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LAMBORGHINI R3 EVO 85 Workshop Manual
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LAMBORGHINI R3 EVO 85 Workshop Manual

LAMBORGHINI R3 EVO 85 Workshop Manual

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Workshop manual
r3 EVo 85 -> 16001
r3 EVo 85 -> 20001
r3 EVo 100 -> 16001
r3 EVo 100 -> 20001
r3 EVo 110 -> 1001
r3 EVo 110 -> 5001

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Summary of Contents for LAMBORGHINI R3 EVO 85

  • Page 1 Workshop manual r3 EVo 85 -> 16001 r3 EVo 85 -> 20001 r3 EVo 100 -> 16001 r3 EVo 100 -> 20001 r3 EVo 110 -> 1001 r3 EVo 110 -> 5001...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 10-9 10.2 - Transmission 10-13 10.2.1 - Transmission (R3 EVO 110 -> 1001) 10-13 10.2.2 - Transmission (R3 EVO 85 -> 16001) 10-23 10.2.3 - Transmission (R3 EVO 85 -> 20001) 10-32 10.2.4 - Transmission (R3 EVO 100 -> 16001) 10-43 10.2.5 - Transmission (R3 EVO 100 ->...
  • Page 4 10-87 10.3.2 - Front axle (R3 EVO 110 -> 5001) 10-90 10.3.3 - Front axle (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-95 10.4 - Hydraulic system 10-100 10.4.1 - Hydraulic system (R3 EVO 110 ->...
  • Page 5 20-35 20.3.8 - Renewal of the shuttle ECU - Editing the comfort parameters (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 20-41 20.3.9 - Renewal of the shuttle ECU - Calibration of the clutch pedal (R3 EVO 100 -> 20001, R3 EVO 110 ->...
  • Page 6 ConTEnTs 30.3.12 - Measuring piston protrusion 30-42 30.3.13 - Valve assembly and disassembly 30-45 30.3.14 - Valve check 30-50 30.3.15 - Check the valve guide 30-51 30.3.16 - Replacing the valve guide (oversized - cast) 30-52 30.3.17 - Check the valve residual 30-56 30.3.18 - Replacing the lined valve seat (oversized) 30-58...
  • Page 7 ConTEnTs 30.3.58 - Removal and refitting of the oil pressure switch 30-216 30.3.59 - Removal and refitting of the water pump 30-218 30.3.60 - Testing the thermostat (after removal) 30-220 30.3.61 - Removal and refitting of the thermostat 30-222 30.3.62 - Removal and assembly of the fan support 30-224 30.3.63 - Removal and refitting of the fan support 30-230...
  • Page 8 ConTEnTs 30.5.31 - Disassembly of the Groundspeed PTO output shaft (R3 EVO 110 -> 1001) 30-344 30.5.32 - Disassembly of the Groundspeed PTO engagement device (R3 EVO 110 -> 1001) 30-346 30.5.33 - Disassembly of the 4WD engagement device - Easyshift (R3 EVO 110 -> 1001) 30-347 30.6 - E0 - Rear axle 30-350...
  • Page 9 ConTEnTs 30.8.14 - Heating control cable (R3 EVO 110 -> 1001) 30-446 30.8.15 - Condenser - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-447 30.8.16 - Receiver drier - Version with high visibility roof (R3 EVO 110 -> 1001) 30-448 30.8.17 - Conditioner evaporator - Version with standard roof (R3 EVO 110 ->...
  • Page 10 40-21 40.2 - Components 40-26 40.2.1 - A - Starting and charging (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-26 40.2.2 - A - Starting and charging (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->...
  • Page 11 ConTEnTs 40.2.15 - F - External lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-116 40.2.16 - F - External lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-118 40.2.17 - G - Interior lights (R3 EVO 100 ->...
  • Page 12 (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-354 40.3.15 - S005 - Instrument panel (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-369 40.3.16 - S005A - Instrument panel - Version with analog instrument panel (R3 EVO 100 ->...
  • Page 13 ConTEnTs instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-490 40.3.26 - S008D - Work lights - Version with high-visibility cab without front lift - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-503 40.3.27 - S009 - Work lights - Version with high-visibility cab with front lift (R3 EVO 100 ->...
  • Page 14 40-991 40.3.69 - S023 - Can Bus (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1003 40.3.70 - S023A - Can bus - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 ->...
  • Page 15 110 -> 5001, R3 EVO 85 -> 16001) 40-1044 40.3.75 - S025 - Negatives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1056 40.3.76 - S025A - Negatives - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 ->...
  • Page 16 40-1216 40.4.29 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with standard cab () 40-1217 40.4.30 - 0.015.7310.4 - Hood lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1219 40.4.31 - 0.016.0373.4/30 - Cab power supply 40-1220 40.4.32 - 0.016.0484.4/60 - Central (U.S.A.)
  • Page 17 ConTEnTs 40.4.50 - 04411923.4 - RH lower headlights 40-1250 40.4.51 - 04411923.4 - LH lower headlights 40-1251 XVII...
  • Page 18 ConTEnTs pagE lEfT InTEnTIonallY blank XVIII...
  • Page 19 0 - InTroduCTIon...

