4 Power Transmission

Service Information
Document Title: Function Group: Information Type: Date:

Clutches, brakes and 400 Service Information 2014/6/26
solenoids
Profile:
Clutches, brakes and solenoids
Figure 1
Table for clutches, brakes and solenoids
Explanation of = applied / (activated)

symbols:
= provides a variable modulating pressure, see description of S11 and S13
= lockup engaged depending on speed, acceleration and retardation
= activated through low pressure
Service Information

Component descriptions 400 Service Information 2014/6/26
Profile:
Component descriptions
ECU Control unit
controls the gear shifting with the aid of information from a number of sensors and switches. This
information is compiled and signals are sent out to solenoids for speed gears, solenoid valves etc.
The ECU also has built-in safety functions, e.g. overspeed protection, protection against incorrect handling
of the gear selector control, etc. (see the Operator"s Manual).
A connector socket for operating with the ECU by-passed in emergencies, is positioned behind the ECU. In
case of a fault in the ECU, connector plugs EA and EB are moved from the ECU to the connector socket to
by-pass the ECU. With this connection it is possible to move the machine forward and reverse in 2nd and
3rd gear.
CAUTION
Note that all safety functions are disconnected.
Contronic display unit (optional)
SW1 Ignition switch

SW2 Gear selector control
Lever position
Reverse: 1st and 2nd gear
Neutral: Brake for 1st gear pressurised
Drive: 1st to 6th gear
3: 1st to 3rd gear
2: 1st and 2nd gear
1: 1st gear (can shift to 2nd gear, but only because of the engine overspeeding protection)
SW47 Switch retarder on/off (serial No. 2901–, US 60001–)

By switching on the switch, the ECU receives signal when retarder is requested (see SE100).
SW99 Switch for gear-shift inhibitor
affects the gear-shifting programme so that upshifting is prevented and downshifting takes place at a
lower engine speed than normal. Upshifting because of overspeeding takes place regardless of the
position of the switch.
S1 – 5 Solenoids for gears
are energised by the ECU in different combinations depending on the required gear (see [Invalid
linktarget] ). The ECU directs the signals to the solenoids in such a way that there will be a certain overlap
of the gears, i.e. one gear remains engaged while the next gear is being applied.
S7 Solenoid for forward gear
When solenoid S7 is energised, clutch 1 for forward gears is applied.
S8 Solenoid for reverse gear

S8 applies and releases clutch K2. Application takes place when S8 is not energised. Solenoid S8 is
energised (clutch 2 is released) in all forward gears apart from 6th gear. When 6th gear forward is
engaged, clutches 1 and 2 are applied. This is achieved by energising S7, but not S8.
S9 Solenoid for lockup
S9 applies the lockup clutch. The ECU interprets the information from SE4 and applies the lockup clutch,
when the correct output speed has been reached. This applies to the 1st, 2nd and 3rd gears. In 4th, 5th
and 6th gear the lockup clutch is always applied.
S11 Modulator valve, main clutch pressure
controls the main clutch pressure in the transmission depending on load or lockup operation. The
modulator valve is controlled by signals from the ECU. If a high load is registered by the ECU (via SE57),
the ECU sends out a signal to the modulator valve which provides a high modulating pressure. This
results in a harder application of the gears. Conversely, a low load will result in a lower modulating
pressure and a softer application of the gears. When operating with the converter engaged, the main
pressure is 1.5 ±0.1 MPa (218 15 psi), but when lockup is engaged, the ECU lowers the pressure to
1.0 MPa (145 psi) via a signal to the modulator valve.
S13 Modulator valve, brake pressure
controls the pressure in the brakes depending on the load. The modulator valve is controlled by signals
from the ECU. If a high load is registered by the ECU (via SE57), the ECU sends out a signal to the
modulator valve which provides a high modulating pressure. This results in a harder application of the
gears. Conversely, a low load will result in a lower modulating pressure and a softer application of the
gears.
SE3 Sensor for input speed
is positioned behind the torque converter where it registers the input speed in the transmission and
monitors overspeeding of the engine. The signals from SE3 and SE86 are compared by the ECU to check
that there is no slippage in the lockup clutch. This check is only carried out when the transmission is
operating with the lockup engaged.
SE4 Sensor for output speed
is positioned on the rear cover of the transmission and is pointing downward. It provides the ECU with
information about the travelling speed of the machine and whether the machine is accelerating or
retarding. This information is used for determining the gear-shifting points. The signals from SE4 and
SE86 are compared by the ECU to check that no slippage arises in the brakes and clutches.
SE11D Sensor, oil sump temperature
If the oil sump temperature exceeds 120 °C (248 °F), the central warning will be switched on and retarder
use is prevented until the temperature has dropped to 110 °C (230 °F).
SE11E Sensor, oil level in transmission – combined with SE11D

If the oil level in the transmission oil sump drops to minimum on the oil dipstick, the ECU receives a
signal and the central warning is activated.
SE12 Sensor, lubricating oil pressure
the ECU checks the transmission lubricating oil pressure via SE12 which should be closed when the
engine is turned off and open when the engine has been started.
SE13 Sensor for retarder oil temperature
is not connected to the ECU, but only to the retarder temperature gauge on the instrument panel. If the
oil temperature from the retarder reaches 145 °C (293 °F) the temperature gauge IM31 (serial No. –2900),
IM1 (serial No. 2901–, US 60001–) will indicate within the red sector and the central warning buzzer will
sound.
SE37 Sensor for raised dump body
is activated when the front edge of the dump body is raised more than 200 mm (8 in).
SE53 Sensor, no-throttle position registered
the ECU sends a signal when no-throttle position is registered = accelerator pedal is let up.
SE56 Sensor, retarder requested
When the foot control for the retarder is pressed down, air is allowed to reach SE56 which provides the
ECU with a signal that retarder has been requested. The ECU checks that:
 the pressure sensor for retarder requested is closed (SE56)

 the travelling speed of the machine exceeds 1.8 km/h (1.1 mph) (SE4)
 the oil sump temperature is below 120 °C (248 °F) (SE11D)
 the engine speed exceeds 840 rpm (SE3)
SE57 Sensor, turbo boost pressure

registers the pressure in the inlet manifold of the engine. The pressure is converted to a signal which is
used by the ECU for adjusting the modulating pressure (see S11 and S13) and to check that the
accelerator pedal is released when retarder is requested.
SE86 Sensor for turbine speed
is positioned on the left side of the transmission, inside the cover where the electrical connector on the
transmission is positioned. The ECU compares the signal from SE86 with the signal from SE3 and SE4 to
check that slippage does not arise in the lockup clutch, other clutches or brakes. The lockup check is only
carried out when the transmission is operating with the lockup engaged.
SE100 Sensor, retarder on/off (serial No. 2901– , US 60001–)

When the sensor in the foot brake valve closes (before the service brakes are applied) the ECU receives a
signal that retarder is requested. The ECU checks that:
 the switch retarder on/off is switched on

 the travelling speed of the machine exceeds 1.8 km/h (1.1 mph) (SE4)
 the oil sump temperature is below 120 °C (248 °F) (SE11D)
 the no-throttle position has been registered (SE53)
 the engine speed exceeds 840 rpm (SE3)
 the accelerator pedal is released (SE57)
SE107 Sensor, gear-shift inhibitor parking brake

When the sensor is open (the parking brake applied) in neutral position, the transmission is not
permitted to leave neutral position, if D, 3, 2, 1 or R is selected.
MA8 Solenoid valve, retarder engagement
is energised, if the conditions are met during the check carried out by the ECU when retarder is
requested, and allows air to reach the retarder valve. When the retarder is disengaged, the air is drained
through MA8.
MA151 Solenoid valve, retarder on/off, overspeed protection (serial No. 2901–, US 60001–)
When retarder is requested the solenoid valve is energised and allows air to reach the retarder valve, if
the prerequisites are met during the ECU check (see SE100)
the overspeed protection activates the solenoid valve and air is allowed to reach the retarder valve after
a delay of 2.0 seconds at engine speeds between 2400 and 2500 rpm. This will take place immediately at
engine speeds above 2500 rpm in 6th gear and in 2nd gear in reverse.
IM1 Retarder temperature gauge (serial No. 2901–, US 60001–)
shows the actual oil temperature in the retarder valve. The temperature gauge is not connected to the
ECU.
IM31 Retarder temperature gauge (serial No. –2900)
shows the actual oil temperature in the retarder valve. The temperature gauge is not connected to the
ECU.
Service Information

Description 400 Service Information 2014/6/26
Profile:
Description
The flywheel housing and the power take-off for driving the hydraulic pumps are built to form one unit. Lubrication takes
place via the engine lubrication system and the oil is transferred back to the engine via a built-in pump.
A drive disc, positioned in the flywheel housing, drives the torque converter in the transmission.
The transmission is of a planetary type and fully automatic with six forward gears and two reverse gears. Lockup is available
in all gears, apart from the reverse gears. The automatic gear shifting is controlled by an electronic control unit which, via the
transmission control system, provides the correct gear in relation to the travelling speed. A hydraulic retarder is also built
into the transmission.
The dropbox has a differential with a locking function.
The ground-dependent hydraulic pump for the secondary steering system is also positioned on the dropbox.
The dropbox is driven from the transmission via a propeller shaft and in its turn drives the front and rear drive axles via
propeller shafts.
The drive axles have a differential with differential lock and are provided with planetary gears positioned in the hubs, so
called hub reduction gears.
The 6-wheel drive can be engaged and disengaged while on the move and is operated together with the longitudinal
differential lock.
Figure 1
Power transmission
1 Engine 8 Propeller shaft (steering joint)

2 Flywheel housing and power take-off 9 Propeller shaft (frame joint)
3 Transmission 10 Intermediate shaft
4 Propeller shaft 11 Front bogie axle (trailer unit) with dropbox 6x6
5 Dropbox 12 Propeller shaft
6 Propeller shaft 13 Rear bogie axle (trailer unit)
7 Front drive axle (tractor unit)
Service Information

Diagnosis using Service 400 Service Information 2014/6/26
Display Unit
Profile:
Diagnosis using Service Display Unit

Error codes
The table below shows a summary of the error codes which may appear on the display unit and the most likely cause of the
fault/error.
In addition to the error code the following trouble-shooting diagram also shows fault symptom, whether the error code
triggers the central warning, type and number of flashes of the LED on the ECU, probable error cause and the action
required to rectify the fault.
∗) Error codes marked with an ∗ in the table will be shown as long as the fault remains. The other error codes are shown
even if an intermittent fault has arisen, i.e. they are stored and displayed until the ignition is turned off.
Service Information

Error messages 400 Service Information 2014/6/26
Profile:
Error messages
Display Cause Transmission fault Central
warning
411 Speed sensor ER Electrical fault sensor circuit (SE4) yes
412 Engine speed ER Electrical fault sensor circuit (SE3) yes
413 Turbine speed ER Electrical fault sensor circuit (SE86) yes
417 Turbo boost pressure Electrical fault sensor circuit (SE57) yes
ER
418 Gear lever ER Electrical fault, gear selector control yes
421 Transmission temp ER Temperature signal missing (SE11C) yes yes
422 Transmission temp Temperature above 110° C (212 °F) yes
high∗
423 Transmission temp Temperature above 120 ° C (248 °F) yes yes
high∗
424 Transmission temp ER Temperature signal, short-circuited to ground yes yes
425 Transmission pressure Electrical fault sensor circuit (SE12) yes yes
ER∗
426 Transmission pressure Too low lubricating oil pressure in the transmission yes yes
low∗
427 Transmission level low Lubricating oil level too low (SE 11E) yes yes
431 Transmission ER Solenoid S1 short-circuited to ground yes yes
442 Transmission ER Retarder solenoid valve short-circuited to ground (MA8) yes yes
443 Transmission ER Solenoid S9 (lockup) short-circuited to ground yes
444 Transmission ER Solenoid S11 (modulation) short-circuited to ground yes
445 Transmission ER Solenoid S13 (modulation) short-circuited to ground yes
446 Transmission ER (serial Solenoid valve, retarder on/off short-circuited to ground yes
No. 2901–, US 60001–) (MA151)
448 Transmission ER Exhaust retarder solenoid valve short-circuited to ground yes
(MA49)
451 Transmission ER Solenoid S1 open circuit or short-circuited to 24 V yes yes
462 Transmission ER Retarder solenoid valve open circuit or short-circuited to yes yes
24 V (MA8)
463 Transmission ER Solenoid S9 (lockup) open circuit or short-circuited to 24 V yes
464 Transmission ER Solenoid S11 (modulation) open circuit or short-circuited to yes yes
24 V
465 Transmission ER Solenoid S13 (modulation) open circuit or short-circuited to yes
24 V
466 Transmission ER (serial Retarder solenoid valve on/off open circuit or short- yes
No. 2901–, US 60001–) circuited to 24 V (MA151)
468 Transmission ER Exhaust retarder solenoid valve open circuit or short- yes
circuited to 24 V (MA49)
488 High engine speed Too high engine speed to leave neutral position
489 High speed Overspeeding (> 2800 rpm) yes yes
491 Slippage ER∗ Slippage, turbine speed higher than output speed yes yes
492 Slippage ER∗ Slippage, turbine speed lower than output speed yes yes
493 Slippage ER∗ Slippage, lockup, that is, engine speed not the same as yes yes
turbine speed
498 Voltage low ER∗ ECU feed voltage lower than 21.5 V yes yes
Service Information

Gearshifting control (serial 400 Service Information 2014/6/26
No. 2901–, 
US 60001–)
Profile:
Gearshifting control (serial No. 2901–,

Gear shifting is controlled by a number of sensors and switches, which are positioned at various points in the transmission.
The signals from sensors and switches are fed to a control unit (ECU), which, after computing the input signals, sends out
signals to solenoids for speed gears, solenoid valves etc. An overview of the gear shifting system is shown in [Invalid
linktarget] . The function of the component parts is described on the following pages.
Figure 1
Gearshifting control
Service Information

