LAMBORGHINI R8.230 DCR Instruction manual
WORKSHOP MANUAL
R8.230 DCR
->WSXJ390200LL10001
R8.270 DCR
->WSXJ400200LL10001
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 - Technical data 10-2
10.2 - Transmission 10-14
10.2.1 - Transmission 10-14
10.2.2 - Rear PTO 10-32
10.3 - Rear axle 10-34
10.3.1 - Rear axle 10-34
10.4 - Front axle 10-36
10.4.1 - Front axle 10-36
10.5 - Hydraulic system 10-37
10.5.1 - Hydraulic system 10-37
10.5.2 - Variable displacement pump 10-39
10.5.3 - Hydraulic pump 10-41
10.5.4 - Steering gear pump 10-45
10.5.5 - Load sensing valve, pressure cut-off valve 10-46
10.5.6 - Priority valve 10-52
10.5.7 - Power steering 10-53
10.5.8 - Pressure relief valve 10-54
10.5.9 - Hydraulic front axle suspension 10-54
10.5.10 - Remote control valve 10-59
10.5.11 - Braking system 10-66
10.5.12 - Hydraulic trailer braking system - Italy version 10-70
10.5.13 - Hydraulic trailer braking system - Export version 10-72
10.5.14 - Air trailer braking system - Italy version 10-74
10.5.15 - Air trailer braking system - Export version 10-75
10.5.16 - Compressor, Pressure reducing valve, Cab suspension valve 10-76
10.5.17 - Trailer air braking valve (2-way) 10-79
10.5.18 - Trailer air braking valve (1-way) 10-80
10.5.19 - Pilot solenoid valve for 1-way trailer air braking valve 10-81
20 - CALIBRATIONS AND ELECTRONIC DIAGNOSIS
20.1 - Diagnostic tools 20-2
20.1.1 - All Round Tester (ART®) 20-2
20.1.2 - ART® Connection - Diagnostics socket 20-6
20.1.3 - SDF Analyser 20-6
20.1.4 - SDF Analyser - Diagnostic socket connection 20-10
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IV
CONTENTS
20.1.5 - SERDIA 2000 level III” software 20-12
20.1.6 - Serdia 20-12
20.1.7 - SERDIA - Diagnostic socket connection 20-13
20.2 - Diagnostic tool screens 20-15
20.2.1 - ECU interrogation 20-15
20.2.2 - Electronic system 20-17
20.2.3 - CAN BUS system 20-18
20.2.4 - Engine control unit - Deutz EMR3 20-19
20.2.5 - HLHP Control unit 20-20
20.2.6 - Transmission control unit 20-26
20.2.7 - Instrument panel 20-28
20.3 - Commissioning and calibrating the tractor 20-29
20.3.1 - Introduction to commissioning the tractor 20-29
20.3.2 - Renewal of the engine control unit - Introduction 20-29
20.3.3 - Renewal of the engine control unit - Reading and saving DATASET 20-29
20.3.4 - Renewal of the engine control unit - Programming the control unit with DATASET 20-30
20.3.5 - HLHP control unit - Calibration of the accelerator pedal 20-31
20.3.6 - HLHP control unit - Calibration of the hand throttle lever 20-34
20.3.7 - Renewal of the transmission control unit - Introduction 20-36
20.3.8 - Renewal of the transmission control unit - Transmission type conguration 20-36
20.3.9 - Renewal of the transmission control unit - Tyres type conguration 20-40
20.3.10 - Renewal of the transmission control unit - Conguration of the wheel circumference
(using the ART) 20-42
20.3.11 - Renewal of the transmission control unit - Conguration of the wheel circumference
(without using the ART) 20-44
20.3.12 - Renewal of the transmission control unit - Conguration of the maximum travel speed 20-44
20.3.13 - Renewal of the transmission control unit - Calibration of the clutch pedal 20-47
20.3.14 - Renewal of the transmission control unit - Calibration of the main clutch 20-49
20.3.15 - Renewal of the HLHP control unit - Introduction 20-52
20.3.16 - Renewal of the HLHP control unit - Initialization of the HLHP control unit 20-52
