LAMBORGHINI R3 EVO 85 Instruction manual
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
III
CONTENTS
0 - INTRODUCTION
0.1 - Introduction 0-2
0.1.1 - Safety notes 0-2
0.1.2 - General safety 0-2
0.1.3 - Precautions to use during performance of the work 0-3
0.1.4 - Lifting instructions 0-4
0.1.5 - Tightening torques 0-5
0.1.6 - Thread lock, adhesive, sealant and lubrication materials 0-8
0.1.7 - Unit of measurement conversion table 0-10
0.2 - Introduction - Engines 0-11
0.2.1 - Safety notes 0-11
0.2.2 - General safety 0-11
0.2.3 - Precautions to use during performance of the work 0-12
0.2.4 - Lifting instructions 0-13
0.2.5 - Tightening torques 0-14
0.2.6 - Thread lock, adhesive, sealant and lubrication materials 0-17
0.2.7 - Unit of measurement conversion table 0-19
0.3 - Tightening torques 0-20
0.3.1 - General information 0-20
0.3.2 - Tightening classes and categories 0-20
0.3.3 - Coefcient of friction 0-20
0.3.4 - Tightening torques 0-21
0.4 - Tightening torques for nuts and bolts of electrical connections 0-30
0.4.1 - Standard tightening torques 0-30
0.4.2 - Battery terminal tightening torques 0-30
0.4.3 - Starter motor tightening torques 0-31
0.4.4 - Alternator tightening torques 0-31
0.5 - Wheel rim to hub screws and nuts tightening torques 0-32
0.6 - Installation of solenoid valves and cartridge valves 0-33
0.6.1 - Installation 0-33
0.6.2 - Solenoid valve tightening torques 0-33
0.6.3 - Cartridge valve tightening torques 0-34
0.7 - Installation of quick couplers 0-35
0.7.1 - Table of tightening torques 0-35
10 - TECHNICAL CHARACTERISTICS
10.1 - Engine 10-2
10.1.1 - Components of the 2012 2V UPS engine 10-2
10.1.2 - Test data and settings 10-8
10.1.3 - Tightening requirements 2012 2V UPS engine 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 -> 20001) 10-52
10.2.6 - Transmission (R3 EVO 110 -> 5001) 10-65
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IV
CONTENTS
10.2.7 - Rear PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-73
10.2.8 - Rear P.T.O. (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3
EVO 85 -> 20001) 10-77
10.2.9 - 2 and 4-speed PTO and Syncro PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-81
10.2.10 - 2 and 4-speed PTO and Groundspeed PTO (R3 EVO 100 -> 16001, R3 EVO 100 ->
20001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-84
10.3 - Front axle 10-87
10.3.1 - Front axle (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 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 -> 1001) 10-100
10.4.2 - Hydraulic system (R3 EVO 85 -> 16001) 10-110
10.4.3 - Hydraulic system (R3 EVO 100 -> 16001) 10-115
10.4.4 - Hydraulic system (R3 EVO 85 -> 20001) 10-120
10.4.5 - Hydraulic system (R3 EVO 100 -> 20001) 10-127
10.4.6 - Hydraulic system (R3 EVO 110 -> 5001) 10-134
10.4.7 - Steering circuit pump - lift circuit pump () 10-139
10.4.8 - Power steering valve (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
10-141
10.4.9 - Power steering valve (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
10-142
10.4.10 - Ancillary utility distributor 4-way version (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-144
10.4.11 - Remote control valve - 6-way version (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-145
10.4.12 - Hydraulic lift control valve (R3 EVO 110 -> 1001) 10-145
10.4.13 - Braking system (R3 EVO 110 -> 1001) 10-152
10.4.14 - Trailer braking valve (R3 EVO 110 -> 1001) 10-153
10.4.15 - Trailer braking valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110 ->
5001, R3 EVO 85 -> 16001) 10-157
10.4.16 - Trailer braking valve (R3 EVO 85 -> 20001) 10-160
10.4.17 - Park Brake system (R3 EVO 110 -> 1001) 10-163
10.4.18 - Park Brake valve (R3 EVO 110 -> 1001) 10-168
10.4.19 - Separate-Brakes valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110 ->
5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-168
10.4.20 - Pressure holding valves assembly (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-174
10.4.21 - Services solenoid valves assembly - Pressure holding valves (R3 EVO 110 -> 1001) 10-176
10.4.22 - Shuttle solenoid valves assembly (R3 EVO 110 -> 1001) 10-179
20 - CALIBRATIONS AND ELECTRONIC DIAGNOSIS
20.1 - Diagnostic tools 20-2
20.1.1 - Position of ECUs and diagnostic instruments 20-2
20.1.2 - All Round Tester (ART® SAME) 20-3
20.1.3 - SDF Analyser 20-8
20.1.4 - Serdia 2000 20-12
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V
CONTENTS
20.2 - Diagnostic tool screens 20-14
20.2.1 - ECU interrogation 20-14
20.3 - Commissioning and calibrating the tractor 20-17
20.3.1 - Digital instrument calibration 20-17
20.3.2 - Renewal of the shuttle ECU - Introduction (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001) 20-22
20.3.3 - Renewal of the shuttle ECU - Initialisation of the ECU (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 20-22
20.3.4 - Renewal of the shuttle ECU - Line end programming (R3 EVO 100 -> 20001, R3 EVO 110
-> 1001, R3 EVO 85 -> 20001) 20-25
20.3.5 - Renewal of the shuttle ECU - Introductory notes (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 20-32
20.3.6 - Renewal of the shuttle ECU - Automatic calibration (R3 EVO 100 -> 20001, R3 EVO 110
