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Related Manuals for LAMBORGHINI R8.230 DCR
Summary of Contents for LAMBORGHINI R8.230 DCR
- Page 1 Workshop manual r8.230 DCr ->WsXJ390200ll10001 r8.270 DCr ->WsXJ400200ll10001...
- Page 2 Find manuals at https://best-manuals.com...
- Page 3 ConTEnTs 0 - InTroDuCTIon 0.1 - Introduction 0.1.1 - Safety notes 0.1.2 - General safety rules 0.1.3 - Safety precautions for removal and refitting operations 0.1.4 - Lifting instructions 0.1.5 - Tightening torques 0.1.6 - Threadlockers, adhesives, sealants and lubricants 0.1.7 - Conversion factors 0-10 10 - TEChnICal CharaCTErIsTICs...
- Page 4 ConTEnTs 20.1.5 - SERDIA 2000 level III” software 20-12 20.1.6 - Serdia 20-12 20.1.7 - SERDIA - Diagnostic socket connection 20-13 20.2 - Diagnostic tool screens 20-15 20.2.1 - ECU interrogation 20-15 20.2.2 - Electronic system 20-17 20.2.3 - CAN BUS system 20-18 20.2.4 - Engine control unit - Deutz EMR3 20-19...
- Page 5 ConTEnTs 20.4.4 - Transmission alarms 20-230 20.4.5 - Armrest alarms 20-291 20.4.6 - HLHP alarms 20-294 20.4.7 - Canbus alarms 20-373 20.4.8 - Electrohydraulic control valve alarms 20-384 30 - mEThoD of InTErvEnTIon 30.1 - B0 - Engine 30-2 30.1.1 - Engine - Separation from the transmission (B0.00.02) 30-2 30.1.2 - Engine (B0.00.01) 30-8...
- Page 6 ConTEnTs 30.1.41 - Removing and installing the fuel pressure sensor 30-115 30.1.42 - Removing and installing the high-pressure pump (Installation position A) 30-116 30.1.43 - Removing and installing the high-pressure pump (Installation position B) 30-123 30.1.44 - Removing and installing the injector 30-130 30.1.45 - Removing and installing the pressure limiting valve 30-140...
- Page 7 ConTEnTs 30.3.5 - Flexible coupling and flywheel (D0.05.01) 30-234 30.3.6 - 4WD output shaft 30-236 30.3.7 - Disassembly and reassembly of the Single Speed P.T.O. 30-237 30.3.8 - Disassembly and reassembly of the dual speed P.T.O. 30-261 30.3.9 - Disassembly and reassembly of Solenoid Valves 30-296 30.3.10 - Disassembly and reassembly of the remote control 30-298...
- Page 8 ConTEnTs 30.4.15 - Reassembling the right brake 30-538 30.4.16 - Reassembling the brake actuator unit 30-543 30.4.17 - Reassembling the output unit 30-545 30.4.18 - Reassembling the PTO shaft 30-554 30.4.19 - Reassembly of the PTO shaft clutch 30-563 30.4.20 - Reassembling the hitch 30-573 30.4.21 - Fitting the gearbox on the rear axle 30-578...
- Page 9 ConTEnTs 30.6.22 - Heater matrix 30-682 30.6.23 - Air conditioner RH fan 30-683 30.6.24 - Air conditioner LH fan 30-684 30.6.25 - Trailer braking air pressure gauge 30-684 30.6.26 - Brake master cylinders 30-686 30.6.27 - Parking brake tie rod 30-687 30.6.28 - Parking brake tie rod - Initial and final adjustment 30-688...
- Page 10 ConTEnTs 30.10 - N0 - Front lift 30-753 30.10.1 - Front lift - Complete assembly (N0.01.01) 30-753 30.10.2 - Cylinder 30-755 30.11 - R0 - Rear lift 30-758 30.11.1 - Lift cylinders 30-758 30.11.2 - Lift arms 30-759 30.11.3 - Draft sensor 30-761 30.11.4 - Position sensor 30-761...
- Page 11 ConTEnTs 40.3.19 - Brakes 40-73 40.3.20 - Trailer brakes - Version with air braking 40-74 40.3.21 - Trailer brakes - Version with hydraulic braking 40-75 40.3.22 - Front axle suspension 40-77 40.3.23 - Lift 40-78 40.4 - Wiring harnesses 40-81 40.4.1 - Battery negative lead - 0.012.4029.4/20 40-81 40.4.2 - Battery negative wiring connector positions...
