2 Transmission 1

2 Transmissio n

Table of Contents 2 Transmission

mm mm m m mm mm mm

2 Transmission.................................................................................................. 3
2.1 Controls and instrumentation ................................................................... 12
2.1.1 Gear and multi-function lever ............................................................... 12
2.2 Torque converter/clutch system ............................................................... 13
2.2.1 Flex plates ........................................................................................... 13
2.6 Lubrication ................................................................................................ 15
2.6.3 Oil cooler .............................................................................................. 18
2.7 Cooling ..................................................................................................... 20
2.7.3 Oil cooler .............................................................................................. 20
2.8 Control system transmission .................................................................... 21
2.8.1 Control unit transmission ..................................................................... 21
2.8.2 Breaking contact declutch .................................................................... 21
2.8.3 Cable harness transmission ................................................................ 21

Workshop manual DRF 100 VDRF04.01GB

2 2 Transmission

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2 Transmission 3

2 Transmission
mm mm mm m m mm mm

Transmission, general
page
–

Supplier documentation
The Workshop manual only describes components and work descrip-
tions that concern installation in the machine. For descriptions of and
instructions for the transmission's components and systems, refer to
the supplier documentation.
References to supplier documentation are only used in exceptional
cases. If information about a component is missing, use the supplier
documentation.

Workshop manual DRF 100 VDRF04.01GB

4 2 Transmission – 2 Transmission

page

Transmission, function description

F
R

<˚ 1
22 5

6, 23 2, 7 19
D790-1 D790-2 D795

D793 D794 D797-F

10, 16, 18, 20, 26 21 25

9 Pa
˚C 24
8 12 13 14 15
Pa ˚C

4 17

11
3

002212
Pos Explanation Signal description Reference
1 The gear selector sends voltage signal to Forward, Conn. F: U = 24 V Section 9 Frame, body, cab and acces-
Control unit KIT (D790-2). Reverse, Conn. R: U = 24 V sories, group 9.1 Controls and instru-
mentation
D1: Diagnostic menu, see section 8
Control system , group 8.4.7.2,
TRANSM, menu 2

2 Control unit KIT (D790-2) sends selected Checked by control and Section 11 Common electric, group
direction of travel (forward or back) on the monitoring system, error 11.5.3.11 Control unit KIT
CAN bus. shown with error code.

3 The transmission's oil pump pumps oil - -

when the engine is running.

4 The transmission's oil filter cleans the oil - -

from impurities.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2 Transmission 5

Pos Explanation Signal description Reference

5 The accelerator pedal sends a signal to U = 0.5-4.5 V Section 1 Engine, group 1.1.2 Accelera-
Control unit cab (D790-1). tor
D5: Diagnostic menu, see section 8
Control system, group 8.4.6.1 ENGINE,
menu 1

6 Control unit cab (D790-1) sends required Checked by control and Section 11 Common electric, group
throttle application on the CAN bus. monitoring system, error 11.5.3.1 Control unit cab
shown with error code.

7 Control unit KIT (D790-2) sends selected Checked by control and Section 11 Common electric, group
shifting program on the CAN bus. monitoring system, error 11.5.3.11 Control unit KIT
shown with error code.

8 Sensor oil pressure sends voltage signal Checked by Control unit D8: Diagnostic menu, see section 8
proportional to oil pressure to Control unit transmission, error shown Control system, group 8.4.7.10
transmission (D793). with error code. TRANSM, menu 10

9 Sensor engine speed and oil temperature Checked by Control unit D9: Diagnostic menu, see section 8
(B758/766) sends pulse signal with fre- transmission, error shown Control system, group 8.4.7.6
quency proportional to engine speed and with error code. TRANSM, menu 6 and 8.4.7.10
voltage signal proportional to transmission TRANSM, menu 10
oil temperature to Control unit transmis-
sion (D793).

10 Control unit transmission (D793) supplies Checked by Control unit Section 11 Common electric, group
voltage to valve block transmission control transmission, error shown 11.5.3.9 Control unit transmission
to obtain required function. with error code.

11 Solenoid valves for travel direction and Checked by Control unit -

gear position in valve block transmission transmission, error shown
control activate gears in the transmission with error code.
and the engine's power is transmitted to
the transmission's output shaft.

