LAMBORGHINI R8.230 DCR Workshop Manual Download

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Workshop manual

r8.230 DCr

->WsXJ390200ll10001

r8.270 DCr

->WsXJ400200ll10001

Summary of Contents for R8.230 DCR

Page 1: ...Workshop manual R8 230 DCR WSXJ390200LL10001 R8 270 DCR WSXJ400200LL10001...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...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 Braki...

Page 4: ...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 Intr...

Page 5: ...ebelt 30 48 30 1 17 Air conditioning compressor belt Tension adjustment 30 49 30 1 18 Renewing the crankshaft sealing ring flywheel side 30 49 30 1 19 Renewing the crankshaft sealing ring opposite sid...

Page 6: ...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 in...

Page 7: ...e 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...

Page 8: ...ropeller 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 a...

Page 9: ...cking 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...

Page 10: ...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...

Page 11: ...nt 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 Br...

Page 12: ...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...

Page 13: ...0 1 0 Introduction...

Page 14: ...ab 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 diagnosi...

Page 15: ...as soon as possible to prevent the risk of slipping and fire l When refitting electrical wiring looms and wires ensure that they are properly secured with their original retaining straps or brackets t...

Page 16: ...e refit 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...

Page 17: ...erobic 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 torque...

Page 18: ...able 3 MET RIC Straight end fittings T end fittings L end fittings 90 end fittings 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 1...

Page 19: ...2x1 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...

Page 20: ...7 FUNCTION NAME DESCRIPTION THREADLOCKER Loctite 222 Colour opaque fluorescent purple Anaerobic product suitable for low strength locking of retaining adjustment and precision fasteners All traces of...

Page 21: ...xi mum tolerance of 0 10 mm filling microvoids caused by flatness errors Very slow curing on most metal surfaces and requires prior application of an activator Loctite 576 Colour brown Anaerobic produ...

Page 22: ...r 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...

Page 23: ...itres x 0 220 Imp gall litres x 0 264 US gall litres x 1 762 pint litres x 0 880 quart min x 0 2642 US gpm kg x 35 25 oz kg x 2 203 lb kgm x 7 233 lb ft kg m x 0 056 lb in kg cm x 14 22 psi kg x 10 00...

Page 24: ...0 12 Introduction PAGE LEFT INTENTIONALLY BLANK...

Page 25: ...10 1 10 Technical characteristics...

Page 26: ...tion looking onto the flywheel TCD 2013 4V left Ignition sequence TCD 2013 L4 4V 1 3 4 2 L6 4V 1 5 3 6 2 4 Cylinder head Valve seat ring bore inlet Standard fit H7 TCD 2013 4V 39 2 mm Valve seat ring...

Page 27: ...TCD 2013 4V 30 0 5 Valve seat angle outlet TCD 2013 4V 45 1 Valve spring Valve spring un clamped normal length TCD 2013 4V 64 48 mm Valve spring wire diameter TCD 2013 4V 3 95 mm Valve clearance Valve...

Page 28: ...ges per TCD 2013 4V 0 25 mm Theoretical clear ance between main bearing crankshaft TCD 2013 4V 0 03 0 092 mm Permissible ax ial clearance of crankshaft TCD 2013 4V 0 1 0 32 mm Wearing ring thickness S...

Page 29: ...sided tra peze ring Outside diam eter inside diam eter x height TCD 2013 4V 108 99 1x3 5 mm Piston ring 2 minute ring Outside diam eter inside diam eter x height TCD 2013 4V 108 99x2 0 mm Piston ring...

Page 30: ...st assembly TCD 2013 4V 0 0 5 mm Cylinder liners Cylinder liner bore Standard TCD 2013 4V 108 0 02 0 mm Cylinder liner collar height TCD 2013 4V 8 07 0 0 02 mm Cylinder liner overhang TCD 2013 4V 0 1...

Page 31: ...ing value Clamping bracket on crankcase TCD 2013 4V 70 Nm Clamping bracket on adapter for en gine assembly block TCD 2013 4V 90 Nm Cylinder head on crankcase M15x2 135 Use new screws TCD 2013 4V 40 Nm...

Page 32: ...case Lock nut TCD 2013 4V 20 Nm Pipe clip breather pipe open at hold er M6x16 10 9 TCD 2013 4V 8 5 Nm Holder oil re turn line pipe clip M6 TCD 2013 4V 8 5 Nm Holder oil re turn line M6x12 TCD 2013 4V...