- Page 12 ConTEnTs 40.4.42 - Cab lower headlights wiring loom - 0441.1923.4 40-147 40.4.43 - Connector positions of lower front lights wiring loom on cab 40-148 40.4.44 - Sidelights and front direction indicators wiring loom - 0442.8092.4 40-149 40.4.45 - Sidelights and front direction indicators wiring loom connector positions 40-150 40.4.46 - Worklights control relay wiring loom - 0.015.3730.4 40-151...
- Page 13 0 - InTroDuCTIon...
- Page 14 InTroDuCTIon 0.1 - InTroDuCTIon The purpose of this workshop manual is to provide instruction for repair technicians and a practical guide to improving the quality of repairs. This manual enables repair technicians to acquire a thorough knowledge of the machine, indicating the correct methods for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections.
- Page 15 InTroDuCTIon DangEr Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion of the work, first connect the positive terminal (+) and then the negative (--). Before carrying out any arc welding (permitted only on implements attached to the machine) always disconnect the battery terminals and unplug all the connectors of the electronic control units and the alternator.
- Page 16 InTroDuCTIon Precautions for refitting operations Tighten nuts and screws to the specified tightening torques. When refitting flexible pipes and cables, take care not to twist or tangle them. Always fit new seals, O-rings, split pins and safety stop rings; make sure that the ends of the cotter pins are separated and bent back so that the pin cannot be withdrawn from the hole.
- Page 17 InTroDuCTIon DangEr Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope strands to untwist or the load to slip; this could lead to serious injury. Never lift a heavy load when the two legs of the ropes form a wide angle. the permitted load (kg) decreases in inverse propor- tion to the angle of suspension;...
- Page 18 InTroDuCTIon fInE M8x1 20.8 – 23.0 15.3 – 17.0 30.6 – 33.8 22.6 – 24.9 35.8 – 39.6 26.4 – 29.2 M10x1.25 40.6 – 44.8 29.9 – 33.0 59.7 – 65.9 44.0 – 48.6 71.2 – 78.6 52.5 – 57.9 M12x1.25 72.2 –...
- Page 19 InTroDuCTIon mET- M6x1 – – M8x1 – – M10x1 M10x1.25 – – M10x1.5 – – M12x1.25 – – M12x1.5 M12x1.75 – – M14x1.5 M14x2 – – M16x1.5 M16x2 – – M18x1.5 M18x2.5 – – M20x1.5 – – M22x1.5 – – M24x1.5 M24x2 –...
- Page 20 InTroDuCTIon Fittings for pipes with banjo union These tightening torques refer to tightening the fitting with new copper sealing washers. Table 6 Unions for one-way fittings Unions for three-way fittings Unions for four-way fittings Thread size Wrench Torque Wrench Torque Wrench Torque ±10%...
- Page 21 InTroDuCTIon DEgrEasErs Loctite 703 Product used for degreasing and cleaning parts prior to applica- anD aCTIvaTors tion of Loctite anaerobic products; after drying, promotes uniform curing of threadlockers Loctite 747 Product used specifically for treatment of passive metals prior to use of slow-cure anaerobic threadlockers (series 5 and 6).
- Page 22 InTroDuCTIon RETAINING COM- Loctite 601 Colour: fluorescent green Anaerobic, fast-curing, high-strength adhesive. Suitable for seal- POUNDS ing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm; used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts. Loctite 638 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, very high strength;...
- Page 23 InTroDuCTIon m² x 1.197 = Sq.yard cm³ x 0.061 = Cu.in. m³ x 0.035 = Cu.ft m³ x 1.311 = Cu.yard litres x 0.220 = Imp.gall. litres x 0.264 = US gall. litres x 1.762 = pint litres x 0.880 = quart ,/min x 0.2642 = US.gpm...
- Page 24 InTroDuCTIon pagE lEfT InTEnTIonallY blank 0-12...
- Page 25 10 - TEChnICal CharaCTErIsTICs 10-1...
- Page 26 TEChnICal CharaCTErIsTICs 10.1 - EngInE 10.1.1 - Technical data Testing and setting data Table 10 namE InformaTIon sErIEs valuE unIT General engine data Lenght of engine TCD 2013 1010 1218 Width of engine TCD 2013 Height of engine TCD 2013 Engine weight TCD 2013...
