Document overview
Workshop Manual for HURLIMANN XV 90 → ZKDKU00200TD50001 from the XV (FARMOTION STAGE 5) family. Digital PDF in English with 1,472 pages.
The corresponding English table of contents contains 51 sections and 532 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: XV (FARMOTION STAGE 5)
- Model: XV 90
- Starting serial number: ZKDKU00200TD50001
- Document type: Workshop Manual
- Language: English
- Pages: 1,472
- File size: 419.64 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match HURLIMANN XV 90 → ZKDKU00200TD50001.
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
- Technical data: Connecting rods
- Technical data: pistons – piston rings
- 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
- Starter motor
- Compensation tank
- Exhaust gas recirculation valve (EGR)
- Alternator
- Manual fuel pump
- Fuel filter
- Fuel prefilter
- Air filter
- Coolant radiator
- Intercooler
- Fuel radiator
- Gearbox oil radiator
- Fuel tank
- Fuel tank
- Fuel tank with front PTO
- Fuel tank – version without PTO
- AdBlue tank
- AdBlue solenoid valve
- AdBlue injector
- AdBlue pump
- AdBlue float sensor
- Exhaust silencer – Catalytic converter (DOC)
- DPF and SCR catalytic converter
Transmission
- Transmission
- Hydraulic reverse power shuttle
- Hydraulic reverse shuttle unit
- HML unit
- Hi-Lo unit
- Gearbox assembly with HML
- Gearbox unit with Hi-Lo
- Gearbox assembly with underdrive
- Range gearbox and parking brake assembly
- Range control rod and parking brake lever
- Dual traction selector unit
Rear axle
- Rear axle F
- Differential assembly
Front axle
- Pinion, differential and differential lock
- Final drive
- Suspended axle valve unit
Bodywork – Cab – Platform
- Air conditioning system
- Air conditioning system – Recharging
- Air conditioning system compressor
- External views of the tractor
- Viste interni cabina
- Main technical data
- Dimensions and weights of the tractor
- Dashboard
- Left hand console
- Right hand console
- Instrument panel
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)
- Braking valve (logic block)
- Base hydraulic circuit
- Optional hydraulic circuit
- Optional hydraulic circuit 1
- Optional hydraulic circuit 2
- Full house hydraulic circuit, GS version
- Base hydraulic circuit, GS version
- Optional hydraulic circuit 1, GS version
Electrical equipment
- Angle sensor ± 45°
- Ambient Temperature Sensor
- Air filter clogged sensor
- Oil pressure switch
- Fuel pressure sensor
- Coolant temperature sensor
- Temperature sensor
- Oil regulator valve block pressure switch
- Brake pressure sensor
Front lift
- Front lift
Rear lift
- Rear lift
- Rear lift distributor
Calibrations and electronic diagnosis
Diagnostic tools
- D-TECH App
- D-Tech and diagnostic ports
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- ECU reset (MVCU)
- Set vehicle model (MVCU)
- Cluster configuration
- Tyre type
- Measurement unit
- PowerShuttle
- 4WD
- Front Power Take-Off (PTO)
- Hydraulic trailer brake MR
- Range
- ActiveDrive
- Cylinders
- Rapid steer system (SDD)
- CAT4
- Rear PTO
- Stabilizer
- Clutch pedal calibration
- Steering angle calibration
- Rear hitch position calibration
- Front suspension calibration
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- ECUs
- ECUs firmware update
- On-board instruments (Cluster/Display) flashing
- Download Dataset FARMotion & Flash ECU
Method of intervention
B0 – Engine
- Complete engine
- Separating the engine from the transmission
- Tightening procedure for engine components
- 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
- 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
- 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
- Fuel pressure sensor
- 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
- Water in fuel sensor
C0 – Engine accessories
- Replacing the coolant
- 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
- Engine coolant radiator
- Complete cooling pack
- Engine air intake fan
- Air filter
- Intercooler
- Diesel radiator
- Transmission oil heat exchanger
- Manual fuel pump
- Fuel and filter and prefilter
- Diesel fuel tank
- Auxiliary fuel tank and AdBlue tank
- Bleeding the fuel circuit
- Compensation tank
- Auxiliary fuel tank
- Auxiliary fuel pump
- AdBlue tank
- AdBlue solenoid valve
- Exhaust pipe – DPF+SCR catalytic converter
- DPF+SCR catalytic converter inlet side exhaust pipe
- Exhaust silencer – Catalytic converter (DOC)
- Starter motor (procedure on vehicle)
D0 – Transmission
- Draining and filling the transmission oil
- Separating the gearbox casing from the rear gearbox casing
- Hydraulic reverse shuttle
- Complete shuttle unit disassembly
- Cover unit
- Cover assembly
- Forward drive clutch unit
- Reverse drive clutch unit
- HML unit
- Assembly of the HI-LO unit in the front gearbox housing
- HML unit assembly in the front gearbox
- Clutch assembly
- Planet gear carrier unit – HML unit
- Gearbox input shaft (with HML)
- Disassembling the gearbox input shaft
- Gearbox input shaft – Version without HML
- Primary shaft (version with HML)
- Primary shaft (version with range selector unit)
- Primary shaft – Version without HML
- Secondary shaft – Version with HML
- Secondary shaft – Version without HML
- Disassembling secondary shaft – Version with range selector unit
- Adjusting endfloat of the secondary shaft gears
- Adjusting endfloat of the secondary shaft gears
- Tone wheel
- Front gearbox from its rear part
- Complete gearbox assembly
- Rear gearbox housing cover
- Assembly of the gearbox forks
- Conical screw assembly
- Pinion
- Differential – Bevel gear set
- Range reduction gearbox shaft
- PTO control clutch
- Rear PTO casing
- Rear PTO drive shaft
- Assembly of PTO output shaft ring nut
- Rear PTO driven shaft
- Rear PTO selector lever
- Parking brake disc sectors
- 4WD output shaft in transmission.
