Document overview
Workshop Manual PDF for HURLIMANN XT 100 → ZKDS9502W0TH10001, XT (STAGE 3A) family. Document language: English; 925 pages.
The corresponding English table of contents contains 46 sections and 292 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: XT (STAGE 3A)
- Model: XT 100
- Starting serial number: ZKDS9502W0TH10001
- Document type: Workshop Manual
- Language: English
- Pages: 925
- File size: 96.93 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XT 100 → ZKDS9502W0TH10001.
Complete table of contents
Introduction
- Tightening Torques
- Tightening torques for nuts and bolts of Deutz engines
- Tightening torques for nuts and bolts of electrical connections
- 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
- Components of the 2012 2V UPS engine
- Test data and settings
- Tightening requirements 2012 2V UPS engine
Transmission
- Transmission
- Shuttle unit
- HML unit
- Gearbox assembly
- Bevel pinion and range gearbox assembly
- Electrohydraulic four-wheel drive engagement assembly
- Differential unit
- Brakes and rear axle assembly
- Rear PTO
- PTO clutch assembly.
- 4-speed PTO and Syncro PTO
Front axle
- Front axle
Bodywork – Cab – Platform
- Air conditioning system
Hydraulic system
- Hydraulic system
- Hydraulic steering, brakes and services diagram – Standard version
- Hydraulic system diagram – Version with front PTO
- Hydraulic steering, brakes and services diagram – Standard version
- Hydraulic steering, brakes and services diagram – Version with hydraulic trailer braking
- Hydraulic lift and remote control valve circuit diagram – Standard version
- Hydraulic lift and remote control valve circuit diagram – Version with 8-way valve, hydraulic trailer braking and supplementary pump
- Hydraulic lift and remote control valve circuit diagram – Version with 8-way valve, hydraulic trailer braking and front lift
- Hydraulic lift and remote control valve circuit diagram – Version with 8-way valve, hydraulic trailer braking, front lift and auxiliary pump
- Steering circuit pump
- Lift circuit gear pump
- Lift circuit auxiliary gear pump
- Power steering
- Remote control valve – 6-way version
- Remote control valve – 8-way version
- Remote control valve – 8-way version with front lift
- Remote control valve – 8-way version with auxiliary front lift pump
- Braking system
- Servo-brake valve for front axle
- Trailer braking valve
- Park Brake system
- Park Brake valve
- Services solenoid valves assembly – Pressure holding valves
- Shuttle solenoid valves assembly
- HML solenoid valve assembly
Front lift
- Front lift
Rear lift
- Rear lift control valve
Calibrations and electronic diagnosis
Diagnostic tools
- Positions of ECUs and diagnostic instruments
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket connection
Serdia 2000
- SERDIA 2000 level III” software
- SERDIA – Diagnostic socket connection
Diagnostic tool screens
- ECU interrogation
Commissioning and calibrating the tractor
- Digital instrument calibration
- Wheel constants
- Commissioning – Purpose of the document
- Commissioning – Instruments and information required
- Commissioning – Description of the commissioning procedure
- Commissioning – Basic procedure
- Commissioning – Eeprom re-initialisation
- Commissioning – Line end programming of the tractor
- Commissioning – Calibration of the shuttle and HML clutches
- Commissioning – StopAndGo calibration
- Commissioning – Lift calibration
- Commissioning – Calibration of the draft sensor
- Commissioning – Remote valve configuration
- Transmission calibration – Purpose of this document
- Transmission calibration – When to calibrate the shuttle clutches
- Transmission calibration – When to calibrate the HML clutches
- Transmission calibration – When to calibrate the StopAndGo function
- Transmission calibration – and information for necessarie per le tarature
- Transmission calibration – Procedure for calibration of the shuttle clutches
- Transmission calibration – Description of the procedure for automatic calibration of the shuttle clutch
- Transmission calibration – Description of the procedure for manual calibration of the shuttle clutch
