LAMBORGHINI R7.190 DCR Instruction manual
WORKSHOP MANUAL
R7.190 DCR
->ZKDS7902W0LL10010
R7.210 DCR -> 10010
III
CONTENTS
0 - INTRODUCTION
0.1 - Introduction 0-2
0.1.1 - Safety notes 0-2
0.1.2 - General safety rules 0-2
0.1.3 - Safety precautions for removal and retting operations 0-3
0.1.4 - Lifting instructions 0-4
0.1.5 - Tightening torques 0-5
0.1.6 - Threadlockers, adhesives, sealants and lubricants 0-8
0.1.7 - Conversion factors 0-10
10 - TECHNICAL CHARACTERISTICS
10.1 - Engine 10-2
10.1.1 - Engine 2013 components 10-2
10.1.2 - Technical data 10-8
10.2 - Transmission 10-9
10.2.1 - Hydraulic shuttle 10-9
10.2.2 - POWER SHIFT Transmission 10-9
10.2.3 - H-M-L unit 10-11
10.2.4 - Intermediate gearbox 10-12
10.2.5 - Rear gearbox 10-13
10.2.6 - Rear PTO 10-14
10.3 - Rear axle 10-15
10.3.1 - Rear axle 10-15
10.4 - Front axle 10-16
10.4.1 - Front axle 10-16
10.4.2 - Differential 10-17
10.5 - Hydraulic system 10-20
10.5.1 - STEERING - TRANSMISSION hydraulic circuit 10-20
10.5.2 - REMOTE VALVES - LIFT hydraulic circuit 10-21
10.5.3 - Variable displacement pump 10-22
10.5.4 - Power steering valve 10-26
10.5.5 - Hydraulic front axle suspension 10-27
10.5.6 - Remote control valve 10-32
10.5.7 - Braking system 10-33
10.5.8 - Trailer braking valve (ITALY version) 10-34
10.5.9 - Trailer braking valve (EXPORT version) 10-34
10.5.10 - POWER SHIFT valves block 10-35
10.6 - Front lift 10-37
10.6.1 - Front lift 10-37
10.7 - Rear lift 10-38
10.7.1 - Rear lift 10-38
20 - CALIBRATIONS AND ELECTRONIC DIAGNOSIS
20.1 - Diagnostic tools 20-2
20.1.1 - Positions of ECUs and diagnostic instruments 20-2
20.1.2 - All Round Tester (ART® SAME) 20-4
20.1.3 - SDF Analyser 20-9
Find manuals at https://best-manuals.com
IV
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
20.3.4 - Putting the transmission ECU into service - Introduction 20-22
20.3.5 - Putting the transmission ECU into service - EEPROM reset 20-23
20.3.6 - Putting the transmission ECU into service - Calibration of the clutch pedal 20-25
20.3.7 - Putting the transmission ECU into service - Calibration of the tilt sensor 20-27
20.3.8 - Putting the transmission ECU into service - Calibration of the range sensor 20-29
20.3.9 - Putting the transmission ECU into service - Automatic calibration of the gearbox clutches 20-30
20.3.10 - Putting the transmission ECU into service - Automatic calibration of the shuttle clutches 20-32
20.3.11 - Putting the transmission ECU into service - Manual calibration of the shuttle clutches 20-35
20.3.12 - Transmission ECU commissioning - Manual calibration of the shuttle clutches 20-37
20.3.13 - Putting the armrest ECU into service - EEPROM reset 20-37
20.3.14 - Putting the armrest ECU into service - Congurations 20-38
20.3.15 - Putting the services ECU into service - EEPROM reset 20-40
20.3.16 - Putting the services ECU into service - Lift calibration 20-41
20.3.17 - Putting the services ECU into service - Calibration of the ASM (SBA) system 20-43
20.3.18 - Putting the services ECU into service - Conguration of the front/rear PTO 20-43
20.3.19 - Commissioning service ECU - Front Suspension Conguration 20-43
20.3.20 - Putting the services ECU into service - Conguration of the electro-hydraulic control
valves 20-44
20.3.21 - Putting the EPB control unit into service - Initialisation 20-46
20.3.22 - Workshop Procedure for EPB Calibration 20-46
20.4 - ECU alarms 20-59
20.4.1 - Key to the “ECU alarms” tables 20-59
20.4.2 - FMI code 20-59
20.4.3 - Engine alarms 20-60
20.4.4 - Transmission alarms 20-76
20.4.5 - HLHP alarms 20-78
20.4.6 - EPB Alarms 20-80
30 - METHOD OF INTERVENTION
30.1 - Commercially available tools 30-2
30.1.1 - Orders 30-2
30.1.2 - 8002 - Pressing pump 30-2
30.1.3 - 8005 - Compression value tester 30-2
30.1.4 - 8011 - Pliers for hose clips 30-3
30.1.5 - 8024 - Assembly pliers 30-3
30.1.6 - 8035 - box spanner insert 30-3
30.1.7 - 8113 - box spanner insert 30-4
30.1.8 - 8114 - box spanner insert 30-4
30.1.9 - 8115 - V-belt tension tester 30-4
30.1.10 - 8189 - Torx tool set 30-5
30.1.11 - 8190 - Rotation angle gauge 30-5
Find manuals at https://best-manuals.com
V
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
30.1.19 - 8199 - Crow’s foot wrench 30-8
30.1.20 - 9017 - Assembly lever 30-8
30.1.21 - 9090 - Circlip pliers 30-8