E0 – Rear axle
- Right-hand rear axle
- Brake flange
- Planet gear carrier
- Removing rear differential
- Bleeding the braking system
F0 – Front axle
- 4WD shaft
- Support with front axle
- Planetary reduction gearbox (Active Drive)
- Front axle (Active Drive)
- Complete 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)
- Replacing the elastic gaiters (Active Drive)
- Pinion-differential assembly (Active Drive)
- Differential lock (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Front axle brake discs (Active Drive)
- Lower oscillating suspension arm (Active Drive)
- Upper oscillating suspension arm (Active Drive)
- Checking free play of lower suspension knuckle (Active Drive)
- Front axle lower ball joint assembly (Active Drive)
- Removing bevel gear set
- Adjustment of the bevel gear set
- Disassembling the differential lock assembly
- Front axle bearing fork adjustment and preload
- Front axle differential assembly
- Disassembling the front differential
- Assembly and adjustment of front differential (Active Drive)
- Steering cylinder (Active Drive)
- Upper oscillating suspension arm (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
- Steering column stalk and reverse shuttle lever
- Instrument panel
- Instrument cluster
- Pillars
- Roof panel
- CAT2 – CAT4 cab air filter
- Seat
- Empty and charge the air conditioning system
- Parking brake lever
- Steering wheel
- Gear lever
- Range shift lever
- Rear PTO speed mode selector lever
- Distributor levers
- Cab air conditioning system
- Brake master cylinders
- Brake fluid reservoir
- 6-way distributor control
H0 – Hydraulic system
- Power steering pump
- Ancillary pump
- Removing the hydraulic pump power take off
- Front mid-mounted connectors
- Rear auxiliary utility distributor
- Hydraulic steering pump (11 cc, LH)
- Hydraulic steering drain block
- Hydraulic power steering unit (Orbitrol)
- Adjusting power steering pump and ancillary pump carrier gear free play
- Power steering pump and ancillary pump carrier
- Load Sensing oil pump filter
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
- Engine control unit
- Reinitialising LOGIC BOX CAT4
- ECU mounting bracket
- MVCU control unit
- OCU control unit
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
- Complete rear lift
S0 – Wheels
- Front Wheels
- Rear wheel
- Steering angle adjustment
V0 – Ballast – towing hitches
- Tow hook
Wiring diagrams
Components
- Location of ECUs
- Engine control Unit
- ECU ISO 11786
- Ad-Blue Module
- Air Conditioning Control Unit
- MVCU ECU
- SVCU ECU
- CTM_AM55 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 (3-cylinder version)
- S001B – Electronic engine governor (4-cylinder version)
- S002 – Preheating
- S003 – Starter
- S004 – Lift
- S005 – Turn indicators
- S006 – Work lights
- S007 – Windscreen wipers
- S008 – Internal illumination
- S009 – Radio
- S010 – Air conditioning
- S011 – Sockets and accessories
- S012 – Transmission
- S013 – Braking system
- S014 – Power take off (PTO)
- S015A – Front axle (ActiveDrive)
- S015B – Front axle (CLS)
- S016 – Stabilisers
- S017 – Trailer brake
- S018 – Isobus
- S020 – Tie-rods and loader
- S021 – CAN Engine
- S022 – CAN vehicle
- S023 – CAN Aux
- S025 – Battery master switch
- S026 – AdBlue
- S027 – Reverse shuttle
Wiring harnesses
- 0.007.7899.3 – Front differential locking solenoid valve
- 0.007.7899.3 – Front PTO solenoid valve
- 0.014.1567.4/30 – Front wiper motor – opening windscreen version
- 0.018.4629 – ASM “V” sensor
- 0.019.2571.4_10 – ISO 11786
- 0.019.8827.4 – SDD (rapid steer system)
- 0.020.9462.4/10A – LH rotating beacon
