Service Information

Document Title: Function Group: Information Type: Date:

Section 4, content, 400 Service Information 2014/7/31
structure
Profile:
ART, A25D [GB]

Section 4, content, structure

The primary organization follows Volvo CE's function group index for articulated haulers. The function groups are based on
Volvo's company standard with 10 main groups, numbered from 0 to 9. There is an additional section on safety. The main
groups are divided into sub-groups which expand in several levels.
Example of function group for final drive according to the below:

4 Power transmission

Level 2 Level 3 Level 4

40 General
41 Clutch, torque converter
42 Transmission, hydraulic control
43 Transmission, mechanical
44 (Not used)
45 Propeller shaft
46 Front axle, rear axle 460 General, common information
461 Front axle 4612 Final drive/
differential gear
4613 Hub, hub reduction
4614 Drive axle, drive
shaft
4616 Axle housing
4617 Drive axle bearings/
universal joint
4618 Drive axle seal
4619 Miscellaneous
463 Rear axle 1
464 Rear axle 2
468 Differential lock, with control
47 (Not used)
48 Power take-off
49 Miscellaneous
 Service Information

Document Title: Function Group: Information Type: Date:

Power transmission, 400 Service Information 2014/7/31
specifications
Profile:
ART, A25D [GB]

Power transmission, specifications

Speed ranges (max.)
A25D equipped with tyres 23.5 R25
A30D equipped with tyres 750/65 R25 alt. 23.5 R25

Gear Speed
Forward
1st 8 km/h (5 mph)
2nd 12 km/h (7 mph)
3rd 22 km/h (14 mph)
4th 31 km/h (19 mph)
5th 40 km/h (25 mph)
6th 53 km/h (33 mph)
Reverse
1st 8 km/h (5 mph)
2nd 13 km/h (8 mph)
 Service Information

Document Title: Function Group: Information Type: Date:

Drivetrain, description 400 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Drivetrain, description
The flywheel housing and power take-off for driving the hydraulic pumps are built as a single unit. Lubrication takes place
via the engine lubrication system and oil is returned to the engine by way of a built-in oil pump.
A flex plate located in the flywheel housing drives the torque converter in the transmission.
The transmission is of planetary type and fully automatic with six forward and two reverse gears, all with lock-up. Automatic
shifting is controlled by an electronic control unit (T-ECU) which, via the transmission control system, always selects the
correct gear for the speed of the vehicle. The transmission also incorporates a retarder.
The dropbox has a differential with locking function.
The ground dependent hydraulic pump for the secondary steering system is also located on the dropbox.
The dropbox is driven by the transmission via a propeller shaft and in turn drives the front and rear drive axles via propeller
shafts.
The drive axles have differentials with differential locks and are equipped with the planetary gears in the hubs, so-called hub
reductions.
Six-wheel drive can be engaged and disengaged while the vehicle is in motion and is operated together with the
longitudinal differential.

Figure 1
Power transmission

1. Engine D10

 A25D EU: D10BACE2

 A25D EPA + EU: D10BADE2
 A30D EU: D10BAAE2
 A30D EPA + EU: D10BABE2

2. Flywheel housing (rear engine transmission) and power take-off

3. Transmission PT1560
4. Propeller shaft
5. Dropbox IL-1
6. Propeller shaft
7. Front drive axle

 A25D: AH56E
  A30D: AH64D

8. Propeller shaft (steering joint)

9. Propeller shaft (frame joint)
10. Propeller shaft
11. Front bogie axle (load unit) with power divider 6x6

 A25D: AH56F
 A30D: AH64E

12. Propeller shaft

13. Rear bogie axle (load unit)

 A25D: AH56G
 A30D: AH64F
 Service Information

Document Title: Function Group: Information Type: Date:

Description 410 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Description

Figure 1

A. Pump rotor
B. Turbine rotor
C. Turbine shaft
D. Stator
E. Space
F. Engine flywheel
G. Lock-up

The torque converter consists of a pump rotor (A), a turbine rotor (B) which is connected to a turbine shaft (C), and a stator
(D). The space (E) between the pump rotor and the turbine rotor is filled with oil.
The pump rotor is attached to the engine flywheel (F). When the flywheel starts to turn, the impellers on the pump rotor
force the oil to flow. The oil flow from the pump rotor flows over to the turbine rotor and forces it to turn in the same
direction as the pump rotor.
The stator, located between the pump rotor and the turbine rotor, is provided with a free-wheel so that, when i.e. Lock-up
clutch is applied, it can rotate freely in one direction. The impellers on the stator direct the oil flow from the turbine rotor
back to the impellers on the pump rotor.
The torque converter provides smooth transmission of the power from the engine to the transmission. The power is
transmitted to the turbine shaft (C), hydraulically or via the direct clutch (Lock-up) (G). Some of the engine power is
transmitted directly to the transmission's oil pumps via a drive sleeve.
 Service Information

Document Title: Function Group: Information Type: Date:

Lock-up clutch 410 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Lock-up clutch
In order to prevent losses in the torque converter when it is not needed, for example, when operating at a constant speed,
the pump rotor and the turbine rotor are locked together by a direct clutch disc called Lock-up (G). It is engaged when the
control unit senses the correct speed (rpm) relation between the turbine speed sensor (SE4213) and input speed sensor
(SE4212).
The Lock-up function is "self-teaching", which means that the engagement time (filling time) is automatically adapted with
consideration of wear and manufacture tolerances.
 Service Information

Document Title: Function Group: Information Type: Date:

Description 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Description

Figure 1
Transmission PT1560, right view

Figure 2
Transmission PT1560, left view

PT1560 is a fully automatic planetary transmission with a built in hydraulic retarder (brake).
The torque converter has a stator and direct clutch (Lock-up).
The transmission has six forward gears and two reverse gears.
Gearshifting is controlled by the position of the gearshift selector and an electronic control unit. Engagement of gears is
controlled by the electro-hydraulic control system.
The engine output torque is transmitted and reinforced by the torque converter to the transmission.
The hydraulic torque transmission is automatically disengaged by the direct clutch (Lock-up) and results in a mechanical
torque transmission.
The transmission is supplied with hydraulic pressure from two pumps driven by the engine via the torque converter.
The retarder is a hydraulic brake in the transmission that is used when braking the machine.
Gears are selected using the gearshift selector. Engagement of gears is controlled by the control unit after impulses from
sensors for engine speed and machine speed. Clutches and brakes are activated by solenoids via relay valves in the
transmission control system.
When shifting gears, a clutch/brake is engaged at the same time as the brake for the previous gear is disengaged.
When a specific gear is selected, a combination of clutches and brakes are applied according to the following table.

Clutche Brakes Solenoids

s
K1 K2 B1 B2 B3 B4 B5 MA MA MA MA MA MA MA PWM PWM PWM
4201 4202 4203 4204 4205 4206 4207 4201 4202 4203
Reverse 1 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Reverse 2 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Neutral N ⁽ᵇ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾
Forward 1 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Forward 2 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Forward 3 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Forward 4 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Forward 5 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾
Forward 6 ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽ᵃ⁾ ⁽⁾ ⁽⁾ ⁽⁾

⁽ᵃ⁾ Activated
⁽ᵇ⁾ Activated with low pressure
⁽ ⁾ Gives a variable modulation pressure
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission of power 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Transmission of power

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft K2 Clutch 2
8 Tubular shaft B1 Brake 1
B2 Brake 2

The power is transmitted from the turbine shaft to the main shaft via clutch K1. The power can also be transmitted to the
tubular shaft via the clutch drum between clutch K1 and clutch K2. The brake B1 locks the tubular shaft in the transmission
housing.
 Service Information

Document Title: Function Group: Information Type: Date:

Planetary gear 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Planetary gear

Figure 1

1 Planetary gear 1 B1 Brake 1

2 Planetary gear 2 B2 Brake 2
3 Planetary gear 3 B3 Brake 3
4 Planetary gear 4 B4 Brake 4
5 Planetary gear 5 B5 Brake 5

The transmission has five planetary gears which are linked and transmit power.
Brake B1 locks the planetary gear carrier in planetary gear 1 and the sun gear in planetary gear 2 in the transmission
housing.
Brake B2 locks the sun gear in planetary gear 1.
Brake B3 locks the ring gears in planetary gear 1 and 3 as well as it locks the planetary carrier in planetary gear 2.
Brake B4 locks the ring gears in planetary gear 2, 4 and 5 as well as it locks the planetary carrier in planetary gear 3.
Brake B5 locks the planetary carrier in planetary gear 5.
Figure 2

A. Sun gear
B. Planetary gear
C. Ring gear
D. Planetary carrier

A planetary gear consists of a number of gears that are constantly engaged.

There is a sun gear in the middle. Around the sun gear, there are planetary gears that are connected by a planetary carrier,
and outermost there is a ring gear with internal teeth. By allowing different parts of the planetary gear to be input respective
output shaft, while other parts are braked or connected, two different reduction ratios are obtained.
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, clutches and 420 Service Information 2014/7/31
brakes
Profile:
ART, A25D [GB]

Transmission, clutches and brakes

Figure 1

Clutches and brakes in transmission

K1 Forward, 1st - 6th gear
K2 Reverse, 6th gear
B1 4th gear
B2 5th gear
B3 3rd gear
B4 2nd gear, forward and reverse
B5 1st gear, forward and reverse
A Control system
B Pump
C Torque converter
D Retarder

Sensors and solenoids in transmission

MA4201 - MA4205/S1 - S5 Solenoids, speed gears
MA4206/S7 Solenoid, forward gear
MA4207/S8 Solenoid, reverse gear, 6th gear forward
PWM4201/S11 Modulating valve, main pressure
PWM4202/S13 Modulating valve, brake pressure
PWM4203/S14 Modulating valve (Lock-up)
SE4202 Sensor, transmission oil temperature (oil sump)
SE4203 Sensor, transmission oil level (oil sump)
SE4212 Sensor, engine speed, input speed (transmission)
SE4213 Turbine speed, behind cover for connector EH
SE4214 Sensor, lubrication oil pressure
SE4307 Sensor, output speed (rpm) transmission

The different reduction ratios are obtained through two clutches that rotate in the transmission and five brakes that lock
different parts of the planetary gears in the transmission housing.
The clutches are designated as K1 and K2. Brakes are designated as B1-B5.
The function of the forward clutch K1 is to connect the turbine shaft with the main shaft. The reverse clutch K2 connects the
turbine shaft with the tubular shaft. The clutches consist of a disc pack where every other disc is made of steel and the
others are coated with a friction material. Each disc pack is compressed by a hydraulic piston.
The function of the brakes B1-B5 is to lock the planetary gears' ring gear, planetary carrier or sun gear in the transmission
housing, so that they cannot rotate. The brakes have the same design as the clutches, that is, a disc pack where every other
disc is made of steel and the others are coated with a friction material. The brake function in the disc packs is obtained by
compression with a hydraulic piston.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F1 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F1

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft B5 Brake 5

Clutch K1 is activated and locks the turbine shaft to the main shaft. Brake B5 is activated and locks the planetary carrier to
planetary gear 5 in the transmission housing. In this way, K1 and B5 engage 1st gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F2 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F2

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft B4 Brake 4

Clutch K1 is activated and locks the turbine shaft to the main shaft. Brake B4 is activated and locks the ring gear to planetary
gear 4 in the transmission housing. In this way, K1 and B4 engage 2nd gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F3 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F3

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft B3 Brake 3

Clutch K1 is activated and locks the turbine shaft to the main shaft. Brake 3 is activated and locks the planetary carrier to
planetary gear 2 in the transmission housing. In this way, K1 and B3 engage 3rd gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F4 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F4

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft B1 Brake 1

Clutch K1 is activated and locks the turbine shaft to the main shaft. Brake B1 is activated and locks the planetary carrier to
planetary gear 1 in the transmission housing. In this way, K1 and B1 engage 4th gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F5 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F5

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft B2 Brake 2

Clutch K1 is activated and locks the turbine shaft to the main shaft. Brake B2 is activated and locks the sun gear to planetary
gear 1 in the transmission housing. In this way, K1 and B2 engage 5th gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Gear F6 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Gear F6

Figure 1

4 Turbine shaft K1 Clutch 1

7 Main shaft K2 Clutch 2
8 Tubular shaft

Clutch K1 is activated and locks the turbine shaft to the main shaft. Clutch K2 is activated and locks the turbine shaft to the
tubular shaft. K1 and K2 lock the planetary gears so that all planetary gears rotate as a single unit, which gives a reduction
ratio of 1:1 in 6th gear.
 Service Information

Document Title: Function Group: Information Type: Date:

Reverse gear R1 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Reverse gear R1

Figure 1

7 Main shaft K2 Clutch 2

8 Tubular shaft B5 Brake 5

The low reverse gear is obtained by transmission of the turbine shaft torque via clutch K2 and the tubular shaft to the sun
gear in planetary gear 2.
The planetary carrier in planetary gear 2 transmits the torque to the ring gear in planetary gear 3.
The planetary gears in planetary gear 3 act as transfer gears and reverse the rotational direction of the main shaft.
The planetary carrier in planetary gear 5 is locked to the transmission housing by brake B5.
 Service Information

Document Title: Function Group: Information Type: Date:

Reverse gear R2 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Reverse gear R2

Figure 1

4 Turbine shaft K2 Clutch 2

8 Tubular shaft B4 Brake 4

The high reverse gear is obtained by clutch K2 locking the turbine shaft to the tubular shaft, and by brake B4 locking the
planetary carrier for planetary gear 3 to the transmission housing.
 Service Information

Document Title: Function Group: Information Type: Date:

Description, retarder 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Description, retarder
The retarder is a hydraulic brake integrated in the transmission.
The retarder consists of a stator (1), a piston (2), a rotor (3) and a counterhold (4).
The stator is attached to the transmission housing while the rotor turns with clutch K1. The counterhold acts as a support for
the rotor.
When the piston is activated by the retarder valve, the space between the rotor and stator is filled with oil, and the oil
pressure increases. Since the stator is fixed (cannot rotate), the oil flow created by the rotor will be braked. This leads to
braking of the rotor and thus, the entire vehicle.
With increased oil pressure between the rotor and stator, the braking torque increases. The oil pressure is controlled by the
retarder valve, which is located on the outside of the transmission.
The retarder valve is controlled by a modulating valve (PWM4204) which in turn is controlled by the T-ECU.
The retarder is activated with the retarder pedal and the brake pedal.
The heat that is generated when the retarder is activated is dissipated using a heat exchanger, which is connected to the
engine's cooling system.

Figure 1

1. Stator
2. Piston
3. Rotor
4. Counterhold
 Service Information

Document Title: Function Group: Information Type: Date:

Pressure accumulation 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Pressure accumulation
Flow from pump P1 via the main oil filter to the main pressure valve MPV and then to:

 safety valve CHV

 relay valve reverse gear RV8
 relay valve forward gear RV7
 relay valve RV9
 all solenoids
 modulating valve PWM4201/S11
 flow from valve MPV to damping valve TV1 and modulating valve PWM4202/S13.

Flow from pump PC goes to:

 torque converter valve CRV

 when the main pressure valve MPV has obtained full pressure, the excess goes to CRV and on to the torque
converter. Then, the oil goes via a restriction to all lubrication points in the transmission. From the torque converter,
the oil goes to RRV and to LRV, via oil cooler and filter.

Description of valves in the transmission control system

Circuit P1
Modulating valve for main pressure, PWM4201/S11
The modulating valve is controlled by the control unit.
The valve controls the PWM pressure to the main pressure valve's spring side and MPV.
Note. High load gives high PM pressure.
Main pressure valve, MPV
The main pressure valve MPV is affected by pressure P1 and back-pressure from the spring and PM pressure.
Modulating valve for brake pressure, TV1
The flow PKR goes from TV1, the pressure in PKR is controlled by TV1, with the help of the spring and PWM4202/S13.
PWM4202/S13 is an electro-magnet (solenoid) which controls the pressure on TV1's spring side. Control functions as
follows; the ECU pulses electrical current to the magnetic coil. Zero current gives max. pressure, max. current gives min.
pressure.
The PKR flow goes via non-return valves NRV2 and NRV3 to relay valves RV1 and RV2.
Circuit PC
torque converter valve CRV
The valve controls the pressure in the torque converter circuit.
Torque converter C
The pump PC fills the torque converter C.
The existing torque converter pressure is determined by the torque converter valve CRV. When the pressure is obtained in
the torque converter, the excess goes to the sump.
Lubrication oil pressure valve LRV
The lubrication oil pressure valve controls the pressure and leads the oil to the lube points in the transmission.
The excess oil is drained to the sump. The transmission also receives lubrication oil pressure from CRV via the restriction
(Ø2.5 mm, 0.1 in).
Relay valves RV - RV9
Clutches K1 and K2 are drained to the sump via relay valves RV7 and RV8. K1 via RV7 and K2 via RV8.
All brakes are drained to the sump by the relay valves
RV - RV5.
Description of events when shifting gears
1st gear forward.
Solenoids MA4201/S1, MA4205/S5, MA4206/S7 and MA4207/S8 are activated.
Relay valve RV7 leads the oil flow to clutch K1. The pressure is also built up to main pressure valve MPV. The valve is
displaced against the spring and modulating pressure so that the valve opens completely. The excess oil is directed via the
torque converter valve CRV, to the torque converter C or to the sump.
Relay valves RV1 and RV5 lead the oil flow to brake 5 (B5).
When the relay valves for B5 open, the pressure drops between damping valve TV1 and relay valves RV1 and RV5. To
compensate for this, TV1 opens and increases flow so that the pressure is increased to the original pressure. When the
pressure in B5 is correct once again, PWM4202/S13 drains excess oil to sump.
Other functions
Direct clutch (Lock-up)
PWM4203/S14 is activated.
Relay valve RV9 leads the oil flow via non-return valve NRV9 to the direct clutch in the torque converter, which has a built-in
damping function.
The control unit lowers the main pressure P1, via the modulating valve PWM4201/S11.
Retarder
Retarder valve RRV is controlled by PWM4204/SE13.
The oil flow from the torque converter C fills the retarder R. When the retarder is filled with oil, it brakes the transmission.
The retarder pumps the retarder oil through oil cooler RC and back to the retarder.
The oil pressure in the circuit is controlled by feedback of pressure PR2 against the control pressure from PWM4204/SE13.
The oil also goes via the retarder valve to the lubrication oil valve LRV.
 Service Information

Document Title: Function Group: Information Type: Date:

Checklist, control system, 420 Service Information 2014/7/31
transmission
Profile:
ART, A25D [GB]

Checklist, control system, transmission

When a malfunction of the transmission control unit (T-ECU) is suspected, measurements against the cable harness should
always be performed before the transmission control unit is removed.
If the measurements on the cable harness show malfunction indications for the cable harness, it is likely that the control unit
function is correct.
Start by checking that the control unit fuses FU23 and FU24 in the electrical distribution box are intact.

WARNING
Changing control units between machines, when troubleshooting or repairing, may not take place for any reason
without reprogramming.

Incorrect individual settings in the control unit may result in personal injury or machine damage.

For reprogramming and read-out of software, see "VCADS Pro User manual".

Conditions for measuring against cable harness

 Battery disconnect switch off.

 Ignition key inposition 0.
 Multi-pin breaker box 999 8551 connected to adapter 951 1355 connected to the cable harness.
 Control unit disconnected.
 Measuring points refer to connection in the multi-pin breaker box or, where "frame" is indicated, it refers to the
frame ground connection by the electrical distribution box.
 Measuring position resistancewith multimeter.
 Service Information

Document Title: Function Group: Information Type: Date:

Component and 420 Service Information 2014/7/31
description
Profile:
ART, A25D [GB]

Component and description

T-ECU Control unit
controls gearshifting by using information from a number of sensors and switches. This information
is processed and signals are sent out to solenoids for speed gears, solenoid valves, etc. The ECU also
has built-in safety functions such as overspeed protection, prevention of incorrect handling of
gearshift selector, etc. (See Operator's Manual).

SW3301 Ignition

SE4201 Gearshift selector

Lever position
Reverse: 1st and 2nd gear
Neutral: Brake for 1st gear pressurized (low pressure)
Drive: 1st up to and incl. 6th gear
3: 1st up to and incl. 3rd gear
2: 1st and 2nd gear
1: Gear 1

When gearshift selector position N is selected and the machine is rolling, the brake for respective gear (K2 for gear F6) is
applied. This means that clutch K1 or K2 needs to be applied when the gearshift selector is moved from the N position.

SW4201 Switch for gearshift interlock (Hold)

affects the gearshifting program so that upshifting is prevented and downshifting takes place at the
lowest possible engine speed. Upshifting due to overspeeding takes place regardless of the position
of the switch.

MA4201-4205/
S1-5 Solenoids for gears
are activated in different combinations depending on the selected gear (see table fig.). The ECU
controls the signals to the solenoids in such a way that a certain gear overlap is achieved, that is, a
gear remains engaged momentarily while the next gear engages.

MA4206/S7 Solenoid for forward gear

When solenoid S7 is activated, clutch 1 for forward gears is engaged.

MA4207/S8 Solenoid for reverse gear

When solenoid S8 is activated, clutch K2 for reverse gears and 6th gear forward is engaged.

PWM4203/S14 Modulating valve for Lock-up

controls the pressure to, and engages the Lock-up clutch. The pressure is increased when slipping is
detected. The transmission control unit (T-ECU) interprets the information from SE4307 and engages
 the Lock-up clutch when the rpm difference is small. This applies to 1st, 2nd and 3rd gear. The lock-
up clutch is always engaged in gears 4, 5 and 6.

PWM4201/S11 Modulating valve, main pressure

controls the main pressure in the transmission depending on the load or Lock-up operation.

The modulating valve is controlled by signals from the ECU. Via SE57, the ECU sends a current to the
modulating valve which gives high pressure at low current, and low pressure at high current. In case
of a current loss, high pressure is obtained.