30.2 - Special tools 30-9
30.2.1 - Orders 30-9
30.2.2 - 100190 - Connector 30-9
30.2.3 - 100320 - Rotation device 30-9
30.2.4 - 100330 - Rotation device 30-10
30.2.5 - 100400 - Dial gauge with stop wheel 30-10
30.2.6 - 100410 - Digital dial gauge 30-10
30.2.7 - 100750 - Measurement device 30-11
30.2.8 - 103050 - Box spanner insert 30-11
30.2.9 - 103220 - Special pliers 30-11
30.2.10 - 110500 - Special wrench 30-12
30.2.11 - 110640 - Lever tool 30-12
30.2.12 - 110700 - Box spanner insert 30-12
30.2.13 - 110900 - Assembly kit 30-13
30.2.14 - 120430 - Assembly device 30-13
30.2.15 - 120680 - Extraction device 30-13
30.2.16 - 120900 - Support stand 30-14
30.2.17 - 120910 - base plate 30-14
30.2.18 - 121330 - Assembly lever 30-14
30.2.19 - 121420 - Assembly bushes 30-15
30.2.20 - 130300 - Universal pliers for piston rings 30-15
30.2.21 - 130420 - Trapezoidal groove wear gauge 30-15
30.2.22 - 130640 - Piston ring compression collar 30-16
30.2.23 - 142810 - Assembly device 30-16
30.2.24 - 142820 - Assembly device 30-16
30.2.25 - 150170 - Universal extractor 30-17
30.2.26 - 150171 - Plate 30-17
30.2.27 - 150180 - Sleeve support 30-17
30.2.28 - 150190 - Assembly lever 30-18
30.2.29 - 150191 - Washer 30-18
30.2.30 - 150800 - Slide hammer extractor 30-18
30.2.31 - 170050 - Special wrench 30-19
30.2.32 - 170160 - Plugs and caps 30-19
30.2.33 - 6066 - Assembly stand 30-19
30.2.34 - 6066/158 - Clamping support 30-20
30.2.35 - 6068 - Suspension device 30-20
30.2.36 - 6692 - Ring gear nut wrench 30-20
30.3 - B0 - Engine 30-21
Find manuals at https://best-manuals.com
VI
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). 30-40
30.3.6 - Valve clearance adjustment (with the exhaust gas recirculation module installed). 30-50
30.3.7 - Removal and retting of the rocker arms and pedestals 30-61
30.3.8 - Disassemble and complete the rocker and support, check 30-66
30.3.9 - Disassembly and assembly of the cylinder head 30-70
30.3.10 - Valve assembly and disassembly 30-77
30.3.11 - Valve check 30-82
30.3.12 - Check the valve guide 30-83
30.3.13 - Check the valve residual 30-84
30.3.14 - Check the endoat of the crankshaft 30-86
30.3.15 - Check the crankshaft 30-91
30.3.16 - Replace the crankshaft O-ring (ywheel end) 30-95
30.3.17 - Replacing the crankshaft O-ring (opposite end to ywheel) 30-99
30.3.18 - Check the connecting rod drum 30-103
30.3.19 - Assembly and disassembly of the crankshaft 30-110
30.3.20 - Disassembly and assembly of the piston and connecting rod drum 30-121
30.3.21 - Check the piston 30-128
30.3.22 - Check the piston rings and piston grooves 30-130
30.3.23 - Assembly and disassembly of piston cooling nozzles 30-135
30.3.24 - Removal and retting of the crankcase breather 30-135
30.3.25 - Cylinder liner check 30-138
30.3.26 - Fitting and removing the cylinder sleeve 30-141
30.3.27 - Check the protrusion of the cylinder liner 30-147
30.3.28 - Removal and retting of the front cover (opposite end to ywheel) 30-148
30.3.29 - Disassembly and assembly of the connector box 30-153
30.3.30 - Disassembly and assembly of the gear case cover 30-156
30.3.31 - Assembly and disassembly of the camshaft 30-166
30.3.32 - Check the camshaft 30-169
30.3.33 - Removal and retting of the turbocharger 30-170
30.3.34 - Removal and retting of the charge air duct 30-176
30.3.35 - Fitting and removing the exhaust gas recirculation module 30-180
30.3.36 - Removing and tting the fuel pump (driven by toothed belt) 30-185
30.3.37 - Removal and retting of the fuel control unit 30-195
30.3.38 - Removal and retting of the high-pressure pump (installation position A) 30-200
30.3.39 - Removal and retting of the high-pressure pump (installation position B) 30-208
30.3.40 - Removal and retting of the common rail 30-217
30.3.41 - Removal and retting of the injectors 30-223
30.3.42 - Removal and retting of the pressure cut-off valve 30-230
30.3.43 - Removal and retting of the fuel pressure sensor 30-232
30.3.44 - Disassembly and assembly of the gear case cover 30-234
30.3.45 - Removal and retting of the oil sump pan. 30-244
30.3.46 - Removal and retting of the oil cooler 30-247
30.3.47 - Disassembly and assembly of the oil radiator housing 30-251
Find manuals at https://best-manuals.com
VII
CONTENTS
