Transmisionnt

10
2 Transmission 2 Transmission
page
Transmission, component position
2 1 5 6
3 9 10 11 12 15
1. 2. 3. 4. 5. 6. 7. 8. Power take-off Oil dipstick and filling point for transmission oil Thermostat Transmission oil cooler Oil pumps transmission Transmission Valve block transmission control Torque converter
8 7
9. 10. 11. 12. 13. 14. 15. Sensor engine speed and oil temperature (B758/766) (from cooler to sump) Temperature monitor torque converter (S221) Sensor turbine speed (B751) Sensor drum speed (B752) Oil filter transmission Sensor output shaft speed (B758) Output shaft
006768
14
13
VDRF03.01GB
Workshop manual DRF 400450
2 Transmission 2 Transmission
11
11 6
10 9 8
1. 2. 3. 4. 5. 6.
page
Accelerator pedal (B690) Control unit KIT (D790-2) Control unit KID (D795) Multi-function lever (S162) Control unit cab (D790-1) Control unit frame rear (D797-R)
7. 8. 9. 10. 11.
Control unit transmission (D793) Diagnostic socket transmission Declutch pedal (S220-1) Make-contact declutch (S220-2) Control unit frame front (D797-F)
Engine and gearbox, separation

Engine alternative Volvo: see section 1 Engine, group 1 Engine and gearbox, separation (engine alternative Volvo) . Engine alternative Cummins: see section 1 Engine, group 1 Engine and gearbox, separation (engine alternative Cummins).
VDRF03.01GB
006752
12
2 Transmission 2.1 Controls and instrumentation
2.1
2.1.1
page
Controls and instrumentation

Gear and multi-function lever
Gear and multi-function lever, description

F
Travel direction is selected with the gear and multi-function lever. Selection of travel direction: F Forward N Neutral R Reverse
The switch is supplied with voltage by and sends signals to Control unit KIT (D790-2).
002209
The signal can be checked from the diagnostic menu, see section 8 Control and monitoring system, group 8.4.7.2 TRANSM, menu 2.
VDRF03.01GB
2 Transmission 2.2 Torque converter/clutch system
13
2.2
2.2.1
page
Torque converter/clutch system

Flex plates
Flex plates, changing (engine alternative Volvo)

1 Machine in service position, see tab B Safety. 2 Remove the flywheel cover plate.
3 Remove the bolts for the flex plate.
VDRF03.01GB
14
2 Transmission 2.2.1 Flex plates
4 Rotate the engine for each bolt for the flex plate that is to be removed. 5 Attach the transmission to an overhead crane. 6 Remove the bolts holding together the transmission and engine.
7 Carefully separate the transmission and engine.
VDRF03.01GB
15
8 Remove the bolts holding the flex plate to the transmission. 9 Change the flex plate. 10 Fit in the reverse order. Tighten the retaining bolts to 40 Nm. 11 Before the machine is put into operation, the transmission must be calibrated, see Transmission, calibrating page 23.
Attachment of flex plate.

page
Flex plates, changing (engine alternative Cummins QSM11)

1 Machine in service position, see tab B Safety. 2 Remove the cover plate. 3 Remove the bolts for the flex plate.
4 Rotate the engine for each bolt for the flex plate that is to be removed. 5 Attach the transmission to an overhead crane. 6 Remove the bolts holding together the transmission and engine.
VDRF03.01GB
16
7 Carefully separate the transmission and engine.
8 Remove the bolts holding the flex plate to the transmission. 9 Change the flex plate. 10 Fit in the reverse order. Tighten the retaining bolts to 40 Nm. 11 Before the machine is put into operation, the transmission must be calibrated, see Transmission, calibrating page 23.
Attachment of flex plate.
VDRF03.01GB
2 Transmission 2.6 Lubrication
17
2.6
page
Lubrication
Lubrication system, description