- Page 27 TEChnICal CharaCTErIsTICs namE InformaTIon sErIEs valuE unIT Valve shaft diam- Standard, fit H7 TCD 2013 7,965 eter outlet -0,015) Valve stem clear- TCD 2013 0,01 - 0,03 ance inlet Valve stem clear- TCD 2013 0,02 - 0,04 ance outlet Valve head diam- TCD 2013 38,2 (+/-0,1) eter inlet...
- Page 28 TEChnICal CharaCTErIsTICs namE InformaTIon sErIEs valuE unIT Main bearing pin, Standard HRc TCD 2013 53 (+3) hardness Fit bearing pin Fit bearing pin, TCD 2013 33,9 (+0,06) width Fit bearing pin 1 undermeasure TCD 2013 stage per Lifting journal Lifting journal, TCD 2013 37,4...
- Page 29 TEChnICal CharaCTErIsTICs namE InformaTIon sErIEs valuE unIT Theoretical clear- TCD 2013 0,036 - 0,096 ance between the big-end bearing / lifting journal Piston bolt Piston bolt diam- TCD 2013 45 (0 / -0,006) eter Piston identification of the installation position on the piston base Piston, diameter, Measuring point TCD 2013...
- Page 30 TEChnICal CharaCTErIsTICs namE InformaTIon sErIEs valuE unIT Camshaft bear- TCD 2013 77 (+0,019) ing, crankcase bore Camshaft bear- Standard TCD 2013 77,100 - 77,145 ing, outside diam- eter Camshaft bear- Liner not mount- TCD 2013 73,100 - 73,175 ing, inside diam- eter Main bearing bore Main...
- Page 31 TEChnICal CharaCTErIsTICs set valve clearance 4-cylinder Ignition sequence: 1 - 3 - 4 - 2 Table 11 valvEs CYlInDEr overlap set to valve overlap Outlet valve is not yet closed, inlet valve begins to open. set valve clearance 6-cylinder Ignition sequence: 1 - 5 - 3 - 6 - 2 - 4 Table 12 valvEs CYlInDEr...
- Page 32 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Piston cool- M8x35 TCD 2013 21 Nm ing nozzle on crankcase Locking screw AM14x1.5-ST- with sealing TCD 2013 34 Nm on crankcase ring (coolant) Front cover on M8x35 / M8x70 with 1 clamping TCD 2013 30 Nm...
- Page 33 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Gearcase M8x30-10.9 / Observe tight- TCD 2013 30 Nm crankcase M8x65-10.9 ening quence. Speed gover- M6x16 TCD 2013 8.5 Nm nor crankshaft on gearcase Speed gover- M6x16 TCD 2013 8.5 Nm camshaft...
- Page 34 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Clamping claw BM8x40 Torx Observe tight- TCD 2013 4 Nm 23 Nm injector on cyl- ening specifi- inder head cation. Loosen bolt after tight- ening with pre-tightening value.
- Page 35 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Fuel pipe (re- M16x1.5 Hollow screw TCD 2013 49 Nm turn) on control block Fuel line (re- M12x1.5 Hollow screw TCD 2013 29 Nm turn) on cylin- der head Cooling coil on TCD 2013...
- Page 36 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Heating M8x25 TCD 2013 30 Nm housing crankcase Temperature M12x1.5 TCD 2013 22 Nm sensor on ther- mostat housing Pipe (coolant) M8x25-10.9 / Bolt and nut TCD 2013 20 Nm on cooler (ex- haust gas re-...
- Page 37 TEChnICal CharaCTErIsTICs namE sCrEW TYpE noTEs / rE- sErIEs prE-Clamp- marks Ing valuE Holder on con- M8x20 TCD 2013 30 Nm sole for gener- ator (operating side) Belt pulley on M17x1.5 TCD 2013 98 - 137 Nm generator shaft Cable connec- Cl.
- Page 38 TEChnICal CharaCTErIsTICs 10.2 - TransmIssIon 10.2.1 - Transmission Introduction The tractors in this series are equipped with a POWER SHUTTLE transmission. In this transmission, reversal of the direction of travel is managed entirely by the electronic control unit without the operator having to depress the clutch pedal. This is achieved by way of a solenoid-operated proportional valve that directly controls the main clutch.