30.3.48 - Removal and retting 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 tting the coolant pump (driven by toothed belt) 30-256
30.3.51 - Testing the thermostat (after removal) 30-267
30.3.52 - Removal and retting of the thermostat 30-269
30.3.53 - Fitting and removing the thermostat housing 30-270
30.3.54 - Removing and retting the torsional vibration damper (toothed belt drive) 30-273
30.3.55 - Removing and tting the V-belt, V-belt pulley 30-273
30.3.56 - Removal and retting of the ywheel 30-287
30.4 - C0 - Engine accessories 30-290
30.4.1 - Disassembly and assembly of the speed indicator (crankshaft) 30-290
30.4.2 - Removal and retting of the camshaft speed sensor 30-294
30.4.3 - Removal and retting of the exhaust manifold 30-296
30.4.4 - Fitting and removing the solenoid valve (exhaust gas recovery module) 30-298
30.4.5 - Removal and retting of the fuel lter head. 30-300
30.4.6 - Removal and retting of the rail pressure sensor 30-305
30.4.7 - Assembly and disassembly of the temperature sender 30-306
30.4.8 - Removal and retting of the engine wiring loom 30-308
30.4.9 - Removal and retting of the alternator (with drivebelt) 30-318
30.4.10 - Disassembly and assembly of the starter 30-323
30.4.11 - Removal and retting of the supply air pressure/temperature sender 30-324
30.5 - D0 - Transmission 30-326
30.5.1 - Complete hydraulic shuttle assembly 30-326
30.5.2 - Shuttle and HML assembly 30-330
30.5.3 - Changing the transmission oil 30-340
30.5.4 - Clutch control assembly 30-342
30.5.5 - Disassembly of the clutch control assembly 30-343
30.5.6 - H clutch assembly 30-346
30.5.7 - Disassembly of the H clutch assembly 30-347
30.5.8 - Slow-medium gear clutch pack 30-352
30.5.9 - Slow/medium epicyclic gear unit 30-356
30.5.10 - Powershift control valve 30-360
30.5.11 - Disassembly of powershift control valve 30-362
30.5.12 - Secondary shaft 30-366
30.5.13 - Primary shaft 30-379
30.5.14 - Rear PTO drive shaft and pumps assembly 30-389
30.5.15 - Front gearbox 30-393
30.5.16 - View of front gearbox from rear 30-393
30.5.17 - Rear gearbox removal 30-396
30.5.18 - Front gearbox cover 30-397
30.5.19 - Range gear control cover 30-400
30.5.20 - Lower gearbox cover 30-401
30.5.21 - Range reduction unit control unit 30-402
30.5.22 - Disassembly of the range reduction unit control assembly 30-404
30.5.23 - Range gear and creeper selector assembly 30-407
30.5.24 - Adjusting the bearings preload 30-415
30.5.25 - Range driving gear 30-417
30.5.26 - Disassembly of the range driving gear 30-420
Find manuals at https://best-manuals.com
VIII
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
30.6 - E0 - Rear axle 30-456
30.6.1 - Rear axle 30-456
30.6.2 - Disassembly of the rear axle 30-457
30.6.3 - Adjustment of rear half-shaft bearings 30-462
30.6.4 - Brake housing 30-463
30.6.5 - Disassembly of the planet carrier 30-464
30.6.6 - Rear differential 30-468
30.6.7 - Disassembly of the rear differential 30-473
30.6.8 - Rear axle brake assembly and brake discs 30-479
30.6.9 - Disassembly of the rear axle brake assembly 30-481
30.6.10 - Brake actuator 30-483
30.6.11 - Rear brakes 30-485
30.6.12 - EPB - Bowden Assembly Adjustment 30-485
30.7 - F0 - Front axle 30-487
30.7.1 - Adjustment of pinion and crown wheel backlash 30-487
30.8 - G0 - Bodywork - Cab - Platform 30-489
30.8.1 - Electronic park brake mechanism 30-489
30.9 - H0 - Hydraulic system 30-492
30.9.1 - Complete pumps assembly 30-492
30.9.2 - Priority valve 30-496
30.9.3 - Brakes lubrication pump 30-497
30.9.4 - Powershift steering pump 30-498
30.9.5 - Transfer pump 30-500
30.9.6 - LS pump 30-502
30.10 - L0 - Electrical system 30-505
30.10.1 - Range gearbox output speed sensor 30-505
30.11 - V1 - AFTERMARKET KITS 30-506
30.11.1 - Installing heat shields 30-506
30.11.2 - Coolant radiator 30-511
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 - Components list 40-26
40.3 - Systems 40-40
Find manuals at https://best-manuals.com
IX
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
40.3.8 - S007 - Cab 2 40-96
40.3.9 - S008 - Cab roof 1 40-103
40.3.10 - S009 - Cab roof 2 40-110
40.3.11 - S010 - Air conditioning 40-118
40.3.12 - S011 - Relay 40-124
40.3.13 - S012 - Positives 40-130
40.3.14 - S013 - Negatives 1 40-137
40.3.15 - S014 - Negatives 2 40-144
40.3.16 - S015 - Negatives 3 40-152
40.3.17 - S016 - Negatives 4 40-160
