LAMBORGHINI R8.230 DCR Instruction manual

WORKSHOP MANUAL
R8.230 DCR
->WSXJ390200LL10001
R8.270 DCR
->WSXJ400200LL10001

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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 - 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 conguration 20-36
20.3.9 - Renewal of the transmission control unit - Tyres type conguration 20-40
20.3.10 - Renewal of the transmission control unit - Conguration of the wheel circumference
(using the ART) 20-42
20.3.11 - Renewal of the transmission control unit - Conguration of the wheel circumference
(without using the ART) 20-44
20.3.12 - Renewal of the transmission control unit - Conguration 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 - Conguration of the tractor model 20-54
20.3.18 - Renewal of the HLHP control unit - Congure 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 - Conguration 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 - Conguring the quantity of auxiliary services 20-67
20.3.26 - Renewal of the HLHP control unit - Rear control valves identication 20-69
20.3.27 - Renewal of the HLHP control unit - Conguration 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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