PWM4202/S13 Modulating valve, brake pressure

controls the pressure in the brakes depending on load and eventual slipping.

The modulating valve is controlled by signals from transmission control unit (T-ECU). If a high load is
registered, the ECU sends a signal to the modulating valve which gives a high modulating pressure.
This gives a fast engagement of the gears. Conversely, a low load gives a lower modulating pressure
and a softer engagement of the gears.

SE4212 Sensor for input speed

is located behind the torque converter where it registers the input speed to the transmission and
monitors overspeeding in the engine. The signals from SE4212 and SE4213 are compared by the
transmission control unit (T-ECU) to check that slipping does not take place in Lock-up. This check is
only performed when the transmission is operating in Lock-up mode.

SE4307 Sensor for output speed

is located on the transmission and provides the transmission control unit (T-ECU) with information
regarding machine speed and if the machine is accelerating or retarding. This information is used to
determine the gearshifting points.

The signals from SE4307 and SE4213 are compared by the transmission control unit (T-ECU) in order
to check that there is no slipping of brakes and clutches.

SE4202 Sensor, oil temperature, sump

If the oil sump temperature exceeds 110°C (230 F), the possibility for retarder use is reduced, and at
120°C (248 F), the retarder function ceases completely. The red central warning and buzzer will be
activated.

SE4203 Sensor transmission oil level - combined with SE4202

If the oil level in the transmission sump drops to a minimum on the dipstick, the transmission
control unit (T-ECU) receives a signal, and the central warning with buzzer is activated.

SE4214 Sensor, lubrication oil pressure

The transmission control unit (T-ECU) controls the transmission lube oil pressure via SE4214, which
should indicate pressures below 0.125 Mpa (18 psi) when the engine is off, and above 0.125 Mpa (18
psi) when the engine is running. In case of low oil pressure, the central warning and buzzer are
activated. See 3012 2F4210, lubrication oil pressure in transmission.

SE4204 Sensor for retarder oil temperature

is located on the retarder valve unit and sends signals to the transmission control unit (T-ECU). The
display is seen on the same gauge that shows transmission temperature. Retarder temperature is
only displayed when the retarder is activated.

SW4215 Position monitor, retarder pedal

is located in the retarder pedal and sends signals to the transmission control unit (T-ECU) when the
 retarder pedal is activated. Used for VEB, among other things.

SE4213 Sensor for turbine speed

is located on the left side of the transmission, inside the cover where the connector on the
transmission (electric connection of transmission) is located.
The signal from SE4213 is compared by the ECU to the signals from SE4212 and SE4307 to check
that there is no slipping in Lock-up, clutches or brakes. Check of Lock-up is only performed when
the transmission is operating in Lock-up mode.

SE4208 Sensor for retarder pedal position

is located in the retarder pedal and sends signals to the transmission control unit (T-ECU) when the
retarder pedal is activated. The transmission control unit (T-ECU) activates PWM4204 in proportion
to the pedal travel if the applicable conditions are fulfilled.

SE5501/02 Monitor/sensor parking brake

When the parking brake is activated in neutral position, the transmission cannot be shifted out of
neutral if D, 3, 2, 1 or R is selected.

PWM4204 Modulating valve, retarder engagement

is activated if the conditions are fulfilled at the ECU check when retarder is requested, and lets oil
flow to the retarder valve.

IM3806 Retarder temperature gauge

shows the oil temperature in the retarder when it is activated. Otherwise, oil temperature in
transmission is shown.
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission PT1560, cut- 420 Service Information 2014/7/31
away
Profile:
ART, A25D [GB]

Transmission PT1560, cut-away

Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic diagram PT 420 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Hydraulic diagram PT
Included components (alphabetical order)
B1-B5 Brakes (speed gears) NRV3 Non-return valve
BF Breather filter NRV9 Non-return valve
C Torque converter P1 Pump, control system
CHV Safety valve PC Pump, torque converter
CRV Valve, torque converter pressure PWM4201/S11 Modulating valve, main
clutch pressure
F1 Main oil filter PWM4202/S13 Modulating valve, brake
pressure
F2 Lube oil filter PWM4203/S14 Modulating valve, Lock-up
K1 Clutch forward, 6th gear PWM4204 Modulating valve, retarder
engagement
K2 Clutch reverse, 6th gear R Retarder
LC Transmission, oil cooler RC Oil cooler, retarder
LCF Pressure filter RRV Engagement valve, retarder
LRV Valve, lubrication oil pressure RV Relay valve, spare
LU Direct clutch (Lock-up) RV1-RV5 Relay valves, gear
engagement (speed gears)
MPV Main pressure valve RV7 Relay valve, forward gear
MA4201/S1 Solenoid, gear RV8 Relay valve, reverse gear
MA4202/S2 Solenoid, gear RV9 Relay valve, direct clutch
(Lock-up)
MA4203/S3 Solenoid, gear SE13 Temperature sensor,
retarder circuit
MA4204/S4 Solenoid, gear SE4202 Sensor, transmission oil
temperature (oil sump)
MA4205/S5 Solenoid, gear SE4203 Sensor, transmission oil level
(oil sump)
MA4206/S7 Solenoid, forward gear SE4214 Sensor, lubrication oil
pressure
MA4207/S8 Solenoid, reverse gear SF Suction filter
NRV2 Non-return valve TV1 Modulating valve, flow
limitation

Pressure check connection/Pressure

B1-B5 Clutch pressure, brakes PC2 Torque converter
pressure OUT
K1 Clutch pressure, forward gear PLU Lock-up pressure (direct
clutch)
K2 Clutch pressure, reverse gear PR1 Retarder pressure IN
P1 Main pressure PR2 Retarder pressure OUT
PC1 Torque converter pressure IN PS Lubrication oil pressure
Version 1
Machine Place of manufacture, serial number
EU US Brazil
A25D —11832 — —
A30D —10445 — —
A35D —11592 —61275 —71016
A40D —10509 —60235 —

Version 2 Change
A25D 11833— — — The modulating valve
A30D 10446— — — PWM4203(S14) for lock-
up has been changed
A35D 11593— 61276— 71017—
from normally being open
A40D 10510— 60236— — to normally being closed.
Figure 1
Hydraulic diagram, PT
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, removing 421 Service Information 2014/7/31
downward
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, removing downward

Op nbr 43774-1

11668020 Retainer plates (3 pcs.)

9993590 Gear
9993681 Lifting tool
9993682 Lifting tool
11668015 Lifting tool

Ratchet block 500 kg (1100 lb) 2 pcs.

Torque wrench 0-400 Nm (0–295 lbf ft)

Puller Kukko 20–10

NOTE!
If there has been a complete transmission breakdown or if there are impurities in filters and oil system, the transmission's oil
cooler must also be changed. If lifting equipment (capacity 2 tons) is available, it is advantageous to remove the
transmission together with the engine. See 210 Engine and transmission, removing, version 1

NOTICE
If there's been a transmission breakdown or if there are impurities in the transmission's oil sump, filter or oil system:

 change the transmission's oil cooler, see Oil cooler, changing.

 Thoroughly clean the lines to the transmission's oil cooler.

WARNING
Risk of crushing injuries

Make sure that the ramps are designed to support the front axle weight of the machine in question.

1. Run up the machine's front axle on ramps, approx. 200 mm (7.9 in) high. Axle pressure unloaded: approx. 13 000 kg
(28 660 lb).
NOTE!
This is done to enable removal of the transmission from the machine.
 Figure 1

2. Park the machine in service position.

3. Lower the front grill and pump up the engine hood.

4. Turn off the electric power with the battery disconnect switch.

5. Lower the front underbody skid plate and remove the rear underbody skid plates.

Figure 2

1. Front underbody skid plate

2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
4. Front cross member
5. Rear cross member

6. Remove the front and rear cross members.

7. Remove the cross stay and torsion bar.

 Figure 3

1. Cross stay
2. Torsion bar

WARNING
Risk of burns! Use protective work gloves.

8. Drain the oil from the transmission. Change volume: approx. 47 litres (12.4 US gal)

Figure 4

9. Disconnect the cannon connector from the transmission connector (EH). Remove the clamp for the cable harness.
Remove the main oil filter with bracket.
NOTE!
Protect the oil channels by covering them with plastic film or similar.
 Figure 5

1. Cannon connector
2. Main oil filter

The following work steps only apply to machines equipped with shut-off valve for the hydraulic oil tank.

Machine Place of manufacture, serial number

EU US Brazil
A25D 11001–11730 61001–61113 –
A30D 10001–10368 60001–60090 –

10. Remove the pin and close the valve for the hydraulic oil tank.

Figure 6

A. Closed
B. Open

1. Pin

11. Mark and remove the suction lines between the rear pumps and the hydraulic oil tank. Plug the connections.
 Figure 7

12. Mark and remove the pressure oil hoses and LS-hoses from the two rear hydraulic pumps. Mark and remove the
leak-oil hoses at the return pipe. Plug the hoses and the connections on the hydraulic pumps and also at the return
pipe for the leak-oil hoses.

Figure 8

1. Pressure oil hose

2. LS-hose
3. Leak-oil hose

13. Remove the two rear hydraulic pumps and O-rings.

Figure 9

1. O-ring

Continuation, see common step afterthe following steps that only apply to version 1 without shut-off valve.
The following work steps only apply to machines without shut-off valve for the hydraulic oil tank.

Machine Place of manufacture, serial number

EU US Brazil
A25D 11731–12999 61114–61118 71001–71999
A30D 10369–11999 60091–60093 70001–72999

14. Mark and remove the pressure oil hoses, the leak-oil hoses and LS-hoses from the two rear hydraulic pumps. Plug
the hoses and the connections on the hydraulic pumps.
 Figure 10

1. Pressure oil hoses

2. Leak-oil hoses
3. LS-hoses

15. Remove the two rear hydraulic pumps and O-rings.

Figure 11

1. O-ring

16. Suspend the pumps by their suction hoses along the machine's left side, use straps to take the weight off the
suction hoses.
Weight hydraulic pump: approx. 25 kg (55 lb)
 Figure 12

1. Attaching straps

Continuation for all types of version 1.

17. Plug the connection holes for the hydraulic pumps.

Figure 13

18. Mark and remove the front hoses on the retarder valve and unplug the connector for the temperature sensor
(SE4204). Plug the hoses and connections on the retarder valve.
 Figure 14

1. Temperature sensor SE4204

19. Remove the lube oil filter with bracket from the retarder valve.
NOTE!
Plug the connections and protect surfaces as needed with plastic film or similar.

Figure 15

20. Loosen and remove the bolt for the front radiator bracket.
 Figure 16
Front view

21. Loosen and remove the outer bolt from the headlight. Swing out the headlight and radiator.

Figure 17

22. Loosen the exhaust pipe at the turbine housing and at the partition opposite the transmission. Loosen the bracket
from the frame. Remove the front pipe and the flex pipe downward.
 Figure 18

23. Remove the three protective covers from the flywheel housing.

Figure 19

1. Flywheel degree markings.

2. Rotating the crankshaft. Tool 999 3590 is placed in the hole in the flywheel housing. A standard ratchet
handle is used, that can be combined with a universal joint and extension from a 1/2″ socket wrench set, if
needed.
3. Removing and mounting bolted joint flex plate–torque converter.

24. Remove the bolts (12 pcs.) between the flex plate and the transmission's torque converter. Use tool 9993590 to
rotate the crankshaft. Rotate the crankshaft so that two bolts at a time can be removed.
 Figure 20

25. Open the battery box and pull out the transmission dipstick.

26. Remove the floor mat.

27. Disconnect the air and electrical connections from the operator's seat. Remove and lift out the operator's seat.
Weight operator's seat: 40 kg (88 lb).

28. Remove the middle and rear floor plates.

29. Remove the right side panel in the cab.

Figure 21

30. Remove the plastic cap over the steering column.

Figure 22
31. Remove the lock pin from the steering shaft's universal joint. Remove the bolt and separate the steering shaft.

Figure 23

32. Loosen and bend aside the retarder pedal and throttle pedal and unplug the differential lock switch (SW 4604).

Figure 24

33. Loosen and press down the brake pedal through the front floor plate without disconnecting the air connections.

Figure 25

34. Mark the position of the steering shaft relative to the steering gear. Bend down the striker plates and remove the
bolts (2 pcs.). Remove the steering shaft from the steering gear's drive flange.
 Figure 26

35. Make sure that the steering shaft can't part. Use cable ties or similar. Remove the front floor plate.
NOTE!
It's important to maintain the relative position of the universal joints.

Figure 27

36. Mark up and remove the connectors for the brake pedal (SE5202, SE5203, SE5204, SW2505).

Figure 28

1. SW2505
2. SE5202
3. SE5204
4. SE5203

37. Remove the clamps for the brake hoses from the lever console. Remove the air connections from the left and right
 brake boosters. Fold aside the brake pedal backwards.

Figure 29

38. Remove the oil filler hose and the upper pipe for the oil level dipstick from the transmission and fold aside. Plug
the connections.

Figure 30

1. Pipe, oil level dipstick

2. Oil filler hose

39. Remove the breather hose for the transmission. Plug the connections.

Figure 31
40. Disconnect the steering gear with bracket from the frame. Place the steering gear on the transmission.

Figure 32

41. Mark and remove the link rod from the steering and dumping valve.
NOTE!
Mark in such a way that the steering settings are maintained when reassembling.

Figure 33

42. Loosen and disconnect the feedback rod from the lever. Use a suitable puller.

Figure 34

43. Cut off the lock wire, loosen and remove the bolts for the lever bracket. Remove the bolt for the cable rail. Pull the
lever bracket rearwards and fold up the steering gear on the left side.
NOTE!
There's a plastic spacer on the right side between the frame and lever bracket.
 Figure 35

WARNING
Risk of crushing injuries

44. Lift out the lever bracket and steering gear from the cab. Weight: approx. 30 kg (66 lb)

45. Loosen and remove the bolted joint between the propeller shaft and drive flange. Bend the propeller shaft down to
the right.

Figure 36
View from below

46. Remove the connector for the output speed sensor SE4307. Remove the clamp for the cable harness.
 Figure 37
View from below

1. SE4307

47. Remove and move aside the two rear pipes from the retarder valve. Unplug the connector for PWM4204. Plug the
pipes and the connections on the retarder valve.

Figure 38

48. Attach lifting tools 9993681 (right) and 9993682 (left) to the transmission.
NOTE!
Use four M16x45 bolts, part no. 955365 (4 pcs.), and four M16 nuts, part no.955785 (4 pcs.).

Figure 39
49. Fit the lifting tool 11668015 in the cab and secure the transmission with two ratchet blocks.

Figure 40

WARNING
Risk of crushing injuries

50. Remove the bolted joint between the transmission and the flywheel housing.

Figure 41

51. Carefully pull the transmission straight back so that the retainer plates 11668020 (3 pcs.) can be fitted on the torque
converter.
NOTE!
Make sure that the torque converter follows the transmission rearwards. It is important to secure the torque
converter adequately as it could otherwise slide out of position and be damaged.
 Figure 42

1. Retainer plate 11668020

52. Back up the transmission, and tilt it down.

Figure 43

53. Lower the transmission and tilt it up to horizontal position before lowering it onto the pallet forks.

Figure 44
54. Pull out the transmission.
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, removing 421 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, removing
Op nbr 421-070

9993590 Gear wheel

9993681 Bracket right
9993682 Bracket left
11668015 Lifting tool
11668020 Transport brace
11668020 Transport brace
11668020 Transport brace

NOTE!
Alternatively, 11668024 Rotation tool can be used instead of 9993590 Gear wheel.

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

 715 Protective plate, removing

NOTE!
It is advantageous to remove the gearbox together with the engine if lifting equipment with a capacity of 2 tons is available.
See 210 Engine and transmission, removing.

IMPORTANT!
If the gearbox has had a major breakdown or if contaminants are found in the gearbox oil sump, filter or oil system, the
gearbox oil cooler should be replaced, see 491 Oil cooler, changing. Carefully clean the pipes and connections to the oil
cooler.

WARNING
Risk of crushing injuries

1. Drive the machine's front axle up onto ramps approx. 200 mm (7.9 in) high.
Unloaded axle weight: approx: 13 000 kg (28 660 lb)
NOTE!
Make sure that the ramps are dimensioned for the machine's current front axle pressure.
 Figure 1

2. Place the machine in the service position. See 191 Service positions.

3. Lower the front grill and open the engine hood.

4. Turn off the electric power with the battery disconnect switch.

5. Drop down the front protective plate and remove the rear protective plates. See the relevant sections of
715 Protective plate, removing.

Figure 2

1. Front underbody skid plate

2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
4. Front cross member
5. Rear cross member

6. Remove the front and rear cross members.

7. Remove the cross stay and torsion bar.

 Figure 3

1. Cross stay
2. Torsion bar

WARNING
Risk of burns! Use protective work gloves.

8. Drain the transmission oil.

Replacement volume: approx. 47 litres (12.4 US gal)
The hose for draining oil is located in the pipe for the ladder on the inside of the front grill.

Figure 4

9. Mark and remove the pressure oil hoses, the leak-oil hoses and LS-hoses from the two rear hydraulic pumps. Plug
the hoses and the connections on the hydraulic pumps.
 Figure 5

1. Pressure oil hoses

2. Leak-oil hoses
3. LS-hoses

10. Loosen the two rear hydraulic pumps and remove the O-rings.

Figure 6

1. O–ring

11. Suspend the pumps by their suction hoses along the machine's left side, use straps to take the weight off the
suction hoses.
Weight, hydraulic pump: approx. 25 kg (55 lbs)
 Figure 7

1. Attaching straps

12. Plug the connection holes for the hydraulic pumps.

Figure 8

13. Disconnect the Cannon connector from the transmission connector (EH). Remove the cable harness clamp. Remove
the main oil filter with holder.
NOTE!
Protect the oil channels by covering them with plastic cling film or similar.

Figure 9
 1. Cannon connector
2. Main oil filter

14. Mark and remove the front pipes on the retarder valve. Plug the pipes and connections on the retarder valve.

Figure 10

15. Suspend the pipes along the machine's left side.

Figure 11

16. Remove the lube oil filter and bracket from the retarder valve.
NOTE!
Plug the connections and protect surfaces as needed with plastic film or similar.

Figure 12

17. Remove the connector for temperature sensor SE4204 and the connector for PWM4204.
 Figure 13

1. PWM4204
2. SE4204

18. Remove the floor mat.

19. Disconnect the air and electrical connections from the operator's seat. Remove and lift out the operator's seat.
Weight operator's seat: 40 kg (88 lb).

20. Remove the middle and rear floor plates.

21. Remove the right side panel in the cab.

Figure 14

22. Remove the plastic cover from the steering column.

 Figure 15

23. Remove the steering column UJ locking pin. Remove the bolt and separate the steering column.

Figure 16

24. Loosen and bend aside the retarder pedal and throttle pedal and unplug the differential lock switch (SW 4604).

Figure 17

25. Loosen and press the brake pedal through the front floor plate without disconnecting the air connections.
 Figure 18

26. Mark the position of the steering shaft relative to the steering gear. Bend down the striker plates and remove the
two bolts (2 pcs.). Remove the steering shaft from the steering gear's drive flange.

Figure 19

27. Make sure that the steering shaft can't part. Use cable ties or similar. Remove the front floor plate.
NOTE!
It's important to maintain the relative position of the universal joints.

Figure 20

28. Mark up and remove the connectors for the brake pedal (SE5202, SE5203, SE5204, SW2505).
 Figure 21

1. SW2505
2. SE5202
3. SE5204
4. SE5203

29. Remove the clamps for the brake hoses from the lever console. Remove the air connections from the left and right
brake boosters. Fold aside the brake pedal backwards.

Figure 22

30. Open the battery compartment and pull out the transmission dipstick.

31. Remove the oil filler hose and the upper pipe for the oil level dipstick from the transmission and fold aside. Plug
the connections.

Figure 23
 1. Pipe, oil level dipstick
2. Oil filler hose

32. Remove the breather hose for the transmission. Plug the connections.

Figure 24

33. Remove the hydraulic hoses (2 pcs.) from the steering and dumping valve.

Figure 25

1. Hydraulic hoses

34. Mark and remove the link rod from the steering and dumping valve.
NOTE!
Mark up in such a way that assembly can be performed with maintained steering settings.
 Figure 26

35. Disconnect the steering gear with bracket from the frame. Place the steering gear on the transmission.

Figure 27

36. Loosen and disconnect the feedback rod from the lever. Use a suitable puller.

Figure 28

37. Cut off the lock wire, loosen and remove the bolts for the lever bracket. Remove the bolt for the cable rail. Pull the
lever bracket rearwards and fold up the steering gear on the left side.
NOTE!
There's a plastic spacer on the right side between the frame and lever bracket.
 Figure 29

WARNING
Risk of crushing injuries

38. Lift out the lever bracket and the steering gear from the cab.
Weight: approx. 30 kg (66 lbs)

39. Remove the connector for the output speed sensor SE4307. Remove the clamp for the cable harness.

Figure 30
View from below

1. SE 4307

40. Loosen and remove the bolts between the propeller shaft and drive flange. Bend the propeller shaft down to the
right.
 Figure 31
View from below

41. Loosen the partition for the exhaust pipe at the transmission's trailing edge.

Figure 32

42. Loosen the front attachment against the frame for the exhaust pipe.

Figure 33

1. Front attachment

43. Loosen the flex pipe at the throttle housing. Remove the pipe connection between the exhaust pressure governor
and air valve. Remove the throttle housing from the turbine housing.
 Figure 34

1. Clamp against flex pipe

2. Clamp against turbine housing
3. Pipe connection

44. Loosen the air valve for the AT-regulator and move the exhaust pipe and flex pipe forward so that it is clear of the
transmission.