40.3.18 - S017 - CAN BUS 40-163
40.3.19 - S018 - Cold climates 40-168
40.4 - Wiring harnesses 40-170
40.4.1 - 0.008.0913.3 - Front PTO wiring 40-170
40.4.2 - 0.010.8707.4/10 - SBA sensor lead 40-170
40.4.3 - 0.010.8711.4/30 - Rear lights wiring 40-170
40.4.4 - 0.011.3824.4/10 - Rotating beacon wiring 40-172
40.4.5 - 0.011.6007.3 - Water reservoir electric lead 40-173
40.4.6 - 0.013.4085.4/20 - Front lights wiring 40-173
40.4.7 - 0.013.4463.4 - Front axle suspension wiring 40-173
40.4.8 - 0.014.1645.4/10 - Hydraulic trailer braking wiring - Italy 40-174
40.4.9 - 0.015.2536.4 - Engine interface wiring 40-174
40.4.10 - 0.016.7899.4 - Front lights wiring 40-175
40.4.11 - 0.016.0260.4/20 - Cab wiring 40-177
40.4.12 - 0.016.0261.4/20 - Front wiring 40-181
40.4.13 - 0.016.0262.4/10 - LH rear wiring 40-183
40.4.14 - 0.016.0263.4/10 - RH rear wiring 40-185
40.4.15 - 0.016.0264.4/10 - Battery leads 40-187
40.4.16 - 0.016.1001.4/20 - Trailer air braking solenoid valve wiring 40-187
40.4.17 - 0.016.1203.4/20 - Fuse box 40-188
40.4.18 - 0.016.1575.4/10 - Cab roof wiring 40-190
40.4.19 - 0.016.6592.4 - Brake wiring 40-192
40.4.20 - 0.016.8489.4 - Trailer air braking solenoid valve wiring 40-192
40.4.21 - 0.900.0783.8 - Air conditioning wiring 40-193
40.4.22 - 0421.4895 - Engine wiring 40-194
40.4.23 - 0.017.1246.4/10 - Front cold climate wiring 40-195
40.4.24 - 0.017.1741.4/10 - Front cold climate wiring 40-195
40.4.25 - 0.017.3382.4 - Heater blowers wiring 40-196
Find manuals at https://best-manuals.com
0-1
0 - INTRODUCTION
0-2
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. The instructions also indicate
the products to use, the tightening torques and the adjustment data. The technical material contained in this manual is reserved to
Authorised Dealers and Service Centres who will be duly informed of any technical changes to the machines in question through the
issue of documents regarding modications, updates and supplements for optional equipment. All technicians and their colleagues
are expressly forbidden from reproducing any part of this manual in any form or from communicating the contents to third parties
without the express written permission of the Manufacturer, who remains the sole owner of this document with all rights reserved in
accordance with applicable laws.
0.1.1 - Safety notes
To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very impor-
tant that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are
safe and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifally
designed for the intended purpose and may be ordered directly from the Manufacturers. DO NOT USE MAKESHIFT TOOLS; not
only is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous
situations, always give priority to personal safety and take the necessary actions to eliminate the danger
0.1.2 - General safety rules
l
Even if you have a thorough knowledge of the machine as regards its components, operation and controls, always take spe-
cial care when carrying out the following operations; Remember that the machine you are working on is in need of repair or
overhaul and consequently may not always behave as expected.
l
Before starting work, clean the tractor thoroughly to remove all mud, dust and road dirt. Also clean the cab to remove all traces
of oil, snow and ice from the access steps and grab rails.
l
When climbing up to or down from the cab, always ensure you maintain three points of contact at a time (foot or handholds)
in order to keep your balance and prevent accidental falls.
l
Always take special care when carrying out fault diagnosis operations; these operations often require two persons, who must
never stand in front of the wheels when the engine is running.
l
When carrying out checks and repairs, wear close-tting clothing, safety goggles and protective gloves that are suitable for
the task (cleaning, draining uids, repairs). When working near moving parts, long hair should be gathered up and tied back
safely under a cap to prevent the risk of entanglement and severe injury.
l
Do not allow anyone who is not directly involved in the work to come near the tractor; ensure that they remain at a safe dis-
tance.
l
Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a
risk of entanglement, even if protected by safety guards.