The transmission lubricating system has the following function: Lubricate gear wheel and bearings Apply the clutches in the gearbox Cool down the torque converter and gearbox Clean the oil of any impurities with two oil filters.
During operation of the engine, the oil pump draws oil from the gearbox oil pan through a strainer, and it then pumps it through two oil filters to a control valve. The control valve supplies oil at the correct pressure to the transmission valve housing to activate the clutch plates for FORWARD or REVERSE and gear 1, 2, 3, or 4. The clutch plates require just a small amount of the oil flow supplied by the pump. The remainder of the oil is pumped through the torque converter circuit to the oil cooler and returns to the transmission for lubrication. See also supplier documentation transmission.
page
Oil and oil filter, changing
NOTE
Read the safety instructions for oil before working, see tab B Safety.
NOTE
The transmission must not be overfilled!
1 Operate and warm up the transmission oil. 2 Machine in service position, see tab B Safety. 3 Remove the drain plug for transmission oil and let the oil drain into the receptacle.
Draining transmission oil
VDRF03.01GB
18
4 Change oil filters. Lubricate the O-ring on the new oil filters with transmission oil. Tighten to contact and then another two-thirds turn. 5 When the transmission oil has drained, fit the drain plug. Make sure that the washer for the oil plug is included.
Oil filter transmission 6 Remove the transmission dipstick and fill new transmission oil through the dipstick's hole to the marking for low level on the dipstick. For volume and quality, see tab F Technical data. 7 Start the engine and let the engine run at idle for at least two minutes. 8 Check that the drain plug for transmission oil seals tight. 9 Check the transmission oil level with the engine running at idle and top up to the marking for low level.
Oil dipstick and filling point transmission oil 10 Warm up the transmission so that the oil temperature is 60-65 C on the display. Use operating menu oil temperature to check the transmission oil temperature. 11 Check the oil level and top up to the MAX marking for oil level.
000356
a b
Operating menu oil temperature a. Transmission oil temperature b. Hydraulic oil temperature
VDRF03.01GB
19
page
Oil level, checking
NOTE
Read the safety instructions for oil before working, see tab B Safety. The transmission's oil filler pipe and dipstick (position B) are located under the service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral position and at operating temperature (approx. 60-65 C in the display). The dipstick has two markings, MAX and MIN, the oil level should be at MAX. Wipe off the dipstick before checking.
NOTE
The dipstick is long. Use gloves.
2 Fill transmission oil (position B) as needed (for volume and quality, see tab F Technical data). Fill wait awhile check on the dipstick.
NOTE
B
A. Position of oil filling point and level check B. Oil filling point and oil dipstick
004871
Work carefully when filling transmission oil to prevent other fluids or particles from contaminating the oil, which means risk of transmission damage.
VDRF03.01GB
20
2 Transmission 2.6.3 Oil cooler
2.6.3
page
Oil cooler
Oil cooler, description

The transmission oil is cooled in the lower section of the cooler assembly. A temperature controlled bypass valve, which only acts on the cooling circuit for transmission oil, is located in a pipe at the lower edge of the radiator (on engine side). The valve closes when oil starts to reach operating temperature. In this way the oil reaches operating temperature more quickly. For more detailed information see supplier documentation transmission.
1 5 4
2
003215
3
Radiator core, engine alternative, Cummins 1. Charge air cooler 2. Radiator, engine 3. Cooler, transmission oil 4. Thermostat, transmission oil 5. Mounting, condenser (to AC)
4 3
Radiator core, engine alternative Volvo

1. Radiator, engine 2. Cooler, transmission oil 3. Thermostat, transmission oil 4. Mounting, condenser (to AC)
VDRF03.01GB
003214

Transmisionnt

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10

Transmission, component position

Workshop manual DRF 400450

Engine and gearbox, separation

Workshop manual DRF 400450

2 Transmission 2.1 Controls and instrumentation

Controls and instrumentation

Gear and multi-function lever, description

Workshop manual DRF 400450

2 Transmission 2.2 Torque converter/clutch system

Torque converter/clutch system

Flex plates, changing (engine alternative Volvo)

3 Remove the bolts for the flex plate.

Workshop manual DRF 400450

2 Transmission 2.2.1 Flex plates

7 Carefully separate the transmission and engine.

Workshop manual DRF 400450

2 Transmission 2.2.1 Flex plates

Attachment of flex plate.

Flex plates, changing (engine alternative Cummins QSM11)

Workshop manual DRF 400450

2 Transmission 2.2.1 Flex plates

7 Carefully separate the transmission and engine.

Attachment of flex plate.

Workshop manual DRF 400450

2 Transmission 2.6 Lubrication

Lubrication system, description

Oil and oil filter, changing

Draining transmission oil

Workshop manual DRF 400450

2 Transmission 2.6 Lubrication

Workshop manual DRF 400450

2 Transmission 2.6 Lubrication

Oil level, checking

Workshop manual DRF 400450

2 Transmission 2.6.3 Oil cooler

Oil cooler, description

Radiator core, engine alternative Volvo

Workshop manual DRF 400450

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