Gearshifting control (serial 400 Service Information 2014/6/26
No. –2900)
Profile:
Gearshifting control (serial No. –2900)

Gear shifting is controlled by a number of sensors and switches, which are positioned at various points in the transmission.
The signals from sensors and switches are fed to a control unit (ECU), which, after computing the input signals, sends out
signals to solenoids for speed gears, solenoid valves etc. An overview of the gear shifting system is shown in [Invalid
linktarget] . The function of the component parts is described on the following pages.
Figure 1
Gearshifting control
Service Information

Missing signal from both 400 Service Information 2014/6/26
engine speed sensor
(SE3) and travelling speed
sensor (SE4)
Profile:
Missing signal from both engine speed sensor (SE3) and travelling
speed sensor (SE4)
When the engine is started, the lubricating oil pressure in the transmission will open sensor SE12. As the ECU does not get a
signal from SE3, this is interpreted as if the engine were turned off and the signal from the open sensor SE12 is interpreted
as incorrect and error code ER 425 is shown.
If the machine is operated, only ER 425 will be shown. The ECU interpreters the missing signals from SE3 and SE4 as if the
engine were turned off and the machine is stationary. The signal from the open sensor SE12 is interpreted as incorrect and
ER 425 is shown. If a fault, as described above, should occur, the transmission will not shift up from 1st gear.
Service Information

Missing signal from engine 400 Service Information 2014/6/26
speed sensor (SE3)
Profile:
Missing signal from engine speed sensor (SE3)

When the engine is started, the lubricating oil pressure in the transmission will open sensor SE12. As the ECU does not get a
signal from SE3, this is interpreted as if the engine were turned off. The signal from the open sensor SE12 is interpreted as
incorrect and error code ER 425 is shown.
If the machine is operated, ER 425 will be replaced by ER 412 (faulty sensor SE3), as the ECU receives information from SE4
that the machine is moving, but no engine speed is registered by SE3. If a fault as described above occurs, the transmission
will shift up as normal, but next time the gear selector is moved to ”N”, the transmission will remain in neutral.
Service Information

Other error causes 400 Service Information 2014/6/26
Profile:
Other error causes

Symptom Probable error cause Action
No or weak retarder action.
1. Faulty sensor SE56 or cable 1. Connect a service display unit. Check Fig.
harness to the same. 5.12, number 10. A digit "1" should be
2. No air to SE56. shown when retarder is requested and a
3. MA8 or cable harness to the digit "0" should be shown when retarder
same are faulty. is not requested. If there are deviations,
4. Faulty retarder valve. investigate sensor SE56 and measure
5. Faulty air pressure regulator resistance according to “Pin numbering
for retarder. in EB”.
2. Disconnect the air hose to MA8, engage
the retarder and check that air is
available at the solenoid valve. If not,
investigate the air system.
3. Connect a service display unit. Operate
the machine at a speed above 1.8 km/h
(1.1 mph). The oil sump temperature
should be below 120 °C (248 °F).
Let up the accelerator pedal and request
retarder. Check function group 5.12,
number 3. A digit "1" should be shown
when retarder is requested and a digit
"0" should be shown when retarder is
not requested.
If a digit "1" is shown and the retarder is
not engaged, check MA8 and the cable
harness for the same.
Measure resistance according to “Pin
numbering in EB”.
4. Check the retarder oil pressure according
to section “Pressure regulator for
retarder, checking and adjusting”.
5. Check and when necessary adjust the
pressure regulator for the retarder, see
section "Pressure regulator for retarder,
checking and adjusting”.
The transmission does not

shift up, or only shifts down 1. Switch for gear-shift inhibitor 1. Check the position of SW99.
when the gear selector control (hold function) SW99 is 2. Connect a service display unit.
is moved to and from ”D” and switched on. Put the gear selector control in position
”N” 2. A fault has occurred in SW99 D.
or the cable harness to the Check function group 6.13 where the
same. second letter after the information text
3. Retarder switch SE56 is Position should be an "H" and under
faulty. number 18 a digit "1" should be shown
4. Air leakage to SE56. when SW99 is switched on. If SW99 is
not switched on, the second letter after
Position not be visible. Under number
18 a digit "0" should be shown. If there
are deviations measure resistance
according to ”Pin numbering in EB”.
3. Connect a service display unit.
Put the gear selector control in position
D.
Check Fig. 5.12, number 10. A digit "1"
should be shown when retarder is
requested and a digit "0" should be
shown when retarder is not requested. If
a digit "1" is shown even though retarder
has not been requested, check SE56 by
disconnecting the cable harness from the
same. If the digit "1" now changes to a
digit "0", SE56 is faulty.
4. Disconnect the air line to MA8. Check
that there is no air flow, apart from when
the floor pedal is depressed.
The machine shifts abnormally

hard. 1. Hose rupture between SE57 1. Check the hose between SE57 and the
and the induction manifold. induction manifold.
2. The ECU does not calibrate 2. Connect a service display unit.
relative to the turbo boost Check function group 6.12.
pressure. After information text Thr the first digit
3. The modulator valve is out of shown should "4" when the engine is
order. started.
Stall the engine/machine and check that
the 1st digit is "0" at idling.
If there are deviations, the ECU or SE57
are faulty.
3. Check the modulator valve according to
the section “Checking main, torque
converter and lubricating oil pressures”.
Service Information

Transmission, clutches and 400 Service Information 2014/6/26
brakes
Profile:
Transmission, clutches and brakes
Figure 1
Transmission
Sensors and solenoids in the transmission Clutches and brakes in the transmission
S1–S5 Solenoids, speed gears K1 Forward, 6th gear
S7 Solenoid, forward gear K2 Reverse, 6th gear
S8 Solenoid, reverse gear, 6th gear forward B1 4th gear
S9 Solenoid, direct drive clutch (lockup) B2 5th gear
S11 Modulator valve, gear shifting B3 3rd gear
S13 Modulator valve, gear shifting B4 2nd gear
SE3 Sensor, engine speed, input speed (transmission) B5 1st gear
SE11D Sensor, transmission oil temperature (oil sump) A Control system
SE11E Sensor, transmission oil level (oil sump) B Pump
SE12 Sensor, low lubricating oil pressure C Torque converter
SE86 Turbine speed, behind junction box for transmission D Retarder
connector
Sensors and solenoid valves on and outside the transmission, connected to the gear-shifting system
SE4 Sensor, travelling speed, output speed
SE13 Sensor, transmission oil temperature (torque converter and retarder)
SE43 Travelling speed sensor (speedometer)
SE56 Sensor, retarder engagement
SE57 Sensor, turbo boost pressure
MA8 Solenoid valve, retarder engagement
MA151 Solenoid valve, retarder on/off (serial No. 2901–, US 60001–)
Pressure checks
Pressure is checked at 1200 rpm and at oil temp. 70°C (158 °F).
Table for oil pressures
Pressure checks in automatic position, ECU connected

N D R
Converter Lockup
P1 ∗0.56 ±0.08 MPa (81 ±12 ∗1.5 ±0.15 MPa (218 ±22 1.0 ±0.15 MPa (145 ±22 ∗1,8 ±0.18 MPa
psi) psi) psi) (261,1 ±26 psi)
PC1 ∗0.56 ±0.08 MPa (81 ±12 X X X
psi)
PS 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa
psi) psi) psi) (33 ±10 psi)
K1 X ∗1.5 ±0.15 MPa (218 ±22 1.0 ±0.1 MPa (145 ±15 X
psi) psi)
K2 X X 1.0 ±0.1 MPa (145 ±15 1.6 ±0.16 MPa
psi) (232 ±23 psi)
B1 X X 1.0 ±0.1 MPa (145 ±15 X
psi)
B2 X X 1.0 ±0.1 MPa (145 ±15 X
psi)
B3 X 1.2 ±0.12 MPa (174 ±17 1.0 ±0.1 MPa (145 ±15 X
psi) psi)
B4 X 1.3 ±0.12 MPa (189 ±17 1.0 ±0.1 MPa (145 ±15 1.3 ±0.12 MPa
psi) psi) (189 ±17 psi)
B5 0.2 ±0.2 MPa (29 ±29 psi) 1.3 ±0.12 MPa (189 ±17 1.0 ±0.1 MPa (145 ±15 1.3 ±0.12 MPa
psi) psi) (189 ±17 psi)
lockup X X 1.0 ±0.1 MPa (145 ±15 X
psi)
NOTE!
Pressure for P1 and K1 marked with an ∗ must be measured with the machine stationary.
The gear selector control is used for selecting the gear shifting range. The engagement of the respective gears is controlled
by the control unit after impulses from sensor (SE4). Clutches and brakes are controlled by the solenoids via relay valves in
the transmission control system.
In order to engage the required gear, a combination of clutches and brakes are applied according to [Invalid linktarget] .
During a gearshift, a clutch/brake set is applied at the same time as the previously engaged set is released.
Pressure checks when a device for operating with the ECU disconnected has been connected
N D R
Converter Converter Converter
P1 2.0 0.2 MPa (290 29 psi) 2.0 0.2 MPa (290 29 psi) 2.0 0.2 MPa (290 29 psi)
PC1 0.56 0.08 MPa (81 12 psi) 0.56 0.08 MPa (81 12 psi) 0.56 0.08 MPa (81 12 psi)
PS 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi)
K1 X 2.0 0.2 MPa (290 29 psi) X
K2 X 1.9 0.2 MPa (276 29 psi) 1.9 0.2 MPa (276 29 psi)
B4 X 1.9 0.2 MPa (276 29 psi) 1.9 0.2 MPa (276 29 psi)
Pressures according to table 2 indicate that springs and spools in the control system function satisfactorily.
CAUTION
When a device for operating with the ECU disconnected has been connected, the protecting and monitoring systems for the
transmission are not functional.
Other pressure checks

Check Checking point Pressures ±0.1 MPa (15 psi) Note

Function, P1 1.5 MPa (218 psi) during converter The drop in pressure from 1.5 MPa to
modulator valve operation 1.0 MPa (145 psi) during 1.0 MPa indicates that the modulator valve
pwm1 lockup operation pwm1 functions satisfactorily.
Function, B5 0.2 MPa (29 psi) Only in neutral.
modulator valve
pwm2
Retarder, PR2 0.05 MPa (7 psi) below the air Operate the machine with the gear selector
pressure pressure to the retarder valve control in position ”D”, with the accelerator
pedal released and at a speed exceeding
1.8 km/h (1.1 mph). Read off the pressure.
Lockup PLU 1.0 MPa (145 psi) Operate the machine sufficiently fast for
the lockup to remain engaged.
Service Information

Trouble-shooting diagram 400 Service Information 2014/6/26
Profile:
Trouble-shooting diagram
∗) Error codes marked with an ∗ in the table will be shown as long as the fault remains. The other error codes are shown
even if an intermittent fault has arisen, i.e. they are stored and displayed until the ignition is turned off.
Error code Symptom Probable error cause Action Service display unit
screen (figure) No.
411 Speed If the gear selector control Faulty sensor or cable
sensor fault is moved to ”N”, the harness to the same. 1. Measure
SE4 transmission will remain in resistance in
”N”. Can shift from 2nd EA13 – 2.
Fig. 6.12
gear to gears 3-4-5-6. but Correct value:
Out: 0 – xxxx rpm
then only because of see curve
overspeeding of the “Measuring
engine. resistance SE3,
SE4 and SE86”
2. Measure EA13
and EA2 against
chassis
(ground). There
must be no
contact.
412 Engine No lockup in gears 1, 2 and Faulty sensor or cable

speed 3. If the gear selector harness to the same. 1. Measure
sensor fault control is moved to ”N” the resistance in
(SE3) transmission will remain in EA12 – 2 and
Fig. 6.12
”N”. (Connector on
In: = input engine speed
the
transmission V
– U) Correct
value: see curve
“Measuring
resistance SE3,
SE4 and SE86”.
2. Measure EA12
and EA2,
(Connector on
transmission V
and U) against
chassis
(ground). There
must be no
contact.
413 Turbine The central warning is Faulty sensor or cable
speed connected for 1.5 s when harness to the same. 1. Measure
sensor fault shifting up and down resistance in
(SE86) respectively EA25 – 2
Fig. 6.12
(Connector on
Turb: = turbine speed
transmission)
P – Q).
2. Measure EA25 –
2, (Connector
on transmission
P – Q) against
chassis
(ground). No
buzzer sound.
417 Shifting takes place at high Plastic pipes and nipples If plastic pipes and cable
Turbo boost pressure, hard gear shifts. from induction manifold harness are serviceable,
sensor fault to sensors may be replace sensors.
(SE57) broken or clogged.
Fig. 6.12
Sensors do not work.
Thr: yxxx
Cable harness faulty.
y= 0, 1, 2, 3 or 4
xxx = 80–250
418∗ Gear The transmission does not Faulty cable harness. Connect service display
selector fault leave neutral, or Faulty switch in the gear unit. Check according to
(SW2) alternatively goes into selector. function group 6.14.
neutral. Mechanical fault in the Continue according to
Fig. 6.14
gear selector. section ”Measuring
resistance in connector
EB”.
421 Oil Signal missing because Measure resistance in
temp. sensor of faulty sensor or cable EA10 –1 (Connector on
(SE11C) harness to the same. transmission W – X)
Correct value: ±10 %
Fig. 6.11
1800–2000 ohm at 0 °C
(32 °F), 900–1100 ohm at
20 °C (68 °F), 120 ohm at
85 °C (248 °F)
422∗ Oil Above 110 °C (230 °F). Frequent retarder and Adapt way of operation.
temp. sensor converter operation.
(SE11C)
Fig. 6.11
423 ∗ Oil Above 120 °C (248 °F) No Frequent retarder and
temp. sensor retarder. converter operation.
(SE11C)
Fig. 6.11
424 ∗ Oil Faulty sensor or cable
temp. sensor harness (short-circuited). 1. Measure EA10 –
(SE11C) 1 (Connector
on transmission
Fig. 6.11
W – X) Correct
value: ±10 %
1800–2000 ohm
at 0 °C (32 °F),
900–1100 ohm
at 20 °C (68 °F),
120 ohm at 85 °
C (185 °F)
2. Also measure
against chassis
(ground).
425 ∗ Faulty cable harness