l
Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations
of toxic gases; always connect suitable fume extraction equipment to the exhaust pipe.
l
Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must
be carried out with the engine stopped.
l
Do not top up fuel, oil or coolant levels when the engine is running.
l
Never smoke and ensure there are no naked ames nearby when topping up fuel or oil. Always remove the battery from the
machine before recharging.
l
Before checking or removing the battery, stop the engine and remove the key from the starter switch.
l
Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0°C.
l
When checking or recharging the battery, do not smoke or allow naked ames in the vicinity as the hydrogen gas given off by
the battery is highly explosive.
l
The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this rea-
son, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any electrolyte
accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if electrolyte
comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion of electro-
lyte, drink copious amounts of water, milk or vegetable oil and take antacids such as magnesium, bicarbonate, etc. and seek
medical attention immediately.
l
Before working on the electrical systems, always disconnect the battery terminals.
0-3
INTRODUCTION
DANGER
Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion of
the work, rst connect the positive terminal (+) and then the negative (--).
l
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.
l
When topping up lubricants, always wear suitable protective gloves.
l
Do not wear clothing contaminated by engine or hydraulic oil; prolonged contact with the skin can be harmful and may cause
allergic reactions.
l
Used engine oil and hydraulic oil must be disposed of properly; recover used lubricants and dispose of them in accordance
with the applicable regulations.
l
Before carrying out any work on the hydraulic or pneumatic systems, discharge all residual pressure from the circuits.
l
Before carrying out any work on the hydraulic system or engine, allow the oil and engine coolant to cool down.
l
When removing and retting certain assemblies, it will be necessary to support the tractor; use stands, jacks or blocks capable
of supporting the weight and arrange them in a triangular pattern to prevent the machine from overturning.
l
To lift heavy components, use a hoist or crane. Check that wire ropes, chains or bre slings are not worn and that hooks are
not damaged.
l
Always use lifting equipment of suitable capacity for the weight of the components to be removed. Ensure lifting equipment is
attached correctly.
l
When lifting or supporting an assembly or component, manoeuvre the parts slowly and carefully to avoid swinging movements
or collision with other components.
l
Never work on components suspended from a hoist or crane.
l
When removing the retaining bolts of a component that could fall, always leave two opposing bolts in place for safety; before
removing these last two bolts, attach the component to suitable lifting equipment or position support blocks.
l
Any oil or fuel spilled during removal or dismantling operations should be cleaned up as soon as possible to prevent the risk
of slipping and re.
l
When retting electrical wiring looms and wires, ensure that they are properly secured with their original retaining straps or
brackets to prevent the possibility of damage caused by vibration.
l
Never insert your ngers or hands to check the alignment between xing holes in components; always use a suitable dowel
of soft material.
l
When retting assemblies or components, always use the specied tightening torques; the tightening torques indicated in the
paragraphs regarding assembly/retting operations have been determined through experimentation and must be scrupulously
adhered to.
l
When retting parts that are subject to vibration or that rotate at high speed, take particular care when carrying out nal instal-
lation checks.
0.1.3 - Safety precautions for removal and retting operations
When removing or retting parts, always take the following safety precautions.
Precautions for removal operations
l
Unless otherwise indicated, lower the lifting equipment until it the component or assembly rests on the ground.
l
After disconnecting hydraulic and fuel system pipes, always t plugs to the open ends of the pipes to prevent ingress of dirt.
l
Before removing a cylinder, fully retract the piston and secure it in this position using a retaining strap.
l
Use containers of sufcient capacity when draining oil, coolant or fuel.
l
Before removing a part from the machine, check for alignment markings indicating the correct assembly position. If necessary,
make new markings to ensure correct assembly.
l
When unplugging electrical connectors, always grip the connectors rmly to avoid pulling on the wires.
l
Where necessary, label wires and pipes before removal to avoid confusion when reconnecting.
l
Check the number and thickness of any shims removed and keep them together in a safe place.
l
To lift the tractor or any of its main components, use lifting equipment of suitable capacity.
l
When using eyebolts for lifting components, rst check that they are not deformed or damaged; screw them fully home and
then turn the bolt so that the eye is aligned with the lifting hook.
l
Before removing a part, clean the surrounding area and, after removing the part, cover it to protect it from dirt and dust.
0-4
INTRODUCTION
Precautions for retting operations
l
Tighten nuts and screws to the specied tightening torques.
l
When retting exible pipes and cables, take care not to twist or tangle them.
l
Always t 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.
l
Ensure that circlips are correctly installed in their seatings.
l
When applying threadlocking compound, rst clean the part to remove all oil and grease, then cover the thread evenly apply-
ing a few drops of the compound.
l
When applying sealant, rst clean the surface removing all traces of oil and grease and check for dirt or indentations, then
apply the sealant evenly making sure that it forms a continuous lm around any xing holes.
l
Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations.
l
Coat all moving parts with a thin lm of engine oil.
l
When reconnecting electrical wiring connectors, rst remove all traces of oil, dust and water from the inside of the connector
and then push the two halves together rmly; connectors with locking tabs should be pushed together until the tab engages
the keeper.
l
Bolt down anged ttings evenly, tightening the screws gradually in a crosswise pattern.