-> 1001, R3 EVO 85 -> 20001) 20-33
20.3.7 - Renewal of the shuttle ECU - Manual calibration (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 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 -> 1001, R3 EVO 85 -> 20001) 20-42
20.3.10 - Renewal of the engine ECU - Introduction 20-45
20.3.11 - Renewal of the engine ECU - Calibration of the accelerator pedal 20-45
20.3.12 - Renewal of the engine ECU - Calibration of the hand throttle lever 20-48
20.4 - ECU alarms 20-51
20.4.1 - Key to the “ECU alarms” tables 20-51
20.4.2 - FMI code 20-52
20.4.3 - Engine alarms 20-52
20.4.4 - Transmission alarms 20-61
20.4.5 - Instrument panel alarms 20-66
30 - METHOD OF INTERVENTION
30.1 - Tools for engine disassembly and reassembly 30-2
30.1.1 - Commercially available tools 30-2
30.2 - Workshop tools for engine disassembly and reassembly 30-6
30.2.1 - Workshop tools for engine disassembly and reassembly 30-6
30.3 - B0 - Engine 30-13
30.3.1 - Air conditioning compressor drive belt 30-13
30.3.2 - Tension adjustment of the fan and air conditioning compressor drive belt 30-13
30.3.3 - Alternator, fuel pump and water pump drive belt 30-14
30.3.4 - Tension adjustment of the alternator, fuel pump and water pump drive belt 30-15
30.3.5 - Compression test 30-15
30.3.6 - Assembly and disassembly of the engine on the assembly stand 30-18
30.3.7 - Adjustment of valve clearance 30-22
30.3.8 - Removal and retting of the rocker arms and pedestals 30-26
30.3.9 - Disassemble and complete the rocker and support, check 30-29
30.3.10 - Disassembly and assembly of the cylinder head 30-32
30.3.11 - Grinding the cylinder head seal surface 30-39
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VI
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
30.3.19 - Check the endoat of the crankshaft 30-64
30.3.20 - Check the crankshaft 30-69
30.3.21 - Replace the crankshaft O-ring (ywheel end) 30-72
30.3.22 - Replacing the crankshaft O-ring (opposite end to ywheel) 30-76
30.3.23 - Check the connecting rod drum 30-80
30.3.24 - Fitting and removing piston pin bush 30-88
30.3.25 - Assembly and disassembly of the crankshaft 30-93
30.3.26 - Fitting and removing counterweight shafts, checking 30-100
30.3.27 - Disassembly and assembly of the piston and connecting rod drum 30-107
30.3.28 - Check the piston 30-113
30.3.29 - Check the piston rings and piston grooves 30-115
30.3.30 - Assembly and disassembly of piston cooling nozzles 30-119
30.3.31 - Removal and retting of the crankcase breather 30-120
30.3.32 - Check the cylinder 30-122
30.3.33 - Removal and retting of the front cover (opposite end to ywheel) 30-123
30.3.34 - Disassembly and assembly of the connector box 30-128
30.3.35 - Fitting and removing the camshaft bearings, checking 30-130
30.3.36 - Disassembly and assembly of the gear case cover 30-135
30.3.37 - Assembly and disassembly of the camshaft 30-139
30.3.38 - Check the camshaft 30-143
30.3.39 - Removal and retting of the rotation device 30-144
30.3.40 - Removing and tting the V-belt pulley 30-146
30.3.41 - Fitting, removing, checking and setting adjuster rod 30-148
30.3.42 - Removal and retting of the heater 30-153
30.3.43 - Removal and retting of the turbocharger 30-155
30.3.44 - Removal and retting of the charge air duct 30-159
30.3.45 - Fitting and removing injection pump 30-163
30.3.46 - Determine the thickness of the shim (engine without injection advance variator) 30-175
30.3.47 - Determine the thickness of the shim (engine with injection advance variator) 30-177
30.3.48 - Determination of the overall dimensions of the injection pump (engine without the
injection advance variator) 30-179
30.3.49 - Determination of the overall dimensions of the injection pump (engine with the injection
advance variator) 30-183
30.3.50 - Fitting and removing injection valves 30-188
30.3.51 - Checking the injection valves 30-192
30.3.52 - Removal and retting of the fuel lift pump 30-196
30.3.53 - Removal and retting of the oil pickup pipe 30-198
30.3.54 - Removing and tting the lubricant oil sump pan (cast iron lubricant oil sump) 30-199
30.3.55 - Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate) 30-203
30.3.56 - Removal and retting of the oil cooler 30-208
30.3.57 - Disassembly and assembly of the oil radiator housing 30-211
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VII
CONTENTS
30.3.58 - Removal and retting of the oil pressure switch 30-216
30.3.59 - Removal and retting of the water pump 30-218
30.3.60 - Testing the thermostat (after removal) 30-220
30.3.61 - Removal and retting of the thermostat 30-222
30.3.62 - Removal and assembly of the fan support 30-224
30.3.63 - Removal and retting of the fan support 30-230
30.3.64 - Removal and retting of the ywheel 30-232
30.3.65 - Replacing the starter motor ring gear on the ywheel 30-234
30.4 - C0 - Engine accessories 30-236
30.4.1 - Starter motor 30-236
30.4.2 - Removing and tting the engine governor 30-237
30.4.3 - Removal and retting of the exhaust manifold 30-239
30.4.4 - Removal and retting of the fuel lter head. 30-242
30.4.5 - Assembly and disassembly of the temperature sender 30-244