Lubricating 1. The machine (open circuit). 1. Measure EA15 –
oil pressure shifts normally, Faulty sensor(s). 2 (Connector
sensor see action (lubricating oil, engine on the
Fig. 5.12 Number 2
(SE12), or according to speed, travelling speed). transmission Y
Normal oil pressure; 0
alternatively points 1 and 2. – Z) Correct
Low oil pressure; 1
engine 2. The machine does value: Max.
speed not shift up, 0.9 ohm (Use
sensor (SE3) action according the buzzer
to point 3. range on the
instrument).
2. Check
lubricating oil
pressure sensor
SE12.
3. Check the
engine speed
sensor SE3 and
the travelling
speed sensor
SE4. ER 425 will
be shown when
the engine is
started, but is
replaced by ER
412, when the
machine is set
in motion.
Signal from SE3
missing. See
explanation in
the section
”Missing signal
from SE3”.
4. Only Er 425 is
shown, when
the engine is
started and the
machine is set
in motion.
Signal missing
from both SE3
and SE4. See
explanation in
section
”Missing signal
from both SE3
and SE4”.
426 ∗ Low Error code is shown at Low oil level. Clogged

lubricating engine speed > 800 rpm. filter. 1. Check oil level,
oil pressure Faulty sensor. oil temperature
(SE12) Faulty lubricating oil and oil filter.
Fig. 5.12 Number 2
valve. 2. Measure the
Normal oil pressure; 0
Low oil temperature. lubricating oil
Low oil pressure; 1
pressure with a
pressure gauge,
see “Checking
main, torque
converter and
lubricating oil
pressures”.
3. If the pressure
is within
specified
values, check
SE12, see the
section
”Measuring
resistance”.
427 ∗ Low oil level. Measure EA14 – 1

Lubricating Faulty cable harness (Connector on
oil level (open circuit). transmission S – X).
(SE11E) Faulty sensor. Correct value max.
Fig. 5.12 Number 1
0.9 ohm.
Normal oil level; 1
Low oil level; 0
431 Shifts to neutral or to gear, Solenoid or cable Measure EA23 – 3
Solenoid where S1 is not used. harness, (+) positive feed (Connector on
(S1) short-circuited to transmission C – R).
ground. Correct value: 98 ohm
±10 %.
(S2) short-circuited to transmission D – R).
±10 %.
(S3) short-circuited to transmission E – R).
±10 %.
(S4) short-circuited to transmission F – R).
±10 %.
(S5) short-circuited to transmission G – R).
±10 %.
437 Shifts to neutral. Solenoid or cable Measure EA4 – 3
Solenoid harness, (+) positive feed (Connector on
(S7) short-circuited to transmission J – R).
±10 %.
438 Shifts to neutral. Solenoid or cable Measure EA6 – 3
(S8) short-circuited to transmission H – R).
±10 %.
442 Retarder Retarder does not work. Solenoid or cable Check cable harness for
solenoid harness, (+) positive feed solenoid valve.
valve (MA8) short-circuited to EA21 – EA3.
ground. Check solenoid valve by
measuring between
electrical terminals and
chassis. There must be
no contact.
443 Lockup does not work. Solenoid or cable Measure EA11 – 3
(S9) short-circuited to transmission K – R).
±10 %.
444 Hard gear shifts. Solenoid or cable Measure EA7 – 3
(S11) short-circuited to transmission B – A).
modulator ground. Correct value: 20–
valve 30 ohm at 20 °C (68 °F).
(S13) short-circuited to transmission M – T).
modulator ground. Correct value: 20–
446 Retarder Retarder does not work. Solenoid valve or cable Check solenoid valve
on/off (serial No. 2901–, harness, (+) positive feed and cable harness.
solenoid US 60001) short-circuited to
valve ground.
(MA151)
448 Solenoid MA49 or cable Measure resistance in
Solenoid harness, (+) positive feed cable harness and check
valve MA49 short-circuited to sensor.
(optional) ground.
451 Shifts to neutral or to gear, Cable harness or Measure EA23 – 3
Solenoid where S1 is not used. solenoid, open circuit or (Connector on
(S1) shorted to 24 V. transmission C – R).
Correct value: 98 ohm
±10 %.
452 Shifts to neutral or to gear, Cable harness or Measure EA5 – 3
(S2) shorted to 24 V. transmission D – R).
±10 %.
453 Shifts to neutral or to gear Cable harness or Measure EA17 – 3
(S3) shorted to 24 V. transmission E – R).
±10 %.
(S4) shorted to 24 V. transmission F – R).
±10 %.
(S5) shorted to 24 V. transmission G – R).
±10 %.
457 Shifts to neutral. Cable harness or Measure EA4 – 3
Solenoid solenoid, open circuit or (Connector on
(S7) shorted to 24 V. transmission J – R)
±10 %.
458 Shifts to neutral. Cable harness or Measure EA6 – 3
(S8) shorted to 24 V. transmission H – R).
±10 %.
462 Retarder does not work. Cable harness or Check cable harness for
Retarder, solenoid valve, open solenoid valve.
solenoid circuit or short-circuited EA21 – EA3.
valve (MA8) to 24 V. Check solenoid valve by
measuring between
electrical terminals and
chassis. There must be
no contact.
463 Lockup does not work. Cable harness or Measure EA11 – 3
(S9) shorted to 24 V. transmission K – R).
±10 %.
464 Hard gear shifts. Cable harness or Measure EA7 – 3
(S11) shorted to 24 V. transmission B – A).
Correct value: 20–
30 ohm at 20 °C (68 °F).
(S13) short-circuited to 24 V. transmission M – T).
modulator Correct value: 20–
466 Retarder Retarder does not work. Solenoid valve or cable Check solenoid valve
on/off (serial No. 2901–, harness, positive feed (+) and cable harness.
solenoid US 60001) short-circuited to 24 V.
valve
(MA151)
468 Cable harness or Measure resistance in
Solenoid solenoid valve MA49 cable harness and check
valve MA49 open circuit or short- sensor.
(optional) circuited to ground.
488 ∗ Too Forward and reverse not Engine speed above See error code ER 412
high engine available. 1100 rpm.
speed to Faulty engine speed
leave neutral sensor.
position
489 High Overspeeding engine.
speed Engine speed above
2400 rpm.
491 ∗ Long gear shifting times. Mechanical or hydraulic
Slippage Ending with a jerk. fault in the transmission. 1. Check the oil
Turbine Low oil level. level.
speed 2. Look for any
Fig. 6.12
higher than error code
travelling shown in
speed connection with
Er 491.
3. See ”Error
codes ER 417”
Error code Symptom Probable error cause Action Service display unit
screen (figure) No.
492 ∗
Slippage 1. Long gear shifting 1. Low oil level. 1. Check the oil
Turbine times during 2. Mechanical or level.
speed lower shifting with hydraulic fault 2. Check pressure,
Fig. 6.12
than retarder. Gear in the see section
travelling shifting ends with transmission. “Checking main,
speed a jerk. torque
converter and
lubricating oil
pressures”.
3. Look for any
error code
shown in
connection with
Er 492.
493∗ Mechanical or hydraulic

Slippage fault in the transmission. 1. Check the oil
lockup Low oil level, see SE86. level.
2. Look for any
Fig. 6.12
error code
shown in
connection with
Er 493.
498 The ECU Forward and reverse not Faulty batteries or cable Check the voltage at
feed voltage available. harness. checking point
below 21.5 V Faulty alternator. EB 1 – 2.
Fig. 5.11
Service Information

Connector EH 421 Service Information 2014/6/26
Profile:
Connector EH
Figure 1
Connector EH, lead end
Lead end
Socket No. Lead end, function

A S11 –, (PMW1)
B S11 +, (PWM1)
C S1
D S2
E S3
F S4
G S5
H S8
J S7
K S9
L -
M S13 +, (PWM2)
N -
P SE86, Turbine speed +
Q SE86, Turbine speed –
R (S1–S9)–
S SE11E, oil level
T S13 –, (PWM2)
U SE3, Input engine speed +
V SE3, Input engine speed –
W SE11D, Oil sump temperature +
X SE11D, Oil sump temperature –
SE11E, Oil level –
Y SE12, Lubricating oil pressure +
Z SE12, Lubricating oil pressure –
Transmission end
Pin No. Transmission end, function

A S11 –, (PWM1)
B S11 +, (PWM1)
C S1
D S2
E S3
F S4
G S5
H S8
J S7
K S9
L -
M S13 +, (PWM2)
N -
P SE86, Turbine speed +
Q SE86, Turbine speed –
R (S1–S9)–
S SE11E, oil level
T S13 –, (PWM2)
U SE3, Input engine speed +
V SE3, Input engine speed –
W SE11D, Oil sump temperature +
X SE11D, Oil sump temperature –
SE11E, Oil level –
Y SE12, Lubricating oil pressure +
Z SE12, Lubricating oil pressure –
Figure 2
Connector EH, transmission end
Service Information

General 421 Service Information 2014/6/26
Profile:
General
CAUTION
Tin-coated and silver-plated contacts must not be mixed in a transmission.
Tin-coated and silver-plated connectors must not be mixed because of the chemical reaction arising between the metals.
When changing to the tin-coated version, all parts concerned must be replaced.
Tin-coated contacts were introduced w.e.fr. serial No. 2641–,
(transmission type PT1663, serial No. 1662–)
Service Information

Multi-pin breaker 421 Service Information 2014/6/26
box
Profile:
Multi-pin breaker box

Part number 11 668 002
Figure 1
Multi-pin breaker box 11 668 002
1. ECU – EA connector
2. ECU – EB connector
3. ECU – EC connector
4. Transmission connector EH
5. Not used in A30C
6. Ground cable
The markings A, B, C etc. on the multi-pin breaker box correspond to the markings on connector EH, see [Invalid linktarget] .
The markings 1. 2. 3 etc. on the multi-pin breaker box correspond to the markings on connectors EA, EB and EC, [Invalid
linktarget] , [Invalid linktarget] and [Invalid linktarget] .
Service Information

Retarder, description of 421 Service Information 2014/6/26
function
Profile:
Retarder, description of function

The retarder is an hydraulic retarder that is mounted in the transmission. It consists of a rotor and a stator. During normal
operation there is no oil in the retarder and the rotor rotates freely with the main shaft (K1) in the transmission. The retarder
is applied in that the space between the stator and the rotor is filled with oil (the same principle as an ”inverted” torque
converter).
The retarder action is dependent on which gear is engaged;
lower gear – greater retarder effect
higher gear – smaller retarder effect.
The retarder is applied with compressed air. The air pressure is taken from the ordinary compressed-air system and reduced
to 650 kPa (6.5 bar) (94 psi).The retarder is applied with the retarder pedal. The retarder action are progressive.
Application with the retarder pedal
See [Invalid linktarget] .
When the retarder pedal (which works as a pressure-reducing valve) is pressed down, air pressure, in proportion to the
distance the pedal is depressed, is let through. The air pressure reaches sensor SE56 (retarder sensor) which is closed and
this is interpreted by the ECU as a request for retarder.
The following conditions must be met if the ECU is to apply the retarder.
 The accelerator pedal must be released, part throttle value = 0, which is registered by SE57 (turbo boost sensor).
 The travelling speed exceeds 1.8 km/h (1.1 mph), which is registered by SE4 (sensor, output speed).
 That the temperature in the transmission is not above 120 °C (248 °F), which is registered by SE11D (sensor,
transmission temperature). If the temperature has been above 120 °C (248 °F), the temperature must drop below
110 °C (230 °F) before the retarder can be used again.
 The engine speed exceeds 14 r/s (840 rpm), which is registered by SE3 (sensor, input speed).
If all conditions are met, the ECU will energise solenoid valve MA8, which opens and lets air pressure through to the retarder
valve and the retarder is applied. The air pressure to the retarder valve varies between 0–650 kPa (0–6.5 bar) (0–94 psi),
depending on how far the retarder pedal has been depressed.
Figure 1
Serial No. –2900
Application through the brake pedal (serial No. 2901–, US 60001–)

See [Invalid linktarget] .
When the brake pedal is being depressed, sensor SE100 (retarder sensor on/off) closes. This sensor is installed in the brake
pedal.
The following conditions must be met if the ECU is to apply the retarder.
 SW47 (retarder in brake pedal) switched on (closed).