  • Page 20: Safety Notes

    InTroduCTIon 0.1 - InTroduCTIon This workshop manual has been prepared to provide instructions for repair technicians and as a practical guide to improve the quality of repairs. This manual is intended as a guide for repair technicians to give them a thorough understanding of the machine, and describes the correct procedures for troubleshooting and performing repair jobs safely, the methods and conditions necessary for checking the dimensions of and visually inspecting parts subject to repair and, lastly, indicates the products, tightening torques, and correct adjustment or setting data to be used.
  • Page 21 InTroduCTIon dangEr First disconnect the negative terminal (--) then the positive one (+); after the repair work, first connect the positive pole (+) then the negative one (--). If any arc welding is necessary (which is permitted in certain special cases only on implements attached to the machine), disconnect the battery terminals, all electronic control unit connectors and the alternator.
  • Page 22 InTroduCTIon precautions for assembly Tighten nuts and screws with the specified torques. Fit hoses and wiring being careful not to bend or twist them. Replace gaskets, O-rings, split pins and safety stop rights with new parts; make sure the tines of the split pin are separated and bent and thus so they cannot come out of their seats.
  • Page 23 InTroduCTIon Do not lift a heavy load when the two ends of the cables form a wide suspension angle. The permitted load (kg) decreases when the suspension angle increases; the table below, indicates the variation in permitted load (based on the suspension angle), for two Ø...
  • Page 24 InTroduCTIon M48x2 G 1/8” G 1/4” G 3/8” G 1/2” G 3/4” G 1” G 1 1/4” G 1 1/2” plugs Table 3 hexagonal head plugs socket head threaded plugs Thread spanner Torque nm ±10% spanner Torque nm ±10% mET- M6x1 –...
  • Page 25 InTroduCTIon unions with seal at 37° Table 4 Thread spanner Torque nm ±10% 7/16” - 20 1/2” - 20 9/16” - 18 3/4” - 16 7/8” - 14 1 1/16” - 12 1 3/16” - 12 1 5/16” - 12 1 5/8”...
  • Page 26 InTroduCTIon 0.1.6 - Thread lock, adhesive, sealant and lubrication materials Table 6 funCTIon dEsIgnaTIon dEsCrIpTIon ThrEad loCk Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for weak thread locking of set, adjust- purple ing and precision screws and nuts. It must be used after having removed all traces of lubricant with a specific activator.
  • Page 27 InTroduCTIon sIlICon sEal- Silastic 738 (Dow Corning) colour: milky Single compound silicon adhesive/sealant, not settling, ready for anTs white use. It cures into a solid rubbery consistency when it reacts with humidity in the air and makes it possible to eliminate traditional gaskets on elastic joints covering backlashes even greater than a millimetre.
  • Page 28 InTroduCTIon 0.1.7 - unit of measurement conversion table Conversion from imperial to metric units Table 7 inch x 25.40 = mm foot x 0.305 yard x 0.914 Eng.miles x 1.609 = km Sq.in. x 6.452 = cm² Sq.ft. x 0.093 = m²...
  • Page 29 InTroduCTIon 0.2 - InTroduCTIon - EngInEs This workshop manual has been prepared to provide instructions for repair technicians and as a practical guide to improve the quality of repairs. The pages composing the manual serve as a guide for repair technicians for an accurate knowledge of the engine, and indicates the correct manner for troubleshooting, carrying out repair jobs without being exposed to danger, methods and conditions necessary for accurate dimension testing and/or inspection of parts subject to repair and lastly indicates the products, torques, and adjustment or setting data to use.
  • Page 30 InTroduCTIon Wait for the oil and water to cool before working on the hydraulic circuits and on the engine. During removal and assembly operations for some groups, it is necessary to support the engine; use saw horses, jacks or blocks suitable for the weight to support and put it in a triangular position to prevent it from flipping over. Use a hoist or a crane to lift heavy components.
  • Page 31 InTroduCTIon precautions to observe at the end of disassembly/assembly operations If you drained the coolant, screw down the drain cap and add new coolant up to the level. Start the engine and let the coolant circulated in the cooling system and then top up. When the hydraulic equipment has been disassembled, add oil up to the indicated level.
  • Page 32 InTroduCTIon 2000 1900 1700 2000 1400 1000 1000 30° 60° 90° 120° 150° Angolo di sospensione: Fig. 1 0.2.5 - Tightening torques screws and nuts dangEr The specific torques for important parts and the tightening to perform with special procedures, are given within the individual assembly paragraphs.
  • Page 33 InTroduCTIon G 1/8” G 1/4” G 3/8” G 1/2” G 3/4” G 1” G 1 1/4” G 1 1/2” plugs Table 11 hexagonal head plugs socket head threaded plugs Thread Wrench Torque nm ±10% Wrench Torque nm ±10% mET- M6x1 M8x1 M10x1 M10x1.25...
  • Page 34 InTroduCTIon unions with seal at 37° Table 12 Thread Wrench Torque nm ±10% 7/16” - 20 1/2” - 20 9/16” - 18 3/4” - 16 7/8” - 14 1 1/16” - 12 1 3/16” - 12 1 5/16” - 12 1 5/8”...
  • Page 35 InTroduCTIon 0.2.6 - Thread lock, adhesive, sealant and lubrication materials Table 14 funCTIon dEsIgnaTIon dEsCrIpTIon ThrEad loCk Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for weak thread locking of set, adjust- purple ing and precision screws and nuts. It must be used after having removed all traces of lubricant with a specific activator.
  • Page 36 InTroduCTIon sIlICon sEal- Silastic 738 (Dow Corning) colour: milky Single compound silicon adhesive/sealant, not settling, ready for anTs white use. It cures into a solid rubbery consistency when it reacts with humidity in the air and makes it possible to eliminate traditional gaskets on elastic joints covering backlashes even greater than a millimetre.
  • Page 37 InTroduCTIon 0.2.7 - unit of measurement conversion table Conversion from imperial to metric units Table 15 inch x 25.40 = mm foot x 0.305 yard x 0.914 Eng.miles x 1.609 = km Sq.in. x 6.452 = cm² Sq.ft. x 0.093 = m²...