30.4.6 - Removal and retting the engine block 30-246
30.4.7 - Removal and retting of the alternator (with drivebelt) 30-247
30.4.8 - Disassembly and assembly of the starter 30-251
30.5 - D0 - Transmission 30-253
30.5.1 - Changing the transmission oil (D0.00.01) (R3 EVO 110 -> 1001) 30-253
30.5.2 - Range selector assembly (R3 EVO 110 -> 1001) 30-254
30.5.3 - Disassembly of the range selector (R3 EVO 110 -> 1001) 30-255
30.5.4 - Separation of housing from transmission (D0.02.01) (R3 EVO 110 -> 1001) 30-257
30.5.5 - Shuttle assembly - complete unit (D0.03.01) (R3 EVO 110 -> 1001) 30-261
30.5.6 - Disassembly of the shuttle unit (R3 EVO 110 -> 1001) 30-263
30.5.7 - Disassembly of the cover unit (R3 EVO 110 -> 1001) 30-266
30.5.8 - Disassembly of the forward drive clutch assembly (R3 EVO 110 -> 1001) 30-268
30.5.9 - Disassembly of the reverse drive clutch assembly (R3 EVO 110 -> 1001) 30-272
30.5.10 - Gearbox and Hi-Lo assembly (R3 EVO 110 -> 1001) 30-277
30.5.11 - Disassembly of the Hi-Lo unit (D0.04.01) (R3 EVO 110 -> 1001) 30-278
30.5.12 - Disassembly of the planet carrier (R3 EVO 110 -> 1001) 30-284
30.5.13 - Disassembly of the Hi range clutch housing (R3 EVO 110 -> 1001) 30-286
30.5.14 - Hi-Lo unit output shaft disassembly procedure (R3 EVO 110 -> 1001) 30-295
30.5.15 - Disassembly of the gearbox input shaft (R3 EVO 110 -> 1001) 30-296
30.5.16 - Torsional spring plate (R3 EVO 110 -> 1001) 30-299
30.5.17 - Disassembly of the primary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-300
30.5.18 - Secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-301
30.5.19 - Disassembly of the secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-305
30.5.20 - Range gearbox and differential assembly - complete assembly (R3 EVO 110 -> 1001) 30-308
30.5.21 - Complete gearbox assembly - Version with Hi-Lo (D0.09.04) (R3 EVO 110 -> 1001) 30-308
30.5.22 - Adjustment of the differential - Bevel gear pair (R3 EVO 110 -> 1001) 30-310
30.5.23 - Disassembly of the rear pinion (D0.11.01) (R3 EVO 110 -> 1001) 30-317
30.5.24 - Disassembly of the 4WD output shaft (R3 EVO 110 -> 1001) 30-322
30.5.25 - PTO clutch. (D0.12.02) (R3 EVO 110 -> 1001) 30-324
30.5.26 - Disassembly of the PTO clutch (R3 EVO 110 -> 1001) 30-328
30.5.27 - Pump drive PTO - Outer gear (R3 EVO 110 -> 1001) 30-332
30.5.28 - Pump drive PTO - Inner gear (R3 EVO 110 -> 1001) 30-334
30.5.29 - PTO output shaft - 4 speed version (D0.14.01) (R3 EVO 110 -> 1001) 30-336
30.5.30 - Disassembly of the PTO output shaft - 4 speed version (R3 EVO 110 -> 1001) 30-340
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VIII
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
30.6.1 - Right-hand rear axle (E0.02.01) (R3 EVO 110 -> 1001) 30-350
30.6.2 - Disassembly of LH/RH rear axle (R3 EVO 110 -> 1001) 30-352
30.6.3 - Left-hand rear axle (E0.02.02) (R3 EVO 110 -> 1001) 30-356
30.6.4 - Disassembly of the planet carrier (R3 EVO 110 -> 1001) 30-357
30.6.5 - Rear differential (E0.02.07) (R3 EVO 110 -> 1001) 30-358
30.6.6 - Disassembly of the rear differential (R3 EVO 110 -> 1001) 30-360
30.6.7 - Park Brake assembly 30-363
30.6.8 - Park Brake unit disassembly 30-365
30.7 - F0 - Front axle 30-369
30.7.1 - Separation of front support from engine (F0.01.01) (R3 EVO 110 -> 1001) 30-369
30.7.2 - Front support (R3 EVO 110 -> 1001) 30-372
30.7.3 - 4WD front axle (F0.03.01) (R3 EVO 110 -> 1001) 30-374
30.7.4 - Adjusting the front axle end oat (R3 EVO 110 -> 1001) 30-376
30.7.5 - Steering cylinders (R3 EVO 110 -> 1001) 30-378
30.7.6 - Steering cylinders disassembly (R3 EVO 110 -> 1001) 30-380
30.7.7 - Steering knuckle housing and half-shaft (R3 EVO 110 -> 1001) 30-383
30.7.8 - Adjustment of steering knuckle housing and axle shaft (R3 EVO 110 -> 1001) 30-388
30.7.9 - Differential unit (R3 EVO 110 -> 1001) 30-390
30.7.10 - Differential disassembly (R3 EVO 110 -> 1001) 30-392
30.7.11 - Differential unit adjustment (R3 EVO 110 -> 1001) 30-394
30.7.12 - Bevel gear pair (R3 EVO 110 -> 1001) 30-397
30.7.13 - Adjustment of the bevel gear pair (R3 EVO 110 -> 1001) 30-401
30.7.14 - Disassembly of the differential (R3 EVO 110 -> 1001) 30-409
30.7.15 - 4WD shaft (F0.04.01) (R3 EVO 110 -> 1001) 30-411
30.7.16 - Planetary reduction gear (F0.06.01) (R3 EVO 110 -> 1001) 30-413
30.7.17 - Disassembly of the planetary reduction gear (R3 EVO 110 -> 1001) 30-414
30.7.18 - Front brake discs (R3 EVO 110 -> 1001) 30-420
30.7.19 - Front axle brake piston (R3 EVO 110 -> 1001) 30-420
30.8 - G0 - Bodywork - Cab - Platform 30-422
30.8.1 - Cab (G0.03.01) (R3 EVO 110 -> 1001) 30-422
30.8.2 - Front hood and side panels (G0.01.01) (R3 EVO 110 -> 1001) 30-428
30.8.3 - Battery support (G0.01.04) (R3 EVO 110 -> 1001) 30-429
30.8.4 - Cab access steps (G0.03.03) (R3 EVO 110 -> 1001) 30-431
30.8.5 - Fenders (G0.04.01) 30-431
30.8.6 - Right-hand console (G0.06.01) (R3 EVO 110 -> 1001) 30-432
30.8.7 - Left-hand console (G0.06.02) (R3 EVO 110 -> 1001) 30-433
30.8.8 - Front instrument panel (G0.06.04) (R3 EVO 110 -> 1001) 30-434
30.8.9 - Roof lining - Version with high visibility cab (G0.06.07) (R3 EVO 110 -> 1001) 30-437
30.8.10 - Heating fan - Version with high visibility cab (R3 EVO 110 -> 1001) 30-438