Figure 35

1. Air valve

45. Mark and remove the connections 30, 31 and 50 from the starter motor.
 Figure 36

1. Connection 30
2. Connection 31
3. Connection 50

46. Remove the starter motor.

Weight: 15 kg (33 lb)

Figure 37

47. Remove the two protective covers from the flywheel housing.

Figure 38

1. Protective cover

48. Remove the twelve bolts between the flex plate and the transmission's torque converter. Use 9993590 Gear wheel
to rotate the crankshaft.
 Figure 39

1. 9993590 Gear wheel

49. Remove the two rear pipes for the retarder valve. Plug the pipes and connections on the retarder valve. Remove the
heat shield for the retarder valve.

Figure 40

1. Heat shield

50. Install 9993681 Bracket right and 9993682 Bracket left on the transmission.
NOTE!
Use four M16x45 bolts and four M16 washers.
 Figure 41

51. Place 11668015 Lifting tool in the cab and secure the transmission with two ratchet blocks.

Figure 42

52. Remove the bolts between the transmission and the flywheel housing.

Figure 43
 WARNING
Risk of crushing injuries

53. Carefully pull the transmission straight back so that three 11668020 Transport brace can be fitted onto the torque
converter.
NOTE!
Make sure that the torque converter follows the transmission rearwards. It is important to secure the torque
converter adequately as it could otherwise slide out of position and be damaged.

Figure 44

1. 11668020 Transport brace

54. Back up the transmission, and tilt it down.

Figure 45

55. Lower the transmission and tilt it up to horizontal position before lowering it onto the pallet forks.
 Figure 46

56. Pull out the transmission.

 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, installing 421 Service Information 2014/7/31
from underneath
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, installing from underneath

Op nbr 43776-1

11668020 Transport retainers (3)

9993590 Gear
9993681 Bracket
9993682 Bracket
11668015 Lifting tool

Ratchet block 500 kg (1100 lb) 2 pcs.

Torque wrench 0–400 Nm (0–295 lbf ft)

WARNING
Risk of crushing injuries

Make sure that the transmission is adequately secured.

Weight: approx. 500 kg (1100 lb)
NOTE!
Maintain cleanliness by protecting surfaces as needed with plastic film or similar.

1. Remove the oil filter and holder from the retarder valve.
NOTE!
Plug and protect surfaces as necessary with plastic cling film or similar.

2. Remove the main oil filter and holder from the transmission.
NOTE!
Plug and protect surfaces as necessary with plastic cling film or similar.

3. Transfer the bleeder nipple from the old transmission.

4. Install lifting tools 9993681 (right) and 9993682 (left) on the transmission.

5. Fit the three retainer plates (3 pcs.) 11668020 on the torque converter.
NOTE!
It is important to secure the torque converter safely as it could easily slide out of position and sustain damage.

6. Move the transmission in underneath machine.

7. Hoist the transmission into a vertical position.

 Figure 1

8. Tilt the transmission to horizontal position.

9. Fit a guide pin M12x70 mm (2.8 in) in the torque converter and remove the retainer plates.

Figure 2

1. Guide pin M12x70 mm (2.8 in)

10. Fit the transmission to the flywheel housing.

NOTE!
Use the locating pin by inserting it through the flexible plate and the lowest hole for the protective covers on the
flywheel housing.

11. Install the bolts and tighten the bolts between the transmission and flywheel housing.
Tightening torque: 85 Nm (63 lbf ft)
 Figure 3

12. Remove the ratchet blocks and lifting tools 11668015, 9993681 and 9993682 from the transmission.

Figure 4

13. Remove the guide pin.

Install and tighten the bolted joint between the drive disc and the transmission's torque converter.
Use tool 9993590 to rotate the crankshaft.
Rotate the engine so that two bolts can be installed at a time.
NOTE!
To prevent the flexible plate from turning, fit all the bolts before tightening them.

Tightening torque: 91 Nm (67 lbf ft)

Figure 5

14. Check the protective cover's gasket, change as needed.

Install the protecting covers.
Tightening torque: 25 Nm (18 lbf ft)

15. Install the front exhaust pipe and flex hose from below.
Install the bracket for the exhaust on the frame.
 NOTE!
Inspect the rubber cushion in the bracket and change it as necessary. Make sure that the exhaust pipe does not
touch the side member at any point.

Figure 6

16. Swing in the radiator and tighten the bolt.

Tightening torque: 230 Nm (170 lbf ft)

Figure 7
Front view

17. Swing in the headlamp and tighten the bolt.

18. Fit the filter holder and oil filter on the retarder valve.
Tightening torque: 20 Nm (15 lbf ft)
NOTE!
Ensure that all protective cling film is removed and inspect the two O–rings on the filter holder.
 Figure 8

19. Install the Cannon connector plug to the connector socket (EH).
Install the cable clamp and secure the cable harness.
NOTE!
Make sure that the cable harness does not touch the exhaust pipe.

20. Fit the filter holder and main oil filter on the transmission.
Tightening torque: 20 Nm (15 lbf ft)
NOTE!
Ensure that all protective cling film is removed and check that the gasket is intact.

Figure 9

1. Cannon connector
2. Main oil filter

21. Plug in the connector to the sensor for output speed (SE4307).
Install the cable clamp and secure the cable harness.
 Figure 10
Bottom view

1. Rpm sensor SE4307

22. Remove the plugs and install the two front hoses on the retarder valve according to earlier marking.
Install the connector for the temperature sensor (SE4204) on the retarder valve.
NOTE!
Inspect the O–rings on the hoses and change as necessary.

Figure 11

1. Temperature sensor SE4204

The following work steps only apply to machines equipped with shut-off valve for the hydraulic oil tank.

Machine Place of manufacture, serial number

EU US Brazil
A25D 11001–11730 61001–61113 –
 A30D 10001–10368 60001–60090 –

23. Fill hydraulic oil in the pumps through the leak-oil connection.
Fit the leak-oil hose.

Figure 12

24. Top up with hydraulic oil in the leak-oil hose.

Plug the leak-oil hose.

Figure 13

25. Remove the plugs and install the O–rings.

O–rings shall be lubed with vaseline.
Install the rear hydraulic pumps.
Use locking fluid on the bolts (Loctite 243 Part no. 1161053). Tightening torque: 85 Nm (63 lbf ft)
NOTE!
Check the O–rings. Change if needed.
 Figure 14

1. O–ring

26. Remove the plugs and fit the leak-oil hoses on the connection by the hydraulic oil tank.

Figure 15

27. Remove the plugs and fit the pressure oil hoses and LS–hoses according to markings made earlier.
NOTE!
Inspect the O–rings on the hydraulic pump connections and change as necessary.
 Figure 16

1. Feed oil hose

2. LS hose
3. Leak-off oil hose

28. Remove the plugs and fit the suction oil lines between the hydraulic oil tank and the rear hydraulic pumps.
NOTE!
Inspect the O–rings on the suction oil line connections and change as necessary.

Figure 17

NOTICE
Check that the hydraulic hoses are in the clear and cannot be damaged.

29. Open the hydraulic tank cock and fit the pin in place.
NOTE!
The hydraulic system must always be bled when the system has been opened.

See 900 Hydraulic system, bleeding Section 9.

 Figure 18

A. Closed
B. Open

1. Pin

Continuation, see common step after the following steps.

The following work steps only apply to machines without shut-off valve for the hydraulic oil tank.

Machine Place of manufacture, serial number

EU US Brazil
A25D 11731–12999 61114–61118 71001–71999
A30D 10369–11999 60091–60093 70001–72999

30. Remove the plugs for the hydraulic pumps and install the O–rings.
O–rings shall be lubed with vaseline.
Loosen the hydraulic pumps that hang along the machine's left side and install them.
Use locking fluid on the bolts (Loctite 243 Part no. 1161053).
Tightening torque: 85 Nm (63 lbf ft)
NOTE!
Check the O-rings, change if needed.

Figure 19

1. O-ring

31. Remove the plugs and fit the pressure oil hoses, leak-oil hoses and the LS–hoses according to markings made
earlier.
NOTE!
Check the O-rings on the hydraulic pumps' connections, change if needed.
 Figure 20

1. Feed oil hose

2. Leak-off oil hose
3. LS hose

NOTICE
Check that the hydraulic hoses are in the clear and cannot be damaged.

Continuation for all types of machines with D10 engine.

32. Fit the torsion bar and cross stay.

Tightening torque
Torsion bar: 240 Nm (177 lbf ft)
Cross stay 540 Nm (398 lbf ft)

Figure 21

1. Cross stay
2. Torsion bar

33. Fit the front and rear cross-members.

34. Remove the plugs and fit the breather hose for the transmission.
 Figure 22

35. Install the connector for PWM4204 on the retarder valve.

Install the rear pipes on the retarder valve.
NOTE!
Check that the plugs and protective cling film have been removed and that the O–rings are intact. Change as
necessary.

Figure 23

36. Fit the propeller shaft and tighten the bolts between the propeller shaft and transmission.
Tightening torque: 180 Nm (133 lbf ft)

Figure 24
37. Lay the lever bracket in place and fit the link rod for the steering and dumping valve according to markings made
earlier.
NOTE!
Use locking fluid on the link rod (Loctite 243 Part no. 1161053).

Tightening torque: 75 Nm (55 lbf ft)

Figure 25

38. Install and tighten the bolts for the lever bracket.
Lock the bolts with lock wire.
Tightening torque: 45 Nm (33 lbf ft)
NOTE!
The plastic spacer should be positioned between the lever bracket and the frame on the right side.

NOTE!
Check that the guide sleeve for the lever bracket's left mounting is intact.

Figure 26

39. Fit the steering gear.

Tightening torque: 80 Nm (59 lbf ft)

40. Fit the feedback rod on the lever and tighten the nut.
Tightening torque: 120 Nm (89 lbf ft)
 Figure 27

41. Remove the plugs and fit the oil filler hose and pipe for the oil level dipstick.

Figure 28

1. Tube, oil dipstick

2. Oil filler hose

42. Install the air hoses on the left and right brake booster.
Install the clamps on the lever bracket.

Figure 29

43. Fit the connectors for SW2505, SE5202, SE5203, SE5204 on the brake pedal as marked earlier.
 Figure 30

1. SW2505
2. SE5202
3. SE5204
4. SE5203

44. Fit the front floor plate.

45. Install the steering column on the steering gear's flange according to earlier marking.
Install and tighten the bolts.
Lock the bolts with the striker plate.
Tightening torque: 20 Nm (15 lbf ft)

Figure 31

46. Install the brake pedal.

Figure 32

47. Fit the bolts in the front floor plate and tighten them.
48. Fit the accelerator and retarder pedals in place and plug in the differential lock connector.

Figure 33

49. Set the wheel in 'straight ahead' position.

Push the steering column and the universal joint together.
Install the bolt and the lock pin.

Figure 34

50. Fit the plastic cap over the steering column.

51. Fit the rear and middle floor plates.

52. Fit the floor mat.

53. Lift in and fit the operator's seat.

Connect the air and electric connections for the operator's seat.
Weight: 40 kg (88 lb).

54. Fit the oil dipstick for the transmission.

55. Fill the transmission with oil.

Change volume: 47 litres (12.4 US gal)

56. Bleed the hydraulic system. See 900 Hydraulic system, bleeding Section 9.

57. Fit the front underbody skid plate.

For machines with software version from and incl. release 2004:3, the following shall be done when
changing transmission:

58. Connect VCADS Pro.

Start operation 40104-2 and activate the sub-test "Return to non-calibrated mode".
Start the engine and operate the machine until warm.
 Carry out the calibration according to the text in the operation.
The following applies to all machines:

59. Start the engine and check functions.

Operate until warm and check the oil level in the transmission.
Check for possible leaks.
NOTE!
When checking transmission oil level, the engine should be running and the transmission oil should have an
operating temperature of 70 °C (158 °F).

60. Fit the rear underbody skid plates.

Figure 35

1. Front underbody skid plate

2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
4. Front cross member
5. Rear cross member
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, installing 421 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, installing
Op nbr 421-072

11668020 Transport brace

11668020 Transport brace
11668020 Transport brace
9993681 Bracket right
9993682 Bracket left
11668015 Lifting tool
11668024 Rotation tool

NOTE!
As alternative to 11668024 Rotation tool, use 9993590 Gear wheel.

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

 715 Protecting plate, installation

WARNING
Risk of crushing injuries

Make sure that the transmission is adequately secured.

Weight: approx. 500 kg (1100 lb)
NOTE!
Maintain cleanliness by protecting surfaces where necessary with plastic film or similar.

1. Place the machine in service position, see 191 Service positions.

2. Remove the oil filter and bracket from the retarder valve.
NOTE!
Plug and protect surfaces as needed with plastic film or similar.

3. Remove the main oil filter and bracket from the transmission.
NOTE!
Plug and protect surfaces as needed with plastic film or similar.

4. Transfer the bleeder nipple from the old transmission.

5. Install 9993681 Bracket right and 9993682 Bracket left on the transmission.

6. Fit three 11668020 Transport brace on the torque converter.

NOTE!
It is important to secure the torque converter adequately as it could otherwise slide out of position and be
damaged.
 7. Move the transmission in underneath machine.

8. Hoist the transmission into a vertical position.

Figure 1

9. Tilt the transmission to horizontal position.

10. Fit a guide pin M12x70 mm (2.8 in) in the torque converter and remove the retainer plates.

Figure 2

1. Guide pin M12x70 mm (2.8 in)

11. Fit the transmission to the flywheel housing.

NOTE!
Use the guide pin by inserting it through the flex plate and the starter ring gear out through the lowest hole for the
protective covers on the flywheel housing.

12. Tighten the attachment bolts between the transmission and the flywheel housing.
Tightening torque: see 200 Engine, tightening torques.
 Figure 3

13. Remove the ratchet block and 11668015 Lifting tool, 9993681 Bracket right and 9993682 Bracket left from the
gearbox.

Figure 4

14. Remove the guide pin.

Fit the bolts between the starter ring gear, flex plate and the transmission's torque converter.
Use 11668024 Rotation tool or alternatively 9993590 Gear wheel to rotate the crankshaft.
Rotate the engine so that one bolt can be installed at a time.
NOTE!
To prevent the flex plate from turning, fit all the bolts before torquing them.

Tighten the bolted joint.

Tightening torque: see 420 Hydraulic transmission, tightening torque.
 Figure 5

1. Tools: 9993590 Gear wheel or alternatively 11668024 Rotation tool

15. Check the protective cover's gasket, change as needed.

Install the protective covers.

16. Fit the starter motor.

Weight: 15 kg (33 lb)
Connect 30, 31 and 50 to the starter motor according to markings made earlier.

Figure 6

17. Fit the heat shield for the retarder valve and connect the two rear pipes for the retarder valve.
 Figure 7

1. Heat shield

18. Fit the propeller shaft and tighten the bolts between the propeller shaft and transmission.
Tightening torque: see 450 Propeller shaft, tightening torque.

Figure 8

19. Move back the front exhaust pipe and the flex hose.
Install the air valve.

Figure 9

1. Air valve
20. Fit the bracket for the exhaust pipe in the frame and assemble the partition at the transmission's trailing edge.
NOTE!
Check the rubber cushion in the bracket, change if needed. Make sure that the exhaust pipe does not touch the
frame member.

Figure 10

21. Fit the throttle housing between the turbine housing and the exhaust pipe.

Figure 11

1. Clamp against flex pipe

2. Clamp against turbine housing
3. Pipe connection

22. Fit the pipe connection between the air valve and AT-regulator.

23. Plug the connector into the output rpm sensor (SE4307).
Install the cable clamp and secure the cable harness.
 Figure 12
View from below

1. Rpm sensor SE4307

24. Remove the plugs and fit the breather hose for the transmission.

Figure 13

25. Lay the lever bracket in place.

NOTE!
The plastic spacer should be positioned between the lever bracket and the frame on the right side.

NOTE!
Check that the guide sleeve for the lever bracket's left mounting is intact.

26. Install and tighten the bolts for the lever bracket.
Lock the bolts with lock wire.
Tightening torque: see 643 Steering linkage, tightening torque.
 Figure 14

27. Fit the adjustment rod to the steering valve in accordance with the previously made markings.
NOTE!
Locking fluid (Loctite 243 Art. No. 116 1053) must be applied to the adjustment rod.

Tightening torque: see 643 Steering linkage, tightening torque.

Figure 15

28. Fit the steering gear.

Tightening torque: see 643 Steering linkage, tightening torque.

29. Fit the feedback rod on the lever and tighten the nut.
Tightening torque: see 643 Steering linkage, tightening torque.

Figure 16
30. Remove the plugs and fit the oil filler hose and pipe for the oil level dipstick.

Figure 17

1. Pipe, oil level dipstick

2. Oil filler hose

31. Fit the hydraulic hoses to the steering valve.

Figure 18

1. Hydraulic hoses

32. Remove the plugs and fit the two front pipes on the retarder valve.
NOTE!
Check the O–rings on the pipe connections, change if needed.

NOTE!
Check that the pipes go clear of each other and that they do not touch the transmission.
 Figure 19

33. Plug in the connector for temperature sensor SE4204 and the connector for PWM4204 on the retarder valve.

Figure 20

1. PWM4204
2. SE4204

34. Fit the filter holder and oil filter on the retarder valve.
Tightening torques: 420 Hydraulic transmission, tightening torque.
NOTE!
Ensure that all protective film is removed and check the two O-rings on the filter bracket.

Figure 21

35. Plug in the Cannon connector plug into the gearbox connector socket (EH).
Install the cable clamp and secure the cable harness.

36. Fit the filter holder and main oil filter on the transmission.
Tightening torques: 420 Hydraulic transmission, tightening torque.
NOTE!
Make sure that all protective film is removed and check that the gasket is intact.
 Figure 22

1. Cannon connector
2. Main oil filter

37. Remove the plugs and install the O–rings.

O–rings shall be lubed with vaseline.
Install the rear hydraulic pumps.
Use locking fluid on the bolts (Loctite 243 Part no. 116 1053).
Tightening torque: see 913 Hydraulic pumps, specifications.
NOTE!
Check the O-rings. Change if needed.

Figure 23

1. O–ring

NOTICE
Check that the hydraulic hoses are in the clear and cannot be damaged.

38. Remove the plugs and fit the pressure oil hoses, leak-oil hoses and the LS–hoses according to markings made
earlier.
NOTE!
Check the O-rings on the hydraulic pumps' connections, change if needed.
 Figure 24

1. Pressure oil hoses

2. Leak-oil hoses
3. LS-hoses

39. Fit the torsion bar and cross stay.

Tightening torque, see: 750 Axle suspension, tightening torque

Figure 25

1. Cross stay
2. Torsion bar

40. Fit the front and rear cross members.

41. Install the air hoses on the left and right brake booster.
Install the clamps on the lever bracket.
 Figure 26

42. Fit the connectors for SW2505, SE5202, SE5203 and SE5204 to the brake pedal in accordance with the previous
markings.

Figure 27

1. SW2505
2. SE5202
3. SE5204
4. SE5203

43. Fit the front floor plate.

44. Install the steering column on the steering gear's flange according to earlier marking.
Install and tighten the bolts.
Lock the bolts with the striker plate.
Tightening torque: see 642 Steering gear, specifications.

Figure 28
45. Fit the brake pedal.

Figure 29

46. Fit and tighten the bolts for the front floor plate.
NOTE!
Check that no air hoses or electric cabling is in contact with the exhaust pipe.

47. Fit the throttle pedal and retarder pedals as well as the differential lock switch.

Figure 30

48. Set the steering wheel so that the wheels point straight ahead.
Push the steering column and the universal joint together.
Install the bolt and the lock pin.

Figure 31

49. Fit the plastic cap over the steering column.

 Figure 32

50. Fit the rear and middle floor plates.

51. Fit the floor mat.

52. Lift in and fit the operator's seat.

Connect the air and electric connections for the operator's seat.

53. Fill the transmission with oil.

Volume: see 400 Hydraulic transmission, capacity.

54. Fit the oil dipstick for the transmission.

55. Fit the front underbody skid plate.

56. Connect VCADS Pro.

Start operation 40104-3 Calibration, and activate the sub-test "Return to non-calibrated mode".
Start the engine and operate the machine until warm.
Carry out the calibration according to the text in the operation.

57. Start the engine and check functions.

Operate until warm and check the oil level in the transmission.
Check for possible leaks.
NOTE!
When checking transmission oil level, the engine should be running and the transmission oil should have an
operating temperature of 70 °C (158 °F).

58. Fit the rear protective plates. See the relevant sections of 715 Protecting plate, installation.

Figure 33
 1. Front underbody skid plate
2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
4. Front cross member
5. Rear cross member

59. Restore the machine from service position.

 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, removing 421 Service Information 2014/7/31
from engine out of
machine, version 1
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, removing from engine out of machine, version 1

Op nbr 42183

999 3590 Gear

999 3681 Bracket
999 3682 Bracket
11 668 012 Lifting tool
11 668 020 Retainer plates

1. Place the engine and transmission on axle stands.

2. Remove the protective covers from the flywheel housing.

3. Remove the bolts between the torque converter and the flex plate. Use tool 9993590 to rotate the crankshaft.

Figure 1

4. Remove the retarder valve's hoses from the engine and plug them.

Figure 2
5. Loosen and fold down the hoses for the retarder valve. Fit lifting tools 9993682 (left), 9993681 (right) and
11668012.