- Page 39 TEChnICal CharaCTErIsTICs Fig. 3 - Torsional spring plate Components Engine Gearbox Shaft Flywheel Torsional spring plate Front axle drive shaft Fluid coupling Description The fluid coupling receives drive from engine (1) and transmits drive to gearbox (2) through shaft (3). The engine (1) transmits motion to the flywheel (4), on which is mounted the impeller (5).
- Page 40 TEChnICal CharaCTErIsTICs Fig. 4 - Fluid coupling Components Engine Gearbox Shaft Flywheel Impeller Turbine Rear PTO drive shaft Front axle drive shaft Filler plug for fluid coupling 10-16...
- Page 41 TEChnICal CharaCTErIsTICs gearbox assembly main components Fig. 5 - Main gearbox assembly components 1/3 Components Hydraulic pump for transmission Hydraulic gearbox control valve Four-wheel drive shaft Transmission oil low pressure sensor Transmission oil temperature sensor 4WD control solenoid valve Transmission oil suction line filter Speed sensor for odometer (nAb) Clutch speed sensor (nHk) 10.
- Page 42 TEChnICal CharaCTErIsTICs Fig. 6 - Main gearbox assembly components 2/3 Components Left brake cylinder Start enabling sensor Speed sensor (Nlsa) Speed sensor (Nlse) Creeper engagement control shaft Gear control shaft Main clutch control solenoid valve RH brake cylinder Rear PTO control solenoid valve 10.
- Page 43 TEChnICal CharaCTErIsTICs Fig. 7 - Main gearbox assembly components 3/3 Components Lift cross shaft Right axle casing Reduction unit oil filler/level plug Rear PTO speed sensor Left axle casing Transmission hydraulic system The transmission is equipped with a hydraulic system served by a gear pump driven from a lateral power-take-off. The gear pump supplies pressurised fluid for the following uses: hydraulic gearbox control valve (5) 1000 PTO solenoid valve (11)
- Page 44 TEChnICal CharaCTErIsTICs Fig. 8 - Transmission hydraulic system diagram Components Suction line filter Filter Filter By-pass valve (opening 0.25 bar) Gear pump (40 cc/rev at 19.8 bar) Cold start safety valve (27-30 bar) Temperature sensor Gearbox control valve 4WD control solenoid valve Solenoid-operated proportional valve for main clutch Main clutch Transmission oil cooler...
- Page 45 TEChnICal CharaCTErIsTICs gearbox Description The gearbox receives drive from coupling (2) and transmits it, through hydraulically controlled gearbox (3), creeper (4), main clutch (5) and 6-speed mechanical gearbox (7), to bevel pinion (8) and power take-off (9), which, in turn, transmits drive to the front axle.
- Page 46 TEChnICal CharaCTErIsTICs main components Fig. 10 - Main components Components Hydraulically-controlled gearbox “C” clutch “A” clutch Creeper unit Creeper unit synchroniser Main clutch Hydraulic pumps PTO drive gear Mechanical gearbox 3rd/4th gear synchroniser 10. 5th/6th gear synchroniser 1st/2nd speed synchroniser 12.
- Page 47 TEChnICal CharaCTErIsTICs Fig. 11 - Main clutch schematic Components Clutch pedal Clutch pedal position sensor Transmission ECU Transmission gear pump Clutch control solenoid-operated proportional valve Main clutch Hydraulic gearbox and shuttle control valve The function of the hydraulic gearbox control valve is to pilot and control the engagement of the gears in the hydraulically-controlled gearbox.
- Page 48 TEChnICal CharaCTErIsTICs Fig. 12 - Control valve main components 10-24...
- Page 49 TEChnICal CharaCTErIsTICs a. gearbox control valve Fig. 13 - Pressure test points Table 14 funCTIon ThrEaD sIZE prEssurE D clutch pressure m10x1 19.8 bar C clutch pressure m10x1 19.8 bar pilot pressure (10 bar) m10x1 10 bar general pressure (18 bar) m10x1 19.8 bar Engagement pressure of clutch A/B or F/G...
- Page 50 TEChnICal CharaCTErIsTICs Fig. 14 - Main components Components B1 Breather valve G1 Clutch selection valve for A/B or F/G clutches S1 Relief valve H2 Clutch engagement valve for C/D clutches H1 Clutch engagement valve for A/B or F/G clutches Y3 Pilot solenoid valve for engagement valve H2 Y4 Pilot solenoid valve for engagement valve H1 Y1 Pilot solenoid valve for clutch selection valve G1 Y5 Pilot solenoid valve for road/field selection valve...
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