20.3.17 - Renewal of the HLHP control unit - Conguration of the tractor model 20-54
20.3.18 - Renewal of the HLHP control unit - Congure the system for presence of front PTO 20-55
20.3.19 - Renewal of the HLHP control unit - SBA / ASM system enable 20-57
20.3.20 - Renewal of the HLHP control unit - Calibration the steering angle sensor 20-58
20.3.21 - Renewal of the HLHP control unit - Conguration for presence of the RADAR 20-60
20.3.22 - Renewal of the HLHP control unit - Calibrating low and high positions of the lift 20-62
20.3.23 - Renewal of the HLHP control unit - Front axle suspension system enable 20-64
20.3.24 - Renewal of the HLHP control unit - Setting the instrument control panel display language 20-65
20.3.25 - Renewal of the HLHP control unit - Conguring the quantity of auxiliary services 20-67
20.3.26 - Renewal of the HLHP control unit - Rear control valves identication 20-69
20.3.27 - Renewal of the HLHP control unit - Conguration for presence of the front lift 20-70
20.3.28 - Renewal of the armrest control unit - Introduction 20-72
20.3.29 - Renewal of the armrest control unit - Calibration of control valves n°3 and n°4 joystick 20-72
20.3.30 - Cancellation of all alarms 20-77
20.4 - ECU alarms 20-79
20.4.1 - ECU Alarm list 20-79
20.4.2 - Alarms - List of semiactive cab alarms (MR-D) 20-96
20.4.3 - Engine alarms 20-97
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V
CONTENTS
20.4.4 - Transmission alarms 20-230
20.4.5 - Armrest alarms 20-291
20.4.6 - HLHP alarms 20-294
20.4.7 - Canbus alarms 20-373
20.4.8 - Electrohydraulic control valve alarms 20-384
30 - METHOD OF INTERVENTION
30.1 - B0 - Engine 30-2
30.1.1 - Engine - Separation from the transmission (B0.00.02) 30-2
30.1.2 - Engine (B0.00.01) 30-8
30.1.3 - Checking the compression pressure 30-14
30.1.4 - Removing and installing the crankcase bleeding 30-16
30.1.5 - Dismantling and assembling the crankcase breather 30-18
30.1.6 - Removing and installing the front cover (opposite side to ywheel) 30-22
30.1.7 - Removing and installing the lubricating oil pan (heavy duty version) 30-24
30.1.8 - Removing and installing the crankshaft 30-26
30.1.9 - Checking the axial clearance of the crankshaft 30-30
30.1.10 - Removing and installing torsional vibration damper 30-32
30.1.11 - Checking the crankshaft 30-37
30.1.12 - Alternator, fuel pump, water pump and fan drivebelt 30-39
30.1.13 - Flywheel 30-40
30.1.14 - Removing and installing the ywheel 30-42
30.1.15 - Fluid coupling and ywheel (R8.270 DCR ->WSXJ400200LL10001) 30-46
30.1.16 - Air conditioning compressor drivebelt 30-48
30.1.17 - Air conditioning compressor belt - Tension adjustment 30-49
30.1.18 - Renewing the crankshaft sealing ring (ywheel side) 30-49
30.1.19 - Renewing the crankshaft sealing ring (opposite side to ywheel) 30-52
30.1.20 - Removing and installing the piston and con rod 30-55
30.1.21 - Checking piston overhang 30-62
30.1.22 - Checking the piston 30-64
30.1.23 - Removing and installing the cylinder liner 30-65
30.1.24 - Checking the overhang of the cylinder liner 30-69
30.1.25 - Testing the cylinder liner 30-70
30.1.26 - Checking the piston rings and piston ring grooves 30-71
30.1.27 - Removing and installing the camshaft 30-74
30.1.28 - Checking the camshaft 30-77
30.1.29 - Removing and installing the connection housing 30-78
30.1.30 - Removing and installing the gearcase 30-80
30.1.31 - Removing and installing the valves 30-84
