Document overview
Workshop Manual for LAMBORGHINI RV.100 → ZKDP7802W0TL1001 / 10001 from the RV (STAGE 3A) family. Digital PDF in English with 1,467 pages.
The corresponding English table of contents contains 58 sections and 431 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: LAMBORGHINI
- Family: RV (STAGE 3A)
- Model: RV.100
- Starting serial number: ZKDP7802W0TL1001 / 10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,467
- File size: 244.97 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match LAMBORGHINI RV.100 → ZKDP7802W0TL1001 / 10001.
Complete table of contents
Introduction
- Tightening Torques
- Tightening torques for nuts and bolts of electrical connections
- Wheel rim to hub screws and nuts tightening torques
- Installation of solenoid valves and cartridge valves
- Installation of quick couplers
- Units of measurement and conversion factors
Safety
Preface
- Important notes concerning safety
Important safety information
- Recognising hazards
- Indications for persons in contact with the tractor
Safety rules
- Risks during tractor preparation
- Risks during maintenance
- Work on machine systems
- Special disassembly/assembly/inspection procedures
Safety pictograms
- Replacing safety pictograms
Environmental risks
- Hazards associated with the operating environment
Technical characteristics
Engine
- Engine block technical data
- Crankshaft technical data
- Technical data for pistons – Piston rings
- Connecting rod technical data
- Camshaft technical data – static advance of 12°
- Timing gears technical data
- Counter-rotating weights technical data
- Technical data and dimensions of valves – valve springs
- Technical data and dimensions of cylinder heads – valve guide – valve seats
- Technical data and dimensions of rocker arms – rocker shafts – tappets
- Engine injectors technical data
- Hydraulic tappets diagram
Engine accessories
- Starter motor
Transmission
- Transmission
- Shuttle
- HML assembly
- Gearbox assembly
- Range and parking brake assembly
- Range control rod and parking brake lever
- Four-wheel drive engagement assembly
Rear axle
- Brakes and rear axle assembly
- Differential unit
Front axle
- Pinion, differential and differential lock
- ActiveDrive system
Bodywork – Cab – Platform
- General introduction to the A/C system
- Changes of the state of matter
- Air conditioning system – Diagnostics
- Charging the A/C system
Hydraulic system
- Hydraulic circuit (base version)
- Hydraulic circuit (full house version)
- Remote valves hydraulic circuit
- Optional remote valves hydraulic circuit
- STEERING/TRANSMISSION pump (11 cm³)
- LIFT/REMOTE VALVES pump (14+11 cm³)
- STEERING/TRANSMISSION pump (16 cm³)
- LIFT/REMOTE VALVES pump (22.5 cm³)
- 2WD steering control valve
- 4WD steering control valve
- 4-way control proportional valve
- Electronic lift control valve
- 6-way remote control valve
- Mechanical lift control valve
- Trailer braking valve (ITALY version)
- Trailer braking valve – (Export Version)
- Services solenoid valve assembly
Front PTO
- Front power take-off
- PTO delivery pump
- PTO clutch
- PTO control solenoid valve assy
Front lift
- Damper assembly
- Front lift
Rear lift
- Rear lift
Calibrations and electronic diagnosis
Diagnostic tools
- Positions of ECUs and diagnostic instruments
- ECU interrogation
SDF Analyser
- SDF Analyser
- SDF Analyser – Diagnostic socket
Diagnostic tool screens
- PC Tester Screens – HLHP – Initial Screen (Active Drive)
- PC Tester Screens – HLHP – Main Menu (Active Drive)
- PC Tester Screens – HLHP – Monitor Menu (Active Drive)
- PC Tester Screens – HLHP – Calibration Menu (Active Drive)
- PC Tester Screens – HLHP – Test Menu (Active Drive)
- PC Tester Screens – HLHP – Alarms Menu (Active Drive)
- PC Tester Screens – Engine ECU – Structure
- PC Tester – ECU 2.8519.084.0* screens
Commissioning and calibrating the tractor
- Digital Instrument Calibration
- Wheels constants
- MIS – Document purpose (Active Drive)
- MIS – Instruments and information required (Active Drive)
- MIS – Procedure description (Active Drive)
- MIS – EEPROM re-initialisation (Active Drive)
- MIS – Tractor configuration (Active Drive)
- MIS – Calibrating the suspended axle (Active Drive)
- MIS – Calibrating the steering angle sensor (Active Drive)
- Commissioning – Engine ECU – Presentation screen
- Commissioning – Engine ECU – Main menu
- Commissioning – Engine ECU – Structure
- Commissioning – Engine ECU – Configuration
- Commissioning – Engine ECU – Engine menu
- Commissioning – Engine ECU – HML menu
- Commissioning – Engine ECU – Preheating menu
- Commissioning – Engine ECU – Alarms Menu
- Commissioning – Engine ECU – Alarms List
- Commissioning – Engine ECU – Wheel Calibration Menu
- Commissioning – Engine ECU – Wheels menu
- Commissioning – Engine ECU – HRT Menu
- Commissioning – Engine ECU – DERATING Menu
- Commissioning – Engine ECU – Engine type config.
