Service Information Document Title: Transmission, check pressure
Function Group: oil 421
Information Type: Service Information
Date: 2015/9/30
Profile: GRD, G930 [GB]
Transmission, check oil pressure Op nbr nbr 421421-002 002 11666052 11666 052 Pres Pressure sure gauge
936445 Testing nipple 936446 Testing nipple 1. Park the machine machine on a firm level level surface. Refer Refer to the first 5 steps steps for placing the machine in the 191 Service position , but do not shut off the battery disconnect switch or allow the machine to cool down fully. NOTE! The engine, transmission and hydraulic systems should be at normal working temperature during the testing procedure. Time for removing installed options such as cab skirts or lower front wipers, are not included in this procedure. 2. If the machine machine cannot cannot be road tested to obtain obtain the pressure pressure reading readings, s, it will be necessary necessary to raise raise the rear of the machine and support the tandem drive wheels elevated off the ground. This will allow you to engage the transmission and run the machine at the normal working temperatures while recording the working pressures. Refer to the Safety Section in the Service Manual and the instructions for: 191 Safety when lifting and supporting supporting complete complete machine, 191 Safety rules when servicing. 3. Locate the test port attenuator attenuator nipples on the upper left left side of the transmission. transmission. Access is gained gained through the the opening between the cab and the frame on the left of the machine.
Figu Figure re 1 Test ports — attenuator locations 4. Remove one of the attenuator attenuator nipples and install an appropriate appropriate size testing testing nipple into into the valve block. block.
Figu Figure re 2 Test nipple with hose to gauge NOTE! Use nipple 936445 if connecting directly into the valve block. Use nipple 936446 if connecting into the attenuator nipple. 5. Connect the Test Gauge 11666052 11666052 to the test nipple with the hose hose supplied with the gauge. gauge.
Figu Figure re 3 Volvo pressure test gauge 6. Enter Enter the cab and signal signal your your intention intention to restart restart the machine. machine. When all bystanders are clear of the area around the tandem drive wheels, restart the machine and engage and differential lock. 7. Engage the transmission transmission and run the machine at the normal working temperature in the specified gear while recording the working pressures at the test port according to the specification table.
8. Shut down the machine. Remove Remove the test gauge gauge nipple and hose line, line, then reinstall reinstall the attenuator into into the test port.
Figu Figure re 4 Attenuator installation 9. Repeat the procedure procedure (steps 3 to 8) and and record the pressure pressure readings at all necessary test ports. ports. 10. When testing is completed, completed, carefully carefully lower the machine machine to the ground and place it back into service.
Service Information Document Title: Transmission, removing
Function Group: 421
Information Type: Service Information
Date: 2015/9/30
Profile: GRD, G930 [GB]
Transmission, removing Op nbr nbr 421421-070 070 Lifting eye bolts (16 mm) 1. Place Place the machin machine e in the 191 Service position. 2. Remove Remove the cab. cab. Refer Refer to 818 Cab, removing. 3. Remove Remove the transmissi transmission on guard. guard. Refer to 715 Transmission guard, removing . 4. Drain the hydraulic hydraulic oil from the transmiss transmission. ion. Refer to 173 Transmission, changing oil and filter .
WARNING Only use lifting devices with adequate capacity. 5. Install lifting eye bolts (16 mm) into into the top of the transmission transmission using chains chains and a safe lifting lifting device.
Figu Figure re 1 Lifting eye bolts and transmission 6. Disconnect the feed feed and return hose to the brake booster. Swing Swing the brake linkage out of the the way. Plug and and cap the hoses to prevent contamination.
Figu Figure re 2 Swinging the brake linkage out of the way NOTE! Do not disconnect the brake lines. 7. Remove the driveshaft driveshaft bolts retaining the upper driveshaft driveshaft to the transmission transmission yoke and collapse collapse the driveshaft. driveshaft. 8. Remove the cushion cushion bolts retaining 426 Rubber cushion, changing .
the
transmission transmission
on
both both
sides
of the
machine.
Refer Refer
to
9. Remove Remove the lower lower drivesha driveshaft. ft. Refer to 451 Drive shaft, removing. NOTE! Mark all hydraulic hoses for identification. 10. Disconnect the parking parking brake, blade lock lock cylinder and differential differential lock hydraulic hydraulic hoses from the combination combination valve located on the front of the transmission. Cap and plug the hoses to prevent contamination.
Figu Figure re 3
1. 2. 3. 4.