Precautions to be taken on completion of removal/retting operations
l
If coolant has been drained from the engine, ret the drain plug and pour in new coolant to the correct level. Start the engine
to circulate the coolant and then check the level again and top up.
l
After removing hydraulic components, top up the hydraulic oil to the specied level. Start the engine to circulate the oil in the
hydraulic circuits and then recheck the level and top up as necessary.
l
After having removed a variable displacement pump, connect the drain pipe and ll the pump casing with oil through the ller
hole provided.
l
Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.
0.1.4 - Lifting instructions
DANGER
Components weighing over 25 kg or of signicant size must be supported and removed using suitable lifting equip-
ment with wire rope or polyester slings.
Wire ropes - slings
l
Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:
Table 1
WIRE ROPES (standard twisted “S” or “Z” type) POLYESTER SLINGS (eye-and-eye - simple loop)
Ø rope mm Capacity (kg) Width (mm) Capacity (kg)
8650 620 500 25 500 400 860 700
10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530
Lifting capacities are calculated with a safety coefcient.
l
The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the rope/
sling, this could cause the load to slip during lifting.
l
Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
0-5
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.
l
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; the table below indicates how the permitted load varies according to the angle of suspension
for two Ø 10 mm ropes each with a load capacity of 1000 kg.
Fig. 1
0.1.5 - Tightening torques
Bolts and nuts
DANGER
The tightening torques for certain specic components and special tightening methods are indicated in the relative
assembly paragraphs.
The tightening torques indicated below refer to screws and nuts assembled without lubrication and, where applicable, with anaerobic
threadlocking compound. the values apply to tightening on steel or cast iron components; for soft materials such as aluminium, cop-
per, plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.
Table 2
BOLT SIZE BOLT CLASS
8.8 10.9 12.9
Nm lb.ft. Nm lb.ft. Nm lb.ft.
M6x1 8.0 – 8.8 5.9 – 6.5 11.8 – 13.0 8.7 – 9.6 13.8 – 15.2 10.2 – 11.2
M8x1.25 19.4 – 21.4 14.3 – 15.8 28.5 – 31.5 21.0 – 23.2 33.3 – 36.9 24.5 – 27.2
M10x1.5 38.4 – 42.4 28.3 – 31.2 56.4 – 62.4 41.6 – 46.0 67.4 – 74.4 49.7 – 54.8
M12x1.75 66.5 – 73.5 49.0 – 54.2 96.9 – 107 71.4 – 78.9 115 – 128 84.8 – 94.3
M14x2 106 – 117 78.1 – 86.2 156 – 172 115.0 – 126.8 184 – 204 135.6 – 150.3
M16x2 164 – 182 120.9 – 134.1 241 – 267 117.6 – 196.8 282 – 312 207.8 – 229.9
M18x2.5 228 – 252 168.0 – 185.7 334 – 370 246.2 – 272.7 391 – 432 288.2 – 318.4
M20x2.5 321 – 355 236.6 – 261.6 472 – 522 347.9 – 384.7 553 – 611 407.6 – 450.3
M22x2.5 441 – 487 325.0 – 358.9 647 – 715 476.8 – 527.0 751 – 830 553.5 – 611.7
M24x3 553 – 611 407.6 – 450.3 812 – 898 598.4 – 661.8 950 – 1050 700.2 – 773.9
M27x3 816 – 902 601.4 – 664.8 1198 – 1324 882.9 – 975.8 1419 – 1569 1045.8 – 1156.4
0-6
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 – 79.8 53.2 – 58.8 106 – 118 78.1 – 87.0 126 – 140 92.9 – 103.2
M12x1.5 69.4 – 76.7 51.1 – 56.5 102 – 112 75.2 – 82.5 121 – 134 89.2 – 98.8
M14x1.5 114 – 126 84.0 – 92.9 168 – 186 123.8 – 137.1 199 – 220 146.7 – 162.1
M16x1.5 175 – 194 129 – 143 257 – 285 189.4 – 210.0 301 – 333 221.8 – 245.4
M18x1.5 256 – 282 188.7 – 207.8 375 – 415 276.4 – 305.9 439 – 485 323.5 – 357.4
M20x1.5 355 – 393 261.6 – 289.6 523 – 578 385.5 – 426.0 611 – 676 450.3 – 498.2
M22x1.5 482 – 532 355.2 – 392.1 708 – 782 521.8 – 576.3 821 – 908 605.1 – 669.2
M24x2 602 – 666 443.7 – 490.8 884 – 978 651.5 – 720.8 1035 – 1143 762.8 – 842.4
Fittings
The tightening torques indicated below refer to ttings assembled on any material.