30.8.11 - Air conditioning system controls - High-visibility roof system (G0.09.01) (R3 EVO 110 ->
1001) 30-439
30.8.12 - Air conditioning system - Standard roof version (R3 EVO 110 -> 1001) 30-442
30.8.13 - Heating and air conditioning unit - Version with high visibility cab (G0.09.03) (R3 EVO
110 -> 1001) 30-444
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IX
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 -> 1001) 30-449
30.8.18 - Air-conditioning evaporator - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-450
30.8.19 - Heating valve - Version with high visibility cab (R3 EVO 110 -> 1001) 30-450
30.8.20 - Heater matrix - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-451
30.8.21 - Heating radiator - Version with standard roof (R3 EVO 110 -> 1001) 30-451
30.8.22 - Heating and air conditioning unit fan - Version with standard roof (R3 EVO 110 -> 1001) 30-453
30.8.23 - Expansion valve - Version with high visibility roof (R3 EVO 110 -> 1001) 30-454
30.8.24 - Expansion valve - Version with standard roof (R3 EVO 110 -> 1001) 30-455
30.8.25 - Antifreeze sensor - Version with high visibility roof (R3 EVO 110 -> 1001) 30-455
30.8.26 - Condenser cooling fans - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-456
30.8.27 - Condenser fan control pressure switch - Version with high visibility roof (R3 EVO 110 ->
1001) 30-456
30.8.28 - Air conditioning temperature control thermostat - Version with standard roof (R3 EVO
110 -> 1001) 30-457
30.8.29 - Remote valve control cables (R3 EVO 110 -> 1001) 30-457
30.8.30 - Adjustment of the control levers (R3 EVO 110 -> 1001) 30-459
30.9 - H0 - Hydraulic system 30-463
30.9.1 - Pump for hydraulic lift and auxiliary services (R3 EVO 110 -> 1001) 30-463
30.9.2 - Power steering valve (H0.02.01) (R3 EVO 110 -> 1001) 30-464
30.9.3 - Power steering disassembly (R3 EVO 110 -> 1001) 30-466
30.9.4 - Pressure relief valve setting (R3 EVO 110 -> 1001) 30-478
30.9.5 - Power steering pump (R3 EVO 110 -> 1001) 30-478
30.9.6 - Gearbox oil cooler (R3 EVO 110 -> 1001) 30-480
30.9.7 - Rear remote control valve (H0.07.01) (R3 EVO 110 -> 1001) 30-481
30.9.8 - Bleeding the braking circuit (E0.03.01) (R3 EVO 110 -> 1001) 30-483
30.9.9 - Parking brake control valve (R3 EVO 110 -> 1001) 30-484
30.9.10 - Braking distributor valve (R3 EVO 110 -> 1001) 30-486
30.9.11 - Services solenoid valve assembly (H0.10.01) (R3 EVO 110 -> 1001) 30-486
30.9.12 - Pressure reduction and holding valve disassembly (R3 EVO 110 -> 1001) 30-489
30.9.13 - Shuttle solenoid valves assembly 30-490
30.10 - L0 - Electrical system 30-492
30.10.1 - Lateral battery (R3 EVO 110 -> 1001) 30-492
30.10.2 - Alternator (R3 EVO 110 -> 1001) 30-493
30.10.3 - Clutch pedal potentiometer (R3 EVO 110 -> 1001) 30-494
30.10.4 - Shuttle output speed sensor (R3 EVO 110 -> 1001) 30-495
30.10.5 - Accelerator pedal position sensor (R3 EVO 110 -> 1001) 30-497
30.10.6 - Hand throttle position sensor (R3 EVO 110 -> 1001) 30-497
30.10.7 - Steering column switch (R3 EVO 110 -> 1001) 30-498
30.10.8 - Shuttle ECU and forward/reverse selector (R3 EVO 110 -> 1001) 30-499
30.11 - M0 - Front PTO 30-501
30.11.1 - Front PTO 30-501
30.11.2 - PTO assembly. 30-504
30.11.3 - Pump assembly 30-513
30.11.4 - Front PTO oil cooler 30-514
30.11.5 - Clutch-brake assembly 30-515
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X
CONTENTS
30.11.6 - Solenoid valve assembly 30-520
30.12 - N0 - Front lift 30-521
30.12.1 - Front lift 30-521
30.12.2 - Disassembly of front lift cylinders 30-523
30.13 - R0 - Rear lift 30-526
30.13.1 - Lift - Complete assembly (R0.02.03) (R3 EVO 110 -> 1001) 30-526
30.13.2 - Disassembly of the lift- complete assembly (R3 EVO 110 -> 1001) 30-529
30.13.3 - Lift cylinder (R3 EVO 110 -> 1001) 30-533
30.13.4 - Bushes (R3 EVO 110 -> 1001) 30-534
30.13.5 - Auxiliary lift cylinders (R3 EVO 110 -> 1001) 30-535
30.13.6 - Disassembly of the lift control valve (R3 EVO 110 -> 1001) 30-536
30.13.7 - Mechanical draft sensor (R3 EVO 110 -> 1001) 30-541
30.13.8 - Mechanical draft sensor disassembly (R3 EVO 110 -> 1001) 30-542
30.13.9 - 3-point linkage (R3 EVO 110 -> 1001) 30-543
30.14 - S0 - Wheels 30-546
30.14.1 - Front wheels 30-546
30.14.2 - Rear wheels 30-546
30.15 - V0 - Ballast - towing hitches 30-548
30.15.1 - Towing hitch slide (V0.02.01) (R3 EVO 110 -> 1001) 30-548
40 - WIRING DIAGRAMS
40.1 - Introduction 40-2
40.1.1 - Introduction 40-2
40.1.2 - Basic electronics for mechanics (1/2) 40-4
40.1.3 - Basic electronics for mechanics (2/2) 40-7
40.1.4 - Electrical and electronic components (1/2) 40-13
40.1.5 - Electrical and electronic components (2/2) 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 ->
16001) 40-26
40.2.3 - B - Fuses (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-27
40.2.4 - B - Fuses (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-35
40.2.5 - B - Fuses (R3 EVO 85 -> 16001) 40-47
40.2.6 - C - Earths (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-58
40.2.7 - C - Earths (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-61
40.2.8 - C - Earths (R3 EVO 85 -> 16001) 40-65