30.1.32 - Checking and setting the valve clearance 30-87
30.1.33 - Checking the valves 30-93
30.1.34 - Checking the valve lag 30-93
30.1.35 - Checking the valve guide 30-95
30.1.36 - Removing and installing the valve control 30-96
30.1.37 - Removing and installing cylinder head 30-100
30.1.38 - Removing and installing the oil cooler housing 30-105
30.1.39 - Removing and installing the oil cooler 30-111
30.1.40 - Removing and installing the control block 30-112
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VI
CONTENTS
30.1.41 - Removing and installing the fuel pressure sensor 30-115
30.1.42 - Removing and installing the high-pressure pump (Installation position A) 30-116
30.1.43 - Removing and installing the high-pressure pump (Installation position B) 30-123
30.1.44 - Removing and installing the injector 30-130
30.1.45 - Removing and installing the pressure limiting valve 30-140
30.1.46 - Removing and installing the rail 30-141
30.1.47 - Removing and installing the coolant pump 30-146
30.1.48 - Removing and installing the cooler (exhaust gas recirculation) 30-151
30.1.49 - Removing and installing the utter valve (exhaust gas recirculation) 30-156
30.1.50 - Removing and installing the actuator (exhaust gas recirculation) 30-161
30.1.51 - Checking radiator cleanliness 30-162
30.1.52 - Remove and install the charge air line 30-163
30.1.53 - Removing and installing the exhaust line 30-165
30.1.54 - Removing and installing the shutoff valve (exhaust gas recirculation) 30-171
30.1.55 - Removing and installing the turbocharger 30-174
30.2 - C0 - Engine accessories 30-181
30.2.1 - Changing the coolant and ushing the circuit (C0.01.02) 30-181
30.2.2 - Engine cooling system radiator (C0.01.01) 30-181
30.2.3 - Expansion tank (C0.01.04) 30-183
30.2.4 - Fan 30-184
30.2.5 - Radiator, coolers - Complete assembly (C0.01.03) 30-185
30.2.6 - Air cleaner - complete assembly (C0.02.01) 30-188
30.2.7 - Intercooler, gearbox oil and fuel coolers (C0.02.02) 30-189
30.2.8 - Left-hand fuel tank (C0.03.01) 30-191
30.2.9 - Right-hand fuel tank (C0.03.02) 30-193
30.2.10 - Removing and installing the fuel supply pump 30-194
30.2.11 - Remove and install the heating ange 30-196
30.2.12 - Starter motor 30-198
30.2.13 - Intermediate manifold (C0.06.03) 30-200
30.2.14 - Exhaust head pipe (C0.06.02) 30-201
30.2.15 - Exhaust silencer (C0.06.01) 30-202
30.2.16 - Removing and installing the air conditioning compressor 30-203
30.2.17 - Removing and installing the pressure/temperature sensor (charge air) 30-205
30.2.18 - Removing and installing temperature transmitter 30-206
30.2.19 - Removing and installing the thermostat housing 30-208
30.2.20 - Removing and installing the thermostat 30-213
30.2.21 - Removing and installing the generator (operating side) 30-217
30.2.22 - Removing and installing the generator (outlet side) 30-219
30.2.23 - Removing and installing the impulse transmitter (camshaft) 30-221
30.2.24 - Removing and installing the impulse transmitter (crankshaft) 30-223
30.2.25 - Removing and installing the oil pressure switch 30-224
30.2.26 - Removing and installing the rail pressure sensor 30-226
30.2.27 - Removing and installing the starter 30-227
30.3 - D0 - Transmission 30-230
30.3.1 - Checking the transmission oil level 30-230
30.3.2 - Changing the transmission oil (D0.00.01) 30-231
30.3.3 - Changing the transmission and rear axle oil lter 30-232