- Commissioning – Engine ECU – Engine type config.
- Commissioning – Engine ECU – Functional diagram
- Electronic lift control unit
- Calibrating the electronic distributors
- Front distributors calibration
ECU alarms
- ECU alarms
Engine alarms
- Engine control unit alarms
Transmission alarms
- PTO and transmission ECU alarms
Instrument panel alarms
- Instrument cluster alarms
HLHP alarms
- HLHP alarms
Lift alarms
- Electronic lift control unit alarms
Electrohydraulic control valve alarms
- DT_Auto and electric-hydraulic distributor ECU alarms
Method of intervention
B0 – Engine
- Separating engine / transmission
- Removing the engine
- Preliminary disassembly operations
- Checking engine block
- Crankshaft
- Crankshaft checks
- Flywheel checks
- Renewal of crankshaft rear oil seal
- Pistons and cylinder liners
- Pistons and rings check
- Cylinder liners check
- Check connecting rods – gudgeon pins – rod cap screws
- Camshaft checks
- Camshaft
- Valve timing
- Timing gear checks
- Adjusting timing gears backlash
- Counter-rotating weights
- Counter-rotating weight checks
- Overhaul of counter-rotating weights assembly
- Valves check
- Valve seats check
- Valves sealing check
- Adjusting valve clearance
- Adjusting valve clearance
- Valve guides check and replacement
- Inspecting the rocker arms and rocker shafts
- Cylinder heads
- Determining correct head gasket thickness
- Valve springs check
- Heat exchanger removal
- Lubrication pump
- Lubrication pump disassembly
- Lubrication pump disassembly
- Oil sump
- INJECTION PUMPS, GOVERNOR AND FUEL SUPPLY
- Synchronising injection pumps
- Injectors assembly
- Checking injectors protrusion – Renewal of copper bushes
- Injectors check
- Injection pump control rod
- Overhaul of the mechanical governor (standard and with LDA valve)
- Electronic governor adjustment
- Installation of electronic governor support
- Engine coolant pump
- Engine coolant pump
- Thermostatic valve
- Checking the thermostat valve
- Cooling and intake ducts
- Final engine checks
- Engine flywheel
- Replacing the engine oil filter cartridge
C0 – Engine accessories
- Replacing the coolant
- Coolant radiator
- Expansion tank
- Fan
- Complete air filter
- Main fuel tank
- Starter motor
- Exhaust pipe
- Exhaust silencer
- Heat exchanger
- Complete radiator pack
- Auxiliary fuel tank
D0 – Transmission
- Changing the transmission oil
- Clutch housing – Separating rear gearbox housing
- Primary shaft (version with range selector unit)
- Adjusting endfloat of the secondary shaft gears
- Range reduction gearbox rod
- Differential – Bevel gear set
- 4WD output shaft
- PTO input shaft
- PTO output shaft
- Ground speed PTO shaft
- Disassembling the parking brake lever
- Adjusting the parking brake lever
- Dual traction engagement device – Version without HML
- Disassembling dual traction engagement device – Version without HML
- Replace the parking brake wear shoes
- Rear pinion
- PTO control clutch
- Disassembling secondary shaft – Version with range selector unit
- Pump drive PTO – internal gear
- Disassembling PTO control clutch
- Range selector rod
- HML unit
- Parking brake
- Planet gear support unit – HML unit
E0 – Rear axle
- Disassembling rear axle
- Rear brake carrier
- Replacing the friction shoes
- Differential
- Bleeding air from the hydraulic brake system
- Rear axle
F0 – Front axle
- 4WD shaft (Active Drive)
- Separating engine from front axle carrier (Active Drive)
- Front axle (Active Drive)
- Complete knuckle assembly (Active Drive)
- Steering tie-rod (Active Drive)
- Damper (Active Drive)
- Adjusting end float (Active Drive)
- Steering cylinder (Active Drive)
- Steering knuckle housing and half-shaft (Active Drive)
- Replacing the elastic gaiters (Active Drive)
- Pinion-differential assembly (Active Drive)
- Differential lock (Active Drive)
- Disassembling the front axle differential (Active Drive)