12 Sensor rpm turbine (B751) sends pulse Checked by Control unit D12: Diagnostic menu, see section 8
signal with frequency proportional to tur- transmission, error shown Control system, group 8.4.7.6 TRANS,
bine's rpm to Control unit transmission with error code. menu 6
(D793).

13 Sensor rpm drum (B752) sends pulse sig- Checked by Control unit D13: Diagnostic menu, see section 8
nal with frequency proportional to drum's transmission, error shown Control system, group 8.4.7.6
rpm to Control unit transmission (D793). with error code. TRANSM, menu 6

14 Sensor rpm output shaft (B758) sends Checked by Control unit D14: Diagnostic menu, see section 8
pulse signal with frequency proportional to transmission, error shown Control system, group 8.4.7.6
output shaft's rpm to Control unit transmis- with error code. TRANSM, menu 6
sion (D793).

15 Temperature monitor torque converter Checked by Control unit D15: Diagnostic menu, see section 8
(S221) sends voltage signal to Control unit transmission, error shown Control system, group 8.4.7.10
transmission (D793) if oil temperature in with error code. TRANSM, menu 10
torque converter becomes too high.

Workshop manual DRF 100 VDRF04.01GB

6 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference

16 Control unit transmission (D793) controls Checked by Control unit Section 11 Common electric, group
gearshifting according to selected shifting transmission, error shown 11.5.3.9 Control unit transmission
program. with error code.

17 The oil cooler cools the transmission oil. A - Oil cooler, description page 20
thermostat senses the oil's temperature
and directs the oil back to the transmission
if the oil is cold.

18 Control unit transmission (D793) sends Checked by control and Section 11 Common electric, group
temperature and rpm information on the monitoring system, error 11.5.3.9 Control unit transmission
CAN bus. shown with error code.

19 Control unit KID (D795) shows transmis- Checked by control and Section 11 Common electric, group
sion information in operating menus. monitoring system, error 11.5.3.12 Control unit KID
shown with error code.

20 If the signal from sensor output shaft - D20: Diagnostic menu, see section 8
(B758) indicates that the machine's speed Control system , group 8.4.7.6
exceeds the speed limitation, then Control TRANSM, menu 6
unit transmission (D793) sends a signal for
reduced engine speed on the CAN-bus.

21 Control unit engine (D794) reduces engine - Section 11 Common electric, group
speed. 11.5.3.10 Control unit engine

22 If the declutch pedal (S220-1) is pressed U = 24 V Section 9 Frame, body, cab and acces-
down it sends a voltage signal to Control sories, group 9.1 Controls and instru-
unit cab (D790-1). mentation
D22: Diagnostic menu, see section 8
Control system , group 8.4.7.1
TRANSM, menu 1

23 Control unit cab (D790-1) sends disen- Checked by control and Section 11 Common electric, group
gage drive on the CAN bus. monitoring system, error 11.5.3.1 Control unit cab
shown with error code.

24 Break contact (opening switch) declutch Brake pressure above Breaking contact disengagement (de-
(S220-2) sends a voltage signal to Control 0.2 MPa: clutch), description page 21
unit frame front (D797-F) if brake pressure Conn 1, U = 24 V D24: Diagnostic menu, see section 8
is high enough to allow disengagement of Control system , group 8.4.7.1
Conn 2, U = 24 V
drive. TRANSM, menu 1
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V

25 Control unit frame front (D797-F) sends Checked by control and Section 11 Common electric, group
disengagement approved on the CAN bus. monitoring system, error 11.5.3.2 Control unit frame front
shown with error code.

26 Control unit transmission (D793) supplies Checked by Control unit Section 11 Common electric, group
voltage to valve block transmission control transmission, error shown 11.5.3.9 Control unit transmission
so that drive is disengaged. with error code.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2 Transmission 7

Gearshifting transmission, function

page
–

description (transmission
alternative TE17000)
7 9 11 13 15
25 5 RSP
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
2 19

1 Fwd 2:nd Rev 1:st 3:rd

008240
29 20 21 22 23 24

Pos Explanation Signal description Reference

1. Bottom strainer oil sump, separates parti- - -
cles from the oil before the pumps.

2. The transmission's oil pump 1 feeds the 92.1 l/min at 2420 rpm -
transmission with control pressure for
control of the transmission.