30.3.4 - Clutch housing 30-234
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VII
CONTENTS
30.3.5 - Flexible coupling and ywheel (D0.05.01) 30-234
30.3.6 - 4WD output shaft 30-236
30.3.7 - Disassembly and reassembly of the Single Speed P.T.O. 30-237
30.3.8 - Disassembly and reassembly of the dual speed P.T.O. 30-261
30.3.9 - Disassembly and reassembly of Solenoid Valves 30-296
30.3.10 - Disassembly and reassembly of the remote control 30-298
30.3.11 - Rear axle gear box detachment and attachment 30-304
30.3.12 - Pump control unit 30-308
30.3.13 - Powershift clutches 30-323
30.3.14 - Powershift clutch - A/C clutch disassembly 30-325
30.3.15 - Powershift clutch - B/D clutch disassembly 30-335
30.3.16 - Powershift clutch - F/G clutch disassembly 30-345
30.3.17 - Front wheel drive shaft 30-354
30.3.18 - Creeper gear control 30-367
30.3.19 - Main clutch 30-372
30.3.20 - Mechanical gear engagement control 30-385
30.3.21 - Main shaft 30-393
30.3.22 - Secondary shaft 30-404
30.3.23 - Gearbox pre-assembly 30-415
30.3.24 - Gearbox cover 30-416
30.3.25 - Clutch axial clearance adjustment 30-418
30.3.26 - Adjustment of creeper gear control engagement limit. 30-421
30.3.27 - Separate and Mounting transmission from the Rear Axle 30-421
30.3.28 - Disassembly and reassembly of the Output 30-426
30.3.29 - Disassembly and reassembly of the Brake Actuation 30-439
30.3.30 - Disassembly and reassembly of the RH Brake 30-441
30.3.31 - Disassembly and reassembly of the LH Brake 30-448
30.3.32 - Disassembly and reassembly of the Differential 30-455
30.3.33 - Disassembly and reassembly of Oil Supply 30-467
30.3.34 - Electro-hydraulic shift control module 30-471
30.3.35 - Control pump gear 30-477
30.3.36 - Gearbox pump xture 30-479
30.3.37 - Disassembly and reassembly of the Power Lift 30-480
30.4 - E0 - Rear axle 30-486
30.4.1 - Disconnection of the rear axle gearbox 30-486
30.4.2 - Disassembling the PTO shaft 30-487
30.4.3 - Disassembling the output unit 30-497
30.4.4 - Disassembling the oil feed unit 30-503
30.4.5 - Disassembling the brake actuator unit 30-505
30.4.6 - Disassembling the right brake 30-506
30.4.7 - Disassembling the left brake 30-508
30.4.8 - Disassembling the differential (limited sliding) 30-512
30.4.9 - Disassembling the solenoid valves 30-516
30.4.10 - Disassembling the hitch 30-516
30.4.11 - Reassembling the differential (limited sliding) 30-518
30.4.12 - Reassembling the oil feed unit 30-529
30.4.13 - Reassembling the solenoid valves 30-532
30.4.14 - Reassembling the left brake 30-534
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VIII
CONTENTS
30.4.15 - Reassembling the right brake 30-538
30.4.16 - Reassembling the brake actuator unit 30-543
30.4.17 - Reassembling the output unit 30-545
30.4.18 - Reassembling the PTO shaft 30-554
30.4.19 - Reassembly of the PTO shaft clutch 30-563
30.4.20 - Reassembling the hitch 30-573
30.4.21 - Fitting the gearbox on the rear axle 30-578
30.4.22 - Disassembling the remote control 30-581
30.4.23 - Reassembling the remote control 30-584
30.5 - F0 - Front axle 30-589
30.5.1 - Troubleshooting 30-589
30.5.2 - Front support - Version without front axle suspension (F0.01.01) 30-592
30.5.3 - Toe-in - steering angle and post-assembly checks 30-593
30.5.4 - Front axle and front support - Version without front axle suspension 30-595
30.5.5 - Front axle - Version without front axle suspension (F0.03.01) 30-597