Table 3
MET-
RIC
Straight end ttings T” end ttings L” end ttings 90° end ttings
Thread size Wrench Torque Nm
±10%
Wrench Torque Nm
±10%
Wrench Torque Nm
±10%
Wrench Torque Nm
±10%
M10x1.25 17 14 14 14 14 14 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33x2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250
M48x2 60 305 60 305 60 305 60 305
G 1/8” 17 13 14 13 14 13 14 13
19 13
G 1/4” 19 37 19 37 19 37 19 37
22 37
G 3/8” 24 53 24 53 24 53 24 53
G 1/2” 27 73 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
G 1” 41 160 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305
Plugs
Table 4
Hex plugs Threaded plugs with hex socket head
Thread size Wrench Torque Nm ±10% Wrench Torque Nm ±10%
0-7
INTRODUCTION
MET-
RIC
M6x1 10 10 – –
M8x1 13 12 – –
M10x1 13 14 5 14
M10x1.25 13 14 – –
M10x1.5 13 14 – –
M12x1.25 17 30 – –
M12x1.5 17 30 6 30
M12x1.75 17 30 – –
M14x1.5 19 40 6 40
M14x2 19 40 – –
M16x1.5 22 48 8 48
M16x2 22 48 – –
M18x1.5 17 58 10 58
M18x2.5 17 58 – –
M20x1.5 19 65 – –
M22x1.5 – – 12 73
M24x1.5 22 80 12 80
M24x2 22 80 – –
M27x2 22 100 – –
M28x1.5 – – 17 110
M30x1.5 22 130 – –
M32x1.5 – – 19 150
M35x1.5 – – 22 180
M40x1.5 – – 24 225
G 1/8” 14 13 – –
G 1/4” 19 37 – –
G 3/8” 22 53 – –
G 1/2” 19 73 – –
G 5/8” 22 85 – –
G 3/4” 22 100 – –
G 1” 22 160 – –
Fittings with seal at 37°
Table 5
Thread size Wrench Torque Nm ±10%
7/16” - 20 14 13
1/2” - 20 16 19
9/16” - 18 17 28
3/4” - 16 22 47
7/8” - 14 27 76
1 1/16” - 12 32 110
36 110
1 3/16” - 12 36 138
1 5/16” - 12 38 155
1 5/8” - 12 50 215
1 7/8” - 12 60 290
2 1/2” - 12 75 345
0-8
INTRODUCTION
Fittings for pipes with banjo union
These tightening torques refer to tightening the tting with new copper sealing washers.
Table 6
Unions for one-way ttings Unions for three-way ttings Unions for four-way ttings
Thread size Wrench Torque Nm
±10%
Wrench Torque Nm
±10%
Wrench Torque Nm
±10%
M8x1 – 12 14 – –
M8x1.25 13 14
M10x1 – – 14 20 14 20
M10x1.25 13 20 ––––
M12x1.25 17 30 ––––
M12x1.5 – – 17 30 17 30
M14x1.5 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48
M18x1.5 22 58 24 58 24 58
M20x1.5 27 65 ––––
M22x1.5 – – 27 73 27 73
M24x1.5 32 80 – – – –
M26x1.5 – – 32 95 32 95
M28x1.5 36 110 ––––
M30x1.5 – – 36 130 36 130
M35x2 41 180 – – – –
M38x1.5 – – 46 200 46 200
M42x2 50 250 ––––
M45x1.5 – – 55 280 55 280
M50x2 60 320 ––––
M52x1.5 – – 60 320 60 320
M65x2 – – 75 450 75 450
0.1.6 - Threadlockers, adhesives, sealants and lubricants
Table 7
FUNCTION NAME DESCRIPTION
THREADLOCKER Loctite 222 Colour: opaque uorescent
purple
Anaerobic product suitable for low-strength locking of retaining,
adjustment and precision fasteners. All traces of lubricant must
rst be removed using the specic activator.
Loctite 242 Colour: uorescent blue Anaerobic product that prevents loosening of all types of nut and
bolt; used in place of conventional mechanical locking systems.
Used for medium-strength locking. All traces of lubricant must
rst be removed using the specic activator.
Loctite 243 Colour: opaque uorescent
blue
Alternative product to 242 ; oil tolerant and so can be used on
lightly lubricated surfaces without prior use of activator.
Loctite 270 Colour: uorescent green Anaerobic product for high-strength locking of bolts and studs
that do not normally require disassembly. Parts must be heated
to approximately 80°C for removal. All traces of lubricant must
rst be removed using the specic activator.
0-9
INTRODUCTION
DEGREASERS
AND ACTIVATORS
Loctite 703 Product used for degreasing and cleaning parts prior to applica-
tion of Loctite anaerobic products; after drying, promotes uniform
curing of threadlockers
Loctite 747 Product used specically for treatment of passive metals prior to
use of slow-cure anaerobic threadlockers (series 5 and 6). Can
also be used to increase cure speed at low temperatures or in ap-
plications where there are large gaps between the parts.