- Transmission calibration – Editing the comfort parameters of the shuttle clutch
- Transmission calibration – Procedure for calibration of StopAndGo operating parameters
- Transmission calibration – Procedure for calibration of HML operating parameters
- Transmission calibration – Description of the procedure for automatic calibration of the HML clutch
- Transmission calibration – Description of the procedure for manual calibration of the HML clutch
- PTO operation
- Electrohydraulic spool valves
ECU alarms
- Alarms – introduction
Engine alarms
- Alarms – Engine ECU alarms list
Transmission alarms
- Alarms – Transmission ECU alarms list
Instrument panel alarms
- Alarms – Instrument alarms list
HLHP alarms
- Alarms – Services alarms list
Lift alarms
- Alarms – Lift ECU alarms list
Method of intervention
- Tools for engine disassembly and reassembly
- Workshop tools for engine disassembly and reassembly
B0 – Engine
- Air conditioning compressor drive belt
- Tension adjustment of the fan and air conditioning compressor drive belt
- Alternator, fuel pump and water pump drive belt
- Tension adjustment of the alternator, fuel pump and water pump drive belt
- Compression test
- Assembly and disassembly of the engine on the assembly stand
- Adjustment of valve clearance
- Removal and refitting of the rocker arms and pedestals
- Disassemble and complete the rocker and support, check
- Disassembly and assembly of the cylinder head
- Grinding the cylinder head seal surface
- Measuring piston protrusion
- Valve assembly and disassembly
- Valve check
- Check the valve guide
- Replacing the valve guide (oversized – cast)
- Check the valve residual
- Replacing the lined valve seat (oversized)
- Check the endfloat of the crankshaft
- Check the crankshaft
- Replace the crankshaft O-ring (flywheel end)
- Replacing the crankshaft O-ring (opposite end to flywheel)
- Check the connecting rod drum
- Fitting and removing piston pin bush
- Assembly and disassembly of the crankshaft
- Fitting and removing counterweight shafts, checking
- Disassembly and assembly of the piston and connecting rod drum
- Check the piston
- Check the piston rings and piston grooves
- Assembly and disassembly of piston cooling nozzles
- Removal and refitting of the crankcase breather
- Check the cylinder
- Removal and refitting of the front cover (opposite end to flywheel)
- Disassembly and assembly of the connector box
- Fitting and removing the camshaft bearings, checking
- Disassembly and assembly of the gear case cover
- Assembly and disassembly of the camshaft
- Check the camshaft
- Removal and refitting of the rotation device
- Removing and fitting the V-belt pulley
- Fitting, removing, checking and setting adjuster rod
- Removal and refitting of the heater
- Removal and refitting of the turbocharger
- Removal and refitting of the charge air duct
- Fitting and removing injection pump
- Determine the thickness of the shim (engine without injection advance variator)
- Determine the thickness of the shim (engine with injection advance variator)
- Determination of the overall dimensions of the injection pump (engine without the injection advance variator)
- Determination of the overall dimensions of the injection pump (engine with the injection advance variator)
- Fitting and removing injection valves
- Checking the injection valves
- Removal and refitting of the fuel lift pump
- Removal and refitting of the oil pickup pipe
- Removing and fitting the lubricant oil sump pan (cast iron lubricant oil sump)
- Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate)
- Removal and refitting of the oil cooler
- Disassembly and assembly of the oil radiator housing
- Removal and refitting of the oil pressure switch
- Removal and refitting of the water pump
- Testing the thermostat (after removal)
- Removal and refitting of the thermostat
- Removal and assembly of the fan support
- Removal and refitting of the fan support
- Removal and refitting of the flywheel
- Replacing the starter motor ring gear on the flywheel
C0 – Engine accessories
- Starter motor
- Removing and fitting the engine governor
- Removal and refitting of the exhaust manifold
- Removal and refitting of the fuel filter head.