40.2.9 - D - Intermediate connections (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-69
40.2.10 - D - Intermediate connections (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-81
40.2.11 - D - Intermediate connections (R3 EVO 85 -> 16001) 40-95
40.2.12 - E - On-board instruments and visual and audible indicators (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-110
40.2.13 - E - On-board instruments and visual and audible indicators (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001) 40-112
40.2.14 - E - On-board instruments and visual and audible indicators (R3 EVO 85 -> 16001) 40-114
Find manuals at https://best-manuals.com
XI
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 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-121
40.2.18 - G - Interior lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-121
40.2.19 - H - Electrical and manual controls (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-121
40.2.20 - H - Electrical and manual controls (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001) 40-122
40.2.21 - I - Circuit breakers (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-122
40.2.22 - I - Circuit breakers (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-130
40.2.23 - I - Circuit breakers (R3 EVO 85 -> 16001) 40-140
40.2.24 - J - Relays (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-150
40.2.25 - J - Relays (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-153
40.2.26 - K - Sensors and transmitters (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-157
40.2.27 - K - Sensors and senders (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-160
40.2.28 - K - Sensors and transmitters (R3 EVO 85 -> 16001) 40-162
40.2.29 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001) 40-165
40.2.30 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001,
R3 EVO 85 -> 16001) 40-165
40.2.31 - M - Electrical/electronic devices, asher units and timers (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-166
40.2.32 - M - Electrical/electronic devices, asher units and timers (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001) 40-166
40.2.33 - M - Electrical/electronic devices, asher units and timers (R3 EVO 85 -> 16001) 40-167
40.2.34 - N - Electric motors and actuators (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001) 40-168
40.2.35 - N - Electric motors and actuators (R3 EVO 85 -> 16001) 40-168
40.2.36 - N - Electric motors and actuators (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-169
40.2.37 - O - Resistors and rheostats (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-169
40.2.38 - O - Resistors and rheostats (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-170
40.2.39 - P - Various services (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
40-170
40.2.40 - P - Various services (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
40-171
40.2.41 - R - Diagnostics (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-173
40.2.42 - R - Diagnostics (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-173
40.2.43 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-173
40.2.44 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001) 40-173
40.3 - Systems 40-175
40.3.1 - S001 - Starting and preheating (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-175
40.3.2 - S001A - Starting and preheating - Version with analog instrument panel (R3 EVO 100 ->
XII
CONTENTS
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-203
40.3.3 - S001D - Starting and preheating - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-229
40.3.4 - S002 - Electronic engine governor (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-254
40.3.5 - S002A - Electronic engine governor - Version with analog instrument panel (R3 EVO 85 ->
16001) 40-262
40.3.6 - S002D - Electronic engine governor - Version with digital instrument panel (R3 EVO 85 ->
16001) 40-269
40.3.7 - S002A - Electronic engine governor - Version with analog instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001) 40-276
40.3.8 - S002D - Electronic engine governor - Version with digital instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001) 40-283
40.3.9 - S003 - Diagnostics and accessories - Version with standard cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-290
40.3.10 - S003A - Accessories and diagnostics - Version with analog instrument panel (R3 EVO
100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-305
40.3.11 - S003D - Accessories and diagnostics - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-315
40.3.12 - S004 - Diagnostics and accessories - Version with high-visibility cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-327
40.3.13 - S004A - Accessories and diagnostics - Version with high-visibility cab - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-342
40.3.14 - S004D - Accessories and diagnostics - Version with high-visibility cab - Version with
digital instrument panel (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 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-383
40.3.17 - S005D - Instrument panel - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-397
