Exhaust silencer – Catalytic converter (DOC)
- DPF and SCR catalytic converter
- AdBlue tank
- AdBlue solenoid valve
- AdBlue injector
- AdBlue pump
- AdBlue float sensor
- Exhaust gas recirculation valve (EGR)
- Alternator
Transmission
- Hydraulic reverse shuttle unit
- Hydraulic reverse power shuttle
- HML unit
- Hi-Lo unit
- Gearbox assembly with HML
- Gearbox unit with Hi-Lo
- Range control rod and parking brake lever
- Range gearbox and parking brake assembly
- Gearbox assembly with underdrive
Rear axle
- Differential assembly
Front axle
- Pinion, differential and differential lock
- Final drive
- Suspended axle valve unit
Bodywork – Cab – Platform
- Viste interni cabina
- Dashboard
- Left hand console
- Right hand console
- Instrument panel
- Air conditioning system – Recharging
- Air conditioning system compressor
- Air conditioning system
Hydraulic system
- STEERING/TRANSMISSION pump (16 cm³)
- LIFT/REMOTE VALVES pump (22.5 cm³)
Front lift
- Front lift
Rear lift
- Rear lift distributor
- Rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- D-TECH App
- D-Tech and diagnostic ports
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs
- Download Dataset FARMotion & Flash ECU
- ECUs firmware update
Method of intervention
- Special tools
B0 – Engine
- Complete engine
- Separating the engine from the transmission
- Tightening procedure for engine components
- Overhauling counter-rotating masses
- 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
- Counter-rotating masses
- Crankshaft
- Crankshaft gears
- 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
- Turbocharger exhaust outlet flange
- Mass air flow sensor
- EGR valve
- AdBlue injector
- NOx sensor
- DOC inlet side exhaust temperature sensor
- DOC outlet 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
- Alternator mount
- Transverse plate
- Mounting brackets
- Engine coolant radiator
- Complete cooling pack
- Compensation tank
- Engine air intake fan
- Air filter
- Intercooler
- Diesel radiator
- Transmission oil heat exchanger
- Fuel pump
- Manual fuel pump
- Fuel prefilter
- Fuel prefilter
- Fuel filter
- Filter mounting plate
- High pressure fuel pump
- Fuel and filter and prefilter
- Filter mounting plate
- High pressure fuel pump
- Diesel fuel tank
- Auxiliary fuel tank and AdBlue tank
- Bleeding the fuel circuit
- Glow plug
- Preheat relay
- Preheat relay
- Starter motor
- Starter motor
- DOC outlet side exhaust flange
- DOC outlet side exhaust flange
- DOC inlet side exhaust flange
- DOC inlet side exhaust flange
- DOC exhaust silencer
- Exhaust silencer – Catalytic converter (DOC)
- Exhaust pipe – DPF+SCR catalytic converter
- DPF+SCR catalytic converter inlet side exhaust pipe
- AdBlue tank
- AdBlue solenoid valve
- Air compressor
- Air compressor
D0 – Transmission
- Draining and filling the transmission oil
- Hydraulic reverse shuttle
- Complete shuttle unit disassembly
- Cover unit
- Forward drive clutch unit
- Reverse drive clutch unit
- HML unit
- HML unit assembly in the front gearbox
- Assembly of the HI-LO unit in the front gearbox housing
- Clutch assembly
- Planet gear carrier unit – HML unit
- Gearbox input shaft (with HML)
- Primary shaft (version with HML)
- Secondary shaft – Version with HML
- Adjusting endfloat of the secondary shaft gears
- Front gearbox from its rear part
- Complete gearbox assembly
- Separating front gearbox housing from rear gearbox housing
- Assembly of the gearbox forks
- Range shift lever
- Differential – Bevel gear set
- Rear pinion casing
- Positioning and shimming of rear bevel gear set and differential
- PTO control clutch
- Rear PTO casing
- Assembly of PTO output shaft ring nut
- Rear PTO selector lever
- Parklock control
- Hand brake cover fixing
- Parklock linkage
- Hand brake adjustment
- Parklock adjustment
E0 – Rear axle
- Right-hand rear axle
- Left-hand rear axle
- Adjusting the bevel gear set and the rear differential
- Rear differential
- Rear differential lock control fork
- Removing rear differential
- Brake flange
- Bleeding the braking system
- Left hand park brake unit
- Right hand park brake unit
- Installing the park brake unit with pressurised system
F0 – Front axle
- Front axle differential assembly
- Disassembling the front differential
- Complete front carrier (Active Drive)
- Cylinder protection (Active Drive)
- Front axle (Active Drive)
- Adjusting end float (Active Drive)
- Complete knuckle assembly (Active Drive)
- Checking free play of upper head (Active Drive)
- Disassembling the knuckle assembly (Active Drive)
- Steering tie-rod (Active Drive)
- Checking free play of lower head (Active Drive)
- Damper (Active Drive)
- Steering cylinder (Active Drive)
- Steering knuckle housing and half-shaft (Active Drive)
- Replacing the elastic gaiters (Active Drive)
- Steering angle sensor (Active Drive)
- Pinion-differential assembly (Active Drive)
- Differential lock (Active Drive)
- Adjusting differential (Active Drive)
- Disassembling the front axle differential (Active Drive)
- 4WD shaft (Active Drive)
- Adjusting pinion/crown wheel backlash (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Front differential assembly and adjustment (Active-Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Wheel side universal joint (Active Drive)
- Differential side universal joint (Active Drive)
- Front axle brake discs (Active Drive)
G0 – Bodywork – Cab – Platform
- Engine hood and front hood panels
- Battery mount
- Cab
- Front cab carrier brackets
- Cab access steps
- Cab mat
- Right hand console
- Left hand console
- Instrument panel
- Dashboard
- Pillars
- Roof panel
- CAT2 – CAT4 cab air filter
- Seat
- Empty and charge the air conditioning system
- Cab air conditioning system
- Brake master cylinders
- Parking brake lever
- Steering wheel
- Steering column stalk
- Gear lever
- Rear PTO speed mode selector lever
- Distributor levers
H0 – Hydraulic system
- Base hydraulic circuit
- Full house hydraulic circuit
- Power steering pump
- Ancillary pump
- Removing the hydraulic pump power take off
- Hydraulic power steering unit (Orbitrol)
- Accumulator block
- Front lift valve block
- Front mid-mounted connectors
- Rear ancillary distributor
- Disassembling the rear ancillary utility distributor
L0 – Electrical system
- 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
- Battery
- Reinitialising LOGIC BOX CAT4
- iMonitor
M0 – Front PTO
- Front power take off
- Disassembling PTO clutch
- Differential lock solenoid valve and front PTO
- Oil filter
N0 – Front lift
- Complete front lift
- Front lift cylinder
R0 – Rear lift
- Rear lift complete with distributor – Part 1
- Rear lift complete with distributor – Part 2
S0 – Wheels
- Front Wheels
- Rear wheels
- Steering angle adjustment
V0 – Ballast – towing hitches
- Tow hook
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
- SCR Heat Protection
- Diagnostic protocol – AdBlue – Float level unit
F0 – FRONT AXLE
- Active Drive Cylinder Malfunction and Cold Start issue
- Bevel gear set loosing screws
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Inaccurate steering during road driving
L0 – ELECTRIC AL SYSTEM
- SERVICE NEWS – M334-M335-M430-M28-M427 New Engine SW release A09 (FarMotion Stage 5)
- SERVICE NEWS – Engine WH connector not properly assembled
R0 – REAR LIFT
- SERVICE NEWS – Frutteto rear lift seal ring damaged
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