 The accelerator pedal must be released, part throttle value = 0, which is registered by SE57 (turbo boost sensor).
 The travelling speed exceeds 1.8 km/h (1.1 mph), which is registered by SE4 (sensor, output speed).
 That the temperature in the transmission is not above 120 °C (248 °F), which is registered by SE11D (sensor,
transmission temperature). If the temperature has been above 120 °C (248 °F), the temperature must drop below
110 °C (230 °F) before the retarder can be used again.
 The engine speed exceeds 14 r/s (840 rpm), which is registered by SE3 (sensor, input speed).
If all conditions are met, the ECU energises solenoid valves MA151 and MA8 at the same time. The air pressure can now pass
through MA151 via MA8 to the retarder valve and the retarder is applied. The air pressure to the retarder valve is 650 kPa
(6.5 bar) (94 psi), which causes full retarder action to be obtained. At the same time sensor SE104 closes and stop lights LA29
and LA30 light up.
SW47 is used for connecting and disconnecting the retarder function in the brake pedal. This is a safety function, among
other reasons it is for preventing wheel locking during slippery road conditions, as the retarder action becomes very strong
when fully applied.
Overspeeding
There is a third case when the retarder is engaged and that is when the engine is overspeeding. The retarder is engaged:
 when the 6th gear has been reached and the engine speed exceeds 40 r/s (2400 rpm) for more than two seconds
 immediately if the engine speed exceeds 41.7 r/s (2500 rpm).
At the same time as the retarder is engaged as an overspeed protection, the lockup is disengaged. During the above
described process, the ECU energises solenoid valves MA151 and MA8 simultaneously.
Figure 2
Serial No. 2901–, US 60001–
Service Information

Checking 421 Service Information 2014/6/26
main, torque converter
 and lubricating oil
pressures
Profile:
Checking main, torque converter

Op nbr 43702
999 3335 Hose, 1 pc

999 3522 Quick-action coupling (female part), 1 pc
930032 Measuring nipple (male part), 1 pc
Pressure gauge, measuring range: 0–1 MPa
(0–10 bar) (0–145 psi)
Pressure gauge, measuring range:
0–2.5 MPa (0–25 bar) (0–363 psi)
Figure 1
Guard plates
1. Front guard plate

2. Rear guard plate, left
3. Rear guard plate, right
4. Front transverse member
5. Rear transverse member
WARNING
Hot oil may cause burns.
CAUTION
When checking pressures, the oil should be at normal operating temperature (70 °C) (158 °F).
1. Let down the rear guard plates (2) and (3) before checking, [Invalid linktarget] .
2. If the transmission oil pressure is to be checked in connection with manual gear shifting, the ECU must first be
disconnected. Therefore move connectors EA and EB to the connectors (A) and (B), see [Invalid linktarget] .
Figure 2
Control unit
EA, EB and EC Connectors. A and B Connectors
3. Check the transmission oil pressures at the outlets which are indicated in [Invalid linktarget] , [Invalid linktarget] and
[Invalid linktarget] (P1, PC1 and PS).
Figure 3
Transmission, left side
P1 Main pressure
4. Carefully clean around the checking points on the transmission. Remove any plugs and install measuring nipples,
quick-action couplings with hose and pressure gauge, see ”Tools”.
Figure 4
Transmission, right side
PC2 Torque converter pressure, OUT

PS Lubricating oil pressure
K2 Clutch pressure, reverse gear
B1–B5 Clutch pressure, brakes
PR1 Retarder pressure IN
PR2 Retarder pressure OUT
5. Apply the foot brake and release the parking brake, so that the wheels are locked and the machine cannot move.
CAUTION
Make sure that there is nobody in front of or behind the machine.
Figure 5
Transmission, seen as from underneath
P1 Main pressure
K1 Clutch pressure forward gear
PC1 Torque converter pressure IN
PLU Lockup clutch pressure
6. Start and rev up the engine to 20.0 r/s (1200 rpm) during the pressure check.
7. Check the transmission oil pressures according to the following tables.
The pressure is checked at 1200 rpm and at an oil temperature of 70 °C (158 °F).

N D R
Converter Lockup
P1 ∗0.56 0.08 MPa (81 12 ∗1.5 0.15 MPa (218 22 1.0 0.15 MPa (145 22 psi) ∗1,8 0.18 MPa
psi) psi) (261,1 26 psi)
PC1 ∗0.56 0.08 MPa (81 12 X X X
psi)
PS 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10
psi)
CAUTION
Pressure for P1 K1 marked with an ∗ must be measured with the machine stationary.
N D R
P1 2.00 0.2 MPa (290 29 psi) 2.00 0.2 MPa (290 29 psi) 2.00 0.2 MPa (290 29 psi)
PC1 0.56 0.08 MPa (81 12 psi) 0.56 0.08 MPa (81 12 psi) 0.56 0.08 MPa (81 12 psi)
PS 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi) 0.23 0.07 MPa (33 10 psi)
Pressures according to the above table indicate that springs and spools in the control system function satisfactorily.
NOTE!
Service Information

Checking modulator valves, 421 Service Information 2014/6/26
retarder
and lockup
Profile:
Checking modulator valves, retarder and lockup

Checking Checking point Pressure ±0.1 MPa Note
Function, P1 1.5 MPa (218 psi) during converter The drop in pressure from 1.5 MPa to
modulator valve operation 1.0 MPa (145 psi) during 1.0 MPa indicates that the modulator valve
pwm1 lockup operation pwm1 functions satisfactorily.
Function, B5 0.2 MPa (29 psi) Only in neutral.
modulator valve
pwm2
Retarder, PR 2 0.05 MPa (7 psi) below the air Operate the machine with the gear selector
pressure pressure to the retarder valve control in position ”D”, with the accelerator
pedal released and at a speed exceeding
1.8 km/h (1.1 mph). Read off the pressure.
lockup PLU 1.0 MPa (145 psi) Operate the machine sufficiently fast for
the lockup to remain engaged.
Service Information

Checking pressure in 421 Service Information 2014/6/26
clutches and brakes
Profile:
Checking pressure in clutches and brakes

The tables show the pressure levels required in the different brakes and clutches depending on the selected gear. Pressure
checking according to this table require that the machine can be operated. The pressure outlets are shown in [Invalid
linktarget] , [Invalid linktarget] and [Invalid linktarget] .
Pressure is checked at 1200 rpm and oil temp. 70 °C (158 °F).

N D R
Converter lockup
P1 ∗0.56 ±0.08 MPa (81 ±12 ∗1.5 ±0.15 MPa (218 ±22 1.0 ±0.15 MPa (145 ±22 ∗1,8 ±0.18 MPa
psi) psi) psi) (261,1 ±26 psi)
PC1 ∗0.56 ±0.08 MPa (81 ±12 X X X
psi)
PS 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa (33 ±10 0.23 ±0.07 MPa
psi) psi) psi) (33 ±10 psi)
K1 X ∗1.5 ±0.15 MPa (218 ±22 1.0 ±0.1 MPa (145 ±15 X
psi) psi)
K2 X X 1.0 ±0.1 MPa (145 ±15 1.6 ±0.16 MPa
psi) (232 ±23 psi)
B1 X X 1.0 ±0.1 MPa (145 ±15 X
psi)
B2 X X 1.0 ±0.1 MPa (145 ±15 X
psi)
B3 X 1.2 ±0.12 MPa (174 ±17 1.0 ±0.1 MPa (145 ±15 X
psi) psi)
B4 X 1.3 ±0.12 MPa (189 ±17 1.0 ±0.1 MPa (145 ±15 1.3 ±0.12 MPa
psi) psi) (189 ±17 psi)
B5 0.2 ±0.2 MPa 1.3 ±0.12 MPa (189 ±17 1.0 ±0.1 MPa (145 ±15 1.3 ±0.12 MPa
(29 ±29 psi) psi) psi) (189 ±17 psi)
lockup X X 1.0 ±0.1 MPa (145 ±15 X
psi)
10 bar = 1.0 MPa, 14 bar = 1.4 MPa, 17 bar = 1.7 MPa
N D R
P1 2.0 ±0.2 MPa (290 ±29 psi) 2.0 ±0.2 MPa (290 ±29 psi) 2.0 ±0.2 MPa (290 ±29 psi)
PC1 0.56 ±0.08 MPa (81 ±12 psi) 0.56 ±0.08 MPa (81 ±12 psi) 0.56 ±0.08 MPa (81 ±12 psi)
PS 0.23 ±0.07 MPa (33 ±10 psi) 0.23 ±0.07 MPa (33 ±10 psi) 0.23 ±0.07 MPa (33 ±10 psi)
K1 X 2.0 ±0.2 MPa (290 ±29 psi) X
K2 X 1.9 0.2 MPa (276 29 psi) 1.9 0.2 MPa (276 29 psi)
B4 X 1.9 0.2 MPa (276 29 psi) 1.9 0.2 MPa (276 29 psi)
Pressures according to the above table indicate that springs and spools in the control system function satisfactorily.
NOTE!
Service Information

Measuring 421 Service Information 2014/6/26
resistance in cable harness
Profile:
Measuring resistance in cable harness

Op nbr 42150
999 6525 Multimeter
11 668 002 Multi-pin breaker box (incl. leads and connectors)
Figure 1
1. Disconnect connectors EA, EB and EC from the ECU. See [Invalid linktarget]
2. Connect multi-pin breaker box with connecting cable and ground cable. With the aid of the table, [Invalid
linktarget] , it is possible to determine which solenoids are energised for the different gears and then it is possible
to measure the resistance directly and determine any faults.
Figure 2
Measuring resistance in connector.
Explanation of symbols: = activated

= provides a variable modulating pressure, see description of S11 and S13
= lockup engaged depending on speed, acceleration and retardation
3. Measure and check against the values in the tables by [Invalid linktarget] , [Invalid linktarget] and [Invalid
linktarget] . Also measure against chassis ground. If the measuring of the connector on the transmission is
satisfactory and the measuring of connectors EA, EB and EC show up a deviating value, the fault is in the cable
harness or in some external sensor.
Service Information

Measuring resistance in 421 Service Information 2014/6/26
SE3, SE4 and
SE86
Profile:
Measuring resistance in SE3, SE4 and SE86
Figure 1
Measuring resistance in SE3, SE4 and SE86
Service Information

sensor for retarder
temperature (SE13)
Profile:
Measuring resistance in sensor for

Function Checking points Value ±10 %
Retarder temp. SE13 On the sensor 1030 ohm at 25 °C ( 77 °F)
–"– –"– 316 ohm at 50 °C (122 °F)
–"– –"– 81 ohm at 90 °C (194 °F)
–"– –"– 37 ohm at 120 °C (248 °F)
–"– –"– 21 ohm at 145 °C (293 °F)
Figure 1
Measuring resistance in SE13
Service Information

solenoids
Profile:
Measuring resistance in solenoids

Op nbr 42151
11 668 002 Multi-pin breaker box
(incl. leads and connectors)
11 666 140 Multimeter
1. Let down the rear left guard plate.
2. Remove the guard plate over the oil filter.
3. Disconnect the connector from the transmission and connect connecting cable, multi-pin breaker box and ground
cable, see [Invalid linktarget] , [Invalid linktarget] and [Invalid linktarget] .
Figure 1
Connecting multi-pin breaker box
4. Measure all points and check the values against the table below. Also measure all points against chassis ground.
There must be no contact. If the measured values are correct, the electrical system in the transmission is serviceable
and the fault is probably in the cable harness (EA).
NOTE!
For measuring SE12, checking points Z – Y, use the multimeter buzzer range, which is intended for values below
20 ohm.
Figure 2
Measuring resistance in connector EH
5. Re-install the connector on the transmission and the guard plate.
Function Checking points in connector Value 10 %

[Invalid linktarget] and [Invalid
linktarget] .
S1 R–C 98 ohm
S2 R–D 98 ohm
S3 R–E 98 ohm
S4 R–F 98 ohm
S5 R–G 98 ohm
S7, forward R–J 98 ohm
S8, reverse and 6th gear R–H 98 ohm
S9, Lockup R–K 98 ohm
S11 R – B[ 1]  25 ohm
S13 M–T 25 ohm
SE3, input engine speed U–V value according to [Invalid
linktarget]
SE11D, oil sump temp. X–W 1800–2000 ohm at 0 °C (32 °F)
900–1100 ohm at 20 °C (68 °F)
120 ohm at 85 °C (185 °F)
SE11 E, oil level X–S 0.7–0.9 ohm
SE12, lubricating oil pressure Z–Y 0.7–0.9 ohm
SE86, turbine speed P–Q value according to [Invalid
linktarget]
[ 1]serial No. –2640 (B–A), serial No. 2641– (R–B)

Service Information

Pin numbering in EA 421 Service Information 2014/6/26
Profile:
Pin numbering in EA
Figure 1
Pin numbering in EA
Function Checking points EA Value 10 %

S1 3 – 23 98 ohm
S2 3–5 98 ohm
S3 3 – 17 98 ohm
S4 3 – 22 98 ohm
S5 3 – 16 98 ohm
S7 3–4 98 ohm
S8 3–6 98 ohm
S9 3 – 11 98 ohm
S11 3–7 25 ohm at 20 °C (68 °F)
S13 3–8 25 ohm at 20 °C (68 °F)
MA8 3 – 21 60 ohm
SE3 2 – 12 See [Invalid linktarget]
SE11D 1 – 10 1800–2000 ohm at 0 °C
900–1100 ohm at 20 °C
120 ohm at 85 °C
SE11E 1 – 14 0.7–0.9 ohm
SE12 1 – 15 0.7–0.9 ohm
1000 ohm
Service Information

Pin numbering in EB 421 Service Information 2014/6/26
Profile:
Pin numbering in EB
Figure 1
Pin numbering in EB
Function Checking points EB Value 10 %

Gear position 1 EA2 – 14, 15, 16 0 ohm
Gear position 1 EA2 – 13, 17 ∞
Gear position 2 EA2 – 14, 15 0 ohm
Gear position 2 EA2 – 13, 16, 17 ∞
Gear position 3 EA2 – 14, 17 0 ohm
Gear position 3 EA2 – 13, 15, 16 ∞
Gear position D EA2 – 14, 16, 17 0 ohm
Gear position D EA2 – 13, 15 ∞
Gear position R EA2 – 13 0 ohm
Gear position R EA2 – 14, 15, 16, 17 ∞
Retarder SE100 triggered (closed) (SW47 on) EC12 – 23 0 ohm
(serial No. 2901–, US 60001–)
Retarder SE100 not triggered (open) EC12 – 23 ∞
(serial No. 2901–, US 60001–)
Exhaust retarder engaged EC12 – 24 0.5 ohm
Exhaust retarder not engaged EC12 – 24 ∞
Hold SW99 on EC12 – 18 0 ohm
Hold SW99 off EC12 – 18 ∞
Service Information

Pin numbering in EC 421 Service Information 2014/6/26
Profile:
Pin numbering in EC
Figure 1
Pin numbering in EC
Function Checking points EC Value 10 %

Lubricating oil pressure SE16 (serial No. –2900) EC15 – ground 0 ohm
Lubricating oil pressure SE16 (serial No. 2901–, EA1 – EB27, EA9 See figure below
US 60001–)
Parking brake pressure sensor SE107 (parking 12 – 5 0 ohm
brake released)
Parking brake sensor SE107 (parking brake 12 – 5 ∞
applied)
Figure 2
Feed voltage from EA9 = 5 V

Service Information

Retarder valve, replacing 421 Service Information 2014/6/26
seal
Profile:
Retarder valve, replacing seal

Op nbr 42157
The retarder valve is positioned on the right side of the transmission.