40.3.18 - S006 - Work lights - Version with standard cab without front lift (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-411
40.3.19 - S006A - Work lights - Version with standard cab without front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-429
40.3.20 - S006D - Work lights - Version with standard cab without front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-437
40.3.21 - S007 - Work lights - Version with standard cab with front lift (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-445
40.3.22 - S007A - Work lights - Version with standard cab with front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-457
40.3.23 - S007D - Work lights - Version with standard cab with front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-465
40.3.24 - Work lights - Version with high-visibility cab without front lift (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-473
40.3.25 - S008A - Work lights - Version with high-visibility cab without front lift - Version with front
XIII
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 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-516
40.3.28 - S009A - Work lights - Version with high-visibility cab with front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-528
40.3.29 - S009D - Work lights - Version with high-visibility cab with front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-536
40.3.30 - S010 - Heating - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-543
40.3.31 - S010A - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-552
40.3.32 - S010D - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-560
40.3.33 - S011 - Heating - Version with high-visibility cab (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-568
40.3.34 - S011A - Heating - Version with high-visibility cab - Version with digital instrument panel
(R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-577
40.3.35 - S011DA - Heating - Version with high-visibility cab - Version with digital instrument panel
(R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-585
40.3.36 - S012 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-593
40.3.37 - S012A - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-611
40.3.38 - S012D - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-629
40.3.39 - S013 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-647
40.3.40 - S013A - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-664
40.3.41 - S013D - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-682
40.3.42 - S014 - Manual climate control - Version with high-visibility cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-701
40.3.43 - S014A - Manual climate control - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-720
40.3.44 - S014D - Manual climate control - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-738
40.3.45 - S015 - Steering column lights switch - Version with cab without front lift (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-756
40.3.46 - S015A - Steering column lights switch - Version with cab without front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-770
40.3.47 - S015D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-784
40.3.48 - S016 - Steering column lights switch – Version with cab with front lift (R3 EVO 100 ->
XIV
CONTENTS
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-798
40.3.49 - S016A - Steering column lights switch - Version with cab without front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-812
40.3.50 - S016D - Steering column lights switch - Version with cab with front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001) 40-827
40.3.51 - S017 - +30 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-840
40.3.52 - S017A - +30 Positives - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-848
40.3.53 - S017A - +30 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-856
40.3.54 - S018 - +15 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-864
40.3.55 - S018A - +15 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-866
40.3.56 - S018D - +15 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-868
40.3.57 - S019 - Windscreen wipers - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-870
40.3.58 - S019AD - Windscreen wipers - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-882
40.3.59 - S019D - Windscreen wipers - Version with standard cab - Version with digital instrument
panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-890
40.3.60 - S020 - Windscreen wipers - Version with high-visibility cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-898
40.3.61 - S020A - Windscreen wipers - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-910
40.3.62 - S020D - Windscreen wipers - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-922
40.3.63 - S021 - Transmission (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-934
40.3.64 - S021A - Transmission - Version with analog instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-951
40.3.65 - S021D - Transmission - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-959