30.5.6 - Steering cylinders assembly 30-598
30.5.7 - Axle shaft assembly 30-602
30.5.8 - Checking the bevel gear pair 30-604
30.5.9 - Differential carrier assembly 30-605
30.5.10 - Differential disassembly 30-612
30.5.11 - Propeller shaft - Front axle drive shaft (F0.04.01) 30-617
30.5.12 - Flange assembly 30-618
30.5.13 - Axle pivot bearings assembly 30-621
30.5.14 - Bevel pinion assembly 30-628
30.5.15 - Planetary reduction gear assembly 30-634
30.5.16 - Wheel hub assembly 30-637
30.6 - G0 - Bodywork - Cab - Platform 30-645
30.6.1 - Cab - Complete assembly (G0.03.01) 30-645
30.6.2 - Hood and side panels (G0.01.01) 30-650
30.6.3 - Tank-battery support (G0.01.04) 30-653
30.6.4 - Engine hood support (G0.01.05) 30-653
30.6.5 - Cab access steps (G0.03.03) 30-655
30.6.6 - Cab air spring 30-656
30.6.7 - Hydraulic damper 30-657
30.6.8 - Front fenders (G0.04.01) 30-658
30.6.9 - Cab door lock - cable 30-658
30.6.10 - Right-hand console (G0.06.01) 30-660
30.6.11 - Left-hand console (G0.06.02) 30-665
30.6.12 - Instrument panel (G0.06.04) 30-668
30.6.13 - Lower instrument panel (G0.06.06) 30-669
30.6.14 - Seat and multifunction armrest (G0.08.01) 30-671
30.6.15 - Air conditioning control panel 30-672
30.6.16 - Air conditioning system (G0.09.01) 30-673
30.6.17 - Air conditioning compressor 30-675
30.6.18 - Condenser (G0.09.02) 30-677
30.6.19 - Receiver-dryer 30-678
30.6.20 - Air conditioning evaporator 30-679
30.6.21 - Heating system shut-off valve 30-681
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IX
CONTENTS
30.6.22 - Heater matrix 30-682
30.6.23 - Air conditioner RH fan 30-683
30.6.24 - Air conditioner LH fan 30-684
30.6.25 - Trailer braking air pressure gauge 30-684
30.6.26 - Brake master cylinders 30-686
30.6.27 - Parking brake tie rod 30-687
30.6.28 - Parking brake tie rod - Initial and nal adjustment 30-688
30.6.29 - Steering wheel, steering column switch unit, instrument panel (G0.13.01) 30-689
30.6.30 - Main gear lever - control cables 30-691
30.6.31 - Creeper gear lever - control cable 30-693
30.7 - H0 - Hydraulic system 30-695
30.7.1 - Power steering pump - Version with compressed air 30-695
30.7.2 - Hydraulic services oil tank (H0.01.02) 30-697
30.7.3 - Load Sensing variable displacement pump (H0.01.03) 30-701
30.7.4 - “Load Sensing” variable displacement pump - Adjustment 30-703
30.7.5 - Priority valve 30-705
30.7.6 - Power steering valve - Complete assembly (H0.02.01) 30-705
30.7.7 - Power steering - Complete assembly - Checks and calibration 30-707
30.7.8 - Power steering valve - Complete assembly - Disassembly and assembly 30-708
30.7.9 - Front axle suspension cylinders 30-715
30.7.10 - Front lift locking shut-off valve 30-717
30.7.11 - Braking circuit 30-718
30.7.12 - Quick-couplers for air trailer braking - (Export version) 30-719
30.7.13 - Quick-coupler for trailer air braking - Italy version 30-720
30.7.14 - 1-way trailer air braking valve - Export D version 30-721
30.7.15 - 2-way trailer air braking valve (H0.09.02) 30-723
30.7.16 - Air reservoir for air braking (H0.09.03) 30-725
30.7.17 - Pressure control valve for the cab suspension 30-727
30.7.18 - Compressed air circuit supply pressure control valve 30-728
30.7.19 - Control solenoid valve for 1-way trailer air braking valve 30-729
30.8 - L0 - Electrical system 30-732
30.8.1 - Battery 30-732
30.8.2 - Engine control unit 30-732
30.8.3 - Parking brake switch 30-733
30.8.4 - Clutch pedal potentiometer 30-734