Figure 3

6. Secure the transmission and remove the bolts between the transmission and the flywheel housing.

Figure 4

7. Lift away the transmission. Weight530 kg (1168 lbs).

8. Fit the retainer plates 11668020 (3 pcs.).

 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, removing 421 Service Information 2014/7/31
from engine out of
machine, version 2
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, removing from engine out of machine, version 2

Op nbr 42183

999 3590 Gear

999 3681 Bracket
999 3682 Bracket
11 668 012 Lifting tool
11 668 020 Retainer plates

1. Place the engine and transmission on axle stands.

2. Remove the retarder valve's hoses from the engine and plug them.

Figure 1

3. Disconnect the bottom pipes for the retarder valve and fold them down.
 Figure 2

4. Disconnect the ground cable and remove the starter motor.

Figure 3

5. Remove the protective covers from the timing gear casing.

Figure 4

6. Remove the bolted joint between the torque converter and the starter ring gear. Use a standard ratchet handle and
tool 9993590 to rotate the crankshaft. If needed, the ratchet handle can be combined a universal joint and
extension from a 1/2" wrench set.
 Figure 5

1. Rotating the crankshaft.

2. Removing bolted joint between starter ring gear and torque converter.

7. Secure the transmission by fitting lifting tools 9993682 (left), 9993681 (right) and 11668012.

Figure 6

8. Remove the bolts between the transmission and the flywheel housing.

Figure 7

9. Lift away the transmission. Weight530 kg (1168 lbs).

10. Fit the retainer plates 11668020 (3 pcs.).

NOTE!
It is important to secure the torque converter since it may otherwise easily slide out of position and be damaged.

Figure 8
 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, mounting on 421 Service Information 2014/7/31
engine out of machine,
version 1
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, mounting on engine out of machine, version 1

Op nbr 42184

999 3590 Gear

999 3681 Bracket
999 3682 Bracket
11 668 012 Lifting tool
11 668 020 Retainer plates

1. Remove the retainer plates 11 668 020 (3 pcs.).

2. Lift the transmission into position. Weight530 kg(1168 lbs).

3. Secure the transmission and fit the bolts between the transmission and the flywheel housing. Tightening torque: 90
Nm (66 lbf ft).

Figure 1

4. Remove the lifting tools.

Figure 2
5. Fit the hoses for the retarder valve.

Figure 3

6. Fit and tighten the bolts between the flex plate and torque converter. Use tool 999 3590 to rotate the crankshaft.
Tightening torque: 90 Nm (66 lbf ft).

Figure 4

7. Fit the protective covers on the flywheel housing.

 Service Information

Document Title: Function Group: Information Type: Date:

Transmission, mounting on 421 Service Information 2014/7/31
engine out of machine,
version 2
Profile:
ART, A25D [GB]

Go back to Index Page

Transmission, mounting on engine out of machine, version 2

Op nbr 42184

999 3590 Gear

999 3681 Bracket
999 3682 Bracket
11 668 012 Lifting tool
11 668 020 Retainer plates

1. Transfer the breather nipple and the quick-drain valve from the old transmission. Remove the filters with filter
brackets for the main oil filter and retarder oil filter. Plug the connections.

2. Grease the torque converter's centre pin. Remove the retainer plates 11668020 (3 pcs.). Fit the guide pin (M12 x
70mm).

Figure 1

1. Guide pin
2. Centre pin
3. Retainer plate 11668020

3. Lift the transmission into place by fitting the guide pin in the starter ring gear's mounting hole. Carefully push
together the transmission and engine. Weight:530 kg(1170 lbs).
 4. Secure the transmission and fit the bolts between the transmission and the flywheel housing. Tightening torque: 90
Nm (66 lbf ft).

Figure 2

5. Remove the guide pin and the lifting tools.

6. Fit the bolted joint between the torque converter and the starter ring gear. Use a standard ratchet handle and tool
9993590 to rotate the crankshaft. If needed, the ratchet handle can be combined a universal joint and extension
from a 1/2" wrench set.
Tightening torque:90 Nm (66 lbf ft)
NOTE!
In order to avoid twisting of the flex plate, fit all bolts before torquing.

Figure 3

1. Rotating the crankshaft.

2. Mounting bolted joint between starter ring gear and torque converter

7. Fit the protective covers on the flywheel housing.

8. Fit the starter motor and the ground cable.

9. Connect the bottom pipes for the retarder valve. Check the O–rings, change if needed.

10. Fit the upper hoses for the retarder valve. Check the O–rings, change if needed.
 Service Information

Document Title: Function Group: Information Type: Date:

Seal for rear output shaft, 421 Service Information 2014/7/31
replacing
Profile:
ART, A25D [GB]

Seal for rear output shaft, replacing

Op nbr 421-054

88830072 Installation drift

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

1. Place the machine in service position, see 191 Service positions.

2. Depressurize the compressed air system by pulling the pin on the valve for the compressed air tank on the back of
the cab.

Figure 1

3. Remove the floor mats.

4. Loosen the bolts that hold the operator seat.

Disconnect the cable harness of the operator's seat.
 Figure 2

5. Disconnect the air connections for the operator's seat.

Lift the operator's seat out of the cab.

Figure 3

6. Remove the centre floor mat.

7. Remove the middle and rear floor plates.

Figure 4

8. Secure the propeller shaft with straps so that it cannot slide apart.
 Figure 5

9. Remove the bolts of the front bolted joint of the propeller shaft.

10. Lower the propeller shaft, push it together, and swing it to the side.

11. Remove the 3 bolts holding the washer to the drive flange at the rear of the transmission. Lock the drive flange
with two bolts and a crowbar to prevent rotation.

Figure 6

12. Remove the drive flange.

Figure 7

13. Remove the seal ring using a suitable puller.

 Figure 8

14. Wipe clean the seal ring seat on the transmission with a clean rag.

15. Install the new seal ring on 88830072 Installation drift.

Figure 9

1. 88830072 Installation drift

2. Seal ring

16. Fit 88830072 Installation drift with seal ring on the transmission.

Figure 10

17. Fit the drive flange washer with three M12x110 Allen bolts.

18. Tighten the bolts so that 88830072 Installation drift and the seal ring are pressed in.
 Figure 11

19. Remove the bolts and the washer. If necessary use a mallet to tap on the tool to check that the seal ring is properly
pressed into its seat. Remove 88830072 Installation drift.

20. Install the drive flange.

21. Fit the washer and bolts. Use two bolts and a crowbar to lock the drive flange and prevent rotation.
Tightening torque, see 420 Hydraulic transmission, tightening torque.

Figure 12

22. Slide the propeller shaft into place.

Figure 13

23. Remove the straps that prevented the propeller shaft from sliding apart.
24. Tighten the bolted joint between the propeller shaft and the drive flange on the transmission.
Tightening torque, see: 450 Propeller shaft, tightening torque

25. Install the middle and rear floor plates.

Screw the two floor plates into place.

Figure 14

26. Route the air lines and cable harness to the operator's seat through the hole beneath the seat.
Install the floor mats.
NOTE!
Make sure that the cable harness is routed so that it ends up in the cable duct in the floor mat when it is installed.

Figure 15

27. Fit the operator's seat.

Disconnect the air and electrical connections.
Bolt down the seat.

Figure 16
28. Reset the machine from the service position, see 191 Service positions.
 Service Information

Document Title: Function Group: Information Type: Date:

Induction sensor for 421 Service Information 2014/7/31
turbine speed, changing
Profile:
ART, A25D [GB]

Induction sensor for turbine speed, changing

Turbine speed sensor SE4213

Op nbr 421-062

9993880 Electric repair kit

E-2502 Sleeve

Drawing of E2502, see 080 E-2502

This operation also includes required tools and times for applicable parts of the following operations: :

 191 Service positions

IMPORTANT!
If any object should be dropped down into the transmission, it must be dismantled and the object must be removed, before
the machine is started again.
Removing

1. Place the machine in service position, see 191 Service positions.

2. Remove all floor mats, except the front, from the cab.

3. Loosen the bolts that hold the floor mat that the seat is mounted on.

Figure 1

4. Lift and slide the floor mat and seat against the rear part of the cab.

5. Loosen and remove the middle floor plate.

6. Loosen the bolts for the Canon connector's housing on the transmission, and remove the housing.
 Figure 2

7. Loosen the cable for the turbine speed sensor.

Figure 3
V1058360

1. Turbine speed sensor, SE4213

2. Cable for turbine speed sensor
3. Housing for Canon connector

8. Get a piece of thin cable, 150 — 200 mm long.

Strip the cable and install a suitable cable terminal from the orange box in 9993880 Electric repair kit.
Fasten the cable on the turbine speed sensor, SE4213.
IMPORTANT!
If any object should be dropped down into the transmission, it must be dismantled and the object must be
removed, before the machine is started again.

9. Insert the cable in the tool E2502, and out through the hole in the socket.
Install the socket, tool E2502, on the turbine speed sensor, SE4213.
 Figure 4

10. Fasten a ratchet handle with short extension on tool E2502.

Loosen the turbine speed sensor, SE4213.

Installing

11. Fasten the piece of cable with the cable terminal, made earlier, on the new sensor.
Insert the cable in tool E2502, and pull it out through the hole.
Insert the sensor in tool E2502.

Figure 5

12. NOTICE
Exceeding the tightening torque can cause damage on the component.

Install the sensor and tighten.

Tightening torque: 20 ±3 Nm (14.75 ±2.21 lbf ft)

Figure 6

1. Turbine speed sensor, SE4213

2. Cable for turbine speed sensor
 3. Housing for Canon connector

13. Remove tool E2502 and the piece of cable.

14. Install the cable on the turbine speed sensor, SE4213.

Check with a mirror or similar that the cable terminals are installed securely on the sensor.

15. Install the housing for the Canon connector, install and tighten the bolts that hold the housing.
Tightening torque: 20 ±3 Nm (14.75 ±2.21 lbf ft)

Figure 7

16. Install the floor plate with the seat.

17. Install the middle floor plate.

18. Install the floor mats.

19. Restore the machine from service position.

 Service Information

Document Title: Function Group: Information Type: Date:

Checking of main, torque 421 Service Information 2014/7/31
converter and lubricating
oil pressure
Profile:
ART, A25D [GB]

Checking of main, torque converter and lubricating oil pressure

Op nbr 421-001

11666019 Pressure gauge

11666019 Pressure gauge
11666019 Pressure gauge
11666037 Hose
11666037 Hose
11666037 Hose
936441 Testing nipple
936441 Testing nipple
936441 Testing nipple

NOTE!
This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

NOTE!
For pressure measurement, the gearbox oil should have an operating temperature of 70 °C.

WARNING
Risk of burns! Use protective work gloves.

1. Place the machine in service position, see 191 Service positions.

2. Lower the rear underbody skid plates.

Figure 1
Underbody skid plates

1. Front underbody skid plate

2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
 4. Front cross member
5. Rear cross member

3. Clean around measurement points P1, PC1 and PS on the gearbox.

Figure 2
Transmission, viewed from underneath

P1 Main pressure
PC1 Torque converter pressure

Figure 3
Transmission, right side

PS Lubrication oil pressure

4. Connect 936441 Testing nipple, 11666037 Hose and 11666019 Pressure gauge to the respective measurement
points.

5. Start the engine, apply the parking brake and foot brake.

NOTICE
Make sure that the wheels lock and that the machine cannot move.

WARNING
Risk of personal injury! Make sure that no persons are in front of or behind the machine.

6. Rev the engine to 1200 rpm and note the oil pressure at gear positions N, D and R.

7. Compare the oil pressures to reference values, see 420 Oil Pressure.

8. Remove the checking equipment and reconnect the protective plates.

9. Restore the machine from service position.
 Service Information

Document Title: Function Group: Information Type: Date:

Transfer gearbox, 430 Service Information 2014/7/31
description
Profile:
ART, A25D [GB]

Transfer gearbox, description

The IL-1/ IL-2 is a dual-shaft conical dropbox with a differential between the front and rear output shafts. The IL-2 has a
take-off for driving a ground-dependent hydraulic pump.
The differential divides the torque equally between front and rear. The differential lock is a dog clutch with 100% locking. It
is activated by spring force and deactivated by compressed air. The design of the differential dogs is such that they strive to
become fully meshed on activation and allow engagement and disengagement while the vehicle is in motion. The position
of the differential lock is monitored by electric position sensor.
The IL-1/IL-2 is fitted with a lubricating oil pump which provides the necessary flow also when the vehicle is moving in
reverse.
 Service Information

Document Title: Function Group: Information Type: Date:

Component position 430 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Component position

Figure 1

1. Bolted joint, oil pump

2. Oil pipes
3. Bolted joint, differential housing
4. Bolted joint, housing halves
5. Rubber pad — position for IL-1
6. Rubber pad — position for IL-2
7. Speed sensor (output speed to axle on tractor) SE4309 — only machines equipped with ATC
8. Position monitor SE4607 (longitudinal differential lock, engaged or disengaged)

Cut-away A — A
Figure 2
Cut-away A — A

1 Front housing half 12 Shims

2 Rear housing half 13 Cover for differential housing
3 Drive flange 14 Differential housing
4 Seal cap/bearing cap 15 Bearing
5 Output shaft, rear 16 Seal ring
6 Shims 17 Oil pipes
7 Upper oil plate 18 Overflow valve
8 Lower oil plate 19 O–ring
9 Lower main gear 20 Seal rings
10 Drive flange 21 Drive flange
11 Seal cap/bearing cap 22 Upper main gear

Cut-away B — B

Figure 3
Cut-away B — B

1 Shims 4 Plastic plug

2 Sealing cap 5 Bearing
3 Drive flange 6 Bearing

Cut-away C — C
Figure 4
Cut-away C — C

1 Drive sleeve 5 Oil pump

2 Ball 6 Washer
3 Oil pump gear 7 Plug
4 Lock ring pinion shaft 8 Bolt for pump rotor holder

Cut-away D–D
Figure 5
Cut-away D–D

1 Cover for control of differential lock 7 Shift fork

2 Shaft for longitudinal differential lock 8 Lock ring
3 Spring 9 Lock nut
4 Piston 10 Differential pressure sensor SE4607
5 Cylinder 11 Lock nut
6 Upper main gear 12 Bolt for lower oil plate

Figure 6
Cut-away F–F Overflow valve, ground-dependent oil pump
 1. Valve
2. Ring
3. Retainer ring
4. Plug

Figure 7
Cut-away E–E Non-return valve, ground-dependent oil pump

1. Ball
2. O–ring
3. Ball socket
4. Retainer ring
5. Washer
6. Plug

Figure 8
View cut-away H–H

1. Washer
2. Rubber bushing
3. Lock ring
 Service Information

Document Title: Function Group: Information Type: Date:

Dropbox, removing 434 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Dropbox, removing
Op nbr 43474-1

11668017 lifting tool with lifting yoke

Ratchet block 500 kg
Lifting sling 500 kg

WARNING
Risk of personal injury! Weight 360 kg. Always make sure that the dropbox is adequately secured.

1. Park the machine in the service position.

2. Cut the electric power with the battery disconnect switch.

WARNING
Risk of burns! Use protective work gloves.

3. Drain the oil from the dropbox

Figure 1

4. Disconnect air and electrical connections from the operator's seat.

5. Detach the driver's seat and lift it out. Weight: 40 kg

6. Remove the floor mats.

7. Remove the cover over the dropbox.

WARNING
Risk of crushing injuries

8. Fit a strap round the front axle propeller shaft so that it cannot come apart. Remove the front and rear bolted
joints. Remove the propeller shaft.
Weight: 30 kg
 Figure 2

WARNING
Risk of crushing injuries

9. Fit a strap round the input propeller shaft in the dropbox so that it cannot come apart. Undo and remove the
bolted joint between the propeller shaft and dropbox. Compress the propeller shaft and bend it down.

Figure 3

10. Remove the breather and oil filler hoses. Unplug the position sensor (SE4607) connector and detach the air
connection for the longitudinal differential lock.

Figure 4

1. Differential lock air connection

2. Bleeding
3. Oil filling
4. Differential lock position sensor (SE4607)
11. Remove the ground-dependent pump and O-ring. Hang up the pump and tension it forwards.

Figure 5

12. Remove the upper attachment for the dropbox.

Figure 6

13. Fit the lifting yoke in the dropbox's upper attachment, using the existing bolts.
NOTE!
The lifting yoke should be positioned at the rear of the attachment.

Figure 7

14. Remove the rear handle and fire extinguisher, if any, in the cab.
 Figure 8

15. Fit lifting tool 11668017 in the cab. Secure the tool in the cab door frame and to the flat iron bar for the instructor's
seat. Secure the dropbox in the lifting tool by means of a ratchet block.
NOTE!
Depending on the length of the chain in the ratchet block, an extension may be required. Fit a lifting sling (500 kg)
between the lifting yoke and the hook of the ratchet block.

Figure 9

16. Undo and remove the bolted joint between the propeller shaft and follower for the rear output shaft on the
dropbox. Compress the propeller shaft and bend it down.

Figure 10
 WARNING
Risk of crushing injuries

17. Undo and remove the bolts and the two lower attachments on the dropbox.

Figure 11

18. Lower the dropbox and turn it through 180°.

Weight: 360 kg

Figure 12

19. Lower the dropbox onto a pallet truck and pull it away from the machine.

Figure 13
 Service Information

Document Title: Function Group: Information Type: Date:

Dropbox, mounting 434 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Dropbox, mounting
Op nbr 43473-1

11668017 lifting tool with lifting yoke

Ratchet block 500 kg
Lifting sling 500 kg
Torque wrench 0-250 Nm

1. Transfer from the old dropbox the air nipple for the longitudinal differential lock and the pipes for venting and oil
filling.

Figure 1

1. Differential lock air nipple

2. Bleeding
3. Oil filling
4. Differential lock position sensor (SE4607)

2. Fit the lifting yoke in the dropbox's upper attachment, using the existing bolts.
NOTE!
The lifting yoke should be positioned at the rear of the attachment.
 Figure 2

3. Place the dropbox on a pallet truck and move it in under the machine.

Figure 3

4. Raise the dropbox by means of the ratchet block. Turn the dropbox through 180°.

Figure 4

5. Fit the two lower attachments to the frame.

Figure 5
6. Raise the dropbox and fit it into the lower attachments. Fit the bolts and tighten them (3 bolts in each attachment).
Tightening torque 230 Nm

Figure 6

7. Remove lifting tool 11668017 and fit the upper attachment in the dropbox.
Tightening torque 230 Nm

Figure 7

8. Fit the O-ring and the ground-dependent pump. Locking fluid (Loctite) should be applied to the bolts.
Tightening torque 85 Nm (62.7 lbf ft)
NOTE!
Inspect the O-ring and change it as necessary.

Figure 8

9. Fit the breather and oil filler hoses. Fit the air connection and plug the connector into the position sensor (SE4607)
for the longitudinal differential lock.
 Figure 9

1. Differential lock air connection

2. Bleeding
3. Oil filling
4. Differential lock position sensor (SE4607)

10. Attach the input propeller shaft to the dropbox. Fit the bolted joint and tighten it.
Tightening torque 180 Nm

Figure 10

11. Attach the rear output propeller shaft to the dropbox. Fit the bolted joint and tighten it.
Tightening torque 180 Nm

Figure 11
12. Fit the front output propeller shaft. Fit the front and rear bolted joints and tighten them.
Tightening torque 180 Nm
NOTE!
To make fitting easier, one of the wheels on the front axle may be raised.

Figure 12

13. Fit the rear handle and fire extinguisher, if any, in the cab.

Figure 13

14. Fit the cover in the floor over the dropbox.

15. Fit the floor mats.

16. Lift the driver's seat into the cab and fit it in place. Weight: 40 kg

17. Connect the air and electrical connections for the operator's seat.

18. Fill the dropbox with oil. Max. volume: 10.4 litres

19. Start the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Differential lock 434 Service Information 2014/7/31
longitudinal, adjustment of
sender unit
Profile:
ART, A25D [GB]

Differential lock longitudinal, adjustment of sender unit

Op nbr 434-064

9998534 Adapter cable

Multimeter

1. Park the machine in the service position.

2. Check that the differential lock is in mesh (activated).

3. Unplug the connector from sensor SE4607.

4. Attach adapter cable 9998534 to sensor SE4607 and connect the multimeter to the cables marked 1 and 2.

5. Screw the sensor in until the circuit is closed.

6. Screw the sensor in one additional turn.

7. Secure the sensor with the lock nut.

8. Plug the connector into sensor SE4607.

9. Restore the machine from service position.

10. Test-run the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Checking and adjusting the 434 Service Information 2014/7/31
longitudinal differential
lock
Profile:
ART, A25D [GB]

Checking and adjusting the longitudinal differential lock

Basic setting of the longitudinal differential lock and its adjustment is carried out on a separate component and no further
adjustment is normally required.
 Service Information

Document Title: Function Group: Information Type: Date:

Propeller shaft 450 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Propeller shaft
All propeller shafts are lifetime lubed in the glide joint. The propeller shafts between dropbox–front axle, countershaft–front
bogie axle, and front bogie axle–rear bogie axle have lifetime lubed universal joints.

Figure 1

1. Propeller shaft, transmission–dropbox

2. Propeller shaft, dropbox–front axle
3. Propeller shaft, steering joint
4. Countershaft, hitch
5. Propeller shaft, countershaft–front bogie axle
6. Propeller shaft, front bogie axle–rear bogie axle
 Service Information

Document Title: Function Group: Information Type: Date:

Intermediate shaft, cut- 450 Service Information 2014/7/31
away view
Profile:
ART, A25D [GB]

Go back to Index Page

Intermediate shaft, cut-away view

Position Designation
1 Drive flange
2 Front seal ring, front
3 O–ring
4 Rear seal ring, front
5 Intermediate shaft
6 Front seal ring, rear
7 O–ring
8 Rear seal ring, rear
9 Brake disc
10 Bearing cap
11 Rear bearing, rear
12 Intermediate ring
13 Front bearing, rear
14 Rear spacer ring
15 Front spacer ring
16 Front bearing
17 Bearing retainer
Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Intermediate shaft, cut- 450 Service Information 2014/7/31
away view
Profile:
ART, A25D [GB]

Go back to Index Page

Intermediate shaft, cut-away view

Position Designation
1 Flange
2 Seal ring, front
3 O–ring
4 O-ring
5 Intermediate shaft
6 Front seal ring, rear
7 O–ring
8 Rear seal ring, rear
9 Brake disc
10 Bearing cap (inner), rear
11 Roller bearing (rear)
12 Bearing cap (outer), rear
13 O-ring
14 Tapered roller bearing, rear
15 Tapered roller bearing, front
16 Ball bearing, front
17 O-ring
18 Filler ring (cellular plastic sheet)
19 Bearing cap, front
Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Intermediate shaft and/or 451 Service Information 2014/7/31
bearing, changing
Profile:
ART, A25D [GB]

Go back to Index Page

Intermediate shaft and/or bearing, changing

Op nbr 45106

6999085 Drift plate

9993714 Puller bolt
9993722 Support
11666013 Pump
11666054 Jack
11667001 Handle
11667080 Drift plate
11667100 Drift plate
11667110 Drift plate
11668013 Dump body support

Bolt M14x70 mm (2.8 in) 4 pcs.