40.3.66 - S022 - PTO (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-967
40.3.67 - S022A - PTO - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-981
40.3.68 - S022D - PTO - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 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 -> 5001, R3 EVO 85 -> 16001) 40-1008
40.3.71 - S023D - Can bus - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1012
40.3.72 - S024 - Brakes (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1016
XV
CONTENTS
40.3.73 - S024A - Brakes - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1031
40.3.74 - S024D - Brakes - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
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 -> 5001, R3 EVO 85 -> 16001) 40-1058
40.3.77 - S025D - Negatives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1061
40.3.78 - S026 - Steering column lights switch – Version with cab without front lift (U.S.A.) (R3
EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1064
40.3.79 - S026D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001) 40-1079
40.3.80 - S027 - Steering column lights switch – Version with cab with front lift (U.S.A.) (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1094
40.3.81 - S027D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001) 40-1109
40.3.82 - S028 - PTO (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-1124
40.3.83 - S028D - PTO (U.S.A.) - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1139
40.3.84 - S029 - Brakes (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001) 40-1153
40.3.85 - S029D - Brakes (U.S.A.) - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1168
40.4 - Wiring harnesses 40-1180
40.4.1 - 0.008.0913.3 - Front PTO 40-1180
40.4.2 - 0.009.7853.3/20 - Air conditioning condenser fan - Version with standard cab 40-1180
40.4.3 - 0.010.2147.2 - Heating - Version with standard cab 40-1182
40.4.4 - 0.010.2153.2 - Air conditioning - Version with standard cab 40-1183
40.4.5 - 0.010.4516.3 - Windscreen wiper - Version with standard cab 40-1186
40.4.6 - 0.011.3597.3 - Windscreen wiper - Version with high-visibility cab 40-1187
40.4.7 - 0.013.4909.4 - Rear lights (U.S.A.) 40-1188
40.4.8 - 0.013.6327.4 - LH rotating beacon 40-1190
40.4.9 - 0.013.6327.4 - RH rotating beacon 40-1190
40.4.10 - 0.014.1645.4/10 - Compressed air pressure sensor 40-1191
40.4.11 - 0.014.3927.4/40 - LH auxiliary work lights - Version with high-visibility cab 40-1192
40.4.12 - 0.014.3927.4/40 - RH auxiliary work lights - Version with high-visibility cab 40-1192
40.4.13 - 0.014.8107.4/30 - Hood lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1193
40.4.14 - 0.014.9195.4/20 - Preheating 40-1195
40.4.15 - 0.015.1418.4/30 - Cab shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1196
40.4.16 - 0.015.1435.4/20 - RH auxiliary work lights - Version with standard cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1197
40.4.17 - 0.015.1435.4/20 - LH auxiliary work lights - Version with standard cab (R3 EVO 100 ->
XVI
CONTENTS
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1198
40.4.18 - 0.015.1983.4/10 - Power supplies 1 40-1199
40.4.19 - 0.015.1983.4/10 - Power supplies 2 40-1200
40.4.20 - 0.015.1983.4/10 - Power supplies 3 40-1201
40.4.21 - 0.015.1998.4/10 - Drivetrain shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-1202
40.4.22 - 0.015.6123.4 - Rear wiper - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1203
40.4.23 - 0.015.6272.4/40 - Cab roof - Version with high-visibility cab 40-1204
40.4.24 - 0.015.7021.4/70 - Central - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1206
40.4.25 - 0.015.7021.4/70 - Central wiring (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001) 40-1209
40.4.26 - 0.015.7023.4/50 - Driveline - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1213
40.4.27 - 0.015.7023.4/50 - Drivetrain (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1214
40.4.28 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with high-visibility cab () 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.) 40-1221
40.4.33 - 0.016.0664.4 - Front lights 40-1225
40.4.34 - 0.016.0865.4/10 - Cab roof - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1227
40.4.35 - 0.016.0865.4/10 - Cab roof - Version with standard cab (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1229
40.4.36 - 0.016.0866.4/10 - Front-rear work lights - Version with standard cab 40-1231
40.4.37 - 0.016.1001.4/20 - Hydraulic trailer braking valve (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-1232
40.4.38 - 0.016.1999.4/10 - Driveline - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1233
40.4.39 - 0.016.2000.4/20 - Engine - Version with front battery 40-1234
40.4.40 - 0.016.2001.4/10 - Engine - Version with lateral battery 40-1237
40.4.41 - 0.016.2002.4/60 - Central - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1238
40.4.42 - 0.017.0473.4 - Battery negative 40-1241
40.4.43 - 0.017.0474.4 - Battery positive 40-1242
40.4.44 - 0.017.1063.4 - Cab earth 40-1242
40.4.45 - 0.018.5825.4 - Cab roof - Version with standard cab (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1243