  • Page 38: Tightening Torques

    InTroduCTIon 0.3 - TIghTEnIng TorquEs 0.3.1 - general information This chapter specifies the tightening torque values and resulting tension forces for tightening standard fastener hardware with ISO metric threads. It is not applicable for components with special self-locking systems, such as micro capsules, nylon lock rings etc. 0.3.2 - Tightening classes and categories Four different tightening torque categories are applicable (1, 2, 3, 4), for three different joint classes (A, B, C), in accordance with procedure GSPO PSM 13.0.0.
  • Page 39 InTroduCTIon 0.3.4 - Tightening torques The method used to calculate tightening torques (Cs) and traction forces (F0) is compliant with the standard VDI 2230-1. The coefficient of safety applied is 0.70 of the yield strength of the material. Tightening torques for 4.8 unI En Iso 898-1 screws Table 20 ThrEad CaTEgorY...
  • Page 40 InTroduCTIon ThrEad CaTEgorY nomInal TIghTEnIng TorquEs µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 20x1.50 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 24x3.00 27x3.00 Tightening torques for 5.8 unI En Iso 898-1 screws and 5 unI En Iso 898-1 nuts Table 21 ThrEad CaTEgorY...
  • Page 41 InTroduCTIon ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 12x1.50 12x1.75 14x1.50 14x2.00 16x1.50 16x2.00 18x1.50 18x2.50 20x1.50 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 24x3.00 27x3.00 0-23...
  • Page 42 InTroduCTIon Tightening torques for 6.8 unI En Iso 898-1 screws and 6 unI En Iso 898-1 nuts Table 22 ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 4x0.70 5x0.80 6x1.00...
  • Page 43 InTroduCTIon ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 24x3.00 27x3.00 Tightening torques for 8.8 unI En Iso 898-1 screws and 8 unI En Iso 898-1 nuts Table 23 ThrEad CaTEgorY...
  • Page 44 InTroduCTIon ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 12x1.75 14x1.50 14x2.00 16x1.50 16x2.00 18x1.50 18x2.50 20x1.50 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 24x3.00 27x3.00 0-26...
  • Page 45 InTroduCTIon Tightening torques for 10.9 unI En Iso 898-1 screws and 10 unI En Iso 898-1 nuts Table 24 ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 4x0.70 5x0.80 6x1.00...
  • Page 46 InTroduCTIon ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 24x3.00 27x3.00 1104 1240 1032 1159 1025 Tightening torques for 12.9 unI En Iso 898-1 screws and 12 unI En Iso 898-1 nuts Table 25 ThrEad CaTEgorY...
  • Page 47 InTroduCTIon ThrEad CaTEgorY CoEffICIEnT of frICTIon µ 0,10 (VI) µ 0.14 (VII) µ 0.17 (II) Cs* nom (nm) Cs* nom (nm) Cs* nom (nm) 12x1.75 14x1.50 14x2.00 16x1.50 16x2.00 18x1.50 18x2.50 20x1.50 20x2.00 20x2.50 22x1.50 22x2.50 24x2.00 1088 1017 24x3.00 27x3.00 1034 1292...