Pipe, inside diameter: 72 mm (2.8 in), outside diameter: 80 mm (3.2 in), length: 110 mm (4.3 in)

Intermediate shaft, Removing

1. Park the machine on level ground, so that the drive flanges end up according to the figure.

Figure 1

2. Angle the machine with full steering angle to the left.

3. Run up the load body and secure it with load body support 11668013 or the load body lock.
 Figure 2

4. Block the wheels on the tractor and trailer.

Figure 3

5. Install a tensioning strap on the propeller shaft in the steering joint, so that the propeller shaft does not come
apart.

Figure 4

6. Loosen and remove the upper bolts in the front and rear bolted joints.
 Figure 5

7. Secure the propeller shaft with a lift sling and overhead crane or similar equipment.

WARNING
Risk of crushing injuries

8. Remove the lower bolts in the front and rear bolted joints.

Figure 6

9. Remove the propeller shaft.

Weight: approx. 35 kg (77 lb)

Figure 7
10. Loosen the front drive flange bolt.

Figure 8

11. Loosen and move aside any equipment for body heating.

12. Remove the protective plate over the parking brake.

Figure 9

13. Remove the caging bolt on the spring brake cylinder.

Figure 10
 1. Transport brace

14. Install the caging bolt.

Release the tension in the spring brake by screwing the nut clockwise.

Figure 11

15. Disconnect the air line from the parking brake.

16. Secure the parking brake unit.

Use lifting slings and ratchet block and insert the slings through the attaching eyes at the head board of the dump
body.
Parking brake assembly, weight: approx. 60 kg (132 lbs)

Figure 12

17. Loosen and remove the bolts (4 pcs) for the parking brake.

Figure 13

18. Lift up the parking brake assembly and lay it on the load unit's leading edge.
Secure the parking brake assembly with a tensioning strap.
 Figure 14

19. Detach the propeller shaft from the brake disc.

Move the propeller shaft over to the right.

Figure 15

20. Install two bolts on the drive flange in the steering joint.
Install a pipe or similar as counterhold.
Loosen the bolt for the brake disc.
Screw out the bolt approx. 4 turns.
 Figure 16

21. Install a suitable puller with 2 M14x70 mm (2.8 in) in the brake disc.
Loosen the brake disc.

Figure 17

22. Remove the puller and the bolt for the brake disc.
Remove the brake disc
Weight: approx. 30 kg (66 lb)

Figure 18

23. Remove the drive flange in the steering joint

Use a suitable puller and suitable spacer between puller and shaft.

Figure 19

24. Remove the bolts (8 pcs.) and bearing cap.

 Figure 20

25. Pull to loosen the intermediate shaft.

Use support 9993722 and puller bolt 9993714.

Figure 21

26. Remove the support and the puller bolt.

Remove the intermediate shaft, the O–ring and the bearing race.

Figure 22

27. Remove the intermediate ring, the bearing race and the seal ring.
Use a suitable puller and suitable counterhold for the puller.
 Figure 23

28. Remove the bolts (8 pcs.) for the bearing retainer in the front bearing position.

Figure 24

29. Clean the threads in the bearing retainer's puller holes.

Use thread tap M10.

Figure 25

30. Install 4 bolts M10x70 mm (2.8 in) in the puller holes.

Pull the bearing retainer until loose.
 Figure 26

31. Remove the bearing retainer, spacer ring and the O–ring.

Figure 27

Rear bearing cap, reconditioning

32. Remove the seal ring.

Use handle 11667001 and drift plate 11667100.

Figure 28

33. Check the removed parts for damage and wear.

Change as needed.
 34. Grease the seal ring.
Only use special grease according to specification, see 740 Hitch, specifications.

Figure 29

35. Install the seal ring.

Tap the seal ring down against the shoulder in the cover.
Use handle 11667001 and drift plate, 11667110.

Figure 30

Bearing retainer, replacing bearings and seal rings

Dismantling

36. Place the intermediate shaft in a press and remove the two rear bearings and the rear spacer ring.
Use a suitable puller.

Figure 31
37. Remove the outer seal ring from the bearing retainer.

Figure 32

38. Remove the lock ring.

Figure 33

39. Place the bearing retainer in a press and remove the bearing.
Use handle 11667001 and drift plate 11667080.
NOTE!
The bearing may be damaged when removing and shall not be reused.
 Figure 34

40. Remove the inner seal ring.

Figure 35

41. Check dismantled parts for damage and wear.

Replace parts as necessary.
Maintain greatest possible cleanliness when handling bearings and seal rings.

Assembling

42. Place the intermediate shaft standing up, with the front end facing up.
The front end is the one with shorter splines

43. Grease the inner seal ring.

Only use special grease according to specification, see 740 Hitch, specifications.

Figure 36

44. Install the inner seal ring.

 See pos. 6 450 Intermediate shaft, cut-away view
Tap the seal ring down against the shoulder in the bearing retainer.
Use handle 11667001 and drift plate, 11667110.

Figure 37

45. Install the front spacer ring on the intermediate shaft.

Figure 38

46. Fit the bearing retainer on the intermediate shaft.

Figure 39
47. Fit the bearing.
Use support 9993722 and puller bolt 9993714.

Figure 40

48. Grease the bearing.

Rotate the bearing while greasing it.
Only use special grease according to specification, see 740 Hitch, specifications.

Figure 41

49. Install the lock ring.

 Figure 42

50. Fill the front seal ring half full with grease.
Only use special grease according to specification, see 740 Hitch, specifications.

Figure 43

51. Install the front seal ring.

Tap down the seal ring flush with the bearing retainer.
Use a suitable drift.

Figure 44

Maintain greatest possible cleanliness when handling bearings and seal rings.
Intermediate shaft, installing

52. Grease the front seal ring rear.

Only use special grease according to specification, see 740 Hitch, specifications.

Figure 45

53. Install the front seal ring rear.

Tap in the seal ring against the shoulder.
Use handle 11667001 and drift plate 11667100.
NOTE!
The seal lip must shall forward, see 450 Intermediate shaft, cut-away view.

Figure 46

WARNING
Risk of frostbite! Use protective gloves.

Cool the bearing race to max. -20 °C (-4 °F).

54. Install the outer bearing race for the front bearing rear. Tap in the bearing race against the shoulder.
Use handle 11667001 and drift plate, 11667110.
 Figure 47

55. Install the intermediate shaft.

NOTE!
Make sure that the front seal ring rear in the hitch is not damaged.

Figure 48

56. Install the bolts for the bearing retainer loosely, this is so that the intermediate shaft and bearing retainer can move
when installing the rear bearing.

57. Fit the rear spacer ring on the intermediate shaft.

Figure 49

58. Grease the front bearing rear.

Only use special grease according to specification, see 740 Hitch, specifications.
 Figure 50

59. Make a sleeve with inside diam.: 72 mm (2.8 in), outside diam.: 80 mm (3.2 in) and length: 110 mm (4.3 in) from
a suitable pipe.

60. Install the front bearing rear.

Press in the bearing against the bearing race.
Use the sleeve, puller bolt 9993714, jack 11666054, pump 11666013 and drift plate 6999085.

Figure 51

1. Puller bolt 9993714

2. Jack 11666054
3. Drift plate 6999085
4. Sleeve inside diam. 72 mm (2.8 in), outside diam. 80 mm (3.2 in), length 110 mm (4.3 in)

61. Grease the bearing some more.

Rotate the bearing while greasing it.
Only use special grease according to specifications, see 740 Hitch, specifications.
NOTE!
It is important that the bearing is not overfilled.
 Figure 52

62. Grease the rear bearing rear.

Only use special grease according to specification, see 740 Hitch, specifications.
NOTE!
It is important that the bearing is not overfilled.

Figure 53

63. Install the rear bearing rear.

Press in the bearing against the inner bearing.
Use the sleeve, puller bolt 9993714, jack 11666054, pump 11666013 and drift plate 6999085.

Figure 54

1. Puller bolt 9993714

2. Jack 11666054
3. Drift plate 6999085
 4. Sleeve inside diam. 72 mm (2.8 in), outside diam. 80 mm (3.2 in), length 110 mm (4.3 in)

64. Remove the puller bolt, jack, drift plate and pipe as well as the support and puller bolt.

65. Fit the intermediate ring.

Figure 55

WARNING
Risk of frostbite! Wear protective work gloves.

Cool down the outer rear bearing race to max. -20 °C (-4 °F).

66. Fit the outer rear bearing race.

Tap in the bearing race until it stops against the bearing.
Use a brass drift.

Figure 56

67. Check that the intermediate shaft turns easily.

68. Install the bearing cover and tighten the bolted joint crosswise.
The intermediate shaft must be rotated during the entire tightening of the bearing cover.
Tightening torque: 50 Nm (37 lbf ft)
 Figure 57

69. Seal the gap between the bearing cap and the back-up ring on the hitch.
Use silicone, part no. 11705751.
This replaces the O–ring between the bearing cap and the back-up ring on the hitch.

Figure 58

70. Tighten the bolts for the front bearing retainer.

Tightening torque: 50 Nm (36.9 lbf ft).

Figure 59

71. Install the O–ring on the bearing retainer.

72. Install the drive flange in the steering joint.

Install two bolts in the drive flange.
Lock the shaft with a piece of pipe or similar.

73. Install the brake disc.

 Apply locking fluid (Loctite 243, part no. 1161053) on the bolt.
Install the bolt and the support washer.
Tightening torque: 550 Nm (406 lbf ft)

Figure 60

74. Install two bolts in the brake disc.

Lock the shaft with a piece of pipe or similar.

75. Install the front drive flange on the intermediate shaft.

Apply locking fluid (Loctite 243, part no. 1161053) on the bolt.
Install the bolt and the support washer.
Tightening torque: 550 Nm (406 lbf ft)

Figure 61

76. Install the propeller shaft in the steering joint.

Tighten the front and rear bolted joints.
Tightening torque: 140 Nm (103 lbf ft)
 Figure 62

77. Install the propeller shaft on the front bogie axle.

Tighten the bolted joint.
Tightening torque: 180 Nm (133 lbf ft)

Figure 63

78. Install the parking brake unit.

Do not tighten the bolts.

Figure 64

79. Apply the spring brake by turning the nut counter-clockwise.

 Figure 65

80. Remove the caging bolt and re-install it on the spring brake cylinder.

Figure 66

1. Transport brace

81. Tighten the bolts for the parking brake unit.

Tightening torque: 430 Nm (317 lbf ft)

82. Connect the air line to the parking brake.

83. Apply and release the parking brake 10–15 times so that the automatic adjustment function adjusts the brake pads
against the brake disc.

84. Install the protective plate over the parking brake.

 Figure 67

85. Install any equipment for body heating.

86. Remove the load body support and lower the body against the frame.
Remove the blocks by the wheels.

87. Start the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Intermediate shaft and/or 451 Service Information 2014/7/31
bearing, replacing (in
frame joint)
Profile:
ART, A25D [GB]

Go back to Index Page

Intermediate shaft and/or bearing, replacing (in frame joint)

Op nbr 451-006

88830046 Dump body support

9993722 Support
9993714 Puller bolt
9996400 Impact puller
9990192 Puller
11667001 Handle
11667110 Drift plate

For designations, see 450 Intermediate shaft, cut-away view.

Intermediate shaft, Removing

1. Park the machine on level ground, so that the drive flanges end up according to the figure.

Figure 1

2. Angle the machine with full steering angle to the left.

3. Elevate the load body and secure it with 88830046 Dump body support or with the load body lock.
 Figure 2

4. Block the wheels of the tractor and trailer unit.

Figure 3

5. Install a tensioning strap on the propeller shaft in the steering joint, so that the propeller shaft does not part.

Figure 4

6. Loosen and remove the upper bolts in the front and rear bolted joints.
 Figure 5

7. Secure the propeller shaft with a lifting sling to an overhead hoist or similar equipment.

WARNING
Risk of crushing injuries

8. Remove the lower bolts in the front and rear bolted joints.

Figure 6

9. Remove the propeller shaft.

Weight: approx.35 kg (77 lbs)

Figure 7
10. Loosen the front drive flange bolt.

Figure 8

11. Loosen and move aside any eventual equipment for body heating.

12. Remove the protective plate over the parking brake.

Figure 9

13. Remove the caging bolt on the spring brake cylinder.

Figure 10
 1. Caging bolt

14. Install the caging bolt.

Release the tension in the spring brake by screwing the nut clockwise.

Figure 11

15. Remove the air connection for the parking brake.

16. Secure the parking brake unit.

Use lifting slings and ratchet block and insert the slings through the attaching eyes at the head board of the dump
body.
Weight: approx. 60 kg (132 lbs)

Figure 12

17. Loosen and remove the bolts (4 pcs) for the parking brake.

Figure 13

18. Lift up the parking brake assembly and lay it on the load unit's leading edge.
Secure the parking brake assembly with a tensioning strap.
 Figure 14

19. Detach the propeller shaft from the brake disc.

Move the propeller shaft over to the right.

Figure 15

20. Install two bolts on the drive flange in the steering joint.
Install a pipe or similar as counterhold.
Loosen the bolt for the brake disc.
Screw out the bolt approx. 4 turns.
 Figure 16

21. Install a suitable puller with 2 M14x70 mm (2.8 in) in the brake disc.
Loosen the brake disc.

Figure 17

22. Remove the puller and the bolt for the brake disc.
Remove the brake disc
Weight: approx. 30 kg (66 lbs)

Figure 18

23. Remove the drive flange in the steering joint.

Use a suitable puller and suitable spacer between puller and shaft.

Figure 19

24. Remove the bolts (4 pcs.) and the bearing cap rear on the hitch. Remove the O-ring that seals between the bearing
 caps and intermediate shaft.

Figure 20

25. Pull loose the intermediate shaft backward from the trailer.
Use 9993722 Support and 9993714 Puller bolt.

Figure 21

26. Remove the support and the puller bolt.

Remove the intermediate shaft and the bearing race.
 Figure 22

27. Remove the bearing race and the bearing rollers.

Use a suitable puller and suitable counterhold for the puller.

Figure 23

28. Remove the seal ring with 9996400 Impact puller and 9990192 Puller.

Figure 24

29. Remove the bolts (8 pcs.) for the bearing retainer in the front bearing position.

Figure 25

30. Remove the bearing cap and the O–ring.

 Figure 26

31. Remove the bearing and sheet metal seal ring.

Figure 27

Rear bearing cap, reconditioning

Bearing retainer, changing bearings and seal rings
Dismantling

32. Place the intermediate shaft in a press and remove the rear bearing race.
Use a suitable puller.
 Figure 28

33. Remove the seal ring from the front bearing cap.

Figure 29

34. Remove the seal ring from the rear bearing cap.

Figure 30
 Maintain greatest possible cleanliness when handling bearings and seal rings.

Assembling

35. Grease the seal ring for the front bearing cap.
Quantity and type of grease: see 740 Hitch, specifications

36. Install the seal ring in the front bearing cap.

Tap the seal ring down against the shoulder in the bearing retainer.
Use 11667001 Handle and 11667110 Drift plate.

Figure 31

37. Grease the seal ring for the rear bearing cap.
Quantity and type of grease: see 740 Hitch, specifications

38. Tap in the seal ring in the rear bearing cap. Use 11667001 Handle and 11667110 Drift plate.

Figure 32

Maintain greatest possible cleanliness when handling bearings and seal rings.

Intermediate shaft, mounting

39. Fill the ball bearing, the front bearing on the intermediate shaft, with grease.
Quantity and type of grease: see 740 Hitch, specifications.

Figure 33

40. Install the sheet metal seal ring and the bearing.
Carefully tap in the bearing with a brass drift and hammer.

Figure 34

41. Install a new O-ring in the front bearing cap and install the bearing cap.
Tighten the bolts crosswise.

Figure 35

42. Place the intermediate shaft standing up, with the rear end facing up.
 WARNING
Risk of burns! Use protective work gloves.

43. Heat the bearing to 100 °C (212 °F).

44. Install the bearing race on the shaft. When the bearing race has cooled slightly, check that it has ended up in the
correct position by hitting a few times with a brass drift and hammer.

Figure 36

WARNING
Risk of frostbite! Use protective gloves.

45. Cool the bearing to a temperature not lower than –20 °C (–4 °F).

46. Install the rear bearing.

Figure 37

47. Drive in the bearing with 11667001 Handle and 11667110 Drift plate.
 Figure 38

48. Push in the intermediate shaft from the rear.

Figure 39

49. Rig 9993722 Support and 9993714 Puller bolt at the front in the hitch.
Secure the puller bolt in the intermediate shaft.
Loch the puller bolt with a wrench so that it and the intermediate shaft cannot rotate.
Screw in the nut on the puller bolt so that the shaft is pulled into place.

Figure 40
50. Apply a bead of silicone (VCE no. 11705751) around the inside on the outer bearing cap rear, as shown in the
figure.
This replaces the O-ring.

Figure 41

1. Silicone bead
2. Bearing cap, outer
3. Intermediate shaft
4. Hitch

51. Install the inner bearing cap rear, and tighten the bolts crosswise.

Figure 42

52. Install the drive flange in the steering joint.

Install two bolts in the drive flange.
Lock the shaft with a piece of pipe or similar.

53. Install the brake disc.

Apply locking fluid (Loctite 243, or similar) to the screw.
Install the bolt and the support washer.
Tightening torque, see: 740 Frame joint, tightening torque
 Figure 43

54. Install two bolts in the brake disc.

Lock the shaft with a piece of pipe or similar.

55. Install the drive flange on the intermediate shaft.

Apply locking fluid (Loctite 243, or similar) to the screw.
Install the bolt and the support washer.
Tightening torque, see: 740 Frame joint, tightening torque

Figure 44

56. Install the propeller shaft in the steering joint.

Tighten the front and rear bolted joints.
Tightening torque, see: 450 Propeller shaft, tightening torque
 Figure 45

57. Install the propeller shaft on the front bogie axle.

Tighten the bolted joint.
Tightening torque, see: 450 Propeller shaft, tightening torque

Figure 46

58. Install the parking brake unit.

Do not tighten the bolts.

Figure 47

59. Apply the spring brake by turning the nut counter-clockwise.

 Figure 48

60. Remove the caging bolt and refit it on the spring brake cylinder.

Figure 49

1. Caging bolt

61. Tighten the bolts for the parking brake unit.

Tightening torque, see: 550 Tightening torque

62. Install the air connection to the parking brake.

63. Apply and release the parking brake 10–15 times so that the automatic adjustment function adjusts the brake pads
against the brake disc.

64. Fit the protective plate over the parking brake.

 Figure 50

65. Fit any eventual equipment for body heating.

66. Remove the load body support and lower the body against the frame.
Remove the blocks by the wheels.

67. Start the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Drive axles, description 460 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Drive axles, description

The drive shafts have fully-floating half shafts and hub reductions of planetary gear type.
The differential carrier assembly has a differential that can be locked by means of a differential lock with dog clutch operated
by compressed air. The front drive axle on the load unit also has a dropbox fitted with a dog clutch for engagement and
disengagement of the drive to the following axle.
NOTE!
Method description for changing wheel spindle and hub seal, see 464 Spindle, replacing one side.
 Service Information

Document Title: Function Group: Information Type: Date:

Final drive, front axle and 460 Service Information 2014/7/31
2nd bogie axle, cut-away
view
Profile:
ART, A25D [GB]

Final drive, front axle and 2nd bogie axle, cut-away view

Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Final drive, 1st bogie axle, 460 Service Information 2014/7/31
cut-away view
Profile:
ART, A25D [GB]

Final drive, 1st bogie axle, cut-away view

Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Oil and seals AH56E-AH56G 460 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Oil and seals AH56E-AH56G

Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Hub end AH56E–AH56G, 460 Service Information 2014/7/31
AH64D–AH64F, cut-away
view
Profile:
ART, A25D [GB]

Hub end AH56E–AH56G, AH64D–AH64F, cut-away view

Position Designation
1 Bolt
2 Brake caliper attachment
3 Bolt
4 Washer
5 Brake caliper
6 Bearing
7 Seal ring
8 Spacer ring
9 O-ring
10 Drive shaft
11 Thrust washer
12 Spindle
13 Wheel stud
14 Wheel hub
15 Bolt
16 Washer
17 Bearing
18 Brake disc
19 Bolt
20 Guide pin (inner)
21 Guide pin (outer)
22 Plug
23 Seal
24 Planetary carrier
25 Planetary gear
26 Lock ring
27 Sun gear
28 Lock ring
29 Lock washer
30 Hub nut
31 Ring gear
32 Ring gear retainer
33 Lock ring
Figure 1
 Service Information

Document Title: Function Group: Information Type: Date:

Final drive, removing and 461 Service Information 2014/7/31
mounting
Profile:
ART, A25D [GB]

Final drive, removing and mounting

Op nbr 46111

9993590 Gear
9993847 Gear segment
9993881 Wrench
9999954 Lift trolley

Guide pin M12x250 mm (9.8 in) 2 pcs.

Thread protector M10x40 mm (1.57 in) 2 pcs.