- Assembly and disassembly of the temperature sender
- Removal and refitting the engine block
- Removal and refitting of the alternator (with drivebelt)
- Disassembly and assembly of the starter
E0 – Rear axle
- Adjustment of supports
- Park Brake assembly
- Park Brake unit disassembly
R0 – Rear lift
- Internal lever setscrew
- Lift
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
- A – Starting and battery charging
- B – Fuses
- C – Earths
- D – Intermediate connections
- E – On-board instruments and visual/audible indicators
- F – External lights
- G – Interior lights
- H – Manual electrical controls
- I – Switches
- J – Relays
- K – Sensors and senders
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices, flasher units and timers
- N – Electric motors and actuators
- O – Resistors and rheostats
- P – Miscellaneous devices
- Q – Protection and safety devices
- R – Diagnostics
Systems
- S001 – Starting and preheating
- S002 – Electronic engine control relay
- S003 – Transmission
- S004 – Instrument panel
- S005 – Lights switch stalk (without front lift)
- S006 – Lights switch stalk (with front lift)
- S007 – Worklights (without front lift)
- S008 – Worklights (with front lift)
- S009 – Manual climate control
- S010 – Heating
- S011 – Power (+15)
- S011 – Power (+30)
- S013 – Negatives
- S014 – CAN BUS
- S015 – PTO
- S016 – Brakes
- S017 – Remote valves and lifts
- S018 – Windscreen wipers
- S019 – Diagnostics – accessories
Wiring harnesses
- 0.017.1063.4 – Cab earth
- 0.017.9016.4/10 – Battery negative – Version with front battery
- 0.017.8922.4/10 – Battery negative – Version with lateral battery
- 0.017.0474.4 – Battery positive
- 0.015.1983.4/10 – Power supplies
- 0.014.9195.4/20 – Preheating
- 0.014.8107.4/30 – Hood lights
- 0.014.8666.4/30 – Hood lights
- 0.016.2000.4/20 – Engine – Version with front battery
- 0.016.2001.4/10 – Engine – Version with lateral battery
- 4215653 – Engine control (engine side)
- 0.016.8047.4 – Engine control wiring (cab side)
- 0.012.2756.3 – Front PTO solenoid valve
- 0.015.9040.4/60 – Central wiring
- 0.017.8385.4/10 – Side console wiring
- 0.010.6468.3/10 – Pneumatic seat
- 0.015.2347.4/20 – Multifunction control lever
- 0.014.9570.4/10 – ISO 11786
- 0.017.7957.4/10 – Transmission
- 0.016.0373.4/30 – Cab power supply
- 0.015.6272.4/40 – Cab roof line
- 0.015.7266.4/30 – Air conditioning condenser fan
- 0.016.0664.4 – Front lights
- 04411923.4 – Lower front lights
- 0.014.3927.4/40 – Auxiliary worklights
- 0.013.4085.4/20 – Hood worklights
- 0.011.3597.3 – Windscreen wiper
- 0.013.6327.4 – Rotating beacon
- 0.016.1001.4/20 – Hydraulic trailer braking valve
- 0.014.1645.4/10 – Compressed air pressure sensor
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
- SDF Parts and SDF Service DVV 04/2014, version 26
- Technical Documentation DVD 03/2010
- New function: Download PDF manuals
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
- Service and Spare Parts – 2017 Subscription
- SDF Parts and SDF Service DVDs 05/2014 version 25
- SDF Parts and SDF Service DVDs 03/2013 version 24
B0 – ENGINE
- Flushing the lubrication circuit
- Deutz AG engine oil specifications
- SerDia 2010 updating license file
- POSSIBLE LEAKAGE OF FUEL INTO THE ENGINE SUMP (LEVEL RISE)
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- Additive for diesel fuel
D0 – TRANSMISSION
- Hydraulic shuttle central disc
- Bushes on shuttle input shafts
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Clutch pedal potentiometer actuator pin
- Air conditioning system recharging
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Resonator failure
- Assembly instructions for solenoid valves and cartridge valves
- L0 – ELECTRIC AL SYSTEM