Removing
1. Remove the upper cover from the retarder valve and pull out the spool, see [Invalid linktarget] .
Figure 1
Retarder valve with spool pulled out
1. Drift
2. Hexagon key
2. Secure with a suitable drift in the leak-off hole on the spool.
Installing
3. Check the spool as regards damage. Replace the seal.
4. Check that the hexagon socket head bolt in the spool is tightened, see [Invalid linktarget]
NOTE!
If this is not the case, apply strong locking fluid and tighten down.
5. Re-fit the cover together with a new O-ring. See [Invalid linktarget] .
Figure 2
Service Information

Seal 421 Service Information 2014/6/26
for rear output shaft,
replacing
Profile:
Seal for rear output shaft, replacing

Op nbr 42154
Lifting sling, 2 m (6.5 ft)
Torque wrench 0–100 N m (0–74 lbf ft)
Ratchet block 750 kg (1653 lb)
Removing
1. Place blocks on either side of the wheels.

Remove the operator seat and the two rear floor plates.
NOTE!
Mark the air hoses on machines which are equipped with a seat with air-suspension.
2. Disconnect the propeller shaft from the transmission. Secure the propeller shaft.
3. Connect a ratchet block between the dropbox and the trailer unit and pull the dropbox rearward until the propeller
shaft clears any obstructions. See [Invalid linktarget] .
NOTE!
The dropbox is rubber mounted.
Figure 1
1. Lifting sling
2. Ratchet block
4. Remove three bolts. See [Invalid linktarget] .

Figure 2
1. Bolts with washers
5. Prize away the seal.
Installing
6. Carefully drive the seal in against the shoulder. Coat the lip of the seal with grease.
7. Install the drive flange.

Lock with bolts and washers.
Tightening torque: 75 N m (7.5 kgf m) (55 lbf ft).
8. Install the propeller shaft.

Tightening torque: 100 N m (10 kgf m) (74 lbf ft).
9. Install the floor plates and the operator seat (and connect the electrical leads and air lines to the seat on machines
which are equipped with such a seat).
10. Remove the ratchet block.
11. Test the function.

Service Information

Transmission 421 Service Information 2014/6/26
retarder valve, adjusting air
pressure
Profile:
Transmission retarder valve, adjusting air pressure

Op nbr 42159
930032-8 Measuring nipple
11 666 035-8 Hose
11 666 018 Manometer 0–2.5 MPa (0–25 bar) (0–363 psi)
The pressure regulator is positioned in the engine compartment under the expansion tank and the window washer reservoir.
Checking
1. Open up the engine hood.
2. Connect the measuring nipple, the hose and the pressure gauge, see [Invalid linktarget] .
Figure 1
1. Nipple
2. Hose
3. Pressure gauge 0–2.5 MPa (0–25 bar)
(0–363 psi)
3. Start the engine and operate the machine. Engage the retarder. Check the pressure, see [Invalid linktarget] . The
pressure in the transmission should be 0.65 MPa (6.5 bar) (94 psi).
CAUTION
To obtain retarder action, the travelling speed must exceed 1.8 km/h (1.1 mph) and the retarder pedal be fully
pressed down.
Figure 2
Checking retarder pressure
Service Information

Transmission, 421 Service Information 2014/6/26
removing – upward
through doorway
Profile:
Transmission, removing – upward through doorway

Op nbr 42168
999 3590 Gear

999 3681 Bracket right
999 3682 Bracket left
999 8002 Socket
E1643 Lifting tool
E1644 Lifting yoke
165 0540-6 Transport braces, 3 pcs
Bolt M16x45 mm, 4 pcs
Nut M16, 4 pcs
Puller Kukko 20-20
This method is to be used when there is sufficient lifting height.

The method assumes that there is an available lifting height of at least 4.90 m (16 ft) and that lifting tool according to
accompanying drawings is used.
The drawings are approved by AB Swedish Plant Inspection.
CAUTION
Before using the lifting tool it must be test-loaded with an overload of 50 % of its maximum rated load.
Our job description is based on that the work is carried out in a workshop which has a traverse hoist.
The method may of course also be used out-of-doors, if another approved lifting device, for example a mobile crane is
available.
WARNING
Removing
1. Turn off the current with the aid of the battery disconnect switch, see [Invalid linktarget] .
Figure 1
Battery disconnect switch
A On
B Off
2. Let down the rear guard plates (2) and (3), se [Invalid linktarget] .
Figure 2
Guard plates

4. Front member
5. Rear member
WARNING
Observe the greatest possible cleanliness when removing the main and lubricating oil filters together with
retainers. Make sure that no contaminants enter the transmission and the retarder valve respectively. Plug
all openings.
3. Drain the oil from the transmission.

Remove the right oil filter complete with retainer, plug.
Remove the guard plate by the connector on the transmission and the left oil filter complete with retainer, plug.
Disconnect the connector from the transmission and detach the cable harness bracket secured to the transmission
oil sump. Remove the bolted joint between the transmission and the lower half of the flywheel housing, 8 pcs
Use tool 999 8002 behind the pumps.
4. Disconnect the connector from the retarder valve.
5. Remove the door stop, the hand rail on the roof and the lock plate on the door frame.
CAUTION
The attaching plate on the door frame is loose. Fasten this when removing the lock plate.
6. Remove the floor mats and the operator seat.

NOTE!
Mark and remove the steering column complete with steering wheel.
7. Remove the floor plates, detach and tie up pedals, controls for retarder and differential lock / 6-wheel drive.
8. Disconnect the front steering rod by the front ball joint, use puller Kukko 20-20. Move it to one side, see [Invalid
linktarget] .
Figure 3
Steering rod
9. Remove the rack and pinion gear complete with bracket, see [Invalid linktarget] .
Figure 4
Rack and pinion gear
10. Disconnect the propeller shaft from the transmission.
11. Disconnect the hoses, the pipes and the cable harness around the transmission.
Remove the differential pressure sensor from the left non-return valve block. Plug, see [Invalid linktarget] .
CAUTION
Plug all openings on transmission, retarder valve and hoses.
Figure 5
Differential pressure sensor. Left non-return valve block
12. Pull the dropbox rearward with the aid of a ratchet block and lifting sling until the propeller shaft clears any
obstructions. Lower the propeller shaft onto the front axle.
NOTE!
CAUTION
Brake pipe under propeller shaft.
13. Detach the breather filter from the front axle and lower them onto the axle, see [Invalid linktarget] .
Figure 6
Brake unit and breather filter
14. Remove the bolted joint between the drive disc and the torque converter.
Use the gear 999 3590 for cranking the engine, see [Invalid linktarget] .
CAUTION
Secure the stop control by the injection pump with a tie so that the engine cannot start while it is being cranked.
Figure 7
Rotating crankshaft
1. The gear 999 3590 should be positioned in the hole in the flywheel housing. A standard ratchet handle is
used and if necessary this can be combined with a universal joint and extension bar from a 1/2" square
drive socket set.
2. Removing and installing the bolted joint drive disc – torque converter
15. Install the lifting tools 999 3681 and 999 3682 on the transmission
CAUTION
Use bolt M16x45, 4 pcs and nut M16, 4 pcs
Then connect the lifting yoke E 1644, see [Invalid linktarget] .
Figure 8
Installing lifting tools
1. 999 3681
2. 999 3682
3. Lifting yoke E 1644
16. Remove the remaining bolts between the transmission and the flywheel housing apart from the two top ones.
17. Attach the traverse hoist hook to the transporting bracket (A) on the E-tool, see [Invalid linktarget] .
Figure 9
Lifting tool E 1643
A. Transporting bracket
B. Lifting bracket
18. Insert the E-tool through the doorway. Hook the ratchet block onto the E-tool and attach the chain to the lifting
yoke.
Change over to lifting bracket (B) on the E-tool.
Tension the chain and remove the two remaining bolts between the transmission and the flywheel housing.
19. Carefully pull the transmission straight rearward until it is possible to install the transport braces on the torque
converter, see [Invalid linktarget] . Lift the transmission up and alternately out using the ratchet block and the hoist.
CAUTION
Make sure that the torque converter comes with the transmission rearward. It is important that the torque
converter is made secure otherwise it may easily slip out of its location and be damaged.
Figure 10
Transport braces
Part No. 1 650 540-6
20. Re-install the filters on the replaced transmission and plug all openings.
Service Information

Transmission, installing – 421 Service Information 2014/6/26
downward
Profile:
Transmission, installing – downward

Op nbr 42172
999 3590 Gear

E 1057C Stand
165 0540-6 Transport brace, 3 pcs
Kukko puller 20-20
Lifting sling, 1 pc, 2 m (6.5 ft)
Ratchet block 750 kg (1653 lb), 2 pcs
Bolt, M16 x 45 mm, 4 pcs
Nut, M16, 4 pcs
Torque wrench 0– 600 N m (0– 443 lbf ft)
WARNING
Observe the greatest possible cleanliness when removing the main and lubricating oil filters together with retainers
and the retarder valve. Make sure that no contaminants enter the transmission and the retarder valve respectively.
Plug all openings.
Installing
1. Move the bleeder nipple over to the new transmission.

Remove the oil filters complete with retainers from the new transmission. Remove the retarder valve from the new
transmission.
CAUTION
Plug all openings in the transmission and the retarder valve.
Move the compressed-air nipple over from the old valve.

Figure 1
Retarder valve
1. Oil filter with retainer and gasket

2. Position of oil hose
4. Electrical connection
5. Compressed air connection
6. Screw
7. Bolt M8x100
2. Connect the retarder valve to hoses (8) and (9). Tighten down the hose connections. Position bolts (6) and (7) in the
retarder valve, see [Invalid linktarget] .
NOTE!
The bolts cannot be installed once the transmission is in position.
3. Position lifting tools 999 3681 and 999 3682 on the new transmission.
4. Check the distance from the torque converter to the attaching flange on the housing. If the distance is greater than
in [Invalid linktarget] , the torque converter must be removed and the reason why it is not sufficiently far in must be
checked.
Make sure that the torque converter is properly secured, compare with point 27 under "Transmission, removing ...".
Figure 2
A = approx. 89 mm (3.50 in)
5. Move the transmission into position under the machine. Connect the ratchet blocks. Lift the transmission, see
[Invalid linktarget] and [Invalid linktarget] . Position the transmission horizontally and remove the transport braces.
CAUTION
Make sure that the torque converter does not slide forward.
Figure 3
6. Align the transmission with the flywheel housing.

Install the bolted joint between the flywheel housing and the transmission.
Tightening torque:85 N m (8.5 kgf m) (63 lbf ft).
CAUTION
The pin on the torque converter must be made to engage with the notch in the drive disc so that the marking on
the torque converter will be correctly positioned in relation to the injection pump, see [Invalid linktarget] . This
design is to make it possible to check the injection angular advance.
Figure 4
7. Remove the ratchet blocks, the tool E 1057C and the lifting tools 999 3681 and 999 3682 from the cab.
Figure 5
1. Notch
2. Pin
8. Tighten down the bolted joint between the transmission and the flywheel housing.
9. Install the retarder valve together with a new gasket.

Connect the electrical lead and the air line to the retarder valve.
Connect hoses (2) and (3) to the retarder valve, see [Invalid linktarget] .
NOTE!
Angle the hoses according to previous measurements.
10. Install the breather hose, oil dipstick / hose and filler hose.
11. Install the right oil filter complete with retainer.

Connect the cable harness to the connector in the oil sump and install cable harness clamps to the left side of the
transmission.
Connect the connector to the transmission and install the left oil filter complete with retainer and guard plate.
12. Install the pumps.
13. Connect the lines to the pumps in the following order:
 signal lines to both pumps

 suction lines to the left and right pumps
 pressure-oil lines to the right and left pumps
 leak-off oil lines to the left and right pumps
14. Install the bolted joint between the drive disc and the torque converter.
Install all twelve bolts loosely.
Torque-tighten.
For rotating (cranking) the engine, see point 22 under "Transmission, removing ...".
CAUTION
Make sure that none of the bolts fall down into the flywheel housing.

Remove the ratchet block and lifting sling.
16. Install the brake units and the breather filter for the front axle, see [Invalid linktarget] .
Figure 6
17. Install the clamp for the output speed sensor cable harness when installing the oil filler hose.
Connect the two output speed sensor connectors to the transmission.
18. Install the differential pressure sensor, see [Invalid linktarget]
Figure 7
Differential pressure sensor on left non-return valve block
19. Install the rack and pinion gear complete with bracket, see [Invalid linktarget] .
Figure 8
20. Install the steering rod, see [Invalid linktarget] .

Tightening torque for the steering rod ball joint: 120 N m (12 kgf m) (89 lbf ft).
CAUTION
Use a new lock nut and medium type locking fluid.
Figure 9
Steering rod
21. Loosely position the front right floor plate.

Install the accelerator pedal, the brake pedal and connect the electrical cables to the brake connectors.
22. Loosely position the front left floor plate.

Install the retarder pedal and the control for differential lock / 6-wheel drive. Tighten down the front floor plates.
NOTE!
Floor plate with rubber bellows is installed last.
23. Install the two rear floor plates.

Install the steering column complete according markings.
Install the steering column rubber bellows.
24. Install the seat (and connect electrical leads and air lines to the seat on machines with such a seat). Put the floor
mats back in the cab.
25. Install the hexagon stay, [Invalid linktarget] .

Figure 10
Hexagon stay
26. Fill oil in the transmission.