Puller bolt M16x70 mm (2.8 in) 2 pcs.

Guide pin M16x180 mm (7.1 in) 4 pcs.

Ratchet block 500 kg (1102 lb)

Lift sling 100 kg (220 lb) 3 pcs.

Torque wrench 30-310 Nm (22-229 lbf ft)

1. Park the machine in the service position. See section Safety 191 Service positions.

Removing

2. Drain the oil from the axle housing.

NOTE!
Take care of the oil in an environmentally sound manner. See section Safety 191 Environment.

Figure 1

WARNING
Risk of crushing injuries

3. Fit a tensioning strap on the propeller shaft for the front axle so that it can't part. Remove the front and rear
 propeller shaft bolts. Remove the prop shaft. Weight: approx. 30 kg (66 lb)

Figure 2

4. Loosen and remove the bolts for the planetary carrier. Fit 2 guide pins M12x250 mm (9.8 in).

Figure 3

5. Clean the threads in the puller holes with thread tap M16.
 Figure 4

6. Make 2 (two) 40 mm (1.57 in) long thread protectors from M10 bolts. Insert the thread protectors through the
puller holes in the planetary carrier and fit 2 (two) puller bolts M16x70 mm (2.8 in).
NOTE!
The thread protectors should bottom out in the wheel hub's threaded holes and act as counterholds for the puller
bolts.

Figure 5

1. Puller bolt M16x70 mm (2.8 in)

2. Thread protector M10x40 mm (1.57 in)
3. Guide pin M12x250 mm (9.8 in)

7. Position an oil drain plate under the hub reduction. Tighten the puller bolts so much that the planetary carrier
releases from the wheel hub.
NOTE!
Take care of the oil in an environmentally sound manner. See section Safety 191 Environment.

Figure 6

8. Secure the planetary carrier with a lift sling in an overhead crane or similar. Remove the planetary carrier. Weight:
approx. 45 kg (99 lb)
 Figure 7

9. Pull out the drive shaft approx. 400 mm (16 in) from the final drive. For easier removal of the drive shaft on the right
side, activate the transverse differential lock.

Figure 8

10. Repeat steps 3-9 on the other side.

11. Remove the cover for the differential lock and pull out the piston to facilitate removal of the final drive.
 Figure 9

12. Lay a square pipe or similar between the battery compartment and the rear handrail. Secure the pipe in the rear
handrail with a tensioning strap or similar. Fit a ratchet block in the pipe.

Figure 10

13. Loosen and remove the bolts for the ground dependent pump. Secure the pump with a lift sling in the ratchet
block. Remove the pump and the O-ring. Tension the pump upward and forward with the ratchet block. Weight:
approx. 25 kg (55 lb)
NOTE!
The drive connection for the ground dependent pump is located slightly lower than the oil level plug for the
dropbox.

NOTE!
Take care of the oil in an environmentally sound manner. See section Safety 191 Environment.

Figure 11

WARNING
Risk of crushing injuries

Final drive, weight: approx. 190 kg (419 lb)

14. Loosen and remove the bolts except the two middle bolts on each side (bolts with spacers). Fit 2 guide pins
M16x180 mm (7.1 in) in the holes above the middle bolts on each side.
 Figure 12

1. Guide pin M16x180 mm (7.1 in)

2. Bolt with spacer

15. Remove the remaining bolts (4 pcs.). Pull out the final drive approx. 30-40 mm (1.2-1.6 in). Fixate the final drive in
this position by putting a wooden block or similar at the top edge between the final drive and the axle housing.

Figure 13

1. Wooden block
2. Guide pin M16x180 mm (7.1 in)

16. Secure the final drive in the lift trolley 9999954. Remove the guide pins (4 pcs.) and the wooden block.

Figure 14

17. Remove the final drive from the axle housing.

 Figure 15

18. Clean the axle housing's sealing surface.

Figure 16

Mounting

19. Transfer the dog-clutch half to the new final drive.

Figure 17

1. Lock ring
2. Washer
3. Dog-clutch half

20. Tap away the lock from the drive flange nut.
 Figure 18

21. Loosen and remove the drive flange nut. Use gear segment 9993847, wrench 9993881 and gear 9993590. Transfer
the drive flange to the new final drive.

Figure 19

1. 9993847 Gear segment

2. 9993881 Wrench
3. 9993590 Gear

22. Tighten the drive flange nut. Use gear segment 9993847, wrench 9993881 and gear 9993590. Tightening torque:
1200 Nm (885 lbf ft)
NOTE!
The tool increases the tightening torque by 15 times. The value on torque wrench should be set to 80 Nm (59 lbf
ft). Rotate the pinion continuously during tightening, at least 10 revolutions.
 Figure 20

1. 9993847 Gear segment

2. 9993881 Wrench
3. 9993590 Gear

23. Lock the drive flange nut against the pinion shaft.

Figure 21

24. Fit the new final drive in lift trolley 9999954.

25. Apply sealant (Loctite 510 Part no. 1161059) inside the bolt holes as well as around the pin to the differential lock.
 Figure 22

26. Fill 0.15 litres (0.04 US gal) hypoid oil in the differential housing.

Figure 23

WARNING
Risk of crushing injuries

Final drive, weight: approx. 190 kg (419 lb)

27. Fit the final drive against the axle housing. Fit 4 guide pins M16x180 mm (7.1 in). Prevent the final drive from
gliding into the axle housing by fitting a wooden block 30-40 mm (1.2-1.6 in) or similar at the top edge between
the final drive and the axle housing. Remove lifting trolley 9999954.
 Figure 24

1. Wooden block
2. Guide pin M16x180 mm (7.1 in)

28. Remove the wooden block and fit the final drive in the axle housing. Make sure that the final drive enters on the
centering lugs in the axle housing. Secure the final drive with the two middle bolts (bolts with spacers) on the left
and right side.

NOTICE
Align and fit the final drive so that the centering lugs in the axle housing are not damaged.

Figure 25

1. Guide pin M16x180 mm (7.1 in)

2. Bolt with spacer

29. Remove the guide pins and fit the remaining bolts. Tighten the bolts for the final drive. Tightening torque: 310 Nm
(229 lbf ft)
 Figure 26

30. Push the drive shafts into the final drive. For easier installation of the drive shaft on the right side, activate the
differential lock mechanically. Use E1750 Differential lock adjusting tool or similar.

Figure 27

31. Fit the piston, diaphragm and cover, and connect the air line for the differential lock. Tighten the bolts. Tightening
torque: 30 Nm (22 lbf ft)

Figure 28
32. Check the O-ring for the ground dependent pump, change if needed. Fit the O-ring and the pump. Tighten the
bolts. Apply locking compound to the bolts (Loctite 243 Part no. 1161053). Tightening torque: 85 Nm (62.7 lbf ft)

Figure 29

33. Remove the ratchet block and the pipe.

34. Tap out the inner guide pins.

Figure 30

35. Tap down the outer guide pins flush with the planetary carrier.
NOTE!
Do not tap them out completely. Mounting of the planetary carrier is easier if they are left in place.
 Figure 31

36. Clean the planetary carriers from old sealant.

Figure 32

37. Apply sealant (Loctite 510 Part no. 1161059) on the planetary carriers.

Figure 33

38. Lift up one of the front wheels. Use a garage jack or similar.

39. Fit the planetary carriers. Remove the guide pins when the planetary gears have entered on the sun gear. Turn the
wheel hub and planetary carrier so that the planetary gears enter in the ring gear. Use the puller bolts to guide the
planetary carrier.
NOTE!
 Make sure that the oil plug lines up with the slot in the wheel hub.

Figure 34

40. Fit the bolts and tighten in the planetary carrier with a few bolts. First tap in the big guide pins and then tap in the
small guide pins.
NOTE!
The openings on the guide pins should be displaced 180° from each other.

Figure 35

41. Tighten the bolts for the planetary carriers. Tightening torque: 145 Nm (107 lbf ft)
 Figure 36

42. Fit the propeller shaft and remove the tensioning strap. Tighten the front and rear prop shaft bolts. Tightening
torque: 140 Nm (103 lbf ft)

Figure 37

43. Lower the front axle and remove the jack.

44. Fill oil in the axle housing and in the hub reductions. Fit and tighten the oil plugs. Tightening torque: 80 Nm (59 lbf
ft)

45. Fill oil in the dropbox.

46. Test-run the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Spindle, replacing one side 461 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Spindle, replacing one side

Op nbr 461-006

1. For changing spindle, follow the relevant description in section 464 Spindle, replacing one side.
 Service Information

Document Title: Function Group: Information Type: Date:

Hub reduction, removing 461 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Hub reduction, removing

Op nbr 461-037

88830163 Lifting tool

11668004 Socket
11668007 Standard Jack Single
11668007 Standard Jack Single
11668010 Wheel forklift
11668018 Bogie Blocks

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

 771 Wheel, removal

1. For removing hub, follow the relevant description in section 463 Spindle, replacing one side.
 Service Information

Document Title: Function Group: Information Type: Date:

Hub reduction, installing 461 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Hub reduction, installing

Op nbr 461-038

88830163 Lifting tool

11668004 Socket
11668007 Standard Jack Single
11668007 Standard Jack Single
11668010 Wheel forklift

This operation also includes required tools and times for applicable parts of the following operations:

 771 Wheel, installation

1. For installing hub, follow the relevant description in section 463 Spindle, replacing one side.
 Service Information

Document Title: Function Group: Information Type: Date:

Centre gear, removing and 463 Service Information 2014/7/31
fitting
Profile:
ART, A25D [GB]

Centre gear, removing and fitting

Op nbr 463-011

11668018 Bogie Blocks

11668018 Bogie Blocks
11668007 Standard Jack Single
11668007 Standard Jack Single
9999954 Lifting equipment
88830126 Gear segment
9993867 Spanner
9993590 Gear wheel

E1750 Differential lock adjusting tool (see 080 Drawings of E-tools)

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

1. Place the machine in service position, see 191 Service positions.

Removing

2. Drain the oil from the axle housing.

NOTE!
Take care of the oil in an environmentally sound manner. See 191 Environment.

Figure 1

3. Fit 11668018 Bogie Blocks between the bogie beam and the frame's rear bogie stop on both the left- and right-
hand sides. Do not screw out the support bolt completely, leave a gap of approx. 2 mm (0.08 in).
 Figure 2

1. 11668018 Bogie Blocks

4. Position two 11668007 Standard Jack Singles under the other bogie axle. Raise the bogie axle. Secure the jacks with
the pins.

Figure 3

WARNING
Risk of crushing injuries

5. Loosen and remove the bolts between the propeller shaft and the final drive. Suspend the propeller shaft in the
bogie beam.

Figure 4
6. Undo and remove the planet-carrier bolts. Insert two guide pins M12x250 mm.

Figure 5

7. Clean the threads in the puller holes with thread tap M16.

Figure 6

8. Make two 40 mm (1.57 in) long thread protectors from M10 bolts. Insert the thread protectors through the planet
carrier puller hole and fit two puller bolts M16x70 mm.
NOTE!
The thread protectors should bottom in the wheel hub's threaded holes and act as counterholds for the puller
bolts.
 Figure 7

1. Puller bolt M16x70 mm

2. Thread protector M10x40 mm
3. Guide pin M12x250 mm

9. Position an oil drain plate under the hub reduction. Tighten the puller bolts so much that the planetary carrier
releases from the wheel hub.
NOTE!
Take care of the oil in an environmentally sound manner. See 191 Environment.

Figure 8

10. Secure the planet carrier with lifting sling to an overhead crane or similar safe support. Remove the planet carrier.
Weight: approx. 45 kg (99 lbs)
 Figure 9

11. Pull out the drive shaft approx.400 mm (16 in) from the final drive. For easier removal of the drive shaft on the left-
hand side, activate the transverse differential lock.

Figure 10

12. Repeat steps 6 — 11 above, at the other end of the axle.

13. Remove the compressed air connection for the control of six-wheel drive.

14. Remove the compressed air connection, cover and diaphragm for the transverse differential lock. Lift up the piston
to facilitate removal of the final drive.
 Figure 11

WARNING
Risk of crushing injuries

Weight, final drive : approx. 270 kg (595 lbs)

15. Loosen and remove the bolts on the upper half of the final drive. Fit three guide pins M16x180 mm, two on the
right-hand side and one on the left-hand side.

Figure 12

1. Guide pin M16x180 mm

16. Remove the remaining bolts for the final drive. Pull out the final drive approx. 30–40 mm (1.2–1.6 in) on the guide
pins. Secure the final drive in this position by putting a wooden block or similar at the top edge between the final
drive and the axle housing. Secure the final drive with 9999954 Lifting equipment.
 Figure 13

1. 9999954 Lifting equipment

2. Guide pin M16x180 mm

17. Remove the guide pins (3 pcs.) and the wooden block. Remove the final drive from the axle housing.

18. Clean the axle housing's sealing surface.

Figure 14

Installing

19. Transfer the dog-clutch half to the new final drive.

Figure 15

1. Lock ring
2. Washer
3. Dog-clutch half

20. Remove the lock ring and lock washer for the drive flange nut.
 Figure 16

21. Loosen and remove the drive flange nut. Use 88830126 Gear segment, 9993867 Spanner and 9993590 Gear wheel.
Transfer the drive flange to the new final drive.

Figure 17

1. 9993590 Gear wheel

2. 9993867 Spanner
3. 88830126 Gear segment

22. Tighten the drive flange nut. Use 88830126 Gear segment, 9993867 Spanner and 9993590 Gear wheel.
Tightening torque, see: 460 Axles, tightening torques
NOTE!
The tool increases the tightening torque by 15 times. The value on torque wrench should be set to 80 Nm (59 lbf
ft). Rotate the pinion continuously during tightening, at least 10 revolutions.
 Figure 18

1. 9993590 Gear wheel

2. 9993867 Spanner
3. 88830126 Gear segment

23. Fit the lock washer and lock ring for the drive flange nut.

Figure 19

24. Mount the new final drive in 9999954 Lifting equipment.

25. Apply sealant (Loctite 510 or similar) inside the screw holes and around the differential-lock shaft.
 Figure 20

26. Fill the differential housing with 0.15 liters (0.04 US gal) of hypoid oil.

Figure 21

WARNING
Risk of crushing injuries

Weight, final drive : approx. 270 kg (595 lbs)

27. Steer in the final drive towards the axle housing. Fit three guide pins M16x180 mm. Prevent the final drive from
sliding into the axle housing by positioning a 30–40 mm (1.2–1.6 in) wooden block, or similar, at the top edge
between the final drive and the axle housing. Remove the lifting trolley 9999954 Lifting equipment.
 Figure 22

1. 9999954 Lifting equipment

2. Guide pin M16x180 mm

28. Remove the wooden block and fit the final drive in the axle housing. Make sure that the final drive enters on the
centring lugs in the axle housing and on the shaft for six-wheel drive. Secure the final drive with the bolts on the
final drive's lower half.

NOTICE
Align and fit the final drive so that the centering lugs in the axle housing are not damaged.

Figure 23

1. Guide pin M16x180 mm

29. Remove the guide pins and fit the remaining bolts. Tighten the final drive bolts.
Tightening torque, see: 460 Axles, tightening torques
 Figure 24

30. Push the drive shafts into the final drive. For easier installation of the left-hand drive shaft, activate the differential
lock mechanically. Use E1750 Differential lock adjusting tool, or similar.

Figure 25

31. Fit the piston, diaphragm and cover and connect the air lead for the differential lock. Tighten the bolts.
Tightening torque, see: 460 Axles, tightening torques

Figure 26

32. Fit the air connection for control of six-wheel drive.

33. Tap out the inner guide pins.

Figure 27

34. Tap down the outer guide pins flush with the planet carrier.
NOTE!
Do not tap them out completely. Mounting of the planetary carriers is easier if they are left in place.

Figure 28

35. Clean the planetary carriers from old sealant.

NOTE!
Later designs of the planet carriers are sealed with an O-ring instead of sealant. In such cases replace the O-ring.
 Figure 29

36. Apply new sealant to the planet carriers (Loctite 510, or similar).
NOTE!
Later designs of the planet carriers are sealed with an O-ring instead of sealant. In such cases replace the O-ring.

Figure 30

37. Fit the planetary carriers.

NOTE!
Make sure that the oil plug lines up with the slot in the wheel hub.

Figure 31

38. Fit the bolts and tighten in the planetary carrier with a few bolts. First tap in the big guide pins and then tap in the
small guide pins.
NOTE!
The guide pin openings should be displaced 180° from each other.
 Figure 32

39. Tighten the planet-carrier bolts.

Tightening torque, see: 460 Axles, tightening torques

Figure 33

40. Install the propeller shaft and tighten the bolted joint.
Tightening torque, see: 450 Propeller shaft, tightening torque

Figure 34

41. Lower the machine. Remove the Stand jacks and the bogie stops.
42. Fill oil in the axle housing and in the hub reductions gears.

43. Restore the machine from service position.

44. Test-run the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Spindle, replacing one side 463 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Spindle, replacing one side

Op nbr 463-006

1. For changing spindle, follow the relevant description in section 464 Spindle, replacing one side.
 Service Information

Document Title: Function Group: Information Type: Date:

Output shaft 6-wheel drive, 463 Service Information 2014/7/31
changing bearing
Profile:
ART, A25D [GB]

Output shaft 6-wheel drive, changing bearing

Op nbr 46507

9993868 Gear segment

9993881 Wrench
9993590 Gear
9993623 Drift ring
Kukko 20-10 Puller

1. Park the machine in the service position. See section Safety 191 Service positions.

2. Elevate the body and lock it with the load body lock.

Figure 1

A. Load body lock

3. Turn off the electric power with the battery disconnect switch.

Dismantling

4. Disconnect the propeller shaft from the drive flange.

 Figure 2

5. Secure the propeller shaft in the A-frame with a tensioning strap.

Figure 3

6. Remove the lock ring.

Figure 4

7. Remove the lock washer.

Figure 5

8. Remove the air connection, cover and the diaphragm for engaging/disengaging 6-wheel drive.
 Figure 6

1. Diaphragm
2. Cover

9. Drill two holes in a flat steel bar (130x20x5 mm) according to the figure.

Figure 7

10. Fit the flat steel bar with two of the existing bolts. Push in the diaphragm sleeve with the flat steel bar. Rotate the
drive flange so that the clutch for 6-wheel drive engages.

Figure 8

11. Fit gear segment 9993868 with two bolts in the drive flange. Fit wrench 9993881 and gear 9993590. Loosen the
drive flange nut.
 Figure 9

12. Remove the drive flange nut and the washer.

Figure 10

13. Remove the drive flange.

Figure 11
14. Remove the seal ring. Use a pry bar.
NOTE!
Work careful to avoid damaging the sealing surface on the axle housing.

Figure 12

15. Remove the lock ring for the shaft and the bearing. Remove the bearing shim.

Figure 13

16. Fit drift ring 9993623, the washer and the drive flange nut.

Figure 14

1. 9993623 Drift ring

 2. Washer
3. Drive flange nut

17. Pull loose the shaft and the outer bearing race by tightening the drive flange nut. Use adjusting shims, if needed.

Figure 15

18. Remove the shaft.

Figure 16

19. Pull off the inner bearing race from the axle housing. Use internal puller Kukko 20-10 and a suitable counterhold.

Figure 17

20. Press both bearings off the shaft.

 Figure 18

Assembling

21. Press two new bearings on the shaft.

Figure 19

22. Tap the outer bearing race into place against the axle housing's shoulder with a brass drift.

Figure 20

23. Lube the bearings lightly with oil for easier installation. Fit the shaft.
24. Tap in the last outer bearing race with a brass drift. Check manually that the shaft rotates and that there is no
clearance.

Figure 21

25. Clean, check and measure the lock ring groove in the axle housing.
Lock ring groove's tolerance in the axle housing:5.15 +0.300/-0 mm.

26. Measure the lock ring's (no. 5) thickness and note the value. Measurement designation is (A).
Lock ring's tolerance: 5.0 +0/-0.15 mm. Change the lock ring, if needed.

27. Fit the lock ring and measure the distance to the outer bearing race. Note the value (B).

Figure 22

28. Calculate the shim's thickness using the noted values. B-A+bearing clearance (0.05–0.20 mm)= shim's thickness.
Shims available from 4.2 to 4.9 mm.
 Figure 23

1. Outer race
2. Outer race
3. Bearing
4. Shims
5. Lock ring
6. Seal
7. Drive flange

29. Fit the calculated shim and the lock ring.

30. Grease and fit the seal ring on the drift ring 9993623.
NOTE!
The old seal ring must always be replaced with a new seal ring.
 Figure 24

1. Seal ring
2. 9993623 Drift ring

31. Fit drift ring 9993623 with the seal ring and drive flange nut on the shaft. Press the seal ring into place by
tightening the drive flange nut.

Figure 25

1. Drive flange nut

2. 9993623 Drift ring
3. Seal ring

32. Tighten the drive flange nut until the distance between the seal ring and axle housing is 7 mm.
 Figure 26

33. Check the dust ring (dust seal) on the drive flange. Change if needed.

Figure 27

1. Dust ring

34. Fit the drive flange.

 Figure 28

35. Fit the washer and the drive flange nut.

Figure 29

36. Tighten the drive flange nut. Use gear segment 9993868, wrench 9993881 and gear 9993590. Tightening torque:
600 Nm (443 lbf ft)
NOTE!
The tool increases the tightening torque by 15 times. The value on the torque wrench should be set to 40 Nm
(29.5 lbf ft).
 Figure 30

1. 9993590 Gear

37. Fit the lock washer.

NOTE!
Tighten the drive flange nut more if the lock washer doesn't fit.