30.8.5 - Clutch pedal potentiometer 30-735
30.8.6 - Accelerator potentiometer 30-736
30.8.7 - Brake lights switches 30-736
30.8.8 - Electronic lift controls 30-737
30.8.9 - Steering position sensor assembly 30-738
30.8.10 - Transmission operating status display 30-746
30.8.11 - Armrest controls 30-746
30.8.12 - Shuttle control selector 30-748
30.8.13 - Control buttons - RH console 30-750
30.9 - M0 - Front PTO 30-751
30.9.1 - Front PTO - Complete assembly (M0.00.01) 30-751
30.9.2 - Front PTO exible coupling 30-752
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X
CONTENTS
30.10 - N0 - Front lift 30-753
30.10.1 - Front lift - Complete assembly (N0.01.01) 30-753
30.10.2 - Cylinder 30-755
30.11 - R0 - Rear lift 30-758
30.11.1 - Lift cylinders 30-758
30.11.2 - Lift arms 30-759
30.11.3 - Draft sensor 30-761
30.11.4 - Position sensor 30-761
30.12 - S0 - Wheels 30-763
30.12.1 - Front wheels (S0.01.01) 30-763
30.12.2 - Rear wheels (S0.02.01) 30-764
30.13 - V0 - Ballast - towing hitches 30-766
30.13.1 - Support and towing hitch (V0.02.01) 30-766
30.13.2 - Remote control towing hitch cable 30-767
30.14 - V1 - AFTERMARKET KITS 30-769
30.14.1 - Installation of the air conditioning kit 30-769
30.14.2 - Installing supplementary fuse box kit 30-783
40 - WIRING DIAGRAMS
40.1 - Introduction 40-2
40.1.1 - Structure of the unit 40-2
40.1.2 - Wiring and components index 40-6
40.1.3 - Basic electronics for mechanics (1/2) 40-13
40.1.4 - Basic electronics for mechanics (2/2) 40-15
40.1.5 - Electrical and electronic components (1/2) 40-21
40.1.6 - Electrical and electronic components (2/2) 40-29
40.2 - Components 40-34
40.2.1 - Components 40-34
40.3 - Systems 40-41
40.3.1 - Earthing points 40-41
40.3.2 - Starting 40-43
40.3.3 - Preheating 40-44
40.3.4 - Electronic engine control 40-45
40.3.5 - Diagnostics 40-47
40.3.6 - Instrument panel 40-48
40.3.7 - Worklights 40-49
40.3.8 - Worklights - Version with front lift 40-52
40.3.9 - Air conditioning 40-54
40.3.10 - Radio 40-55
40.3.11 - Lights - Version without front lift 40-57
40.3.12 - Lights - Version with front lift 40-59
40.3.13 - Wipers 40-63
40.3.14 - PTO 40-64
40.3.15 - Transmission 40-66
40.3.16 - CANBUS 40-68
40.3.17 - Accessories 40-70
40.3.18 - Control valves 40-71
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XI
CONTENTS
40.3.19 - Brakes 40-73
40.3.20 - Trailer brakes - Version with air braking 40-74
40.3.21 - Trailer brakes - Version with hydraulic braking 40-75
40.3.22 - Front axle suspension 40-77
40.3.23 - Lift 40-78
40.4 - Wiring harnesses 40-81
40.4.1 - Battery negative lead - 0.012.4029.4/20 40-81
40.4.2 - Battery negative wiring connector positions 40-82
40.4.3 - Battery positive lead - 0442.2156/20 40-83
40.4.4 - Battery positive wiring connector positions 40-84
40.4.5 - Power supply wiring - 0.015.0765.4/20 40-85
40.4.6 - Power supply wiring connector positions 40-86
40.4.7 - Engine hood wiring loom - 0.015.3369.4 40-88
40.4.8 - Engine hood wiring connector positions 40-89
40.4.9 - Front axle suspension wiring loom - 0.015.3974.4/10 40-90
40.4.10 - Engine wiring - 0421.3623 - 0421.5274 40-91
40.4.11 - Lights selector switch wiring loom - 0443.8656 40-92
40.4.12 - Lights selector switch wiring loom connector positions 40-93
40.4.13 - ISO 11786 Wiring loom - 0.014.9570.4 40-94
40.4.14 - RH transmission line wiring loom - 0.015.0755.4/20 40-95
40.4.15 - RH transmission wiring connector positions 40-97