40.4.46 - 0.018.5825.4 - Cab roof - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1245
40.4.47 - 04214707 - Engine (R3 EVO 85 -> 16001) 40-1247
40.4.48 - 04215655 - Engine (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-1248
40.4.49 - 04215655 - Engine (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
40-1249
XVII
CONTENTS
40.4.50 - 04411923.4 - RH lower headlights 40-1250
40.4.51 - 04411923.4 - LH lower headlights 40-1251
XVIII
CONTENTS
PAGE LEFT INTENTIONALLY BLANK
0-1
0 - INTRODUCTION
0-2
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. The material contained in this manual is of a condential technical nature, and is
intended for dealers and authorised workshops only. In the event of any changes of a strictly technical nature regarding the machines,
the intended recipients will be notied promptly with supplements to the manual illustrating modications, updates and additional
optional devices. Technicians and their employees shall not distribute, reproduce or divulge the material contained herein to others
without written permission from the Manufacturer who is the exclusive owner thereof and who reserves the right to take legal action
based on current laws to protect its rights.
0.1.1 - Safety notes
For the machine to continue to function correctly, it is crucial that all repairs are performed properly by a service centre authorised to
repair and service these machines. The testing and repair techniques recommended and described in this manual are effective and
safe methods for obtaining good operation. Some of the described operations require the use of special and dedicated tools; these
can be requested from the Manufacturer who has specically designed them for their intended purpose. DO NOT USE IMPROVISED
TOOLS; they could create potentially dangerous situations and do not always correspond to the specic functions for which they
are created and used. If a dangerous situation occurs or is anticipated, consider safety rst of all and take the necessary actions to
handle the situation
0.1.2 - General safety
l
Even if you are completely familiar with the construction, functions and controls of this machine, always observe extreme cau-
tion when manoeuvring and operating the machine Always bear in mind that a machine brought to the workshop is in need of
repair or servicing, and may therefore react unpredictably to controls.
l
Before starting work, clean the machine thoroughly to remove mud, dust and gravel. Also clean the cab thoroughly to remove
all residue of oil, snow or ice from the steps, handles and grips normally used to access and leave the cab.
l
When climbing into or out of the machine, maintain three points of contact at all times prevent loss of balance and the risk of
falling.
l
Observe extreme caution when troubleshooting faults, which must often be performed by two operators: never stand in front
of the wheels while the engine is running.
l
When performing tests and repairs, always wear close tting clothing, goggles and gloves suitable for the operation to perform
(cleaning, draining uids, repairs). Do not go near moving parts with long hair that has not been tied back, hair can get caught
and create serious injury.
l
Keep unauthorised persons away from the machine they must be required to remain at a safe distance.
l
Keep away from moving parts; with the engine on, some parts are not very visible and thus, even if protected, may represent
a potential danger of being drawn in.
l
When starting the engine, make sure that the area is well ventilated to avoid a build up of toxic gases; always apply the ex-
haust pipe of the forced fume extraction devices.
l
Absolutely avoid running the engine without guards; all repair and/or adjustment operations must be performed with the en-
gine off.
l
Do not ll up fuel, oil or coolant with the engine running.
l
Do not smoke when lling up fuel or lubricant and make sure there are no open ames in the vicinity. Do not charge the battery
on board the machine.
l
Before working on the battery to check it or remove it, stop the engine and remove the key.
l
Remove the battery and recharge it in a well ventilated area and with a temperature greater than 0°C.
l
Do not smoke during battery testing and recharging, and do not go near it with open ames since the hydrogen emitted during
chemical reactions may explode.
l
The liquid (electrolyte) contained in the battery is dangerous for the skins and above all for the eyes; for this reason when test-
ing the battery always wear gloves and safety goggles with side shields. If you accidentally get electrolyte on you immediately
wash the contaminated parts for a long time with water; if your clothes are contaminated change them as quickly as possible.
If you accidentally swallow electrolyte, drink plenty of water, milk, vegetable oil and antacids such as magnesium, bicarbonate,
etc., and go to an emergency room as soon as possible.
l
If work needs to be done on the electrical circuits, disconnect the terminals from the battery.
This manual suits for next models
6
Table of contents
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