Figure 31

38. Fit the lock ring.

Figure 32

39. Fit the propeller shaft and tighten the bolts.

Tightening torque: 180 Nm (133 lbf ft)
 Figure 33

40. Remove the flat steel bar. Fit the diaphragm and the cover as well as the air connection.

Figure 34

1. Diaphragm
2. Cover

41. Turn on the electric power with the battery disconnect switch.

42. Remove the load body lock and lower the body against the frame.

43. Start the engine and check functions.

Figure 35
 Service Information

Document Title: Function Group: Information Type: Date:

Dog-clutch for six-wheel 463 Service Information 2014/7/31
drive (6x6), checking and
adjusting
Profile:
ART, A25D [GB]

Dog-clutch for six-wheel drive (6x6), checking and adjusting

Op nbr 46316-2

E1750 Differential lock adjusting tool

Hydraulic jack

Checking

1. Park the machine in the service position.

2. Block one of the wheels.

3. Lift up the right wheel of the rear bogie axle.

4. Remove the diaphragm cover and the diaphragm for engaging six-wheel drive.

5. Check the diaphragm sleeve position relative to the machined surface on the axle housing. The distance should
be3 mm (0.12 in). Use tool E1750, level 1.
(This is done to make sure that the stroke of the diaphragm sleeve is correct.)
 Figure 1
Sleeve in disengaged position

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve

6. Fit a bolt and push down the diaphragm sleeve to "tooth-to-tooth" position with tool E1750. The clearance
between disengaged (unaffected) position and "tooth-to-tooth" position should be 1 mm (0.04 in).
 Figure 2
Tooth-to-tooth position

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve
4. Retainer bolt

7. Push down the diaphragm sleeve with tool E1750 and turn the lifted wheel so that the teeth are fully engaged. The
total stroke should be5mm (0.20 in).
 Figure 3
Fully engaged

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve
4. Retainer bolt

Adjusting

8. Turn the diaphragm sleeve counter-clockwise so that the teeth are fully engaged.

9. Apply Loctite, medium type, on the threads of the diaphragm sleeve and turn in the diaphragm sleeve approx. 1
1/2 turn clockwise until "tooth-to-tooth" position is obtained. Turn another 1/2 turn clockwise. Check the
clearance according to earlier checking instruction.

10. Tighten the lock bolt.

Tightening torque 30 Nm (22.1 lbf ft).

11. Refit the diaphragm and the diaphragm cover.

 Service Information

Document Title: Function Group: Information Type: Date:

Final drive, removing and 464 Service Information 2014/7/31
mounting
Profile:
ART, A25D [GB]

Final drive, removing and mounting

Op nbr 46411

9993590 Gear
9993868 Gear segment
9993585 Wrench
9999954 Lift trolley

Guide pin M12x250 mm (9.8 in) 2 pcs.

Thread protector M10x40 mm (1.57 in) 2 pcs.

Puller bolt M16x70 mm (2.8 in) 2 pcs.

Guide pin M16x180 mm (7.1 in) 4 pcs.

Torque wrench 30-310 Nm (22-229 lbf ft)

1. Park the machine in the service position. See section Safety 191 Service positions.

Removing

2. Drain the oil from the axle housing.

NOTE!
Take care of the oil in an environmentally sound manner. See section Safety 191 Environment.

Figure 1

WARNING
Risk of crushing injuries

3. Loosen and remove the rear bolts on the propeller shaft. Suspend the propeller shaft in the bogie beam with a
tensioning strap.
 Figure 2

4. Loosen and remove the bolts for the planetary carrier. Fit 2 guide pins M12x250 mm (9.8 in).

Figure 3

5. Clean the threads in the puller holes with thread tap M16.

Figure 4
6. Make 2 (two) 40 mm (1.57 in) long thread protectors from M10 bolts. Insert the thread protectors through the
puller holes in the planetary carrier and fit 2 (two) puller bolts M16x70 mm (2.8 in).
NOTE!
The thread protectors should bottom out in the wheel hub's threaded holes and act as counterholds for the puller
bolts.

Figure 5

1. Puller bolt M16x70 mm (2.8 in)

2. Thread protector M10x40 mm (1.57 in)
3. Guide pin M12x250 mm (9.8 in)

7. Position an oil drain plate under the hub reduction. Tighten the puller bolts so much that the planetary carrier
releases from the wheel hub.
NOTE!
Take care of the oil in an environmentally sound manner. See section Safety 191 Environment.

Figure 6

8. Secure the planetary carrier with a lift sling in an overhead crane or similar. Remove the planetary carrier. Weight:
approx. 45 kg (99 lb)
 Figure 7

9. Pull out the drive shaft approx. 400 mm (16 in) from the final drive. For easier removal of the drive shaft on the right
side, activate the transverse differential lock.

Figure 8

10. Repeat steps 3-9 on the other side.

11. Remove the cover for the differential lock and pull out the piston to facilitate removal of the final drive.
 Figure 9

WARNING
Risk of crushing injuries

Final drive, weight: approx. 190 kg (419 lb)

12. Loosen and remove the bolts except the two middle bolts on each side (bolts with spacers). Fit 2 guide pins
M16x180 mm (7.1 in) on each side.

Figure 10

1. Guide pin M16x180 mm (7.1 in)

2. Bolt with spacer

13. Remove the remaining bolts (4 pcs.). Pull out the final drive approx. 30-40 mm (1.2-1.6 in). Fixate the final drive in
this position by putting a wooden block or similar at the top edge between the final drive and the axle housing.

Figure 11

1. Wooden block
2. Guide pin M16x180 mm (7.1 in)

14. Secure the final drive in the lift trolley 9999954. Remove the guide pins (4 pcs.) and the wooden block.
 Figure 12

15. Remove the final drive from the axle housing.

Figure 13

16. Clean the axle housing's sealing surface.

Figure 14

Mounting

17. Transfer the dog-clutch half to the new final drive.

 Figure 15

1. Lock ring
2. Washer
3. Dog-clutch half

18. Tap away the lock from the drive flange nut.

Figure 16

19. Loosen and remove the drive flange nut. Use gear segment 9993868, wrench 9993585 and gear 9993590. Transfer
the drive flange to the new final drive.

Figure 17
V1003483
 1. 9993868 Gear segment
2. 9993585 Wrench
3. 9993590 Gear

20. Tighten the drive flange nut. Use gear segment 9993868, wrench 9993585 and gear 9993590. Tightening torque:
1200 Nm (885 lbf ft)
NOTE!
The tool increases the tightening torque by 15 times. The value on torque wrench should be set to 80 Nm (59 lbf
ft). Rotate the pinion continuously during tightening, at least 10 revolutions.

Figure 18
V1003483

1. 9993868 Gear segment

2. 9993585 Wrench
3. 9993590 Gear

21. Lock the drive flange nut against the pinion shaft.

Figure 19

22. Fit the new final drive in lift trolley 9999954.

23. Apply sealant (Loctite 510 Part no. 1161059) inside the bolt holes as well as around the pin to the differential lock.
 Figure 20

24. Fill 0.15 litres (0.04 US gal) hypoid oil in the differential housing.

Figure 21

WARNING
Risk of crushing injuries

Final drive, weight: approx. 190 kg (419 lb)

25. Fit the final drive against the axle housing. Fit 4 guide pins M16x180 mm (7.1 in). Prevent the final drive from
gliding into the axle housing by fitting a wooden block 30-40 mm (1.2-1.6 in) or similar at the top edge between
the final drive and the axle housing. Remove lifting trolley 9999954.
 Figure 22

1. Wooden block
2. Guide pin M16x180 mm (7.1 in)

26. Remove the wooden block and fit the final drive in the axle housing. Make sure that the final drive enters on the
centering lugs in the axle housing. Secure the final drive with the two middle bolts (bolts with spacers) on the left
and right side.

NOTICE
Align and fit the final drive so that the centering lugs in the axle housing are not damaged.

Figure 23

1. Guide pin M16x180 mm (7.1 in)

2. Bolt with spacer

27. Remove the guide pins and fit the remaining bolts. Tighten the bolts for the final drive. Tightening torque: 310 Nm
(229 lbf ft)
 Figure 24

28. Push the drive shafts into the final drive. For easier installation of the drive shaft on the right side, activate the
differential lock mechanically. Use E1750 Differential lock adjusting tool or similar.

Figure 25

29. Fit the piston, diaphragm and cover, and connect the air line for the differential lock. Tighten the bolts. Tightening
torque: 30 Nm (22 lbf ft)

Figure 26

30. Tap out the inner guide pins.

 Figure 27

31. Tap down the outer guide pins flush with the planetary carrier.
NOTE!
Do not tap them out completely. Mounting of the planetary carriers is easier if they are left in place.

Figure 28

32. Clean the planetary carriers from old sealant.

 Figure 29

33. Apply sealant (Loctite 510 Part no. 1161059) on the planetary carriers.

Figure 30

34. Lift up one of the wheels. Use a garage jack or similar.

35. Fit the planetary carriers. Remove the guide pins when the planetary gears have entered on the sun gear. Turn the
wheel hub and planetary carrier so that the planetary gears enter in the ring gear. Use the puller bolts to guide the
planetary carrier.
NOTE!
Make sure that the oil plug lines up with the slot in the wheel hub.

Figure 31

36. Fit the bolts and tighten in the planetary carrier with a few bolts. First tap in the big guide pins and then tap in the
small guide pins.
NOTE!
The openings on the guide pins should be displaced 180° from each other.
 Figure 32

37. Tighten the bolts for the planetary carriers. Tightening torque: 145 Nm (107 lbf ft)

Figure 33

38. Fit the propeller shaft and remove the tensioning strap. Tighten the rear bolts. Tightening torque: 180 Nm (133 lbf
ft)

Figure 34

39. Lower the wheel and remove the jack.

40. Fill oil in the axle housing and in the hub reductions. Fit and tighten the oil plugs. Tightening torque: 80 Nm (59 lbf
ft)

41. Test-run the machine and check functions.

 Service Information

Document Title: Function Group: Information Type: Date:

Spindle, replacing one side 464 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Spindle, replacing one side

Op nbr 464-084

11668018 Bogie Blocks

11668018 Bogie Blocks
11668007 Standard Jack Single
11668007 Standard Jack Single
11668010 Wheel forklift
11668014 Lifting equipment
11668004 Socket
88830046 Dump body support

NOTE!
Alternatively, 11668013 Dump body support can be used instead of 88830046 Dump body support.

This operation also includes required tools and times for applicable parts of the following operations:

 191 Service positions

 560 Brake system, bleeding

1. Place the machine in service position, see 191 Service positions.

2. Loosen the wheel nuts on the wheel in question.

NOTICE
Do not remove the wheel nuts before the axle is raised and the wheel has been secured with a wheel forklift
or similar equipment.

3. Fit 11668018 Bogie Blocks between the bogie member and the frame's rear bogie stop on the left- and right-hand
sides. Do not screw the support bolt up completely but leave a space of about 2 mm (0.079 in).

Figure 1

1. 11668018 Bogie Blocks

4. Position two 11668007 Standard Jack Single under the bogie axle in question. Lift up the bogie axle. Secure the
stand jacks with pins.

Figure 2

5. Fit 11668010 Wheel forklift or similar equipment. Secure the wheel in the wheel trolley.

Figure 3

6. Remove the wheel nuts and remove the wheel.

7. Drain all oil from the hub reduction and 8-10 litres (2.11–2.64 US gal) from the axle housing.

Figure 4

8. Remove the brake shields (4 pcs.).

 Figure 5

9. Remove the outer bracket for the brake lines.

Figure 6

10. Remove and plug the brake lines at the brake calipers.

Figure 7

11. Remove the bolts and the retainers as well as the brake pads.
 Figure 8

12. Loosen the bolts for the brake calipers.

NOTE!
Fit 2 lifting eyes and secure the brake calipers before removing all bolts.

Figure 9

13. Set up 11668014 Lifting equipment.

NOTE!
Make sure that the hub lifting device is supported inside of the wheel spindle.

Figure 10

14. Remove the bolts and the brake caliper.

Weight: 36 kg (79 lbs)
 Figure 11

15. Remove the other brake caliper.

Planet carrier, removing

16. Unscrew the planet carrier bolts. Fit two guide pins M12x160 mm.

Figure 12

17. Clean the threads for the puller bolts with thread tap M16.

Figure 13

18. Make two 40 mm (1.57 in) long thread protectors from M10 bolts. Insert the thread protectors through the planet
carrier puller hole and fit two puller bolts M16x160 mm.
NOTE!
The thread protectors should bottom in the wheel hub's threaded holes and act as counterholds for the puller
 bolts.

Figure 14

1. Puller bolt M16

2. Thread protector M10x40 mm
3. Guide pin 12x120 mm

19. Tighten the puller bolts so much that the planet carrier can be secured with a lifting eye. Remove the planet carrier.
Weight: 45 kg (99 lbs)

Figure 15

20. Remove the guide pins and the thread protectors.

21. Loosen the bolts for the brake disc, if it is to be changed.

 Figure 16

Wheel hub, removing

22. Remove the lock ring and the sun gear.

Figure 17

23. Remove the lock ring and the lock washer.

Figure 18

24. Undo the hub nut. Use 11668004 Socket.

NOTICE
Do not remove the hub nut before the ring gear and wheel hub have been secured.
 Figure 19

25. Secure the ring gear in the wheel hub with 2 (two) M14 bolts, each provided with a flat washer.

Figure 20

1. Bolt M14 with flat washer

26. Secure the wheel hub in the hub lifting device and remove the hub nut.

Figure 21

27. Remove the wheel hub.

Weight: 125 kg (276 lbs)
 Figure 22

28. Remove the inner bearing and the spacer ring.

Figure 23

29. Remove the thrust washer.

Figure 24

30. Mark up the position of the brake caliper brackets relative to the axle housing.
 Figure 25

Spindle, removing

31. Loosen the bolts for the wheel spindle. Remove one of the upper bolts and fit a guide pin M20x90 mm.

Figure 26

32. Secure the wheel spindle with a lifting sling in the lifting device. Remove the bolts and the brake caliper brackets.

Figure 27

33. Remove the wheel spindle.

 Figure 28

34. Remove the drive shaft.

Weight: 30 kg (66 lbs)
NOTE!
On the AH64D–AH64F axles of the A30 it is possible to remove the drive shaft before removing the wheel spindle.

35. Clean and inspect the dismantled parts for damage and wear. Change damaged or worn parts.

Brake disc, changing

36. Remove the bolts and change the brake disc. It is advantageous to tighten the bolts to the specified torque when
the wheel hub is mounted on the axle.
Tightening torque, see: 460 Axles, tightening torques

Figure 29

Wheel spindle, assembling

37. Fit a new O-ring on the wheel spindle. Lube the O-ring with vaseline.
 Figure 30

38. Fit the drive shaft.

NOTE!
For axles on the A25, the drive shaft must be fitted before the spindle.

39. Fit a M20x90mm guide pin in one of the upper holes. Fit the wheel spindle.

Figure 31

40. Fit the brake caliper brackets according to markings made when removing, then fit the bolts.

Figure 32

41. Tighten the bolts crosswise.

 Tightening torque: 460 Axles, tightening torques

Figure 33

42. Fit the thrust washer.

Figure 34

43. Fit a new O-ring on the spacer ring. Lube the O-ring with vaseline.

Figure 35

44. Install the spacer ring.

 Figure 36

45. Fit the inner bearing.

Figure 37

Wheel hub, mounting

46. Apply sealant (silicone part no. 1161240) on the sealing ring. Fit the sealing ring. Tap down the sealing ring until it
is flush with the wheel hub. Use a suitable drift plate.

Figure 38

47. Fit the wheel hub and secure it with the hub nut.
 Figure 39

48. Remove the lifting device and the bolts/washers that secured the ring gear.

49. Tighten the hub nut with 11668004 Socket.

Tightening torque: 460 Axles, tightening torques

Figure 40

50. Rotate the wheel hub 4-5 turns and loosen the hub nut 1/2 turn.

51. Tighten the hub nut. Rotate the wheel hub 1-2 turns and tighten again. Repeat until the required torque is
obtained.
Tightening torque, see: 460 Axles, tightening torques

52. Tighten the hub nut 12° (the angular spacing between two bolt holes in the planet carrier is 12°), this gives the
correct torque. Using a steel wire in the hub nut socket makes it easier to check that the hub nut is tightened one
hole spacing.
 Figure 41

53. Fit the lock washer and the lock ring. There are two versions of the lock washer. Use the washer that requires the
least adjustment to reach a lock position.
NOTE!
Never loosen the hub nut, tighten to the closest lock position.

Figure 42

54. Fit the sun gear and the lock ring.

NOTE!
The sun gear must be fitted with the ground side facing in.

Figure 43
 55. Tighten the brake disc bolts, if the disc has been removed. Tightening torque: see 460 Axles, tightening torques.

Figure 44

Planet carrier, mounting

56. Tap out the inner guide pins completely.

Figure 45

57. Tap down the outer guide pins flush with the planet carrier.
NOTE!
Do not tap them out completely. Mounting of the planet carrier on the hub is made easier if they are left in place.
 Figure 46

58. Clean the wheel hub and planet carrier from old sealant.

Figure 47

59. Apply new sealant (Loctite 510, or equivalent) to the planet carrier.

Figure 48

60. Fit two guide pins M12x160 mm in the wheel hub. Fit the planet carrier. Use the puller bolts as guides.
NOTE!
Make sure that the oil plug lines up with the slot in the wheel hub.
 Figure 49

61. Pull in the planet carrier by tightening four bolts and tap in the guide pins. Tap in the big guide pins first, then the
small guide pins.
NOTE!
The guide pin openings should be displaced 180° from each other.

Figure 50

62. Tighten the bolts for the planet carrier.

Tightening torque, see: 460 Axles, tightening torques

Figure 51
Brake caliper, mounting

63. Fit the brake calipers and the bolts (8 bolts/brake caliper).

Figure 52

64. Remove the lifting eyes and the hub lifting device 11668014.

65. Tighten the bolts for the brake calipers.

Tightening torque, see: 460 Axles, tightening torques

Figure 53

66. Fit the brake pads and the brake pad retainers. Fit and tighten the bolts. Use locking fluid on the bolts (Loctite 243,
or equivalent).
Tightening torque, see: 460 Axles, tightening torques

Figure 54
67. Fit and tighten the brake lines on the brake calipers.

Figure 55

68. Fit and tighten the outer bracket for the brake lines.

Figure 56

69. Bleed the brake system, see 560 Brake system, bleeding.
NOTE!
Only the circuit that has been open needs to be bled.

70. Fit the brake shields (4 pcs.).

Figure 57

71. Fit the wheel and tighten the wheel nuts.

 Tightening torque, see: 460 Axles, tightening torques

72. Lower the machine.

73. Check the oil level in the axle and fill the required amount of oil. Start with the hub reductions and continue with
the axle housing.

74. Restore the machine from service position.

 Service Information

Document Title: Function Group: Information Type: Date:

ATC, description 468 Service Information 2014/7/31
Profile:
ART, A25D [GB]

ATC, description
Description
ATC (Automatic Traction Control) is a function for automatic operation of the longitudinal differential lock in the dropbox,
and the clutch for six-wheel drive (6x6), in the first bogie axle. It is also a monitoring function for this differential lock and
this clutch. The function uses a number of signals where the most important is the steering angle, and the speed (rpm)
difference between the propeller shafts for the front axle and both bogie axles. These signals are used for slip calculation. If
slip is detected, the function automatically engages a suitable combination of differential locks to achieve better
performance, without unnecessary machine wear.
The monitoring function's task is to prevent the differential lock or clutch from engaging in a way that damages the
drivetrain, which may occur at, e.g., too high speed (rpm) difference between the propeller shafts.
The ATC function can, without any action from the operator, automatically and independent of each other engage and
disengage longitudinal differential lock in the dropbox and the clutch for six-wheel drive (6x6).
The switch for manual engagement of longitudinal differential lock and the clutch for six-wheel drive (SW4603), available on
standard machines, is removed on machines equipped with ATC. The switch for manual engagement of transverse
differential lock on the front axle (SW4602) is hidden, for machines equipped with ATC, under a cover in the place where it is
located on standard machines. However, if desired by the operator the switch can be uncovered.
The ATC function monitors engagement of the longitudinal differential lock and the clutch for six-wheel drive regardless of if
they are engaged manually or automatically. This is to prevent component damage. Manual engagement of all differential
locks with the switch on the floor (SW4604, see 370 Components, list and positions) works in the same way as for standard
machines, that is, all differential locks and six-wheel drive are engaged at activation. If the parking brake or emergency brake
function is activated, the longitudinal differential lock is engaged as well. The longitudinal differential lock is also activated
together with the clutch for six-wheel drive when the retarder (see 420 Description, retarder) is activated if parameter DQQ is
set to “on” (done with VCADS).

Figure 1

1. SW4603
2. SW4602

If a signal that affects the ATC function disappears, or becomes incorrect, the function goes into an “error mode” and the
clutches are no longer engaged and disengaged automatically. If the vehicle's speed is lower than 5 km/h (3.1 mph), the
differential lock and clutch shall be engaged if the malfunction is critical for the ATC function. At lower speeds than 15 km/h
(9.3 mph) and malfunction of the ATC function id detected, the differential lock and clutch are engaged. In both cases, the
differential lock/clutch remain engaged until the malfunction has been fixed.
The clutch for six-wheel drive is not engaged if the air pressure sensor for the trailer's compressed air circuit is incorrect, or
the air pressure in the compressed air circuit is below 6.1 bar (88.5 PSI). The exception is if the emergency brake is activated.
If the foot brake is used and the vehicle's speed is higher than 4.5 km/h (2.8 mph), the ATC function cannot activate
differential lock and clutch, respectively.
At normal operation with ATC, the control lights for engaged differential locks on the operator's panel shallnot be activated,
the exception is when using the retarder, when the control lights are activated in the same way as for a standard machine.
Only in case of a malfunction in the ATC function, and the longitudinal differential lock as well as the clutch for six-wheel
drive are engaged, is when the control lights are activated. Amber central warning and a warning symbol are activated at the
same time. However, it is also possible to display which differential locks are engaged at the time by a parameter (GIV) for
this being set to “on” with VCADS.