3. The oil filter cleans the oil. - -

4. The by-pass valve in the filter bracket Opening pressure: 390 kPa -
leads the oil past the filter if the resistance
through the filter becomes too high.

5. The pressure governor releases pressure Opening pressure: 2500-2900 kPa -

to the torque converter if the pressure be-
comes too high.

6. The pressure reducer reduces the feed 1200 kPa -

pressure to servo pressure.

7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8

(Y6066) controls Valve slide neutral posi- Control and monitoring system,
tion. group 8.4.7.7 TRANSM, menu 7

8. Valve slide neutral position opens or clos- - -

es to allow control pressure to the trans-
mission.

9. Solenoid valve drive forward (Y630) con- 0-1000 mA Diagnostic menu, see section 8
trols Pressure booster drive forward. Control and monitoring system,
group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9

Workshop manual DRF 100 VDRF04.01GB

8 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference

10. Pressure booster forward increases the 0-2000 kPa -
pressure and pressurizes Drive clutch for-
ward.

11. Solenoid valve gear 2 (Y6069) controls 0-1000 mA Diagnostic menu, see section 8
Pressure booster gear 2. Control and monitoring system,
group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9

12. Pressure booster gear 2 increases the 0-3000 kPa -

pressure and feeds Valve slide gear se-
lection 2.

13. Solenoid valve drive reverse controls 0-1000 mA Diagnostic menu, see section 8
Pressure booster drive reverse. Control and monitoring system,
group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9

14. Pressure booster reverse increases the 0-2000 kPa -

pressure and pressurizes Drive clutch re-
verse.

15. Solenoid valve 1/3 (Y6067) controls Pres- 0-1000 mA Diagnostic menu, see section 8
sure booster gear 1/3. Control and monitoring system,
group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9

16. Pressure booster gear 1/3 increases the 0-2000 kPa -

pressure and feeds Valve slide gear se-
lection 1/3 as well as .

17. Contact drive sends signal to the control -

unit to verify that drive clutches for travel
direction and gear selection are activated
when solenoid valve neutral position
(RSP) (Y6066) is activated.

18. Solenoid valve VFS 1/3 (Y6075) controls 0-1000 mA Diagnostic menu, see section 8
servo pressure to Valve slide gear selec- Control and monitoring system,
tion 1/3. group 8.4.7.7 TRANSM, menu 7

19. Valve slide gear selection 1/3 pressurizes 0-2000 kPa -

Drive clutch gear 1 or Drive clutch gear 3.

20. Drive clutch forward locks transmission in 0-2000 kPa -

forward drive when the clutch is pressu-
rized.

21. Drive clutch 2nd gear locks transmission 0-2000 kPa -

in 2nd gear when the clutch is pressu-
rized.

22. Drive clutch reverse locks transmission in 0-2000 kPa -

reverse drive when the clutch is pressu-
rized.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2 Transmission 9

Pos Explanation Signal description Reference

22. Drive clutch 1st gear locks transmission in 0-2000 kPa -
1st gear when the clutch is pressurized.

24. Drive clutch 3rd gear locks transmission in 0-2000 kPa -

3rd gear when the clutch is pressurized.

25. The safety valve leads the oil back to the Opening pressure: 850 kPa -
sump if the pressure to the torque convert-
er becomes too high.

26. The torque converter transmits the en- - -

gine's power to the transmission.

27. The transmission oil cooler cools the oil. - -

28. The by-pass valve torque converter leads Opening pressure: 400 kPa
the oil past the torque converter if the
pressure becomes too high.