  • Page 48: Standard Tightening Torques

    InTroduCTIon 0.4 - TIghTEnIng TorquEs for nuTs and bolTs of ElECTrICal ConnEC- TIons Tighten all nuts and bolts of wiring harnesses, leaving the battery negative cable until last. For closing torque, where not specified use class 9 N.93810 0.4.1 - standard tightening torques Table 26 gEnEral TablE pITCh...
  • Page 49 InTroduCTIon 0.4.3 - starter motor tightening torques Fig. 3 0.4.4 - alternator tightening torques Fig. 4 0-31...
  • Page 50 InTroduCTIon 0.5 - WhEEl rIm To hub sCrEWs and nuTs TIghTEnIng TorquEs dangEr These tightening torques are not applicable to special self-locking fixing systems. Table 28 dEsCrIpTIon Class TIghTEnIng TorquE TolEranCE 2.0122.511.6 Screw M14x1.5 120 Nm (12.2 kgm) ± 5% 2.0122.615.2 Screw M16x1.5 184.5 Nm (18.8 kgm)

  • Page 51: Installation

    InTroduCTIon 0.6 - InsTallaTIon of solEnoId ValVEs and CarTrIdgE ValVEs 0.6.1 - Installation Remove packaging and protective coverings from solenoid valve bodies and cartridge valves only at the moment of installa- tion, so as to minimize the risk of contamination. Lubricate all O-rings fitted to solenoid valves and valve cartridges using a suitable mineral oil or grease compatible with AK- ROS oil.
  • Page 52 InTroduCTIon TYpE of solEnoId ValVE ThrEads TIghTEnIng TorquE a (nm) b (nm) M33X2 2.3729.709.0/XX 45-50 Fig. 9 0.6.3 - Cartridge valve tightening torques Table 30 TYpE of ValVE ThrEads TIghTEnIng TorquE a (nm) M18X1.5 2.3729.686.0/XX 35-40 2.3719.760.0/XX Fig. 10 3/4”-16 UNF 2.3729.691.0/XX 35-40 Fig.
  • Page 53 InTroduCTIon 0.7 - InsTallaTIon of quICk CouplErs 0.7.1 - Table of tightening torques Table 31 TYpE of quICk CouplEr ThrEads TIghTEnIng TorquE a (nm) M22X1.5 0.010.8473.0/XX 60-66 Fig. 14 M22X1.5 0.010.9832.0/XX 60-66 Fig. 15 0-35...
  • Page 54 InTroduCTIon pagE lEfT InTEnTIonallY blank 0-36...
  • Page 55 10 - TEChnICal CharaCTErIsTICs 10-1...

  • Page 56: Technical Characteristics

    TEChnICal CharaCTErIsTICs 10.1 - EngInE 10.1.1 - Components of the 2012 2V ups engine Engine type These instructions concern the following engine types: TCD 2012 L04 2V TCD 2012 L06 2V TCD 2013 L04 2V TCD 2013 L06 2V TD 2012 L04 2V m TCD 2012 L04 2V m TCD 2013 L04 2V m Table 32...

  • Page 57: Engine Number

    TEChnICal CharaCTErIsTICs location of the model plate Plate C is fixed on the cylinder head cowling or on the crankcase. Fig. 17 Engine number The engine number D is punched on the crankcase (arrow) and on the model plate. Fig. 18 Cylinder numbering Cylinder layout The cylinders are numbered progressively from (1) from the flywheel side.
  • Page 58 TEChnICal CharaCTErIsTICs Illustration of the 2012 2V ups engine View from right hand side (example) Fig. 20 Key: Crankcase breather Lubricant oil filler cap Injection pump Lubricant oil dipstick Lubricant oil radiator Lubricant oil cartridge filter Lubricant oil drain screw Fuel cartridge filter V-belt 10.
  • Page 59 TEChnICal CharaCTErIsTICs View from left hand side (example) Fig. 21 Key: Combustion air intake Coolant outlet Coolant inlet Supply air radiator connections Exhaust gas outlet Starter 10-5...
  • Page 60 TEChnICal CharaCTErIsTICs lubrication oil system Fig. 22 Key: (Example) Lubricant oil sump Lubricant oil pump Pressure relief valve TD/TCD 2013 Lubricant oil radiator Check valve TD/TCD 2012 Bypass valve Bypass valve Pressure regulator valve Lubricant oil filter 10. Primary lubricant oil channel Piston cooling nozzle 12.
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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