SEALANTS (for
faces and ttings)
Loctite 510 Colour: red Super-rapid anaerobic sealant for sealing between rigid metal
faces; can eliminate the need for conventional gaskets as it can
ll gaps up to 0.4 mm. Does not shrink and therefore fasteners
do not need re-tightening to specied torque values after curing.
Loctite 542 Colour: Brown Anaerobic product used as a liquid sealant for threaded ttings
up to 3/4” gas; rapid curing and parts may be disassembled with
ordinary tools.
Loctite 554 Colour: red Anaerobic sealant and locking compound used for sealing cool-
ing and industrial uid circuits. Slow curing, also suitable for use
on non-ferrous alloys
Loctite 572 Colour: White Anaerobic sealant and locking compound used for sealing pipes
and threaded ttings up to 2” in diameter. Very slow curing on
most metal surfaces.
Loctite 573 Colour: green Thixotropic anaerobic product used for sealing joints between
metal faces. Ensures total contact between surfaces with maxi-
mum tolerance of 0.10 mm, lling microvoids caused by atness
errors. Very slow curing on most metal surfaces and requires
prior application of an activator.
Loctite 576 Colour: brown Anaerobic product used as a liquid thread sealant for large diam-
eter threaded ttings (up to 2”). Very slow curing; also suitable for
non-ferrous alloys and parts requiring subsequent removal.
INSTANT ADHE-
SIVES
Loctite 401 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a wide range
of acidic and porous materials including, ceramics, wood, rub-
ber and plastic (excluding polyolen). Curing takes place in a few
seconds as an effect of the condensed humidity present on the
surfaces to be bonded, and is independent of environmental con-
ditions.
Loctite 495 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a rubber,
plastics and metal in any combination.
SEALANTS SILI-
CONE
Silastic 738 (Dow Corning) Colour: milky
white
One-part silicone adhesive/sealant, non dhrinking, ready for use.
Cures on exposure to air to form a rubbery solid and obviates the
need for conventional seals on exible joints, lling gaps greater
than 1 mm.
Dirko Transparent Colour: transparent One-part silicone adhesive/sealant, shrinking, ready for use.
Cures rapidly when exposed to humidity in the air to form a rub-
bery solid; resistant to high temperatures.
SEALANTS POL-
URETHANE
Betaseal HV3 (Gurit Essex) Colour: black Polyurethane prepolymer based adhesive/sealant, high viscosity,
suitable for permanent, high-strength exible bonding. Slow cur-
ing, used for bonding glass to frames, wire mesh, metal plates,
etc. surfaces must be degreased with primer.
0-10
INTRODUCTION
RETAINING COM-
POUNDS
Loctite 601 Colour: uorescent green Anaerobic, fast-curing, high-strength adhesive. Suitable for seal-
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: uorescent green Anaerobic structural adhesive, quick-curing, very high strength;
suitable for bonding cylindrical parts in non-ferrous alloys.
Loctite 648 Colour: uorescent green Anaerobic structural adhesive, quick-curing, high-strength; suit-
able for bonding cylindrical parts, permanent retention of thread-
ed parts, sealing of refrigeration systems, retention of bearings,
etc. Alternative to Loctite 601 in high-temperature applications.
Loctite 986/AVX Colour: Fluorescent red Anaerobic sealant/retaining compound for metal cylindrical parts.
Slow-curing, high-strength, heat-resistant and resistant to chemi-
cal attack. Parts must be rst treated with an activator.
LUBRICANTS Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose Lithium grease used for lubrication of seals, to pre-
vent oxidization and to facilitate assembly operations.
Molikote (Dow Corning) Anti-wear compound, contains Molybdenum bisulphate, used
neat or diluted with engine oil for assembly of main engine bear-
ings.
Vaseline Neutral pH compound used to protect battery terminals against
oxidization and corrosion.
Engine oil 10W - 30 Used to dilute Molikote anti-wear lubricant during assembly of
main engine bearings.
0.1.7 - Conversion factors
Conversion from British to metric units
Table 8
inch x 25.40 = mm
foot x 0.305 = m
yard x 0.914
Eng.miles x 1.609 = km
Sq.in. x 6.452 = cm²
Sq.ft. x 0.093 = m²
Sq.yard x 0.835
Cu.in. x 16.39 = cm³
Cu.ft. x 28.36 = m³
Cu.yard x 0.763
Imp.gall. x 4.547 = litres
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785 = ,/min
oz. x 0.028 = kg
lb. x 0.454
lb.ft. x 0.139 = kgm
lb.in. x 17.87 = kg/m
psi x 0.070 = kg/cm²
lb./Imp.gall x 0.100 = kg/,
lb./US.gall x 0.120
lb./cu.ft. x 16.21 = kg/m³
lb.ft. x 1.356 = Nm
psi x 1.379 = bar
Conversion from metric to British units
Table 9
mm x 0.0394 = inch
m x 3.281 = foot
m x 1,094 = yard
km x 0.622 = Brit.miles
cm² x 0.155 = Sq.in.
m² x 10.77 = Sq.ft.
This manual suits for next models
3
Table of contents
Other LAMBORGHINI Tractor manuals