Capacity when changing: 38 litres (10 US gal)including filter.
27. Remove the tie by the injection pump and by the shut-off valve for the hydraulic oil tank.
NOTE!
Change oil and filter 50 operating hours after the replacement of the transmission.
Operate until warm and test the function. Check the oil level in the transmission according to the Operator"s
Manual. Check-tighten the retarder valve.
28. Install rear member (5) and front member (4) loosely.
NOTE!
Do not bolt on member (4) until guard plates (2) and (3) have been installed.
Bolt on front member (4).

Install front plate (1), see [Invalid linktarget] .
Figure 11
Guard plates

Service Information

Transmission, installing – 421 Service Information 2014/6/26
upward
through doorway
Profile:
Transmission, installing – upward through doorway

Op nbr 42169
999 3590 Gear

999 8002 Socket
E1643 Lifting tool
E1644 Lifting yoke
Bolt M16x45 mm, 4 pcs
Nut M16, 4 pcs
Puller Kukko 20-20
WARNING
Observe the greatest possible cleanliness when removing the main and lubricating oil filters together with retainers.
Make sure that no contaminants enter the transmission and the retarder valve respectively. Plug all openings.
Installing
1. Check the distance from the torque converter to the attaching flange on the housing, when the transport braces
have been removed and the torque converter has been pressed into its inner location.
If the distance is greater than in [Invalid linktarget] , the torque converter must be removed and the reason why it is
not sufficiently far in must be checked. Make sure that the torque converter is properly secured with transport
braces.
Figure 1
A = approx. 89 mm (3.50 in)
2. Move the required connections from the replaced transmission to the new one. Remove the main and lubricating
oil filters together with retainers from the new transmission.
CAUTION
Plug all openings in the transmission and the retarder valve.
Connect the lifting device.
3. Lift the transmission into the cab, see [Invalid linktarget] .

Move the transmission toward the flywheel housing and remove the transport braces.
CAUTION
Make sure that the torque converter does not slide forward, and that the nipple on the leak-off oil line for the
hydraulic pump is not damaged.
Figure 2
4. Align the transmission with the flywheel housing.
Install the bolted joint between the flywheel housing and the transmission.
5. The pin on the torque converter must be made to engage with the notch in the drive disc so that the marking on
the torque converter will be correctly positioned in relation to injection pump, see [Invalid linktarget]
The purpose of this design is to make it possible to check the injection angular advance.
Figure 3
1. Notch
2. Pin
6. Install the main and lubricating oil filters together with retainers.
7. Install the bolted joint between the drive disc and the torque converter.
To rotate (crank) the engine, see "Transmission, removing ...", point 14.
CAUTION
Make sure that none of the bolts fall down into the flywheel housing.
8. Install the steering rod and the rack and pinion gear complete with bracket.
Tightening torque for the steering rod ball joint: 120 N m (12 kgf m) (89 lbf ft). See [Invalid linktarget] and [Invalid
linktarget] .
CAUTION
Use a new lock nut and medium type locking fluid.
Figure 4
9. Install the breather filter for the front axle, the brake units and the propeller shaft.
Tightening torque for propeller shaft: 180 N m (18 kgf m) (133 lbf ft).
CAUTION
Use new lock nuts.
Remove the ratchet block.
Figure 5
Steering rod
10. Remove plugs. Install the differential pressure sensor on the left non-return valve block and connect hoses, pipes
and electrical cables to the transmission, see [Invalid linktarget] .
Figure 6
Differential pressure sensor
Left non-return valve block
11. Fill oil in the transmission.

Capacity when changing: 38 litres (10 US gal) including filter.
Remove the tie from the stop control.
NOTE!
Change oil and filter 50 operating hours after the replacement of the transmission.
Operate until warm and test the function. Check the oil level in the transmission according to the Operator"s
Manual. Check-tighten the retarder valve.
12. Install the floor plates, the pedals and the controls.
NOTE!
The floor plate with the rubber bellows is installed last.
Install the steering column complete according markings.
13. Install the operator seat (and connect electrical leads and air lines to the seat on machines with such a seat) and
then install the rubber mats and hand rails on the roof, door stop and lock plate.
Service Information

Transmission, removing – 421 Service Information 2014/6/26
downward
Profile:
Transmission, removing – downward

Op nbr 42170
999 3590 Gear

E 1057C Stand
Kukko puller 20-20
Lifting sling, 1 pc, 2 m (6.5 ft)
Bolt, M16 x 45 mm, 4 pcs
Nut, M16, 4 pcs
Torque wrench 0–100 N m (0–10 kgf m) (0–74 lbf ft)
Torque wrench 0–400 N m (0–40 kgf m) (0–295 lbf ft)
Torque wrench 0– 600 N m (0–60 kgf m) (0– 443 lbf ft)
WARNING
CAUTION
Observe the greatest possible cleanliness when working on the hydraulic system.
Removing
Figure 1
Battery disconnect switch
A On
B Off
1. Drive the front wheels of the machine up onto 150 mm (6 in) high wooden blocks.
Turn off the current with the aid of the battery disconnect switch, [Invalid linktarget] .
2. Remove the rear guard plates (1), (2) and (3) and the front and rear members (4) and (5), [Invalid linktarget] .
Figure 2
Guard plates

3. Drain the oil from the transmission.
4. Release the pressure in the air reservoirs, so that the whole system will be without pressure. Remove the floor mats
and the seat.
NOTE!
5. Remove the two rear floor plates in the cab.

Mark and remove the steering column complete with steering wheel. Detach at universal joint under rubber
bellows.
6. Remove the left, front floor plate. Detach the retarder pedal and the control for differential lock / 6-wheel drive.
Remove the accelerator pedal, the brake pedal and the right, front floor plate.
7. Disconnect the front steering rod at the front ball joint, use puller type Kukko 20-20. Move the steering rod to one
side, see [Invalid linktarget] .
Figure 3
Steering rod
8. Remove the rack and pinion gear complete with bracket, see [Invalid linktarget] .
Figure 4
9. Remove the brake units and the breather filter for the front axle, see [Invalid linktarget]
Figure 5
10. Disconnect the propeller shaft from the transmission.
obstructions, see [Invalid linktarget] . Lower the propeller shaft onto the front axle.
NOTE!
CAUTION
Brake pipe under propeller shaft.
Figure 6
1. Lifting sling, 2 pcs
2. Ratchet block, 750 kg (1653 lb)
12. Remove the hexagon stay under the oil sump, see [Invalid linktarget] .
Figure 7
Hexagon stay
13. Close the valve for the hydraulic tank. Secure with a tie, see [Invalid linktarget] .
Figure 8
1. Shut-off valve for hydraulic oil tank
14. Disconnect the suction line, the pressure line, the L-S line and the leak-off oil line from the right and left rear
pumps. Plug. Remove the rear right and rear left pumps.
WARNING
Observe the greatest possible cleanliness when removing the main and lubricating oil filters together with
retainers and the retarder valve. Make sure that no contaminants enter the transmission and the retarder
valve respectively. Plug all openings.
15. Remove the right oil filter complete with retainer (1), see [Invalid linktarget] .
Figure 9
Retarder valve
1. Oil filter with retainer and gasket

4. Electrical connection
5. Compressed air connection
6. Screw
7. Bolt M8x100
16. Disconnect the oil hoses (2) and (3), see [Invalid linktarget] , using a special combination spanner according to
[Invalid linktarget] and attach on the right side. Plug.
NOTE!
Measure the position of both hoses relative to the transmission before they are disconnected.
Figure 10
Combination spanner 2
17. Disconnect the lead from the electrical connection (4) and the air line (5) from the retarder valve, see [Invalid
linktarget] .
18. Detach the retarder valve from the transmission.

NOTE!
Plug all openings on the transmission and the retarder valve.
11 bolts in all.
19. Remove the guard plate by the connector on the transmission and the left oil filter complete with retainer.
CAUTION
Plug all openings on the transmission. Disconnect the connector from the transmission and detach the cable
harness bracket secured to the transmission oil sump.
Figure 11
Differential pressure sensor
20. Remove the oil dipstick / hose, the filler hose, the breather hose and the cable harness clamps from the
transmission. Plug.
21. Remove the differential pressure sensor. Plug. See [Invalid linktarget] .
22. Remove the bolted joint between the drive disc and the torque converter,12 bolts. Use the gear 999 3590 for
cranking the engine, see [Invalid linktarget] .
NOTE!
Secure the stop control by the injection pump so that the engine cannot start while it is being cranked.
Figure 12
Rotating crankshaft
1. The gear 999 3590 should be positioned in the hole in the flywheel housing. A standard ratchet handle is
used and if necessary this can be combined with a universal joint and extension bar from a 1/2" square
drive socket set.
2. Removing and installing the bolted joint drive disc – torque converter
23. Remove the bolted joint between the transmission and

the flywheel housing.
NOTE!
Leave the two topmost bolts in place.
24. Attach lifting tools 999 3681 and 999 3682 to the transmission, see [Invalid linktarget] .
NOTE!
Use four M16 x 45 mm bolts and four nuts.
Figure 13
1. 999 3681, bracket right

2. 999 3682, bracket left
3. E 1057C, Stand
4. Ratchet block 750 kg (1653 lb), 2 pcs
25. Install tool E 1057C. Hook the ratchet blocks onto the E-tool and attach the chains to 999 3682 and 999 3681.
Tension the ratchet blocks. Remove the two remaining bolts between the transmission and the engine.
26. Carefully move the transmission straight rearward until it is possible to install the transport braces on the torque
converter, see [Invalid linktarget] and [Invalid linktarget] .
Figure 14
Figure 15
Transport braces
Part No. 1 650 540-6
27. Make sure that the torque converter comes away with the transmission rearward. It is important that the torque
converter is made secure otherwise it may easily slip out of its location and be damaged.
28. Lift the rear end of the transmission so that it is leaning forward and then lower it with the aid of the ratchet blocks,
see [Invalid linktarget] .
NOTE!
The weight of the transmission together with the torque converter is approx. 490 kg (1080 lb).
Figure 16
29. Remove the retarder valve from hoses (8) and (9) and plug them. Install the retarder valve, the main and lubricating
oil filters together with retainers on the replaced transmission and plug all openings, see [Invalid linktarget] .
Service Information

Turbine 421 Service Information 2014/6/26
speed sensor, replacing
Profile:
Turbine speed sensor, replacing

Op nbr 42149
Box spanner type Bocker 18–19 mm
Two electrical cables 200 mm (8 in) long
with spade terminals
The sensor is positioned on the inside of the junction box for the connector on the transmission above the main oil filter.
Removing
WARNING
Observe the greatest possible cleanliness when removing the main oil filter together with retainer. Make sure that
no dirt or contaminants enter the transmission by plugging all openings.
Figure 1
Guard plates

1. Place the machine on level ground and turn off the current with the aid of the battery disconnect switch.
2. Lower the left guard plate (2), see [Invalid linktarget] .
3. Remove the main oil filter together with retainer and guard.
CAUTION
Plug all openings on the transmission.
4. Disconnect the connector from the transmission and unscrew the cover for the turbine speed sensor. Secure the
cover, see [Invalid linktarget] .
CAUTION
Make sure that the gasket is not damaged.
Figure 2
1. Position for main oil filter

2. Securing cover
3. Gasket
5. Disconnect the electrical leads from the turbine speed sensor. Insert the two 200 mm (8 in) long electrical cables
with spade terminals through the box spanner, see [Invalid linktarget] and attach the spade terminals to the turbine
speed sensor.
Figure 3
Box spanner type Bocker 18 – 19 mm ∗ Max. outside measurement 26 mm (1.024 in)
6. Unscrew the old sensor and replace it with a new one, see [Invalid linktarget] .
NOTE!
The leads are used as ”safety lines” to prevent the sensor from falling down into the transmission.

Because of variations in the casting of the transmission housing by the turbine speed sensor, it is recommended
that a waist should be ground on the box spanner to provide better accessibility.
Figure 4
Removing turbine speed sensor
Installing
7. Re-install the cover and connector on the transmission. Re-install filter with plate guard.
8. Raise and secure the guard plate. Switch on the battery disconnect switch and test the function.
Service Information

General 434 Service Information 2014/6/26
Profile:
General
Figure 1
Dropbox
Tightening torques
1 80 N m ( 8.0 kgf m) ( 59 lbf ft)
2 80 N m ( 8.0 kgf m) ( 59 lbf ft)
3 46 N m ( 4.6 kgf m) ( 34 lbf ft)
4 68 N m ( 6.8 kgf m) ( 50 lbf ft)
5 46 N m ( 4.6 kgf m) ( 34 lbf ft)
6 46 N m ( 4.6 kgf m) ( 34 lbf ft)
7 80 N m ( 8.0 kgf m) ( 59 lbf ft)
8 850 N m (85.0 kgf m) (627 lbf ft)
9[ 1]  400 N m (40.0 kgf m) (295 lbf ft)
10 62 N m ( 6.2 kgf m) ( 46 lbf ft)
11 80 N m ( 8.0 kgf m) ( 59 lbf ft)
[ 1]Install the lock washer. If it does not fit, continue to tighten the nut until the lock washer can be installed.
Service Information

Differential 434 Service Information 2014/6/26
lock, longitudinal,
adjusting engagement
Profile:
Differential lock, longitudinal, adjusting engagement

Op nbr 43461
E 1750 Adjusting tool
1. Place the machine on level ground and block one of the trailer wheels.
2. Raise the left wheel on the front axle off the ground using a jack.
3. Remove the diaphragm cover and the diaphragm for engagement of longitudinal differential lock.
4. Check the position of the sleeve relative to the machined face on the dropbox. The distance should be
3–4 mm (0.12–0.16 in). Use tool E 1750, face 1 (this will give the link arm the correct working length) see [Invalid
linktarget] .
Figure 1
Sleeve in not actuated position
1. Machined face
2. Tool E 1750
3. Sleeve
5. Adjust when necessary. Loosen the lock screw and turn the sleeve to the correct position. Tighten down the lock
screw, see [Invalid linktarget] .
Figure 2
1. Hook spanner or alternatively a suitable pair of pliers
6. Insert a bolt and depress the sleeve with tool E 1750. Turn the road wheel so that the differential lock dog clutch
halves in the dropbox stand tooth against tooth. The position of the sleeve relative to the machined face on the
dropbox should be approx. 2 mm (0.08 in), see [Invalid linktarget] . Check with tool E 1750, face 2.
Figure 3
Tooth against tooth position
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
7. With tool E 1750 check that the sleeve has a further clearance of 1 mm (0.04 in) between the teeth when they stand
opposite each other, see [Invalid linktarget] .
Figure 4
1 mm (0.039 in) clearance
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
Checking and adjusting sensor for longitudinal differential lock (SE20).
8. Leave the differential lock dog clutch halves in the tooth against tooth position. Turn the ignition key to position ”1
– running position”.
9. Turn sensor SE20 until the control lamp for the longitudinal differential lock on the instrument panel lights up. (Use
a buzzer as an alternative method.)
Turn the sensor half a turn counter-clockwise and tighten down the lock nut.
10. Install the diaphragm and the diaphragm cover.