- Adjusting differential (Active Drive)
- Adjusting pinion/crown wheel backlash (Active Drive)
- Adjusting pinion bearings (Active Drive)
- Disassembling the planetary reduction gearbox (Active Drive)
- Front axle brake discs (Active Drive)
G0 – Bodywork – Cab – Platform
- Charging the air conditioner system
- Air conditioning compressor
- Front mudguards
- Engine hood
- Cab access steps
- Cab
- Steering wheel
- Dashboard
- Driver seat
- Battery cover
- Cab mat
- Battery mount
- Control console
- Roof panel trim
- Brake master cylinders
- Lower cowl cover
- Engine hood frame
H0 – Hydraulic system
- Ancillary pump
- Front differential lock control pipes
- Power steering pump
- Power steering
- Accumulator block
- Ancillary utility distributor
- Oil cooler
- Steering cylinder hydraulic system
- Front carrier suspension system
- Front lift hydraulic system
- Services solenoid valve assembly
- Front brake pipes
L0 – Electrical system
- Alternator
M0 – Front PTO
- Front power take-off
- Front PTO housing, guard
- Disassembling PTO clutch
- Oil filter
N0 – Front lift
- Front lift
R0 – Rear lift
- Rear lift
- Disassembling the lift control cylinder – Version with mechanical lift
- 3-point linkage
S0 – Wheels
- Front Wheels
- Rear wheels
- Steering angle adjustment
V0 – Ballast – towing hitches
- Tow hook sled
Wiring diagrams
Introduction
- Introduction
- Basic electronics for mechanics (1/2)
- Basic electronics for mechanics (2/2)
- Electrical and electronic components (1/2)
- Electrical and electronic components (2/2)
Components
- Engine control unit
- PTO ECU
- Rear lift control unit
- Front 4-way auxiliary distributor and automatic four wheel drive control unit
- HLHP suspended axle ECU
- A – Starting and charging
- B – FUSES
- C – Grounds
- D – Intermediate connections
- E – On-board instruments and visual and audible indicators
- F – External lights
- G – Interior lights
- H – Manual electrical controls (steering column stalk)
- I – Circuit breakers
- J – Relays
- K – Sensors and transmitters
- L – Electromagnets and solenoid valves
- M – Electrical/electronic devices, Flasher units and Timers
- N – Electric motors and actuators
- O – RESISTORS AND RHEOSTATS
- P – Various services
- R – Diagnostics
Systems
- S001 – Electronic engine throttle (10001/ActiveDrive)
- S001 – Electronic engine throttle (1001)
- S002 – Preheat (10001/ActiveDrive)
- S002 – Preheat (1001)
- S003 – Starter (10001/ActiveDrive)
- S003 – Starter (1001)
- S004 – Lights (Europe market)
- S004 – Lights (USA market)
- S005 – Cab lights
- S006 – Air conditioner (10001/ActiveDrive)
- S006 – Air conditioner (1001)
- S007 – Windscreen wipers
- S008 – Radio
- S009 – Rear lift
- S010 – 3-point linkage electronic control
- S011 – Transmission (1001)
- S011 – Transmission (10001/ActiveDrive)
- S012 – Front distributors (1001)
- S012 – Front distributors (10001)
- S012 – Front distributors (ActiveDrive)
- S013 – Dual traction and differential lock (1001)
- S013 – Dual traction and differential lock (10001)
- S013 – Dual traction and differential lock (ActiveDrive)
- S014 – PTO – Europe market
- S014 – PTO – USA market
- S015 – Diagnostics (1001)
- S015 – Diagnostics (10001)
- S015 – Diagnostics (ActiveDrive)
- S016 – Front axle (ActiveDrive)
- S017 – Accessories
- S018 – Instrument cluster (1001)
- S018 – Instrument cluster (10001/ActiveDrive)
Wiring harnesses
- Wire colour reference table
- 0.007.7899.3 – Front PTO solenoid valve
- 0.010.6708.3/20 – Battery wiring
- 0.011.2025.4/40 – Electronic rear lift
- 0.011.7711.3 – Oil regulator valve block pressure switch
- 0.011.7840.4 – Rotating beacon
- 0.011.9828.3 – Cab earth
- 0.012.0101.4 – Electrohydraulically controlled 3-point linkage
- 0.012.2103.3 – Hydraulic trailer braking
- 0.012.3825.4 – ROPS rotating beacons (USA market)
- 0.013.6326.4 – ROPS rotating beacons
- 0.013.6327.4 – Rotating beacon socket
- 0.015.0070.4 – Solenoid valves