Page 33: ...e M8x100 8 8 Pin boit TCD 2013 4V 20 Nm Mixing pipe on heating flange charge air pipe M8 Nut TCD 2013 4V 20 Nm Cooler on charge air pipe exhaust gas return M8x35 10 9 TCD 2013 4V 20 Nm Flutter valve h...

Page 34: ...llow screw Observe as sembly specifi cation TCD 2013 4V 26 Nm Fuel pipe on control block D10 Hollow screw Observe as sembly specifi cation TCD 2013 4V 34 Nm Union screw for pressure pipe nozzle M22x1...

Page 35: ...Nm Lubricating oil pipe on exhaust gas turbocharger Lubricating oil pipe on crank case D10 Hollow screw TCD 2013 4V 39 Nm Pipe union oil return on ex haust gas tur bocharger M8x20 TCD 2013 4V 30 Nm H...

Page 36: ...D 2013 4V 42 Nm Idler rollers on console M10x45 M10x65 TCD 2013 4V 42 Nm Idler roller on bearing block TCD 2013 4V 50 Nm Air conditioning compressor on console M10x50 TCD 2013 4V 20 Nm Console air con...

Page 37: ...2013 4V 1 5 Nm Cable rail on rocker arm brackets M6 Hexagon sock et head TCD 2013 4V 8 5 Nm Pressure tem perature sen sor on charge air line TCD 2013 4V 7 5 Nm Cable connec tion on injector TCD 2013 4...

Page 38: ...enoid operated proportional valve that directly controls the main clutch l The transmission can be divided into the following sections m A Transmission engine coupling m B Gearbox m C Rear axle m D Re...

Page 39: ...1 and transmits drive to gearbox 2 through shaft 3 The engine 1 transmits motion to the flywheel 4 on which is mounted the impeller 5 As the impeller rotates it picks up oil and flings it against the...

Page 40: ...16 Technical characteristics Fig 4 Fluid coupling Components 1 Engine 2 Gearbox 3 Shaft 4 Flywheel 5 Impeller 6 Turbine 7 Rear PTO drive shaft 8 Front axle drive shaft 9 Filler plug for fluid couplin...

Page 41: ...nents 1 Hydraulic pump for transmission 2 Hydraulic gearbox control valve 3 Four wheel drive shaft 4 Transmission oil low pressure sensor 5 Transmission oil temperature sensor 6 4WD control solenoid v...

Page 42: ...abling sensor 3 Speed sensor Nlsa 4 Speed sensor Nlse 5 Creeper engagement control shaft 6 Gear control shaft 7 Main clutch control solenoid valve 8 RH brake cylinder 9 Rear PTO control solenoid valve...

Page 43: ...with a hydraulic system served by a gear pump driven from a lateral power take off The gear pump supplies pressurised fluid for the following uses l hydraulic gearbox control valve 5 l 1000 PTO solen...

Page 44: ...valve 7 Solenoid operated proportional valve for main clutch 8 Main clutch 9 Transmission oil cooler 10 Rear and front differential lock solenoid valve 11 1000 PTO solenoid valve 12 750 PTO solenoid...

Page 45: ...power take off 9 which in turn transmits drive to the front axle The gearbox also has a double power take off 6 to drive the hydraulic system pumps Fig 9 Gearbox schematic Components 1 Engine 2 Drive...

Page 46: ...roniser 12 Rear PTO drive shaft 13 1st 2nd gear drive shaft 14 Pinion 15 4WD control clutch 16 Creeper unit driven shaft 17 B clutch 18 F clutch 19 G clutch 20 D clutch Main clutch The main clutch is...

Page 47: ...The function of the hydraulic gearbox control valve is to pilot and control the engagement of the gears in the hydraulically controlled gearbox The control valve controls the operation of l A by hydr...

Page 48: ...10 24 Technical characteristics Fig 12 Control valve main components...

Page 49: ...0 bar 5 General pressure 18 bar M10x1 19 8 bar 6 Engagement pressure of clutch A B or F G M10x1 19 8 bar 7 Modulated pressure M18x1 5 19 8 bar 8 Engagement pressure of clutch C or D M10x1 19 8 bar 9 P...

Page 50: ...agement valve H2 l Y4 Pilot solenoid valve for engagement valve H1 l Y1 Pilot solenoid valve for clutch selection valve G1 l Y5 Pilot solenoid valve for road field selection valve l Y2 Pilot solenoid...

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