Remove the jack.
Service Information

Dropbox, 434 Service Information 2014/6/26
removing
Profile:
Dropbox, removing
Op nbr 43474
Member, length approx. 1.5 m ((59 in), 2 pcs
Member, length approx. 0.5 m (20 in), 1 pc
Lifting sling, 1 tonne, 2 m (6.5 ft)
Lifting eye, M16 thread
Torque wrench 0–400 N m (0–40 kgf m)
(0–295 lbf ft)
WARNING
CAUTION
Plug all pipes, hoses and connections after disconnection.
Removing
1. Run the engine unit up onto 150 mm (6 in) high wooden blocks.
Apply the parking brake and block the trailer unit wheels.
Turn off the battery disconnect switch.
2. Loosen and push the operator seat forward.

NOTE!
On machines which are equipped with air-suspended seat; make sure that the electrical leads and air hoses do not
become damaged.
Remove the mat and the rear floor plate.
3. Remove the guard plates by the tipping and steering valves.
4. Remove brackets for the hoses over the frame joint, see [Invalid linktarget] .
Figure 1
A. Brackets by frame joint
5. Remove the suction line from the ground-dependent pump.

Remove the signal line between pump and steering valve (by steering valve).
6. Detach and pull out the ground-dependent pump.

Remove the breather and oil filler hoses and the oil filler nipple from the dropbox.
7. Remove the front output propeller shaft. Detach the rear output propeller shaft from the dropbox, see [Invalid
linktarget]
Figure 2
Dropbox
1. Input propeller shaft

2. Rear output propeller shaft
3. Front output propeller shaft
8. Remove the steering cylinder hydraulic hoses from the bracket on the dropbox and remove the bracket.
9. Disconnect the electrical cables and the air line from the longitudinal differential lock.
10. Mark and disconnect the hydraulic hoses from the left steering cylinder. Move the steering cylinder to one side.
11. Detach the front input propeller shaft from the dropbox, see [Invalid linktarget] .
12. Disconnect the hose from the tipping valve, see [Invalid linktarget] .
Figure 3
Hose to tipping valve by rear cab wall.
13. Detach and remove the spill guard.
14. Connect a lifting device to the dropbox according to the following points and see [Invalid linktarget] .
 Position two members between the cab roof and the dump body. Place a cross member on top of these
by the rear edge of the cab.
 Connect a lifting device to the top of the dropbox.
Figure 4
Lifting device for lifting out dropbox
1. Member, length approx. 0.5 m (20 in), 1 pc

2. Member, length approx. 1.5 m ((59 in), 2 pcs[ 1] 
3. Lifting sling
4. Ratchet block 750 kg (1653 lb)
5. Lifting eye, M16 thread
15. Remove the bolted joint. Lower the dropbox onto a pallet trolley with the aid of the ratchet block and support the
dropbox on the trolley, see [Invalid linktarget] .
Figure 5
16. Move the bracket and the nipples over to the new dropbox.
[ 1]The dropbox weighs 330 kg (728 lb)

Service Information

Dropbox, 434 Service Information 2014/6/26
replacing seal for front
output shaft
Profile:
Dropbox, replacing seal for front output shaft

Op nbr 43402
999 3847 Tooth segment, incl. counterhold washer with spacers

999 3581 Spanner 65 mm
999 3590 Gear
(0–148 lbf ft)
Removing
1. Disconnect the propeller shaft from the dropbox, see [Invalid linktarget] , move it to one side and secure it with
some steel wire. Remove lock ring and lock washer from the drive flange.
Figure 1
1. Front output shaft on dropbox
2. Install tooth segment 999 3847, spanner 999 3581 and gear 999 3590, see [Invalid linktarget] . Remove the nut and
the plain washer.
Figure 2
Removing / installing nut
1. 999 3847 Tooth segment, incl. counterhold washer with spacers)

2. 999 3581 Spanner 65 mm
3. Handle (torque wrench when installing)
4. 999 3590 Gear
3. Position a vessel under the dropbox for collecting the oil. Remove the drive flange and prize away the seal ring, see
[Invalid linktarget] .
Figure 3
Removing seal ring
Installing
4. Coat the new seal ring with grease and tap it in against the shoulder.
5. Install the drive flange, the plain washer and the nut. To make gear segment 999 3847 engage the nut properly,
remove the spring pin from the drive flange.
Tighten the nut according to [Invalid linktarget] .
Tightening torque: 400 N m (40 kgf m) (295 lbf ft)
Install the lock washer. If it does not fit, continue to tighten the nut until the lock washer can be installed.
NOTE!
The tool in [Invalid linktarget] raises the torque on the nut 15 times.
6. Insert the spring pin in the drive flange. Align the recess in the lock washer with the spring pin. To increase the
number of aligning possibilities, the lock washer can be turned. Install the lock ring.
7. Install the front output propeller shaft, see [Invalid linktarget] .

8. Check the oil level in the dropbox.
Top up when required.
Service Information

Dropbox, installing 434 Service Information 2014/6/26
Profile:
Dropbox, installing
Op nbr 43473
Member, length approx. 1.5 m ((59 in), 2 pcs
Member, length approx. 0.5 m (20 in), 1 pc
Lifting sling, 1 tonne, 2 m (6.5 ft)
(0–295 lbf ft)
WARNING
Installing
1. Move the new dropbox in under the machine and connect the lifting device, see [Invalid linktarget] .
2. Lift the dropbox into position.

Insert the bolts and tighten down.
Tightening torque:220 N m (22 kgf m) (162 lbf ft).
Leave the ratchet block in place to keep the dropbox pulled slightly rearward.
3. Install the input propeller shaft, see [Invalid linktarget] .

Loosen the ratchet block.
Figure 1
Dropbox
4. Install the front output propeller shaft, se [Invalid linktarget] .

NOTE!
If a washer is missing, install washer 11 050 693-8 on all bolts.
5. Connect the electrical cables and the air line to the longitudinal differential lock.
6. Remove the lifting device and the lifting eye.

Install the bracket for the steering cylinder hydraulic hoses.
Re-install the hydraulic hoses in the bracket.
7. Connect the hydraulic hose to the tipping valve, see [Invalid linktarget] .
Install the ground-dependent pump.
NOTE!
If the pump does not engage, raise one wheel and rotate it.
Figure 2
Hose to tipping valve at rear cab wall
8. Connect the L-S line to the pump.

Install the nipple and the hoses for the oil filler and the dropbox breather.
9. Install the suction line to the ground-dependent pump.
10. Install the brackets for the hoses over the frame joint, see [Invalid linktarget] .
Figure 3
Brackets by frame joint
1. Tightening torque:
220 N m (22 kgf m) (162 lbf ft)
2. Tightening torque: Standard
11. Install the rear output propeller shaft.

Tightening torque: 135 N m (13,5 kgf m) (100 lbf ft).
12. Install the bracket with hydraulic hoses to the top of the dropbox.
13. Install the guard plates.
14. Re-install the floor, the operator seat and the floor mat.
15. Fill the dropbox with oil. See the Operator"s Manual. Test the function.
Service Information

Dropbox, replacing seal for 434 Service Information 2014/6/26
input shaft
Profile:
Dropbox, replacing seal for input shaft

Op nbr 43415
999 3585 Spanner 75 mm

999 3590 Gear
999 3868 Tooth segment
(0–74 lbf ft)
Removing
1. Remove the operator seat, the mats and the floor plates.
NOTE!
Disconnect the required number of hoses from the steering cylinders and remove the bracket, so that the rear end
of the propeller shaft becomes accessible. Plug the hoses.
2. Disconnect the propeller shaft completely from the drive flanges.
3. Arrange a lifting sling around the upper part of the dropbox and pull it rearward with the aid of a ratchet block (the
dropbox is rubber mounted). Lift the propeller shaft to one side so that the drive flange becomes accessible.
4. Remove the lock ring and the lock washer from the centre nut.
Remove the centre nut with the aid of spanner 999 3585, gear 999 3590 and tooth segment 999 3868, see [Invalid
linktarget]
Figure 1
Removing centre nut
1. Handle (torque wrench when installing)

2. 999 3590 Gear (obscured)
3. 999 3585 Spanner 75 mm
4. 999 3868 Tooth segment
5. Remove the drive flange together with V-ring.
6. Remove the seal ring.
Installing
7. Coat a new seal ring with grease and tap it in against the shoulder.
8. Install the drive flange together with a new V-ring and the centre nut.
Tighten the centre nut, see [Invalid linktarget] .
NOTE!
The tools raise the torque on the nut 15 times.
Install the lock washer and the lock ring.
9. Install the propeller shaft. Remove the ratchet block and lifting sling. Tightening torque: 100 N m (10 kgf m)
(74 lbf ft).
10. Connect the pipes and the hoses to the steering and tipping valves.
11. Install the floor plates, the mats and the operator seat.
NOTE!
On machines which are equipped with air-suspended seat; make sure that electrical leads and air hoses are not
damaged.
Service Information

Dropbox, replacing seal for 434 Service Information 2014/6/26
rear output
shaft
Profile:
Dropbox, replacing seal for rear output shaft

Op nbr 43404
Socket 60 mm
(0–740 lbf ft)
Removing
1. Steer the machine fully to the right and remove the rear output propeller shaft (23 kg) (51 lb), see [Invalid
linktarget]
Figure 1
Removing and installing drive flange nut
2. Remove the lock ring and the lock washer.
3. Remove the nut with the aid of a 60 mm and a nut runner. Remove the drive flange.
4. Prize away the seal ring.
Installing
5. Coat the new seal ring with grease and tap it in against the shoulder.
6. Install the drive flange and tighten the nut.

Install the lock washer. If it does not fit, continue to tighten the nut until the lock washer can be installed. Install the
lock ring.
7. Install the rear output propeller shaft, see [Invalid linktarget] and tighten the bolted joints.
Service Information

Propeller 451 Service Information 2014/6/26
shaft for front bogie axle,
replacing
Profile:
Propeller shaft for front bogie axle, replacing

Op nbr 45104
999 6892 Socket

E 1645 Dump body support
11 668 008 Stand jack or similar equipment
Blocks (2 pcs)
Torque wrench, 0–200 N m (0–20 kgf m) (0–148 lbf ft)
Ratchet block
WARNING
It is forbidden to be under a raised dump body without first having secured it with the dump body lock or dump
body support E 1645.
Removing
1. Place the machine on level ground. Make sure that there is full pressure in the compressed-air system. Block the
wheels.
2. Raise the dump body and secure with the dump body lock or with dump body support E 1645. Release the parking
brake (OFF position).
3. Position the jacks under the bogie axle. Lift until it is possible to turn the wheels. See [Invalid linktarget] .
Figure 1
Lifting with jacks
4. Place a cross member on the frame and connect a lifting device to the propeller shaft. See [Invalid linktarget] .
Figure 2
Connecting lifting device
5. Remove the bolted joint from the rear end of the propeller shaft.
6. Remove the bolted joint from the front end. Use tool 999 6892.
7. Lower the propeller shaft, see [Invalid linktarget] .
Figure 3
Lowering of the propeller shaft
Installing
8. Lift the new propeller shaft into position and first install the front bolted joint.
9. Install the rear bolted joint.

10. Lower the machine and remove the stand jacks. Remove the dump body support, the blocks and lower the dump
body.
Service Information

Propeller shaft between 451 Service Information 2014/6/26
transmission and
dropbox, replacing
Profile:
Propeller shaft between transmission

Op nbr 45114
Ratchet block, 750 kg (1653 lb)
(89 lbf ft)
Removing
1. Position the machine on level ground and block the wheels.
2. Remove the operator seat, the floor mat and the floor plates.
3. Remove the bolted joint for the propeller shaft.
obstructions. See [Invalid linktarget] .
NOTE!
Figure 1
Detaching propeller shaft
1. Lifting eye, M16 thread

2. Lifting sling, 2 pcs
3. Ratchet block 750 kg (1653 lb)
5. Lift out the propeller shaft, see [Invalid linktarget] .

Figure 2
Installing
6. Install a new propeller shaft and remove the ratchet block.
7. Install the bolted joint for the propeller shaft.

Tightening torque: 183 N m (18,3 kgf m) (135 lbf ft).
CAUTION
Use new lock nuts.
8. Install the floor plates, the floor mat and the operator seat.
Service Information

Propeller shaft for rear 451 Service Information 2014/6/26
bogie axle,
replacing
Profile:
Propeller shaft for rear bogie axle, replacing

Op nbr 45105
999 6892 Socket

E 1645 Dump body support
(0–148 lbf ft)
WARNING
It is forbidden to be under a raised dump body without first having secured it with the dump body lock or dump
body support E 1645.
Removing
2. Raise the dump body and secure with the dump body lock or the dump body support E 1645.
3. Use tool 999 6892 and remove the bolted joints for the propeller shaft. See [Invalid linktarget] .
Figure 1
Replacing propeller shaft
1. Bolted joints
4. Remove the propeller shaft.
Installing
5. Install the new propeller shaft. Tighten the bolted joints.