- 0.015.3160.4 – Platform ground
- Front lights and horn
- 0.016.0328.4 – Battery master switch ground
- 0.016.0560.4 – Rear wiring loom
- 0.016.0552.4 – Front, 3 cylinders
- 0.016.0553.4 – Front, 4 cylinders
- 0.016.0551.4/20 – Central wiring loom (1001)
- 0.016.0561.4 – Work light
- 0.016.0562.4/10 – Front distributor controls
- 0.016.0569.4 – Cab + platform power feed (4 cylinder version)
- 0.016.0570.4 – Cab + platform power feed (3 cylinder version)
- 0.016.0571.4 – Platform power feed (4 cylinder version)
- 0.016.0572.4 – Platform power feed (3 cylinder version)
- 0.016.0766.4/20 – Cab roof (1001)
- 0.016.0767.4/10 – Air conditioner
- 0.016.0768.4/10 – Work lights, windscreen wipers and rotating beacon
- 0.016.0769.4 – Roof power feed
- 0.016.0771.4 – Headlights on cab
- 0.016.0772.4 – Headlights on cab (USA market)
- 0.016.6292.4 – Adapter for position sensor
- 0.018.4612.4 – Front, 3 cylinders
- 0.018.4613.4 – Front, 4 cylinders
- 0.018.4622.4/10 – Rear wiring loom (10001)
- 0.018.4621.4 – Central wiring loom (10001)
- 0.018.4616.4 – Central wiring loom (10001) – USA market
- 0.018.4614.4 – Rear wiring loom (10001) – USA market
- 0.018.4623.4 – Manual dual traction controls (version with auxiliary distributors)
- 0.018.4624.4 – Automatic dual traction controls (version with auxiliary distributors)
- 0.018.4625.4 – Automatic dual traction controls
- 0.018.4626.4 – Manual dual traction controls
- 0.018.4627.4 – Front distributors
- 0.018.4628.4 / 0.018.4629.4 / 0.018.4630.4 – Steering sensor
- 0.018.4638.4 – Work lights, windscreen wipers and rotating beacon (version without radio)
- 0.018.4639.4 – Loudspeakers
- 0.018.4640.4/20 – Cab roof (10001)
- 0.023.2609.4/10 – Front axle with ActiveDrive
- 0.023.2611.4/20 – Central wiring loom (version with ActiveDrive)
- 0.023.2612.4 – Distributor joystick (version with ActiveDrive)
- 0.023.2613.4/10 – Piston sensors (version with ActiveDrive)
- 0.023.2616.4/20 – Front axle solenoid valves (version with ActiveDrive)
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
- Diagnostics 2023 subscription
- Diagnostics 2024 subscription
- Diagnostics 2022 subscription
- Diagnostics 2021 subscription
- Technical Documentation DVD 06/2009
- SDF LUBRICANTS: Lubricant oils and coolant fluids
- After-sales 2024 subscription
- After-sales 2023 subscription
- After-sales 2022 subscription
- After-sales 2021 subscription
- After-sales 2019 subscription
- SDF Parts and SDF Service DVV 04/2014, version 26
- Technical Documentation DVD 03/2010
- New function: Download PDF manuals
- Diagnostics – 2020 subscription
- After-sales – 2020 subscription
- After-sales – 2018 subscription
- Service and Spare Parts – 2017 Subscription
- SDF Parts and SDF Service DVDs 05/2014 version 25
- SDF Parts and SDF Service DVDs 03/2013 version 24
B0 – ENGINE
- Flushing the lubrication circuit
- Engine fan belt
- Front crankshaft main bearing
- Deutz AG engine oil specifications
C0 – ENGINE ACCESSORIES
- Diagnostic protocol – AdBlue – Float level unit
- Auxiliary fuel pump
- Filter and prefilter tool p/n 5.9035.865.0
- Fuel auxiliary pump breakage
- Oil Leakage From Active Drive
D0 – TRANSMISSION
- SERVICE NEWS – Forward Gear p.n. 0.013.1652.0 improvement
- Bushes on shuttle input shafts
F0 – FRONT AXLE
- Check the front axle steering knuckles for wear
- Active Drive rubber boot breakage
- Wear of the final drive reduction units, planetary gear
- Steering behavior check procedure
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- Auxiliary hydraulic distributor control levers
- Rear lift control levers
- Clutch pedal potentiometer actuator pin
- Assembly of parking brake control rod
- Blanking cover for hood
- Cowl locking device
- Air conditioning system recharging
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
- Assembly instructions for solenoid valves and cartridge valves
- L0 – ELECTRIC AL SYSTEM