29. The oil is distributed to different lubrication - -

points in the transmission.

page

Workshop manual DRF 100 VDRF04.01GB

10 2 Transmission – 2 Transmission

Transmission, component position

5
3 4

6 7

2
1

14 13 12

15
16 8
17
9
19
10

009267
18 11

1. Valve block transmission control 11. Oil filter transmission

2. Connection cooler (out from transmission) 12. Inlet radiator
3. Oil pump transmission 13. Outlet radiator
4. Power take-off 14. Transmission oil cooler
5. Radiator core 15. Connection cooler (from cooler to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Breather filter transmission 17. Sensor turbine speed (B751)
8. Sensor drum speed (B752) 18. Sensor output shaft speed (B758)
9. Sensor engine speed and oil temperature (B758/766) 19 Output shaft
10. Sensor oil pressure

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2 Transmission 11

1 2 3 4 5

10
7
9
8

006711
1. Accelerator pedal (B690) 6. Control unit frame rear (D797-R)
2. Control unit KIT (D790-2) 7. Control unit transmission (D793)
3. Control unit KID (D795) 8. Declutch pedal (S220-1)
4. Multi-function lever (S162) 9. Control unit frame front (D797-F)
5. Control unit cab (D790-1) 10. Make-contact declutch (S220-2)

Engine and gearbox, separation

page
–

See section 1 Engine.

Workshop manual DRF 100 VDRF04.01GB

12 2 Transmission – 2.1 Controls and instrumentation

2.1 Controls and instrumentation

2.1.1 Gear and multi-function lever
Gear and multi-function lever, description
page
–

Travel direction is selected with the gear and multi-function lever.

F
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied with voltage by and sends signals to Control
unit KIT (D790-2).
002209 The signal can be checked from the diagnostic menu, see section 8
R
Control and monitoring system, group 8.4.7.2 TRANSM, menu 2.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2.2 Torque converter/clutch system 13

2.2 Torque converter/clutch

system
2.2.1 Flex plates
Flex plates, changing (engine alternative Volvo
page
–

TAD760VE)
1 Machine in service position, see section B Safety.
2 Remove the flywheel cover plate.

Cover plate flywheel.

3 Remove the attaching nuts for the flex plate.
4 Rotate the engine for each bolt for the flex plate that is to be re-
moved.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.

Attaching nut flex plate.

7 Carefully separate the transmission and engine.

Fitting flex plate.

Workshop manual DRF 100 VDRF04.01GB

14 2 Transmission – 2.2.1 Flex plates

8 Remove the bolts holding the flex plate to the transmission.

9 Change the flex plate.
10 Install in reverse order. Install the flex plate's attaching bolts to
the transmission with 40 Nm. Install the flex plate's attaching nuts
to the flywheel with 46-50 Nm.
11 Before the machine is put into operation, the transmission must
be calibrated, see Transmission, calibrating page 21.

Attachment of flex plate.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2.6 Lubrication 15

2.6 Lubrication
Lubrication system, description
page
–

The transmission lubricating system has the following function:

• Lubricate gear wheel and bearings
• Apply the clutches in the gearbox
• Cool down the torque converter and gearbox
• Clean the oil of any impurities with the oil filter.
During operation of the engine, the oil pump draws oil from the trans-
mission's oil sump through a strainer, and it then pumps it through the
oil filter to a control valve.
The control valve supplies oil at the correct pressure to the gearbox
valve housing to activate the clutch plates for FORWARD or RE-
VERSE and gear 1, 2, or 3. The clutch plates require just a small
amount of the oil flow supplied by the pump. The remainder of the oil
is pumped through the torque converter circuit to the oil cooler and re-
turns to the gearbox for lubrication.
See also supplier documentation transmission.

Oil and oil filter, changing

page
–

NOTE
Read the safety instructions for oil before working, see section F
Technical data.
1 Operate and warm up the transmission oil.
2 Machine in service position, see section B Safety.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.

Draining transmission oil

Workshop manual DRF 100 VDRF04.01GB

16 2 Transmission – 2.6 Lubrication

4 Clean the area around the oil filter.

5 Remove the oil filter.
6 Install a new oil filter.
Lubricate the O-ring on the new oil filter with transmission oil.
Tighten to contact and then another two-thirds turn.
7 When the transmission oil has drained, fit the drain plug.
Make sure that the washer for the oil plug is included.