Figure 2
Symbol with control lights on operator's panel

1. Transverse differential lock, front axle

2. Longitudinal differential lock
3. Transverse differential lock, front bogie axle
4. Six-wheel drive, dog-clutch
5. Transverse differential lock, rear bogie axle

Figure 3
Warning symbol on operator's panel in case of ATC problem

The ATC function uses five sensors that are unique to the function; three speed (rpm) sensors, one steering angle sensor,
and an air pressure sensor, in addition to the standard sensors on the machine. Sensor positions can be seen in the following
figure.
Machines equipped with ATC also have another dropbox and another final drive (differential carrier assembly) in the first
bogie axle than standard machines. The dropbox and final drive (differential carrier assembly) are equipped with a dog-
clutch that is unique to ATC.
Figure 4
Sensor positions for sensors that provide signals to the ATC function

1. Speed (rpm) sensor on dropbox SE4309 — measures output rpm to axle on the tractor (ATC)
2. Speed (rpm) sensor on final drive (differential carrier assembly) on the trailer's first axle SE4311 — measures rpm on
the trailer's first axle (ATC)
3. Steering angle sensor SE6403 — measures the angle between the tractor and trailer (ATC)
4. Speed (rpm) sensor SE4310 — measures input rpm for rear axle on the trailer (ATC)
5. Air pressure sensor SE4608 — senses the air pressure in the compressed air system mounted on the trailer (ATC)
6. Speed (rpm) sensor SE4307 — measures output rpm from the transmission (standard)
7. Sensor SE3801 — measures the vehicle's longitudinal inclination (standard)
8. Speed (rpm) sensor SE4212 — measures input rpm to the transmission (standard)
9. Position monitor SE4607 — gives the position of the longitudinal differential lock, that is, engaged or disengaged
(standard)
 Service Information

Document Title: Function Group: Information Type: Date:

Checking and adjusting 468 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Checking and adjusting

Automatic calibrations, ATC program module
In ATC's program module, there are built-in automatic calibration functions for calibration of steering angle sensor and for
calibration of difference in tore dimension. Both these calibrations are performed when the machine's speed is above 38 km/
h (23.6 mph) for at least 2.5 minutes. Then the machine is assumed to be travelling straight ahead.

Steering angle calibration

When calibrating steering angle, an offset value is calculated for front steering angle when the machine is travelling
straight ahead, and the value for the middle position is corrected in the program module. The calculated value for
the middle position is also used as a correction factor for the machine's steering angle. It is also used for slip
calculation, by the program module.
In order to be able to change the value for steering angle in the program module, the condition is that four valid
calibrations after each other, with the same result, lasting at least 75 seconds, have been performed.

Tire calibration
For tire calibration, an correction value (offset value) is calculated between the rotational speed over the
longitudinal differential lock and the rotational speed over the differential lock for six-wheel drive in the front bogie
axle. The difference in rotational speed over the differential locks can be caused by difference in tire dimension, e.g.,
wear, use of snow chains, etc.
To enable the program module to correct for slipping, it is required that the rpm difference is less than 5% over
both differential locks, otherwise the rpm difference is regarded as slipping. It is required that the machine is
operated a distance of at least 2 km (1.2 miles) in addition to above mentioned conditions, in order to enable
change of the correction value.

Checks via VCADS Pro

Checking sensors
In VCADS Pro, there is an operation Sensors ATC, checking operation number 46075–3, that checks the function
of the five unique sensors for ATC, that is, steering angle sensor SE6403, air pressure sensor trailer SE4608, speed
(rpm) sensor forward output speed dropbox SE4309, speed (rpm) sensor rear output speed dropbox SE4311, speed
(rpm) sensor input speed rear bogie axle SE4310. The purpose of the test is to check the sensors' function in the
ATC–system.
 Service Information

Document Title: Function Group: Information Type: Date:

Transverse differential 468 Service Information 2014/7/31
lock/axle, checking and
adjusting
Profile:
ART, A25D [GB]

Transverse differential lock/axle, checking and adjusting

Op nbr 46805-2

E1750 Differential lock adjusting tool

Hydraulic jack

Checking

1. Park the machine in the service position.

2. Block one of the wheels.

NOTE!
Do not activate the parking brake. Make sure that the machine’s compressed air system is at full operating pressure
(applies to front axle and first bogie axle).

3. Lift up for checking and adjusting of:

 front axle, right wheel

 front bogie axle, left wheel
 rear bogie axle, right wheel

4. Remove the diaphragm cover and the diaphragm.

5. Check the position of the diaphragm sleeve relative to the machined surface on the axle housing. The distance
should be 3 mm (0.12 in). Use tool E1750, level 1. (This is done to make sure that the stroke of the diaphragm
sleeve is correct.)
 Figure 1

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve

6. Fit a bolt and push down the diaphragm sleeve to "tooth-to-tooth" position with tool E1750. The clearance
between disengaged (unaffected) position and "tooth-to-tooth" position should be 1 mm (0.04 in).
 Figure 2
Tooth-to-tooth position

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve
4. Retainer bolt

7. Push down the diaphragm sleeve with tool E1750 and turn the wheel so that the teeth are fully engaged. The total
stroke should be5 mm (0.20 in).

Figure 3
Fully engaged

1. Machined surface
2. Tool E1750
3. Diaphragm sleeve
4. Retainer bolt

Adjusting

8. Loosen the lock bolt and turn out the diaphragm sleeve counter-clockwise so that the teeth are fully engaged.

9. Turn in the diaphragm sleeve approx. 2 1/2 turns clockwise until "tooth-to-tooth" position is achieved. Turn
another 1 turn clockwise. Check the clearance according to earlier checking instruction. Tighten the lock bolt.
Tightening torque 30 Nm (22.1 lbf ft).

10. Refit the diaphragm and the diaphragm cover.

11. Remove the hydraulic jack.

 Service Information

Document Title: Function Group: Information Type: Date:

Power take-off, between 482 Service Information 2014/7/31
engine and gearbox,
reconditioning
Profile:
ART, A25D [GB]

Power take-off, between engine and gearbox, reconditioning

Applies to machines with D9B-engines; A25D/A25D 4x4/A30D/A25E/A25E 4x4/A30E

Op nbr 482-004

88830051 Lifting tool

11667001 Handle
11667060 Drift plate
11667100 Drift plate
9992000 Handle
9990113 Installation tool
9990117 Cone
9998389 Press tool
9998601 Installation tool

Prerequisite for this method is that the engine and transmission are removed from the machine. Also, that the transmission
is removed from the engine. For instructions about these steps, see section: 210 Engine and transmission, removing,
421 Transmission, remove from a non mounted engine

Figure 1

1. Flywheel housing with power take-off

1. Loosen and remove the bolts for the oil sump.

2. Loosen the oil filler hose and oil level hose for the sump.

Figure 2

1. Oil filler hose

2. Oil level hose
3. Connector for oil level sensor

3. Unplug the connector for the oil level sensor.

4. Install lifting tool 88830051 Lifting tool

5. Lift up the engine and remove the oil sump.

6. Place the engine on two or three axle stands, and so that the transmission housing and power take-off can be
accessed for removal, and that it is stable.

Figure 3
 Figure 4

1 Transmission housing 10 Flange screw 18 Cover

2 gear 10 Gasket 19 Toothed wheel
Install suitable spacer between the bearings so that
correct clearance is obtained when tightening, see
215 Engine transmission, specification
3 Roller bearings 11 Spring 20 Ring gear
4 Spacer ring 12 Restricting 21 Flexible disc
NOTE! washer
Sizes from 6.20 (0.244 in) mm – 7.0 mm (0.275 in)

5 O–ring 13 Shaft 22 Six-point socket

screw
6 Stub axle 14 Reduction 23 Flange lock nut
7 Striker plate 15 Elbow nipple 24 Thrust plate
8 Six-point socket screw 16 Pipe 25 Bolt
9 Flange screw 17 Crankshaft oil seal 27

7. Loosen and remove the bolts (14 pcs. for the thrust plate (24) for the flex plate (21), sensor ring (19) and ring gear
(20). Remove the flex plate (21), sensor ring (19) and ring gear (20).

8. Remove the cover and the gear.

 Figure 5

1. Gear
2. Packbox

9. Remove the heat exchanger with bracket.

Figure 6

10. Remove the valve cover.

11. Remove inlet pipe and preheating coil.

Figure 7

1. Inlet pipe
 2. Preheating coil

NOTE!
Protect the inlet from dirt.

12. Loosen the oil connection and pressure pipe for the cooling circuit on the compressor.

13. Remove the oil trap with associated cooling circuit.

Figure 8

14. Loosen and remove the compressor, weight approx. 16 kg (35 lbs)

Figure 9

15. Remove the engine mount.

 Figure 10

16. Unplug the connectors for the camshaft sensor and the engine speed sensor.

Figure 11

1. Camshaft sensor
2. Speed sensor for flywheel

17. Loosen and fold up the casing to avoid unplugging the electric connection. Secure the casing with a tensioning
strap.

Figure 12

18. Secure the transmission housing with 2 pcs. M10 lifting eyes as well as lifting sling. Weight approx. 150 kg (330
lbs)
 Figure 13

1. M10 lifting eyes

19. Loosen the bolts for the transmission housing (9 pcs. M8 and 11 pcs. M12).

20. Lift away the transmission housing. Weight approx. 150 kg (330 lbs)

Figure 14

Flywheel housing, overhauling

21. Remove the gear for the compressor.

 Figure 15

22. Tap out the crankshaft seal.

Figure 16

23. Tap up the striker plate and loosen the bolts (6 pcs.) for the gear's stub shaft.

Figure 17

24. Use two M8 x 30 mm (1.18 in) puller bolts to remove the stub axle for the gear.
 Figure 18

25. Remove the gear and its ball bearing as well as the stub axle.

Figure 19

26. Remove the O-ring.

Figure 20

27. Loosen and remove the pressure pipes for the power take-off. For the pipe on the right, there is also a spring and a
restriction.
 Figure 21

1. Delivery pipe

A. Restriction washer
B. Spring

28. Loosen the power take-off's bolts (8 pcs.). Carefully pry apart the unit.

Figure 22

29. Loosen the hex bolts (6 pcs.). Install two puller bolts M8 x 30 mm (1.18 in) in the bolted joint for the gear.

Figure 23

1. Puller bolts

30. Remove the shaft and catch the gear and ball bearings (2 pcs.).
 Figure 24

NOTE!
Mark up the gear's rotational direction to avoid turning it the wrong way when installing.

31. Remove the sensor for the crankshaft and any shims.

Figure 25
 Figure 26

1 Transmission housing 9 Flange nut 17 O-ring

2 Retainer ring 10 Screw stud 18 Delivery pipe
3 Ball bearing 11 Strainer 19 Union screw
4 Spacer ring 12 Spring 20 Gasket
5 Gear 13 Flat gasket 21 Restricting washer
6 Shaft 14 Nipple 22 Oil hose
7 Splined sleeve 15 Flange screw
8 Pin 16 Cover

Power take-off, reconditioning

32. Place the power take-off on a stable surface. Weight approx. 30 kg (66 lbs)

33. Loosen and remove the nipple for the strainer as well as the spring and flat gasket. Remove the protective covers.
 Figure 27

1. Nipple
2. Flat gasket
3. Spring
4. Strainer

NOTE!
The number of splined sleeves varies depending on the engine's serial number.

34. Remove the retainer ring for the splined sleeve.

Figure 28

1. Splined sleeve
2. Retainer ring

35. Remove the retainer rings on both sides of the roller bearings as well as the retainer rings for the shafts in the
power take-offs.

Figure 29

1. Retainer ring for roller bearing

36. Place the power take-off in a press.

 Figure 30

37. Press out the shaft with roller bearing and catch these from below. Use 11667060 Drift plate11667001 Handle

Figure 31

1. Drift plate
2. Drift handle

38. Remove the upper roller bearing.

 Figure 32

1. Upper roller bearing

39. Remove gear and spacer ring.

Figure 33

40. Repeat the previous method step for the other power take-off.

41. Install the shaft in the press and press out the roller bearing and spacer ring.

Figure 34

1. Roller bearings
2. Spacer ring
3. Shaft

42. Check that the bearing surfaces are free from damages and dirt. Blow clean the lubrication channels with air.

Figure 35

Power take-off, assembling

43. Place the shaft and spacer ring in the press. Press on the roller bearing with a pipe, inside Ø 65 mm (2.55 in) outside
Ø 80 mm (3.14 in), length 50 mm (1.96 in).

WARNING
Risk of burns! Use protective work gloves.
 WARNING
Risk of frostbite! Use protective gloves.

44. Heat the gears to 175 °C. Cool the shafts with roller bearings to, at the lowest, -20 °C (-4 °F).

45. Install the shaft and gear in the power take-off.

Figure 36

1. Shaft
2. gear

46. Install the spacer ring.

Figure 37
 1. Spacer ring

47. Place the power take-off in a press, use suitable counterhold or drift plate 11667100 Drift plate to keep the shaft in
place from below.
NOTE!
The sealed roller bearings shall be installed in the power take-offs, which are provided with lubrication channels,
and turned with the seal facing in against the gear. This is to safeguard lubrication of the bearing. The lubrication
oil channels are located on the suction strainer side.

Figure 38

1. Retainer ring
2. Roller bearings
3. Spacer ring
4. Lubrication oil channel

48. Press in the roller bearing with the pipe that was used in earlier method step.

Figure 39

1. Pipe

49. Assemble the snap ring on the shaft.

 Figure 40

1. Retainer ring

50. Install the retainer rings on the roller bearings in the power take-off on both sides.

Figure 41

1. Retainer ring

51. Repeat the previous method step for the other take-off.

52. Install the protective covers for the power take-off.

53. Clean and install strainer, spring, and flat gasket as well as nipple in the power take-off.

Figure 42

1. Nipple
2. Flat gasket
3. Spring
4. Strainer

Overhauling the bigger and smaller gears

54. Tap out the bearing races from the inside and outward on the transfer gear, see figure.

Figure 43

55. Repeat above step on the smaller transfer gear.

Figure 44

56. Clean and check the surfaces on the bearing races and gears.

57. Press in the bearing race for the bigger transfer gear.

Figure 45

1. Bearing race

58. Press in the bearing races for the smaller transfer gear.
 Figure 46

1. Bearing race

Shaft for gear, overhauling

59.

Figure 47

60. Remove the spacer ring on the smaller transfer gear.

 Figure 48

1. Spacer ring

61. Drive off the roller bearing with suitable puller.

Figure 49

62. Remove the O-ring, change if needed.

 Figure 50

1. O-ring

63. Check so that there is no dirt or damage, change parts as needed.

64. Press on the roller bearing on the shaft for the bigger gear. Use suitable pipe.

Figure 51

NOTE!
In the shaft for the bigger gear, there is a restriction. Check that the hole in the restriction washer is not clogged by
dirt.
 Figure 52

1. Restriction Figure 53
2. Shaft

65. Repeat previous method step for the shaft for the smaller gear. Check all parts and change as needed.

Power take-off, assembling

66. Install the ball bearing in the gear and install it with the shaft in the power take-off. Install suitable spacer between
the bearings so that correct clearance is obtained when tightening, see 215 Engine transmission, specification.
Tighten the bolts crosswise, see 482 Power take-off, tightening torque, and measure the clearance with dial
indicator acc. to figure.
NOTE!
The gear must be rotated at least five revolutions when tightening.

Figure 54

Figure 55
 Dial test indicator with magnetic base

67. Clean the power take-off's contact faces and apply a bead of silicone of approx. 2 mm (0.08 in). Place an extra bead
around the holes for the guide pins.

Figure 56

68. Assemble the power take-off and the transmission housing (8 bolts).

Figure 57

69. Apply a 2 mm (0.08 in) bead of silicone on the transmission housing's contact faces.

Figure 58
70. Install the gear for the compressor in the transmission housing.

Figure 59

71. Apply silicone (part no. 11713514) around the opening for the lubrication oil channel and install the O-ring.

Figure 60

1. Lubrication oil channel

2. O-ring

NOTE!
The transmission housing has to be installed and torque-tightened within 20 minutes of applying the sealant.

72. Align the transmission housing with the engine block. Install the bolts, for tightening torque, see section
215 Engine transmission, specification
 Figure 61

1. M10 lifting eyes

73. Place a 2 mm (0.08 in) bead of sealant (part no. 11713514) on the upper transmission housing's contact face
against the cylinder head. Install the rubber seals.

Figure 62

74. Install the upper housing on the flywheel housing. Tighten the bolts by hand. Press down the housing with 9998389
Press tooland 9998601 Installation tool so that the cylinder head's and transmission housing's sealing surfaces are
flush. For tightening torque, see section 215 Engine transmission, specification

Figure 63
 1. 9998389 Press tool

75. Install the compressor.Weight 16 kg (35 lbs).

Figure 64

76. Install the oil connection and pressure pipe for the compressor.

77. Install the oil trap with associated cooling circuit.

Figure 65

78. Install inlet pipe and preheating coil.

 Figure 66

1. Preheating coil
2. Induction pipe

79. Install the engine mount.

80. Install the camshaft sensor, speed sensor for the flywheel as well as their connectors. If the speed sensor has been
changed, a new adjustment shall be performed. See section: 210 Engine rotation speed sensor (camshaft), replacing

81. Install the valve cover. For tightening torque, see section 211 Tightening torques, valve cover

82. Install tool 9990117 Cone on 9990113 Installation tool Apply silicone-based grease, part no.: 1161325 on the seal
lip. Place the seal on 9990113 Installation tool via 9990117 Cone. Remove 9990117 Cone.

Figure 67

83. Install the rear crankshaft seal with 9990113 Installation tool and 9992000 Handle.

Figure 68
84. Install the O-ring in the housing for the small gear.

Figure 69

85. Install bearing and gear on the upper shaft. Install suitable spacer between the bearings so that correct clearance is
obtained when tightening, see 215 Engine transmission, specification. Secure in a vice and measure the clearance
with dial indicator acc. to figure.

Figure 70

1. Sleeve as spacer for bearing

2. Dial test indicator with magnetic base

NOTE!
The gear must be rotated at least five revolutions when tightening.

86. Install the gear, roller bearing, shaft, and suitable spacer ring without tightening the bolts completely, see section
482 Power take-off, tightening torque ("First tightening") and rotate the gears.

Figure 71
 NOTE!
Without shims the distance is 0.3-1.45 mm (0.01 - 0.05 in) between the shaft's flange and the PTO-housing,
depending on different tolerances. The distance must be measured to enable installation of correct number of
shims. To obtain correct bearing preload, the distance shall be 0.3 ± 0.1 mm (0.01 ± 0.004 in) between the shaft's
flange and the PTO-housing before the bolts are tightened completely.

87. Loosen the bolts and measure the distance (t) between the housing and shaft. Then subtract 0.3 mm (0.01 in) from
the above measurement. s= t - 0.3 mm (0.01 in) This gives the correct shims pack (s).

Figure 72
s = t – 0.3 mm (0.01 in)

88. Remove the shaft and install shims.

89. Apply thread locking fluid, medium. Tighten the bolts, for tightening torque, see
482 Power take-off, tightening torque ("Second tightening"). Now the distance will be zero and the bearings will
have correct preload.

90. Push in the striker plates.

Figure 73

91. Install the gear.

 Figure 74

92. Pry out the old seal ring from the cover.

Figure 75

93. Apply silicone-based grease, part no.: 1161325 on the seal.

94. Press in the new seal ring with 9990113 Installation tool and 9992000 Handle. Make sure that the contact face is
clean.

95. Change the O–ring. Lube the new O–ring with some vaseline.

Figure 76

96. Install the outer lock.

 Figure 77

97. Install the ring gear, sensor ring, flex plate, and thrust plate. Tightening torque, see section:
216 Flywheel, tightening torques

98. Install the oil sump.

 Service Information

Document Title: Function Group: Information Type: Date:

Oil cooler, replacing 491 Service Information 2014/7/31
Profile:
ART, A25D [GB]

Oil cooler, replacing

Op nbr 491-006

Conditions
To change oil cooler, the engine and transmission shall be removed from the machine, see:
210 Engine and transmission, removing

Rear oil cooler

1. Disconnect and move aside the oil pipes that come from the retarder valve. Plug all openings. Loosen and remove
the coolant pipe and the rubber gaiter that are installed above the oil cooler. Disconnect the other coolant
connection and move aside the pipe.

Figure 1

2. Remove the oil cooler's flat iron bar and tensioning plates.
NOTE!
Retain the pipe spacers

Figure 2
 1. Pipe spacer
2. Tensioning screw
3. Through-bolt

3. Lift away the oil cooler.

Weight: approx. 25 kg (33 lbs)

4. Repeat the steps for the oil cooler installed on the engine's inlet side.

Installing

5. The oil coolers rest on rubber pads. Change to new ones and install them.

Figure 3

6. Lift the oil coolers into place.

Weight: approx. 25 kg (33 lbs)

7. Install new rubber-coated tensioning plates.

NOTE!
Fit the pipe spacers

8. Install the tensioning plates with the bolts through the spacer sleeves.

9. Loosen the lock nut and torque-tighten the bolt that acts on the tensioning plates. Lock with the lock nut and
repeat on the other tensioning bolts. See: 490 Oil cooler, specifications

Figure 4

1. Pipe spacer
2. Tensioning screw
3. Through-bolt
10. Install the coolant pipes and the oil pipes with new O-rings and clamps. Make sure that hoses and pipes cannot
chafe or rub against each other. Tightening torque for hose clamps, see: 200 Engine, tightening torques

Figure 5

11. Secure the hoses with cable ties.

12. Repeat the steps for the oil cooler installed on the engine's inlet side.
 Thank you for your purchase.
Have a nice day.

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