- 0.020.9462.4/10B – RH rotating beacon
- 0.021.0490.4/10 – Trailer ABS
- 0.023.1281.4 – Injectors (3 cylinder version)
- 0.023.1282.4_10 – Injectors (4 cylinder version)
- 0.023.2613.4/20 – Shock-absorber sensors (version with ActiveDrive)
- 0.023.2616.4/20 – Front axle solenoid valves (version with ActiveDrive)
- 0.027.5538.4 – License plate light
- 0.027.7652.4/10 – Cowl
- 0.028.5244.4/10 – Cab roof work lights
- 0.028.5352.4/20 – Front axle (version with ActiveDrive)
- 0.029.1625.4A – Wiring harness for RH front cab roof working lights (LED)
- 0.029.1625.4B – Wiring harness for supplementary RH front cab roof working lights (LED)
- 0.029.1625.4C – Wiring harness for supplementary LH rear cab roof working lights (LED)
- 0.029.1625.4D – Wiring harness for LH rear cab roof working lights (LED)
- 0.029.1625.4E – Wiring harness for LH rear cab roof working lights (LED)
- 0.029.1625.4F – Wiring harness for RH rear cab roof working lights (LED)
- 0.029.8764.4 – TOP lights
- 0.030.6479.4 – Engine (3 cylinder version)
- 0.030.6480.4/10 – Engine (4 cylinder version)
- 0.032.5468.4_10 – Glowplugs (3 cylinder version)
- 0.032.5469.4/10 – Glowplugs (4 cylinder version)
- 0.033.4758.4/10 – ASM 1 RH
- 0.033.8944.4/20A – LH LED TOP lights adapter
- 0.033.8944.4/20B – RH LED TOP lights adapter
- 0.036.0966.4 – Junction terminal board
- 0.037.0325.4/20 – Front wiring loom
- 0.037.0995.4 – Preheating
- 0.037.2286.4 – Steering wiring loom
- 0.040.0681.4/10 – Roof panel
- 0.040.1119.4/10 – SVCU control unit
- 0.040.1233.4/10 – Rear wiring loom
- 0.040.1236.4/10 – Cat. 2 air conditioning system
- 0.040.1237.4/10 – Cat. 4 air conditioning system
- 0.040.1240.4/20 – Hydraulic reverse shuttle
- 0.040.1242.4/10 – Hydraulic stabilizers
- 0.040.1243.4/10 – CTM control unit
- 0.040.1244.4/50 – Cab
- 0.041.4739.4/10 – Console
- 0.041.4740.4/10 – Lateral console adapter wiring loom
- 0.041.4741.4/10A – Front work lights for LH side of cab
- 0.041.4741.4/10B – Front work lights for RH side of cab
- 0.041.4742.4/10 – Battery wiring
- 0.041.4772.4 – Battery negative
- 0.041.4773.4 – Starting
- 0.041.4798.4 – Lights selector and Smart Lever wiring loom
- 04422324.4/10 – ISO 11786 socket
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
- After-sales 2024 subscription
- After-sales 2023 subscription
- After-sales 2022 subscription
B0 – ENGINE
- Leakage from turbo inlet oil pipe
- FARMotion seal ring leakage
- Belt Tensioner FarMotion Engine
C0 – ENGINE ACCESSORIES
- M339 error code on FarMotion Stage 5 models
- SCR Heat Protection
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
- Oil Leakage From Active Drive
F0 – FRONT AXLE
- Active Drive Cylinder Malfunction and Cold Start issue
- Bevel gear set loosing screws
- Active Drive rubber boot breakage
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Difficulty to regulate temperature inside the cabin
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
- Oil Cooler leakage – Frutteto Mechanical GS Stage 5
- Stuck angular command of hydraulic distributors
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
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- Brakes Switch malfunction
- SerDia4.0
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- ALARM CODE T19 – T20
- Lost connection diagnostic tools
- PTO switch not working
- T12 – T13 error code on Frutteto Mechanical Stage 5 (PT356 project)
- PTO activation after engine start (Frutteto Mechanical GS Stage 5 – PT356 GS project)
R0 – REAR LIFT
- SERVICE NEWS – Frutteto rear lift seal ring damaged
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
