LAMBORGHINI R7.190 DCR Workshop Manual
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LAMBORGHINI R7.190 DCR Workshop Manual

LAMBORGHINI R7.190 DCR Workshop Manual

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r7.190 DCr
->ZkDs7902W0ll10010
r7.210 DCr -> 10010

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Summary of Contents for LAMBORGHINI R7.190 DCR

  • Page 1 Workshop manual r7.190 DCr ->ZkDs7902W0ll10010 r7.210 DCr -> 10010...
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Table Of Contents

    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 20.1.4 - Serdia 2000 20-15 20.2 - Diagnostic tool screens 20-19 20.2.1 - ECU interrogation 20-19 20.3 - Commissioning and calibrating the tractor 20-22 20.3.1 - Tractor commissioning - table of contents 20-22 20.3.2 - Scope of the document 20-22 20.3.3 - Instruments and information required 20-22...
  • Page 5 ConTEnTs 30.1.12 - 8191 - Screwdriver insert 30-5 30.1.13 - 8192 - Bowlen wrench 30-6 30.1.14 - 8193 - Screwdriver insert 30-6 30.1.15 - 8194 - Screwdriver insert 30-6 30.1.16 - 8195 - Multi-tooth screwdriver bit 30-7 30.1.17 - 8196 - Open-ended wrench 30-7 30.1.18 - 8198 - Bradawl 30-7...
  • Page 6 ConTEnTs 30.3.1 - Test data and settings 30-21 30.3.2 - Tightening torque 30-26 30.3.3 - Compression test 30-33 30.3.4 - Assembly and disassembly of the engine on the assembly stand 30-35 30.3.5 - Valve clearance adjustment (with the exhaust gas recirculation module absent or removed).
  • Page 7 ConTEnTs 30.3.48 - Removal and refitting of the oil pressure switch 30-252 30.3.49 - Fitting and removing the fuel pressure regulator valve 30-254 30.3.50 - Removing and fitting the coolant pump (driven by toothed belt) 30-256 30.3.51 - Testing the thermostat (after removal) 30-267 30.3.52 - Removal and refitting of the thermostat 30-269...
  • Page 8 ConTEnTs 30.5.27 - Range driving gear 30-424 30.5.28 - Creeper planetary reduction unit 30-426 30.5.29 - Disassembly of the creeper planetary gear unit 30-426 30.5.30 - PTO clutch 30-427 30.5.31 - PTO output shaft 30-429 30.5.32 - PTO output shaft 30-433 30.5.33 - 4WD shaft and clutch 30-440...
  • Page 9 ConTEnTs 40.3.1 - S001 - Engine ECU 40-40 40.3.2 - S002 - Armrest 40-48 40.3.3 - S003 - Transmission ECU 40-57 40.3.4 - S004 - Services ECU 40-66 40.3.5 - S005 - Instrument panel (w/ hydraulic braking) 40-74 40.3.6 - S005 - Instrument panel (w/ air braking) 40-82 40.3.7 - S006 - Cab 1 40-89...
  • Page 10 ConTEnTs pagE lEfT InTEnTIonallY blank Find manuals at https://best-manuals.com...

  • Page 11: Introduction

    0 - InTroDuCTIon...

  • Page 12: Safety Notes

    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 13: Safety Precautions For Removal And Refitting Operations

    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 14: Lifting Instructions

    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 15: Tightening Torques

    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 16 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 17 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 18: Threadlockers, Adhesives, Sealants And Lubricants

    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 19 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 20: Conversion Factors

    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 21 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 22 InTroDuCTIon pagE lEfT InTEnTIonallY blank 0-12...

  • Page 23: Technical Characteristics

    10 - TEChnICal CharaCTErIsTICs 10-1...