40.4.16 - LH transmission line wiring loom - 0.015.0746.4/10 40-101
40.4.17 - LH transmission wiring connector positions 40-103
40.4.18 - Lateral instrument panel wiring loom - 0.015.0740.4/20 40-107
40.4.19 - Lateral instrument panel wiring connector positions 40-111
40.4.20 - Front instrument panel wiring loom - 0.015.0712.4/10 40-116
40.4.21 - Front instrument panel wiring loom connector positions 40-118
40.4.22 - Braking and front lift interface wiring loom - 0.015.7461.4/10 40-121
40.4.23 - Braking and front lift interface connector positions 40-122
40.4.24 - Fender wiring loom - 0.015.3692.4 40-123
40.4.25 - Position of fenders wiring loom connectors 40-124
40.4.26 - Directional control valves wiring loom - 0.014.1612.4/20 40-126
40.4.27 - Control valves wiring loom connector positions 40-127
40.4.28 - Roof wiring loom - 0.015.0713.4/10 40-128
40.4.29 - Roof line wiring connector positions 40-130
40.4.30 - Air conditioning system wiring loom - 0.900.0783.8 40-132
40.4.31 - Air conditioning wiring loom connector positions 40-133
40.4.32 - Lower front worklights wiring loom on cab - Version without front lift - 0442.5602 40-134
40.4.33 - Connector positions of lower front worklights wiring loom on tractor cab - version without
front lift 40-136
40.4.34 - Headlamps test lead wiring loom - 0.013.4085.4/20 40-137
40.4.35 - Headlamps test lead wiring connector positions 40-138
40.4.36 - Cab roof front and rear worklights wiring loom - RH side - 0443.7856 40-140
40.4.37 - Connector positions of front and rear worklights wiring loom on cab roof - RH side 40-141
40.4.38 - Cab roof front and rear worklights wiring loom - LH side - 0443.7857 40-143
40.4.39 - Connector positions of front and rear worklights wiring loom on cab roof - LH side 40-144
40.4.40 - Windscreen wiper motor wiring loom - 0441.2045 40-145
40.4.41 - Windscreen wiper motor connector positions wiring 40-146
XII
CONTENTS
40.4.42 - Cab lower headlights wiring loom - 0441.1923.4 40-147
40.4.43 - Connector positions of lower front lights wiring loom on cab 40-148
40.4.44 - Sidelights and front direction indicators wiring loom - 0442.8092.4 40-149
40.4.45 - Sidelights and front direction indicators wiring loom connector positions 40-150
40.4.46 - Worklights control relay wiring loom - 0.015.3730.4 40-151
40.4.47 - Worklights relay connector positions 40-152
40.4.48 - Number plate light wiring loom - 0.012.2018.4/20 40-153
40.4.49 - Number plate light wiring loom connector positions 40-154
40.4.50 - Rotating beacon extension wiring loom - 0.012.4108.4 40-155
40.4.51 - Rotary beacon extension wiring loom connector positions 40-156
40.4.52 - Rotating beacon wiring loom - 0443.6707 40-157
40.4.53 - Position of rotary beacon wiring connectors 40-158
40.4.54 - Trailer air braking wiring loom - 0443.6174/20 40-159
40.4.55 - Trailer air braking wiring loom connector positions 40-160
40.4.56 - Front lift control wiring loom on drivetrain - 0.015.5429.4/20 40-161
40.4.57 - Comfort package wiring loom - 0.015.5452.4 40-162
40.4.58 - Cab comfort package connectors position 40-163
40.4.59 - Wiring for hydraulic trailer braking - Italy version - 0.012.6404.4/20 40-164
40.4.60 - Agrosky wiring loom - 0.014.4992.4/10 40-165
40.4.61 - 0.016.0234.4/30 - Semi-active cab suspension 40-165
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.
This manual suits for next models
3
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