Parking brake hydraulic hose Blade lock hydraulic hose Differential lock hydraulic hose Transmission combination valve
11. Disconnect the two cooler hydraulic hoses at the pressure pressure regulator valve. valve. Cap and plug plug the hoses to prevent prevent contamination.
Figu Figure re 4
1.
Hydraulic hoses - cooler
12. Disconnect the transmission transmission lubrication hydraulic hydraulic hose at the transmission transmission manifold. manifold. Cap and plug plug the hose to prevent contamination.
Figu Figure re 5
1. 2.
Hydraulic hose - transmission lubrication lubrication Transmission manifold
13. Disconnect the pump pump drive drain drain hydraulic hose. hose. Cap and plug plug the hose to prevent contamination. contamination.
Figu Figure re 6
1.
Hyd Hydrau raulic lic hose hose - pum ump p dr drive ive dra draiin
14. Disconnect the oil filler tube tube from behind the left rear cab mount.
WARNING Only use lifting devices with adequate capacity. 15. Safely Safely lift lift the transmissi transmission on out of the the machine. machine. Weight 772 kg (1700 lbs)
Figu Figure re 7 Lifting the transmission out of the machine NOTE! Clearly identify wiring harness and hose locations prior to removal. 16. Remove all necessary necessary parts from the transmission transmission removed from the machine and install them on the replacement transmission.
Service Information Document Title: Transmission, installing
Function Group: 421
Information Type: Service Information
Date: 2015/9/30
Profile: GRD, G930 [GB]
Transmission, installing Op nbr nbr 421421-072 072 Lifting eye bolts, 16 mm 1. Install Install the necessar necessaryy parts removed removed from from the replac replaced ed transmiss transmission ion onto onto the new transmis transmission sion.. Refer to 421 Transmission, removing.
WARNING Only use lifting devices with adequate capacity. 2. Attach lifting eyes and a safe lifting device to the transmission transmission before installation. installation. Lift and position the the transmission into place using an alignment tool to line up the mounting plate with the mount on the frame.
Figu Figure re 1
1. 2. 3.
Alignment tool Transmission Transmission mount
3. Install the cushion bolts, making sure the washers are in in place, before before completely lowering lowering the transmission transmission onto the mount. 4. Install Install the nuts and and torque the the cushion cushion bolts to specifi specificatio cation. n. 5. Reinstall Reinstall the the oil filler filler tube tube to the machine machine frame. frame. 6. Reinstall the upper upper driveshaft to the input input yoke on the transmission. transmission. Torque the bolts to specification. specification. Refer Refer to
451 Drive shaft, installing . 7. Reinstall the lower driveshaft to the output yoke on the transmission. Refer to 451 Drive shaft, installing . 8. Reconnect Reconnect all all hydraulic hydraulic hoses hoses to the transmiss transmission. ion. NOTE! Be sure to check all O-rings at the connections. 9. Set the brake assembly assembly back into approximate approximate position, prior prior to putting the cab cab back on. Reconnect Reconnect the fittings back onto the brake assembly, but do not tighten, as an adjustment may later be required. When satisfied with the adjustments, tighten the fittings. 10. Fill the transmission transmission with oil and change change 173 Transmission, changing oil and filter . Check for any leaks. 11. Instal Installl the cab. cab. Refer Refer to 818 Cab, installing. 12. Place Place the machin machine e back back in servic service. e.
the
transmission transmission
oil
filter. filter.
Refer
to
Service Information Document Title: Transmission removing
Function Group: pump, 421
Information Type: Service Information
Date: 2015/9/30
Profile: GRD, G930 [GB]
Transmission pump, removing Op nbr nbr 442442-011 011 Container, 20 l (5 US gal.) 1. Articulate Articulate the the machine machine to open open up the right right side. side.
Figu Figure re 1 Machine articulated with right side open 2. Place Place the machin machine e in the 191 Service position. 3. Remove Remove the transmissi transmission on guard. guard. Refer to 715 Transmission guard, removing . 4. Remove Remove the lower front front right right hydraulic hydraulic oil oil tank cover. cover. 5. Drain approximately approximately 20 litres litres (5 US gal.) of transmission transmission fluid fluid into a suitable suitable container. container. 6. Remove the four four nuts holding holding the brake brake master cylinder cylinder to the brake booster.
Figu Figure re 2 Brake master cylinder and brake booster 7. Remove the hydraulic hose from the top of the the transmission pump. pump. This hydraulic hose supplies oil pressure to the brake booster. Plug and cap the hydraulic hose immediately.
