LAMBORGHINI R7.190 DCR Instruction manual

WORKSHOP MANUAL
R7.190 DCR
->ZKDS7902W0LL10010
R7.210 DCR -> 10010

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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 retting 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
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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 - Congurations 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 - Conguration of the front/rear PTO 20-43
20.3.19 - Commissioning service ECU - Front Suspension Conguration 20-43
20.3.20 - Putting the services ECU into service - Conguration 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
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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
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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 retting 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 endoat 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 retting 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 retting 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 retting of the turbocharger 30-170
30.3.34 - Removal and retting 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 retting of the fuel control unit 30-195
30.3.38 - Removal and retting of the high-pressure pump (installation position A) 30-200
30.3.39 - Removal and retting of the high-pressure pump (installation position B) 30-208
30.3.40 - Removal and retting of the common rail 30-217
30.3.41 - Removal and retting of the injectors 30-223
30.3.42 - Removal and retting of the pressure cut-off valve 30-230
30.3.43 - Removal and retting 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 retting of the oil sump pan. 30-244
30.3.46 - Removal and retting of the oil cooler 30-247
30.3.47 - Disassembly and assembly of the oil radiator housing 30-251
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VII
CONTENTS
30.3.48 - Removal and retting 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 retting of the thermostat 30-269
30.3.53 - Fitting and removing the thermostat housing 30-270
30.3.54 - Removing and retting 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 retting 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 retting of the camshaft speed sensor 30-294
30.4.3 - Removal and retting 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 retting of the fuel lter head. 30-300
30.4.6 - Removal and retting of the rail pressure sensor 30-305
30.4.7 - Assembly and disassembly of the temperature sender 30-306
30.4.8 - Removal and retting of the engine wiring loom 30-308
30.4.9 - Removal and retting of the alternator (with drivebelt) 30-318
30.4.10 - Disassembly and assembly of the starter 30-323
30.4.11 - Removal and retting 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
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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
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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
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X
CONTENTS
PAGE LEFT INTENTIONALLY BLANK
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