  • Page 24: Engine

    TEChnICal CharaCTErIsTICs 10.1 - EngInE 10.1.1 - Engine 2013 components Right-hand view Fig. 2 - TCD 2013 L06 2V Right-hand view (example) Engine crankcase breather Lubricating oil filler Common rail Lubricating oil cooler Lubricating oil cartridge filter Oil dipstick Fuel cartridge filter Lubricating oil drain plug Alternator 10-2...
  • Page 25 TEChnICal CharaCTErIsTICs Left-hand view Fig. 3 - TCD 2013 L06 2V Left-hand view (example) Exhaust outlet Combustion air inlet Coolant outlet Coolant inlet Intercooler connections Starter motor Lubricating oil drain plug 10-3...
  • Page 26 TEChnICal CharaCTErIsTICs Lubricating oil diagram Fig. 4 - Lubricating oil system Lubricating oil diagram Lubricating oil sump Lubricating oil pump Pressure limiting valve Lubricating oil cooler Check valve (TD/TCD 2012) Bypass valve Bypass valve Pressure control valve Lubricating oil filter 10.
  • Page 27 TEChnICal CharaCTErIsTICs Fuel system diagram Fig. 5 - Fuel flow diagram (example) Fuel system diagram Fuel tank Fuel pre-filter Fuel lift pump Fuel cartridge filter Fuel supply line to FCU (Fuel Control Unit) FCU (Fuel Control Unit) High-pressure pump Common rail Nozzle 10.
  • Page 28 TEChnICal CharaCTErIsTICs Coolant circuit diagram Fig. 6 - Coolant circuit diagram (example Coolant circuit diagram Radiator Coolant inlet Coolant pump Partial flow of coolant to lubricating oil cooler Lubricating oil cooler Coolant supply line for engine cooling Cylinder lining/head cooling Cab heating connection Heat exchanger 10.
  • Page 29 TEChnICal CharaCTErIsTICs Electrical/electronic system Fig. 7 - Electronic engine control Engine side 1. Fuel pressure transducer 2. Coolant temperature sender 3. Intake air pressure sender, intake air temperature transducer (TCD 2012/2013 L06) 4. Intake air pressure transducer, intake air temperature transducer (TCD 2012/2013 L04) 5.

  • Page 30: Technical Data

    TEChnICal CharaCTErIsTICs 19. Position not utilised 20. Start/stop keyswitch 21. Position not utilised 22. Fault warning light 23. Diagnostic interface/CAN bus 10.1.2 - Technical data Table 10 namE InformaTIon sErIEs valuE General engine data Engine weight according to DIN 70020-A approx. without cooling system TCD 2013 Operating mode TCD 2013...

  • Page 31: Transmission

    TEChnICal CharaCTErIsTICs 10.2 - TransmIssIon 10.2.1 - Hydraulic shuttle Fig. 8 - Hydraulic shuttle Components key Clutches Concentric primary shafts Transmission casing 10.2.2 - poWEr shIfT Transmission The transmission receives drive from the engine and transmits it through the hydraulic shuttle (1), HML unit (2), the range gearbox (4) and 4WD transfer box (3) to either the rear wheels alone or to the front and rear wheels.
  • Page 32 TEChnICal CharaCTErIsTICs Fig. 9 - POWER SHIFT Transmission Components key Hydraulic shuttle H-M-L unit Four-wheel drive transfer box Range gearbox Rear PTO 10-10...

  • Page 33: H-M-L Unit

    TEChnICal CharaCTErIsTICs 10.2.3 - h-m-l unit Fig. 10 - H-M-L unit Components key Gear Clutch Secondary shaft Concentric primary shafts 10-11...

  • Page 34: Intermediate Gearbox

    TEChnICal CharaCTErIsTICs 10.2.4 - Intermediate gearbox Fig. 11 - Intermediate gearbox Components key Gear Clutch H-M-L unit Secondary shaft Concentric primary shafts 10-12...

  • Page 35: Rear Gearbox

    TEChnICal CharaCTErIsTICs 10.2.5 - Rear gearbox Fig. 12 - Rear gearbox Components key Concentric primary shafts Secondary output shaft of HML unit Gear Clutch 4WD shaft Bevel pinion 10-13...
  • Page 36 TEChnICal CharaCTErIsTICs 10.2.6 - rear pTo Fig. 13 - Rear PTO powerflow diagram Components key Clutch Primary shaft PTO drive shaft Gear PTO output shaft 10-14...
  • Page 37 TEChnICal CharaCTErIsTICs 10.3 - rEar axlE 10.3.1 - rear axle Fig. 14 - Rear axle Components key Axle housing Differential lock Axle shaft Axle shaft Crown wheel of bevel gear pair Differential 10-15...
  • Page 38 TEChnICal CharaCTErIsTICs 10.4 - fronT axlE 10.4.1 - front axle Fig. 15 - Front axle Characteristics Track (A): 2164 mm Dimension “B”: 195 mm Dimension “C”: 338 mm Components key Differential lock engagement connection Filler and oil level plug for differential Differential oil drain plug Filler plug and oil drain for final drive 10-16...

  • Page 39: Differential

    TEChnICal CharaCTErIsTICs 10.4.2 - Differential Differential - version without front axle suspension Fig. 16 - Differential - version without front axle suspension Differential housing Ring gear Pivot pin Flange Planetary reduction gear Taper roller bearing Planet pinion Differential carrier Taper roller bearing 10.
  • Page 40 TEChnICal CharaCTErIsTICs Fig. 16 - Differential - version without front axle suspension 21. Differential lock clutch 10-18...
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

R7.210 dcrZkds7902w0ll1001010010

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