Figu Figure re 3 Oil pressure hose location 8. Remove the hydraulic hydraulic hose located located under the rear of the transmission transmission pump that connects to the the transmission hydraulic filter. Plug and cap the hydraulic hose immediately. 9. Remove the transmission transmission pump supply supply hose located at the lower right hand side of the transmission transmission from the elbow connected to the transmission sump. Plug and cap the hydraulic hose and port immediately.
Figu Figure re 4 Removing the transmission pump supply hose
WARNING Only use lifting devices with adequate capacity. 10. Support the transmission and remove the four transmission mounting bolts. bolts.
Figu Figure re 5 Supporting Supporting the transmission 11. Move the transmission forward forward slightly in in order to gain enough access to remove the two Allen head head screws that mount the transmission pump to the transmission case. NOTE! Only remove the top left and bottom and bottom right Allen head screws.
Figu Figure re 6 Allen head screws removed from the transmission pump 12. Remove the transmission pump with with the supply supply hose still attached. attached. NOTE! Be careful not to lose the drive coupling between the transmission pump and the transmission reverse shaft. 13. Remove Remove and inspect inspect the transmissio transmission n pump drive drive coupling. coupling. 14. Remove the four four retaining bolts that hold the supply hose to the transmission pump
Service Information Document Title: Transmission installing
Function Group: pump, 421
Information Type: Service Information
Date: 2015/9/30
Profile: GRD, G930 [GB]
Transmission pump, installing Op nbr nbr 442442-012 012 1. Install Install fittings fittings into into the new new transmissi transmission on pump. pump. 2. Install a new O-ring O-ring in the supply hose hose flange. Reinstall the supply hose to the transmission transmission pump with the four four retaining bolts. NOTE! Orient the supply hose on the bottom of the transmission pump to face the left side of the machine when installed. 3. Install Install a new O-ring O-ring on the transmis transmission sion pump pump pilot. pilot. 4. Reinstall the transmission pump drive drive coupling coupling into the transmission. transmission. 5. Lower the the transmissio transmission n pump into into place while while guiding guiding the the supply supply hose to line up with with the elbow elbow from the transmission sump. 6. Align the transmission pump pump drive to match the pump shaft. Install the transmission transmission pump. NOTE! The transmission pump may have have to be rotated slightly to line up the pump drive drive to the transmission coupling. 7. Install the transmission transmission pump to the transmission case case using the two two Allen head screws. Torque the the Allen head screws to specification. 8. Reinstall Reinstall the the supply supply hose to the transmissi transmission on sump elbow. elbow. 9. Reinstall the transmission hydraulic hydraulic filter hose to the bottom bottom of the transmission transmission pump. pump. 10. Reinstall the brake booster hose to the top of the transmission pump. pump. 11. Move the transmission transmission back and line up the transmission transmission mounts with the support support brackets. NOTE! Place the large washers between the support brackets and the tops of the mounts.
Figu Figure re 1 Supporting Supporting the transmission 12. Reinstall Reinstall the four transmiss transmission ion bolts. bolts. Torque to specificati specification. on. 13. Reinstall the brake brake master cylinder cylinder assembly to the the brake booster using using the four mounting mounting nuts. Torque Torque to specification.
Figu Figure re 2 Brake master cylinder and brake booster 14. Fill the the transmiss transmission ion with with oil to the prope properr level. level. 15. Place Place the machin machine e back back in servic service. e. 16. Check the the operation of the machine. Ensure Ensure that there are no leaks. 17. Reinstall Reinstall the hydraulic hydraulic oil tank cover. cover. Refer Refer to 821 Engine hood, installing . 18. Place Place the machin machine e back back in servic service. e.
Service Information Document Title: Function Group: Transmission temperature 421 sensor, replacing
Information Type: Service Information
Profile: GRD, G930 [GB]
Transmission temperature sensor, replacing Op nbr nbr 386386-004 004
Removing 1. Place Place the machin machine e in the 191 Service position. 2. Lower the transmissi transmission on guard. guard. Refer Refer to 715 Transmission guard, removing . 3. Disconnect the the wiring harness connector connector from the temperature temperature sensor SE4202.
Figu Figure re 1 Transmission temperature switch location 4. Create Create a special special wrench wrench e tool measu measuring ring 152 152 mm (6 in.). in.).
Figu Figure re 2
Date: 2015/9/30
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