004331

Oil filter transmission

8 Remove the transmission dipstick and fill new transmission oil
B through the dipstick's hole to the marking for low level on the dip-
stick.
For volume and quality, see section section F Technical data .
9 Start the engine and let the engine run at idle for at least two min-
utes.
10 Check that the drain plug for transmission oil seals tight.
A 11 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.
006477

A. Position of oil filling point and level check

B. Oil filling point and oil dipstick
12 Warm up the transmission so that the oil temperature is 60-65 °C.
Use the operating menu oil temperature to check the transmis-
sion oil temperature.
a
13 Check the oil level and top up to the MAX marking for oil level.
b
000356

Operating menu oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2.6 Lubrication 17

Oil level, checking

page
–

NOTE
B
Read the safety instructions for oil before working, see section F
Technical data.
The transmission's oil filler pipe and dipstick (position B) are located
under the service hatch in front of the cab.

1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 °C in the
display). The dipstick has two markings, MAX and MIN, the oil
A
level should be at MAX.
Wipe off the dipstick before checking.

NOTE
The dipstick is long. Use gloves.
006477
2 Fill transmission oil (position B) as needed (for volume and qual-
A. Position of oil filling point and level check ity, see section F Technical data).
B. Oil filling point and oil dipstick Fill – wait awhile – check on the dipstick.

NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means
risk of transmission damage.

Workshop manual DRF 100 VDRF04.01GB

18 2 Transmission – 2.6.3 Oil cooler

2.6.3 Oil cooler

Oil cooler, description
page
–

The transmission oil is cooled in the lower section of the cooler unit.
A temperature-controlled bypass valve, which only acts on the trans-
mission oil cooling circuit, is located in a pipe on the underside of the
1 cooler (engine side). The valve closes when the oil starts to reach
working temperature. This means that the oil reaches normal working
temperature more quickly.
For more detailed information see supplier documentation transmis-
sion.

3
003215

Radiator core
1. Intercooler (charge-air cooler)
2. Radiator engine
3. Cooler transmission oil
4. Thermostat transmission oil
5. Attachment condenser (to AC)
page
–

VDRF04.01GB Workshop manual DRF 100

2 Transmission – 2.6.3 Oil cooler 19

Thermostat transmission oil cooler, changing

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Machine in service position, see section B Safety.

2 Drain the transmission of oil, see Oil and oil filter, changing page
15.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change as need-
ed.
5 Install the new thermostat, and the cover plug.

007447
IM P OR TA NT
It is very important that the thermostat is used with
the temperature bulb facing out as shown.

6 Fill transmission oil, see Oil and oil filter, changing page 15.
7 Start the engine and check for leaks.
8 Check the oil level in the transmission, see Oil level, checking
page 17.

Workshop manual DRF 100 VDRF04.01GB

20 2 Transmission – 2.7 Cooling

2.7 Cooling
2.7.3 Oil cooler
Oil cooler, description
page
–

See Oil cooler, description page 18.

VDRF04.01GB Workshop manual DRF 100

 2 Transmission – 2.8 Control system transmission 21

2.8 Control system transmission

Transmission, calibrating
page
–

See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.

2.8.1 Control unit transmission

Control unit, transmission, general
page
–

See section 11 Common electric, group 11.5.3.9 Control unit, trans-

mission and supplier documentation transmission.

2.8.2 Breaking contact declutch

Breaking contact disengagement (declutch),
page
–

description
The break contact for disengagement senses if the wheel brakes are
1 pressurised. The break contact is located on the distribution block for
10
2 the brake system, above the drive axle's differential.
1
3 The sensor can be checked from the diagnostic menu, see section 8
3 Control and monitoring system, group 8.4.7.1 TRANSM, menu 1.
4
5
5
9 6
8 7
000439

1. Connection brake cooling, return from wheel brake

2. Connection brake cooling, return to radiator and
tank
3. Connection brake cooling, to wheel brake
4. Connection brake cooling, from accumulator
charging valve
5. Connection brake cylinder, to wheel brake
6. Connection brake pressure, from brake valve
7. Make-contact, declutch (S220)
8. Make-contact, wheel brake (S216)
9. Test outlet, brake pressure
10. Test outlet, back-pressure brake cooling

2.8.3 Cable harness transmission

Cable harness transmission, description
page
–

See section E Diagrams .

Workshop manual DRF 100 VDRF04.01GB