6. Remove the dump body support, the blocks and lower the dump body.
Service Information

Propeller shaft in steering 451 Service Information 2014/6/26
joint,
replacing
Profile:
Propeller shaft in steering joint, replacing

Op nbr 45107
(0–148 lbf ft)
Removing
1. Place the machine on level ground. Steer the machine to the right. Block the wheels.
2. Remove the bolted joints for the propeller shaft and remove the complete shaft with universal joints. See [Invalid
linktarget] .
Figure 1
Removing bolted joint for propeller shaft
Installing

Service Information

Propeller shaft, front 451 Service Information 2014/6/26
output shaft on
dropbox, replacing
Profile:
Propeller shaft, front output shaft

Op nbr 45110
(0–148 lbf ft)
Removing
Figure 1
Propeller shafts

2. Remove the bolted joints for the propeller shaft, see [Invalid linktarget] .
Figure 2
Removing bolted joint
1. Bolted joints
3. Lower and remove the propeller shaft.
Installing
4. Lift and install the new propeller shaft. Tighten the bolts.
Service Information

Drive axles 461 Service Information 2014/6/26
Profile:
Drive axles
Figure 1
Drive axles
1. AH63I (serial No. –2900), AH63Q (serial No. 2901–)

2. AH63J (serial No. –2900), AH63R (serial No. 2901–)
3. AH63K (serial No. –2900), AH63S (serial No. 2901–)
Service Information

Hub, 461 Service Information 2014/6/26
replacing seals (one side)
Profile:
Hub, replacing seals (one side)

Op nbr 46143
E 1751 Lifting device

E 1752 Lifting yoke
947358 Puller bolt (3 pcs)
11 668 004 Socket, hub nut
11 668 007 Stand jack (or similar equipment)
13 971 013-1 Guide screw (2 pcs) (sawn-off bolt head)
Wheel handling trolley (or similar equipment)
Ratchet block, 750 kg (1653 lb)
Lifting sling, 2 m (6.5 ft)
NOTE!
When replacing seals in the hub reduction gear, see also Service Manual ”Drive Axles Articulated Hauler”.
Figure 1
Removing
1. Place the machine in service position, i.e. the machine should stand on level and hard ground. The steering joint
lock should be connected and at least one wheel should be blocked, see [Invalid linktarget] .
2. Lift the axle with a stand jack (or alternatively with a jack and axle stand), see [Invalid linktarget] .
Figure 2
3. Remove the wheel with a wheel handling trolley or equivalent equipment, see [Invalid linktarget] and [Invalid
linktarget] .
Figure 3
4. Raise the axle further to prevent oil from running out of the axle housing. Empty the oil out of the hub.
Figure 4
5. Remove the brake guards, the brake pads, the brake pipes and the brake calipers.
CAUTION
Plug the connections.
6. Arrange the lifting device E 17501, see [Invalid linktarget] .
Figure 5
7. Insert 10 x 35 mm pins in the puller holes to protect the threads in the hub.
8. Install the guide pins M12x120 in two holes. Pull off using M16 x 60 mm bolts. Pull out the planet carrier onto the
guide pins and lower it.
9. Remove the lock ring and the sun gear. Leave the half shaft in place. See [Invalid linktarget] .
Figure 6
1. Sun gear
2. Half shaft
10. Remove the lock ring and lock the washer from the shaft stud, see [Invalid linktarget] .
Figure 7
11. Loosen and remove the hub nut using hub nut socket 11 668 004, see [Invalid linktarget] .
Figure 8
1. Hub nut socket 11 668 004

12. Secure the ring gear with two large washers and two bolts, see [Invalid linktarget]
Figure 9
1. Securing ring gear
13. Connect the lifting yoke E 1752 to the hub and lower the hub and the ring gear, see [Invalid linktarget] .
Figure 10
14. Place the hub on the floor with the brake disc upward.
Installing
15. Replace seal (1), see [Invalid linktarget] . If the wear ring is noticeably worn, replace it as well.
Figure 11
1. Seal
16. Lift the hub together with ring gear into position.
17. Tighten the hub to approx. 600–800 N m (60–80 kgf m) (443–590 lbf ft) with the aid of the hub nut socket
11 668 004 and a (1 m (39 in) handle and a weight of 60–80 kg (132–176 lb)).
18. Rotate the hub 4–5 revolutions and loosen the hub nut 1/2 a turn.
19. Tighten the hub nut to 300 N m (30 kgf m) (221 lbf ft).
20. Adjust the indicator pin on the hub nut socket 11 668 004 so that it aligns with one of the bolt holes in the hub, see
[Invalid linktarget] .
Figure 12
21. Tighten the hub nut until the indicator pin reaches the next hole (12°) in the hub.
22. Install lock the washer and the lock ring, see [Invalid linktarget] .
CAUTION
Never loosen the hub nut to make it align with the lock washer Two different versions of the lock washer are
available.
23. Install the sun gear together with the lock ring.
24. Clean the planet carrier and the hub. Apply new sealant.
25. Install the planet carrier and a few bolts. Knock in the outer guide pins before the inner ones.
NOTE!
The guide pin slots should point in the direction of rotation of the hub, see [Invalid linktarget] .
Tighten down the bolts. Torque-tighten to 130 N m (13 kgf m) (96 lbf ft).
Figure 13
Guide pin slots in the direction of rotation of the hub.
26. Install the brake caliper. Torque-tighten to 550 N m (55 kgf m) (406 lbf ft). Install the brake pipes.
27. Install the pads. Apply locking fluid (medium locking) to the bolts and install the stop.
Bleed the brake system, see [Invalid linktarget] .
NOTE!
Only the system on the axle on which work has been carried out needs to be bled.
28. Install brake guard and wheel. Torque-tighten the wheel nuts to 800 N m (80 kgf m) (590 lbf ft). Fill oil in the hub,
approximately 3 litres (0.8 US gal).
29. Check the oil level in the axle. Top up when required. Remove the blocks.
30. Test the function.

Service Information

Dog clutch 465 Service Information 2014/6/26
6x6, checking and
adjusting
Profile:
Dog clutch 6x6, checking and adjusting

Op nbr 46516
Checking
1. Place the machine on level ground and block one of the wheels.
2. Lift the right wheel of the rear bogie axle using a trolley jack.
3. Remove the diaphragm cover and the diaphragm for engagement of the 6-wheel drive.
4. Check the position of the sleeve relative to the machined face on the axle housing. The distance should be 3 mm
(0.12 in). Use tool E 1750, face 1. See [Invalid linktarget] . (This work is carried out to make sure that the stroke of
the sleeve is correct.)
Figure 1
1. Machined face
2. Tool E 1750
3. Sleeve
5. Insert one bolt and depress the sleeve to the tooth against tooth position using tool E 1750, see [Invalid linktarget] .
The clearance between the non-actuated position and the tooth against tooth position should be 1 mm (0.04 in).
Figure 2
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
6. Press down the sleeve with tool E 1750 and turn the lifted wheel so that the dog clutch teeth engage fully. The total
stroke should be 5 mm (0.20 in), see [Invalid linktarget] .
Figure 3
Full engagement
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
Adjusting
7. Screw out the sleeve counter-clockwise until the gear teeth are fully engaged.
8. Apply Loctite type medium to the threads on the sleeve and screw in the sleeve approx. 1 1/2 turnclockwise until
the tooth against tooth position arises. Turn a further 1/2 turn clockwise. Check the clearance according to earlier
checking instructions.
9. Tighten down the lock screw.

10. Install the diaphragm and the diaphragm cover.

Remove the jack.
Service Information

Differential 468 Service Information 2014/6/26
lock, transverse, adjusting engagement
(per axle)
Profile:
Differential lock, transverse,

Op nbr 46805
Checking
1. Place the machine on level ground and block one of the wheels.
CAUTION
Do not apply the parking brake. Make sure that the compressed-air system is at full working pressure (applies to
the front axle and the first bogie axle).
2. To check and adjust, using a jack, lift:
 the front axle, the right wheel

 the front bogie axle, the left wheel
 the rear bogie axle, the right wheel.
3. Remove the diaphragm cover and the diaphragm.
4. Check the position of the differential sleeve in relation to the machined face on the axle housing, [Invalid
linktarget] . The distance should be 3 mm (0.12 in). Use tool E 1750, face 1. (This work is done to make sure that
the stroke of the differential sleeve is correct.)
Figure 1
1. Machined face
2. Tool E 1750
3. Sleeve
5. Insert one bolt and depress the sleeve to the tooth against tooth position using tool E 1750, see [Invalid linktarget] .
The clearance between the non-actuated position and the tooth against tooth position should be 1 mm (0.04 in).
Figure 2
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
6. Press down the sleeve with tool E 1750 and turn the wheel so that the dog clutch teeth engage fully, see [Invalid
linktarget] . The total stroke should be 5 mm (0.20 in).
Figure 3
Full engagement
1. Machined face
2. Tool E 1750
3. Sleeve
4. Counterhold bolt
Adjusting
7. Loosen the lock screw and screw out the sleeve until the gear teeth are fully engaged.
8. Screw in the sleeve approx. 2 1/2 turnsclockwise until the tooth against tooth position arises. Screw one further
turn clockwise. Check the clearance according to earlier checking instructions. Tighten down the lock screw.
9. Install the diaphragm and the diaphragm cover. Remove the jack.
Service Information

Transmission 490 Service Information 2014/6/26
PT1663
Profile:
Transmission PT1663
Figure 1
Transmission PT1760
Service Information

Transmission, 490 Service Information 2014/6/26
hydraulic diagram,
Profile:
Transmission, hydraulic diagram,

COMPONENT PARTS (alphabetical order)
B1–B5 Brakes (speed gears)
BF Breather filter
C Torque converter
CHV Safety valve
CRV Valve, torque converter pressure
F1 Main oil filter
F2 Lubricating oil filter
K1 Clutch, forward gear
K2 Clutch, reverse gear
LC Transmission, oil cooler
LRV Valve, lubricating oil pressure
LU Direct drive clutch (lockup)
MPV Main pressure valve
NRV1 Non-return valve
P1 Pump, control system
PC Pump, torque converter
PWM1 (S11) Modulator valve
PWM2 (S13) Modulator valve
R Retarder
RC Oil cooler, retarder
RRV Engagement valve, retarder
RV Relay valve, unassigned
RV1–RV5 Relay valves, gear engagement (speed gears)
RV7 Relay valve, forward gear
RV8 Relay valve, reverse gear
RV9 Relay valve, direct drive clutch (lockup)
S1–S5 Solenoids, gear engagement (speed gears)
S7 Solenoid, forward gear
S8 Solenoid, reverse gear, 6th gear forward
S9 Solenoid, direct drive clutch (lockup)
SE11D Temperature sensor, oil temperature, transmission
SE11E Sensor, oil level, transmission (oil sump)
SE12 Sensor, low lubricating oil pressure
SE13 Temperature sensor, retarder circuit
SF Suction filter
TV1 Modulator valve (flow limitation)
Pressure outlet / pressure

B1–B5 Clutch pressure, brakes
K1 Clutch pressure, forward gear
K2 Clutch pressure, reverse gear
P1 Main pressure
PC1 Torque converter pressure IN
PC2 Torque converter pressure, OUT
PLU Lockup clutch pressure
PR1 Retarder pressure IN
PR2 Retarder pressure OUT
PS Lubricating oil pressure
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/26 14:21:28]

4 Power Transmission

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Service Information

Document Title: Function Group: Information Type: Date:

Clutches, brakes and solenoids

Explanation of = applied / (activated)

Document Title: Function Group: Information Type: Date:

Contronic display unit (optional)

SW1 Ignition switch

Reverse: 1st and 2nd gear

Neutral: Brake for 1st gear pressurised

Drive: 1st to 6th gear

3: 1st to 3rd gear

2: 1st and 2nd gear

SW47 Switch retarder on/off (serial No. 2901–, US 60001–)

S8 Solenoid for reverse gear

SE11E Sensor, oil level in transmission – combined with SE11D

 the pressure sensor for retarder requested is closed (SE56)

SE57 Sensor, turbo boost pressure

SE100 Sensor, retarder on/off (serial No. 2901– , US 60001–)

 the switch retarder on/off is switched on

SE107 Sensor, gear-shift inhibitor parking brake

Document Title: Function Group: Information Type: Date:

1 Engine 8 Propeller shaft (steering joint)

Document Title: Function Group: Information Type: Date:

Diagnosis using Service Display Unit

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Gearshifting control (serial No. 2901–,

Document Title: Function Group: Information Type: Date:

Gearshifting control (serial No. –2900)

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Missing signal from engine speed sensor (SE3)

Document Title: Function Group: Information Type: Date:

Other error causes

The transmission does not

The machine shifts abnormally

Document Title: Function Group: Information Type: Date:

Transmission, clutches and brakes

Pressure checks in automatic position, ECU connected

Other pressure checks

Check Checking point Pressures ±0.1 MPa (15 psi) Note

Document Title: Function Group: Information Type: Date:

412 Engine No lockup in gears 1, 2 and Faulty sensor or cable

425 ∗ Faulty cable harness

426 ∗ Low Error code is shown at Low oil level. Clogged

427 ∗ Low oil level. Measure EA14 – 1

493∗ Mechanical or hydraulic

Document Title: Function Group: Information Type: Date:

Socket No. Lead end, function

Pin No. Transmission end, function

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Multi-pin breaker box

Document Title: Function Group: Information Type: Date:

Retarder, description of function

Application through the brake pedal (serial No. 2901–, US 60001–)

 SW47 (retarder in brake pedal) switched on (closed).

Document Title: Function Group: Information Type: Date:

Checking main, torque converter

999 3335 Hose, 1 pc

930032 Measuring nipple (male part), 1 pc

Pressure gauge, measuring range: 0–1 MPa

(0–10 bar) (0–145 psi)

Pressure gauge, measuring range: