Service Information

Document Title: Function Group: Information Type: Date:

Description 200 Service Information 2014/6/26
Profile:

Description
Articulated Hauler A30C is equipped with an engine type TD103KBE (serial No.–2958, US –60026) and TD104KAE (serial
No. 2959–, US 60027–).
The engine is a straight, six-cylinder, direct-injection, turbocharged diesel engine with intercooler.
The engine type designation, part and serial numbers are stamped into the left side of the cylinder block. The cylinder heads,
one for each cylinder, are mutually interchangeable. The heads have replaceable valve seats and valve guides for both inlet
and exhaust valves.
The valve mechanism receives its movement from the camshaft via push rods and rocker arms.
The injection pump is equipped with a smoke limiter in order to limit the engine torque. The injectors are installed in
replaceable copper sleeves which are pressed into the cylinder head and in direct contact with the circulating coolant.
For repair work on the engine we refer to a separate Service Manual, see the Foreword.
 Service Information

Document Title: Function Group: Information Type: Date:

Diagnosis using Service 200 Service Information 2014/6/26
Display Unit
Profile:

Diagnosis using Service Display Unit

Error codes
The table below shows a summary of error codes which may appear on the display unit and the most likely cause of the
fault/error.
The following trouble-shooting diagram shows, in addition to error codes, also error symptoms, probable error cause and
the action required to rectify the fault as well as a reference to the service display unit.
Error messages

Display Cause Control lamp, Central

malfunction in warning
transmission
201 Engine pressure ER Electrical fault sensor circuit (SE16) – –
202 Engine pressure low Too low lubricating oil pressure, engine – yes

Trouble-shooting diagram

Error code Symptom Probable error cause Action Service display unit
screen (figure) No.
201 Faulty sensor SE16 or Measure resistance in
Engine oil faulty cable harness to cable harness and check
pressure, the same. sensor.
sensor fault
Figure 5.12 Number 23
(SE16)
Normal oil pressure; 0
Low oil pressure; 1
202 Lubricating oil pressure
Low engine too low.
oil pressure
(SE16)
Figure 5.12 Number 23
Normal oil pressure; 0
Low oil pressure; 1
 Service Information

Document Title: Function Group: Information Type: Date:

Tightening torques 200 Service Information 2014/6/26
Profile:

Tightening torques
Engine
Engine – Flywheel housing 140 N m, 14 kgf m (103 lbf ft)
Front engine mounting, see [Invalid linktarget]
Item 1 220 N m, 22 kgf m (162 lbf ft)
Item 2 140 N m, 14 kgf m (103 lbf ft)
Item 3 50 N m, 5 kgf m (37 lbf ft)
Rear engine mounting, see [Invalid linktarget]
Item 1 85 N m, 8.5 kgf m (63 lbf ft)
Item 2 134 N m, 13.4 kgf m (100 lbf ft)
Item 3 220 N m, 22 kgf m (162 lbf ft)
Item 4 220 N m, 22 kgf m (162 lbf ft)

Figure 1
Figure 2
 Service Information

Document Title: Function Group: Information Type: Date:

Trouble-shooting 200 Service Information 2014/6/26
Profile:

Trouble-shooting
Methods and aids
When a fault is suspected or found, it is important immediately to determine the cause of the fault and identify the faulty
component.
Certain faults are indicated by the red central warning lamp on the instrument panel lighting up at the same time as the
buzzer is sounding or in that the LED (Light Emitting Diode) on the ECU is flashing.
In case of a warning, the engine should be stopped immediately and a service engineer should be called.
In order to facilitate and make the trouble-shooting more efficient, there are a number of aids available.

 Contronic Display Unit

 Contronic Service Display Unit 999 3721
 Multimeter 11 666 140
 Multi-pin breaker box 11 668 002

With the aid of the Service Display Unit it is possible to determine sensor faults, engine oil pressure and low engine oil
pressure.
In case of a fault/error the Service Display Unit will show an error code (ER indication) and a reading (value) deviating from
the normal. Error codes, possible causes of malfunction and suitable action are described under ”Diagnosis using Service
Display Unit”.
When an error code or a deviating value is shown, measuring resistance is used to establish whether the fault is in a
component e.g. sensor) or if the cable harness to the same is faulty.
 Service Information

Document Title: Function Group: Information Type: Date:

Compression test, warm 210 Service Information 2014/6/26
engine
Profile:

Compression test, warm engine

Op nbr 21002

999 6643 Puller

999 8009 Adapter
998 8539 Compression gauge

Prerequisite condition: The valves are correctly adjusted, see [Invalid linktarget] .

1. Place the machine on level ground and apply the parking brake.

2. Carefully clean around the injectors and at the connections for the fuel delivery pipes and the leak-off fuel pipes.

WARNING
The fuel delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped.

If a pressure prestressed fuel delivery pipe is bent or deformed, there is a great risk that the pipe will break.

A damaged delivery pipe must always be replaced with a new pipe!

Removing

3. Remove the fuel delivery pipes.

CAUTION
Place protective caps on all injectors and on the injection pump connections.

4. Remove the leak-off fuel pipe.

Figure 1

1. 999 6643 Extractor

5. Remove the injector for the number 1 cylinder. When necessary use extractor 999 6643 for taking out the injector.
 See [Invalid linktarget] . Make sure that the copper washer which is positioned between the injector and the
copper sleeve comes out together with the injector, [Invalid linktarget] . If it does not come out, use a hook made
from a piece of wire to get it out.

Figure 2

1. Copper washer

6. Install the adapter 999 8009 and secure it using the injector retaining yoke and nut. See [Invalid linktarget] .
Tightening torque: 50 N m (5.0 kgf m) (37 lbf ft).

Figure 3

1. 999 8009, Adapter

2. 999 8539, Compression gauge

7. Connect compression gauge 998 8539. See [Invalid linktarget] .

8. Pull out the stop button and secure the injection pump stop lever in the stop position. This is to prevent fuel from
running out of the delivery valves when the engine is cranked with the starter motor.

9. Check that the gear selector is in neutral.

10. Crank the engine with the starter motor for 5 seconds.

11. Remove the testing equipment and re-install the injector together with a new copper washer.
Tightening torque: 50 N m (5.0 kgf m) (37 lbf ft).

12. Carry out a compression test of cylinders 2, 3, 4, 5 and 6 in the same way as for cylinder number 1.
Remove the pipe between the turbocharger and intercooler when testing cylinder number 6.
 Normal compression pressure is 2.6 MPa (26 bar) (377 psi) at 220 rpm.

CAUTION
Differences of 10 % in the compression pressure between the cylinders is fully acceptable and does not constitute a
reason for further action as for example valve reconditioning.

Installing

13. Install the leak-off fuel pipe together with new copper washers.

14. Re-install the pipe between the turbocharger and the intercooler.

WARNING
The fuel delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped. If a
pressure prestressed fuel delivery pipe is bent or deformed, there is a great risk that the pipe will break. A
damaged delivery pipe must always be replaced!

15. Install the fuel delivery pipes. Observe the greatest possible cleanliness and make sure that the pipes are not bent
or deformed. Tighten the pipe nuts.
Tightening torque: 15–25 N m (1.5–2.5 kgf m) (18 lbf ft).

16. Restore the stop function. Start the engine and check that there are no leaks.
 Service Information

Document Title: Function Group: Information Type: Date:

Engine and transmission, 210 Service Information 2014/6/26
installing
Profile:

Engine and transmission, installing

Op nbr 21074

999 2754 Lifting tool

999 2755 Lifting tool
999 2756 Lifting tool
999 6052 Lifting tool

Torque wrench 0–400 N m (0–40 kgf m)

(0–295 lbf ft)

1. Connect the lifting device to the engine. Incline the engine and transmission to the correct angle.

2. Lower the unit and install the engine mountings (the front ones first).
Tightening torque, front: 220 N m (22 kgf m) (162 lbf ft).
Tightening torque, rear: 140 N m (14 kgf m) (103 lbf ft).

3. Install the propeller shaft.

Tightening torque: 180 N m (18 kgf m) (133 lbf ft).

4. Install the components on the transmission:

 two new oil filters

 connector EH
 oil filler pipe and oil dipstick
 hose for breather filter
 connector for retarder valve and connector for sensor S13.

5. Connect the hoses to the extra oil cooler for the transmission.

6. Connect the hose to the power take-off lubricating oil pump.

7. Connect the suction lines to pumps 1, 2 and 4.

8. Connect the return oil hoses for the hydraulic pumps.

9. Connect the hoses (B, C, D, E and F) to the collecting pipe. See [Invalid linktarget]

Figure 1
Collecting pipe for leak-off oil

A. Return oil line from fan motor (9/16 UNF)

 B. Leak-off oil line from thermostat valve (9/16 UNF)
C. Leak-off oil line from pump 1 (steering and tipping system) (7/8 UNF)
D. Leak-off oil line from pump 4 (steering and tipping system) (7/8 UNF)
E. Leak-off oil line from pump 2 (steering and tipping system) (7/8 UNF)
F. Leak-off oil line from pump 3 (fan drive) (7/8 UNF)

10. Install governor control arm and stop control cables. Connect the hoses to the brake pump. Install alternator,
exhaust pipe and oil filters. Install the air cleaner.

11. Connect coolant hoses, oil coolers, the fuel lines to injection pump.

12. Install engine hood and the left side plate.

13. Clamp hoses and electrical leads where clamping has been removed.

14. Open the hydraulic oil tank shut-off valve.

15. Fill with coolant, see [Invalid linktarget] . Fill hydraulic oil. See the Operator"s Manual, ”Hydraulic oil, changing”.
Fill engine oil. See the Operator"s Manual, ”Engine, changing oil”.
Check that there is a sufficient amount of oil in the transmission, before starting the engine.

16. Bleed the fuel system, see [Invalid linktarget] .

17. Swing in the radiator and tighten down.

18. Switch on the current with the battery disconnect switch, see [Invalid linktarget] .

Figure 2

A. On
B. Off

1. Front guard plate

2. Front, transverse member
3. Rear guard plate, left
4. Rear guard plate, right
5. Rear, transverse member

19. Start the engine and test the function. Check that there are no leaks. Run until warm and check the coolant level
and the transmission oil level.

20. Install the front (2) and the rear (5) transverse members. Install guard plates (1), (3) and (4), see [Invalid linktarget] .
21. Close the engine hood and test-run the machine.
 Service Information

Document Title: Function Group: Information Type: Date:

Engine and transmission, 210 Service Information 2014/6/26
removing
Profile:

Engine and transmission, removing

Op nbr 21073

999 2754 Lifting tool

999 2755 Lifting tool
999 2756 Lifting tool
999 6052 Lifting tool

Torque wrench 0–400 N m (0–40 kgf m)

(0–295 lbf ft)

WARNING
There is a danger of scalding when removing the expansion tank cap (radiator cap), as the cooling system is
pressurised when hot.

Hot oil may cause burns.

CAUTION
Plug all pipes, hoses and connections after disconnection.

Removing

1. Place the machine in the service position.

Figure 1

A. On
 B. Off

1. Front guard plate

2. Front, transverse member
3. Rear guard plate, left
4. Rear guard plate, right
5. Rear, transverse member

2. Turn off the current with the battery disconnect switch, see [Invalid linktarget] .

3. Open up the engine hood and swing out the radiator.

WARNING
The protecting plate may be full of for instance clay and weigh considerable more than 50 kg (110 lb).

4. Lower and remove the front (1) guard plate (approx. 50 kg (110 lb)) and the two rear (3, 4) guard plates, see [Invalid
linktarget] .
Remove the front (2) and rear (5) transverse members under the engine, weight approx. 30 kg (66 lb) each.

5. Remove the engine hood and the left side plate.

6. Remove the cap from the radiator expansion tank.

Drain the coolant from the engine, see [Invalid linktarget] .

CAUTION
Mark where required. Plug all pipes, hoses and connections when removing.

Exposing engine
Left side

7. Remove the hose between the turbocharger and the air cleaner. Remove the flexible hose of the exhaust pipe.

8. Disconnect the electrical leads and the hoses. Remove the alternator, the oil filter and the fuel system water trap.

9. Disconnect the governor control arm and the stop control cable and secure the stop control, see [Invalid
linktarget] .

Figure 2

1. Securing the stop control

Right side

10. Disconnect hoses, pipes and electrical leads from the engine.
Remove the coolant hose.

11. Detach the AC-compressor, if installed, without opening the system.

 NOTE!
Secure the compressor to the frame with ties or similar.

Figure 3

1. Shut-off valve for hydraulic oil tank

12. Close the hydraulic oil tank shut-off valve and secure with locking wire or a tie. Detach the control cable. See
[Invalid linktarget] .

13. Remove the suction lines for hydraulic pumps 1, 2 and 4, see [Invalid linktarget] .

Figure 4
Hydraulic pumps on power take-off

F Travelling direction
1.2 and 4 Hydraulic pumps (steering and tipping systems)
3 Hydraulic pump (fan drive)

14. Mark and disconnect the hoses (B, C, D, E and F) at the collecting pipe, see [Invalid linktarget] .

Figure 5
Collecting pipe for leak-off oil

A. Return oil line from fan motor (9/16 UNF)

B. Leak-off oil line from thermostat valve (9/16 UNF)
C. Leak-off oil line from pump 1 (steering and tipping system) (7/8 UNF)
D. Leak-off oil line from pump 4 (steering and tipping system) (7/8 UNF)
E. Leak-off oil line from pump 2 (steering and tipping system) (7/8 UNF)
 F. Leak-off oil line from pump 3 (fan drive) (7/8 UNF)

15. Drain the oil from the engine power take-off, (approx. 1 litre = 0.26 US gal).

16. Disconnect the hoses at the front and rear hydraulic pumps. Place the hoses so that they are not deformed.

17. Disconnect the return oil hose at the hydraulic tank.

18. Remove the engine oil cooler.

19. Disconnect the fuel lines at the fuel injection pump.

Exposing transmission

20. Remove the two transmission filters.

21. Disconnect connector EH, the oil filler pipe, the oil dipstick, the hose for the breather filter, the connector for the
retarder valve and the connector for sensor S13.

22. Detach the propeller shaft between the transmission and the dropbox at the transmission. Secure the propeller
shaft.

23. Pull the dropbox rearward using a tensioning strap around the upper part of the dropbox and the trailer unit frame.
See [Invalid linktarget] .

Figure 6

1. Sling
2. Ratchet block, 750 kg (1653 lb)

24. Connect a lifting device to the engine, see [Invalid linktarget] . The lifting device consists of lifting tools 999 2754,
999 2755, 999 2756 and 999 6052.
 Figure 7

25. Loosen the four mountings for the engine, see [Invalid linktarget] and [Invalid linktarget] .

Figure 8

1. Parting rear engine mountings

Figure 9

1. Parting at front engine mountings

26. Balance and incline the unit to the correct angle and carefully lift out the engine and the transmission. See [Invalid
linktarget] .
Lower the unit to the floor, support it and make sure that it stands securely.
NOTE!
Check that no hoses become deformed.

Figure 10
Lifting engine-transmission unit
 Service Information

Document Title: Function Group: Information Type: Date:

Engine, installing 210 Service Information 2014/6/26
Profile:

Engine, installing
Op nbr 21072

999 3590 Gear

Lifting sling

Ratchet block 750 kg (1653 lb)

Ratchet block 1500 kg (3307 lb), 2 pcs

1. Apply grease to the torque converter centre pin. Check the distance between the torque converter and
transmission. If distance A is greater than approx. 89 mm (3.50 in), see [Invalid linktarget] , lift and carefully press
back the torque converter. The torque converter may have to be removed and the cause why it does not go
sufficiently far in, be investigated.

Figure 1

A. = approximately 89 mm (3.50 in)

2. Connect a lifting device to the engine and lift it into position in the machine. See [Invalid linktarget] .
Remove the brace for the torque converter and carefully push engine and transmission together.

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 angular advance mechanism.
 Figure 2

1. Notch
2. Pin

3. Tighten the bolted joint between the flywheel housing and the transmission.
Tightening torque: 85 N m (8.5 kgf m) (63 lbf ft).

4. Tighten the bolted joint between the drive disc and the torque converter.
Tightening torque: 55 N m (5.5 kgf m) (41 lbf ft).

5. Lift the unit and remove any supports from under the transmission.

6. Position and tighten down the engine mountings.

Tightening torque: front 220 N m (22.0 kgf m) (162 lbf ft), rear 220 N m (22.0 kgf m) (162 lbf ft).

7. Remove the lifting device.

Remove the ratchet block between the dropbox and the frame.

Right side of the engine

8. Install the pipes, the hoses and the electrical leads.

At the front end of the engine

9. Connect the hoses and the connectors and repositon the AC compressor.

At the top of the engine

10. Connect and clamp the hoses and the electrical cables.

Left side of the engine

11. Install the hoses, the exhaust pipe, the accelerator and stop controls, the brake pump, the alternator and the
electrical leads.
NOTE!
Check that the stop arm on the injection pump is in its stop position, when the hydraulic oil tank shut-off valve is
closed.

Under the engine

12. Install the hydraulic pumps against the power take-off.

CAUTION
Install new O-rings. Coat the bolts with locking fluid (normal).

Tightening torque: 50 N m (5.0 kgf m) (37 lbf ft).

 Connect the suction lines.

13. Open the hydraulic oil tank shut-off valve, [Invalid linktarget] .

14. Install the front, transverse member.

Figure 3

1. Shut-off valve for hydraulic oil tank

15. Connect the return lines to the collecting pipe between engine and cab. See [Invalid linktarget] .

Figure 4

1. Collecting pipe for leak-off oil

16. Check that no leads and hoses are loose or pinched, clamp when necessary.

17. Install the cover plate behind the air cleaner.

Install the air cleaner and the inlet hose.

18. Fill coolant, see [Invalid linktarget] .

Fill hydraulic oil. See the Operator"s Manual, ”Hydraulic oil, changing”.
Fill engine oil. See the Operator"s Manual, ”Engine, changing oil”.
Check that there is a sufficient amount of oil in the transmission, before starting the engine.
Swing in the radiator and tighten down.
Bleed the fuel system, see [Invalid linktarget] .

19. Start the engine and test the function and check for leaks.
Check the coolant level and the transmission oil level, when engine and transmission have been run until warm.

20. Install guard plates (1), (3) and (4) under the engine. See [Invalid linktarget] .
 Figure 5

1. Front guard plate

2. Rear guard plate, left
3. Rear guard plate, right
4. Front, transverse member
5. Rear, transverse member

21. Close the engine hood. Test-run the machine.

 Service Information

Document Title: Function Group: Information Type: Date:

Engine, removing 210 Service Information 2014/6/26
Profile:

Engine, removing
Op nbr 21070

999 3590 Gear

Lifting sling

Ratchet block 750 kg (1653 lb)

Ratchet block 1500 kg (3307 lb), 2 pcs

WARNING
There is a danger of scalding when removing the expansion tank cap (radiator cap), as the cooling system is
pressurised when hot.

Hot oil may cause burns.

CAUTION
Plug all pipes, hoses and connections after disconnection.

Removing

1. Turn off the current with the battery disconnect switch, see [Invalid linktarget] .

Figure 1

A. On
B. Off
 1. Front guard plate
2. Front, transverse member
3. Rear guard plate, left
4. Rear guard plate, right
5. Rear, transverse member

2. Open up the engine hood and swing out the radiator.

3. Remove the cap from the radiator expansion tank. Drain the coolant from the engine, see [Invalid linktarget] .

WARNING
The protecting plate may be full of for instance clay and weigh considerable more than 50 kg (110 lb).

4. Lower and remove the front and the two rear guard plates, see [Invalid linktarget] .
Remove the front, transverse member (2) under the engine, weight approx. 30 kg (66 lb), see [Invalid linktarget] .

5. Close the hydraulic oil tank shut-off valve, secure with locking wire or a tie. See [Invalid linktarget] .

Figure 2

1. Shut-off valve for hydraulic oil tank

6. Drain the oil from the engine power take-off, approx. 1 litre (0.26 US gal).

7. Remove the suction-pipes from the two rear hydraulic pumps, and the front, left hydraulic pump.
Detach the four hydraulic pumps from the power take-off, and place them so that none of the hoses become
deformed.

8. Disconnect and mark the lines from collecting pipe (1) positioned between cab and engine, see [Invalid linktarget] .

Figure 3

1. Collecting pipe for leak-off oil

 CAUTION
Mark where required. Plug all pipes, hoses and connections when removing.

Exposing engine
Left side of the engine

9. Remove the alternator, the governor control arm and the stop control cable and the return hoses.

10. Remove the air cleaner, the plate behind the air cleaner, the inlet hose and the exhaust pipe from the turbocharger.

At the top of the engine

11. Disconnect the hoses and the electrical leads from the engine.

At the front end of the engine

12. Detach AC-compressor, if installed, without opening the system. Discconnect the hoses and the connectors from
the engine hood.

Right side of the engine

13. Remove hoses, pipes and electrical leads from the engine. Disconnect at the connections on the transmission oil
cooler.

Safety

14. Connect a sling and ratchet block around the upper part of the dropbox and the frame. See [Invalid linktarget] .
NOTE!
The dropbox is rubber mounted.

Figure 4

1. Sling
2. Ratchet block, 750 kg (1653 lb)

15. Connect a lifting device to the engine, weight approx. 1360 kg (2998 lb), see [Invalid linktarget] .
 Figure 5

1. Ratchet block 1500 kg (3307 lb), 2 pcs

2. Ratchet block, 750 kg (1653 lb)

16. Loosen the four mountings for the engine, see [Invalid linktarget] and [Invalid linktarget] .

Figure 6
Parting rear engine mountings

Figure 7

1. Parting at front engine mountings

17. Lift the engine approx. 20 mm (0.79 in) and position a couple of wooden blocks between the transmission oil sump
and the rear transverse member, [Invalid linktarget] .
Lower the unit against the wooden blocks, but keep the sling from the lifting device tight.
 Figure 8

1. Wooden blocks
2. Rear member

18. Remove the bolted joint between drive disc and torque converter. Use the gear 999 3590 to rotate the crankshaft.
See [Invalid linktarget] .

Figure 9

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.
3. Drive disc graduation.

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

20. Pull the engine forward and when necessary the dropbox rearward. Check that the torque converter disengages
from the drive disc and not from the transmission.
Secure the torque converter with a transport brace, [Invalid linktarget] , or alternatively use locking wire.

CAUTION
It is important that the torque converter is secured, as it may easily slide out of its location and could be
damaged.
 Figure 10

1. Transport brace

21. Carefully lift out the engine. See [Invalid linktarget] .

Check that no hoses become deformed.
Lower the engine to the floor, support it and make sure that it stands securely.

Figure 11
 Service Information

Document Title: Function Group: Information Type: Date:

Valves, 214 Service Information 2014/6/26
adjusting
Profile:

Valves, adjusting
Op nbr 21412

999 3590 Gear

WARNING
To eliminate the risk ot the engine starting when the crankshaft is rotated, the stop control pulled out, the ignition
key turned off and the engine should have cooled down.

1. Open up the engine hood.

2. Expose the anti-freeze reservoir.

3. Clean around the valve covers, loosen and remove them.

4. Remove the plate plug from hole (1) and the upper rubber plug from hole (2). See [Invalid linktarget] .

Figure 1

1. The gear 999 3590 should be positioned in the hole in the flywheel housing.
2. Inspection hole for flywheel graduation

5. Install gear 999 3590 in hole (1) in the flywheel housing. Use a standard ratchet handle and if necessary this can be
combined with a universal joint and extension bar from a
1/2" square drive socket set.
 Figure 2
Valve position (engine seen from above)

Inlet
Exhaust

6. Adjust the valve clearance according to the dual-position method.

 Rotate the flywheel in the direction of rotation of the engine (clockwise) until the valves for the 6th
cylinder are rocking and the flywheel graduation is at 0 degrees.
 The piston in the 1st cylinder is then at the upper turning point after the compression stroke (T.D.C.).
 Adjust valves 1, 2, 4, 5, 8 and 9.
The clearance should be 0.40 mm (0.016 in) for the inlet valves and 0.70 mm (0.028 in) for the exhaust
valves (cold engine).
Valve position. See [Invalid linktarget] .

7. Then rotate the flywheel a further revolution in the direction of rotation of the engine (clockwise) until the valves
for the 1st cylinder are rocking and the flywheel graduation is at 0 degrees. The piston in the 1st cylinder is turning
after the compression stroke.

 Adjust the valves 3, 6, 7, 10, 11 and 12.

CAUTION
Never adjust the valves with the engine running, as the valves may strike the piston and cause serious damage.

8. Remove the gear from the flywheel housing.

9. Install the plate plug and the upper rubber plug in the flywheel housing.

10. Re-install and tighten down the valve covers.

Tightening torque: 24 N m (2.4 kgf m) (18 lbf ft).

11. Install the anti-freeze reservoir.

12. Test-run the engine and lower the engine hood.

 Service Information

Document Title: Function Group: Information Type: Date:

Description 220 Service Information 2014/6/26
Profile:

Description
The engine is lubricated through force-feed lubrication from an oil pump driven by the crankshaft via a an intermediate
gear.
The oil pump is of the double pump type. The front main pump provides the lubrication system with oil. The rear pump
transfers oil from the rear part of the oil sump to its front part in order to safeguard supply of oil when operating up steep
inclines.
The main pump forces the oil via the oil cooler, the two full-flow filters, ducts in the cylinder block and pipes out to all
lubrication points.
Oil valves
The designations below refer to [Invalid linktarget] .
A Pressure-limiting valve
The pressure-limiting valve opens when the oil pressure becomes to high and conducts the surplus oil back to the oil sump.
B Overflow valve, full-flow oil filter

Figure 1
Oil system valves

A. Pressure-limiting valve
B. Overflow valve, full-flow filter
C. Overflow valve, oil cooler
D. Piston cooling valve
E. Oil cooling nozzle

The overflow valve opens if, for example, the filters have become clogged, and conducts the unfiltered oil directly out to the
engine lubrication points and thereby ensures lubrication.
COverflow valve, oil cooler
The overflow valve opens when the drop in pressure across the oil cooler is too high, for example when starting a cold
engine. When the valve opens, the oil passes by the oil cooler and thus reaches out to the engine lubrication points quicker.
D Piston cooling valve
The valve opens when the engine speed has increased to just above low idling and the oil pressure has increased. The oil is
then conducted via a drilled duct in the cylinder block to the piston cooling nozzles (E). Six nozzles are connected to the oil
duct, one for each piston, and from these oil is sprayed up against the underside of the pistons. The valve closes the oil
supply at low engine speeds, so that all oil is supplied to the lubrication system, thus ensuring lubrication of the engine at
low speeds.
 Service Information

Document Title: Function Group: Information Type: Date:

Injection timing adjuster 230 Service Information 2014/6/26
<br />(angular
advance mechanism)
Profile:

Injection timing adjuster

General
The injection timing adjuster is positioned between the pump gear in the timing casing and the injection pump. Its purpose
is to advance the injection (from 9 to 15° B.T.D.C.) at engine speeds above 1620 rpm. See [Invalid linktarget] .

Figure 1
Injection timing adjuster. The figure shows the injection timing adjuster in the fully advanced position.

1 Thrust bearing (thrust washer) 11 Pull rod

2 Bearing housing 12 Control sleeve
3 Front drive flange 13 Oil duct
3 Rotary piston 14 Return oil duct
5 Rear drive flange 15 Slot, control sleeve (4 pcs)
6 Oil duct 16 Piston seal
7 Pressure-oil duct 17 Compression spring, rotary piston
8 Oil inlet 18 Compression spring, control sleeve
9 Flyweight (4 pcs) 19 Adjusting sleeve (spring seat)
10 Rear seal 20 Return oil outlet

Design
Function
Low speed, no angular adjustment
The engine lubricating oil is conducted into oil inlet (8) on the timing adjuster, [Invalid linktarget] .
When the engine is running at low speeds, the oil is only used for lubrication and returns to the oil sump via flyweights (9)
and slot (15) in control sleeve (12). See [Invalid linktarget] .
Figure 2

High speed (above 1620 rpm), maximum advance (6°)

When the engine speed exceeds 1140 rpm flyweights (9) are forced outward and close the oil flow, [Invalid linktarget] . At
the same time a pressure arises behind control sleeve (12). When this pressure exceeds the spring pressure, the control
sleeve is pushed in and the oil flow through the slots ceases. Rotary piston (4) is then pressed in and advances the injection
angle as much as possible (6°). See [Invalid linktarget] .

Figure 3
 Service Information

Document Title: Function Group: Information Type: Date:

Low-emission engines 230 Service Information 2014/6/26
Profile:

Low-emission engines
According to legal provisions all low-emission engines have to fulfil certain norms as regards exhaust emissions. To ensure
that all requirements are met, the engine is meticulously specified and adjusted. Certain parts are therefore locked/sealed in
order to prevent inappropriate alterations. On TD103 KBE and TD104 this applies to injection pump and injection angle
(timing).

CAUTION
Changes to locked/sealed items may only be carried out by workshops authorised by Volvo or Bosch.

Figure 1
Security sealing of injection pump

A. Bolt for clamp joint for setting injection angle. The bolt is locked with a lock sleeve.
B. The cover over the smoke limiter is locked with two shear screws.
C. The cover over quantity screws are locked with two shear screws.
D. The adjusting screw for too high speed is locked with cover plate and a shear screw.

Figure 2
Locking device for clamping bolt

1. Sleeve
2. Bolt for clamp joint
 3. Lock sleeve
4. Puller bolt, 999 3824

Figure 3

1. Bolt for clamp joint, locked position

2. Removing lock sleeve
3. Installing lock sleeve
 Service Information

Document Title: Function Group: Information Type: Date:

Feed pump, checking feed 233 Service Information 2014/6/26
pressure
Profile:

Feed pump, checking feed pressure

Op nbr 23304

999 3871 Measuring nipple

11 666 017 Pressure gauge 0–600 kPa (0–6 bar)

(0–87 psi)

11 666 037 Hose

WARNING
Make sure that fuel under high pressure cannot come into contact with unprotected parts of your body when
working with fuel injection equipment (for example when adjusting injectors).

CAUTION
Observe the greatest possible cleanliness when working on the fuel system.

1. Remove the bleeder screw from the filter housing.

2. Install measuring nipple 999 3871. See [Invalid linktarget] .

Figure 1
Measuring feed pressure

1. Measuring nipple 999 3871

3. Connect the pressure gauge together with the hose.

4. Start the engine.

5. Read off the feed pressure.

Correct feed pressure is 130–180 kPa (1.3–1.8 bar)
(19–26 psi).

6. Turn off the engine.

7. Remove pressure gauge, hose and measuring nipple.

8. Install the bleeder screw on the filter housing.

9. Start the engine and check that there are no leaks.

 Service Information

Document Title: Function Group: Information Type: Date:

Fuel 233 Service Information 2014/6/26
system, air bleeding
Profile:

Fuel system, air bleeding

Op nbr 23301

WARNING
Make sure that fuel under high pressure cannot come into contact with unprotected parts of your body when
working with fuel injection equipment.

If the tank has been run dry, or if air for any other reason has entered the system, it must be bled for air.

CAUTION
Under no circumstances may starting attempts be made before the system has been bled, as otherwise the injection pump
may be seriously damaged.

Figure 1

A. Bleeder screw
B. Hand pump
C. Delivery pipes

1. Loosen bleeder screw (A) on the filter head. See [Invalid linktarget] .
 CAUTION
Do not spill fuel on the alternator or other electrical components.

2. Pump with hand pump (B) until the fuel which flows out is free from air bubbles.

3. Tighten the bleeder screw.

4. Then pump approximately another 15 strokes with hand pump (B). In this way air is removed automatically from
the injection pump through the overflow valve and the return-fuel line.

5. Slightly loosen delivery pipe unions (C) at the injectors and crank with the starter motor until fuel free from air jets
out.

CAUTION
The fuel delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped.

6. Tighten the delivery pipe unions: 25 N m (2.5 kgf m) (18 lbf ft).

CAUTION
Do not tighten the unions too hard as the threads and the pipes may otherwise be damaged.

7. Start the engine.

CAUTION
Check, after starting, that there are no leaks. Take care of waste oil/fluids in an environmentally safe way.
 Service Information

Document Title: Function Group: Information Type: Date:

Injection angle (injection 236 Service Information 2014/6/26
timing) B.T.D.C., checking
and
adjusting
Profile:

Injection angle (injection timing) B.T.D.C., checking and adjusting

Op nbr 23630

998 7057 Injection timing tool

999 3590 Gear

WARNING
In order to eliminate the risk of the engine starting when the crankshaft is turned, the stop control should be
secured in the off position and the engine should be cold. The crankshaft should be rotated carefully.

CAUTION
Changes to locked/sealed items may only be carried out by workshops authorised by Volvo or Bosch.

1. Remove the valve cover over the number 1 cylinder.

2. Remove plate plug (1) and the upper rubber plug from hole (2) on the flywheel housing, see [Invalid linktarget] .

Figure 1

1. Position of tool 999 3590

2. Inspection hole for flywheel graduation

3. Install gear 999 3590 in hole ( 1) in the flywheel housing. Use a standard ratchet handle and if necessary this can be
combined with a universal joint and extension bar from a
1/2" square drive socket set, se [Invalid linktarget] .
4. Turn the flywheel until the piston in the number 1 cylinder is in its compression stroke (0 on the flexible disc
marking and the valves closed). See [Invalid linktarget] .

Figure 2

5. Remove the plug from the governor housing and install the injection timing tool sensor. See [Invalid linktarget] .
Connect the earth lead to ground in a suitable place.

CAUTION
The governor housing contains oil.

Figure 3

6. Reverse the crankshaft 1/4 of a turn and then turn it in the direction of rotation of the engine until both the lamps
on the injection timing tool light up. See [Invalid linktarget] . Read off the number of degrees on the flexible disc.
The value should be 9°+1/–0 B.T.D.C.
 Figure 4

7. If the shaft is turned too far, start again according to the previous point.

8. Remove the injection timing tool. Install plugs and valve cover.

Adjusting

9. Turn the crankshaft in the direction of rotation of the engine up to the correct number of degrees on the flexible
disc.

10. Install the injection timing tool in the governor housing, see [Invalid linktarget] .

11. Slacken the pump coupling clamping bolt. See [Invalid linktarget] .

Figure 5

12. Turn the pump coupling a 1/4 of a turn in the direction of rotation of the pump. See [Invalid linktarget] .
 Figure 6

13. Tighten the clamping bolt until the coupling can just about be turned against the direction of rotation of the pump
until both the light emitting diodes on the injection timing tool light up. See [Invalid linktarget] .

Figure 7

14. Tighten down the clamping bolt to 115 N m (11.5 kgf m) (85 lbf ft). Check again according to points 5–7.
 Service Information

Document Title: Function Group: Information Type: Date:

Injection timing adjuster, 236 Service Information 2014/6/26
checking
Profile:

Injection timing adjuster, checking

Op nbr 23631

999 3590 Gear

999 3721 Service display unit

11 668 003 Injection timing tool

Injection timing tool 11 668 003 consists of electronic control unit, cables and two sensors. The sensors read off the
difference between a groove in the transmission torque converter, which shows when the piston in the number 1 cylinder
passes the top dead centre (T.D.C.), and a cam in the injection pump governor housing, which shows the position of the
pump camshaft at the beginning of the fuel injection into the number 1 cylinder. See [Invalid linktarget] .
The result is read off on service display unit 999 3721.

Figure 1

A. 1–1,5 turn

1. Sensor in the flywheel housing

2. Sensor on the injection pump
3. Injection timing tool 11 668 003
4. Service Display Unit 999 3721
5. Socket 24 V

1. Open the engine hood. Remove the plate plug from hole (1) and the rubber plug from hole (2). See [Invalid
linktarget] .
 Figure 2

1. Position of tool 999 3590

2. Inspection hole for flywheel graduation

2. Check that the crankshaft is not within the 0–20° B.T.D.C. area. This is because the sensor which is inserted into the
flywheel housing must not come directly opposite the index groove in the transmission torque converter when
adjusting. (If the crankshaft needs to be rotated, install gear 999 3590 in hole 1), see [Invalid linktarget] .

3. Swing out the radiator.

4. Install the sensor in the flywheel housing. Carefully screw it in against the torque converter. Back it off one turn and
lock with the jam nut, see [Invalid linktarget] .

Figure 3

1. Sensor

5. Install the sensor in the fuel pump governor housing. Have a vessel ready for collecting the oil that will run out
(approx. 0.3 litre = 0.6 US pint).

6. Connect together the sensor, the electronic control unit and the service display unit. Switch on electric power, see
[Invalid linktarget] .

7. The initial display will be shown for approx. four seconds. See [Invalid linktarget] .
 Figure 4

8. Then [Invalid linktarget] will be shown.

Figure 5

9. Start the engine. If the sensors are functional, [Invalid linktarget] will be shown and you can proceed to point 12.

Figure 6

10. If injection pump sensor does not function, [Invalid linktarget] will be shown.

Figure 7

11. If the sensor in the flywheel housing does not function or if the sensor has not been screwed out approx. one turn
from the torque converter, [Invalid linktarget] will be shown.

Figure 8

12.

If the sensors are functional, press the key,

[Invalid linktarget] will be shown.
 Figure 9

13.

Increase the engine speed to 1200 rpm. Press the key to set to zero.
Example is shown in [Invalid linktarget] .

Figure 10

14. Increase the engine speed to 2200 rpm and press the key .
Example is shown in [Invalid linktarget] .

Figure 11

Figure 12

Full angular change (maximum injection timing advance) should now have taken place. The change in injection
timing should be 6°±1°.

After measuring, the α° value may show 0.5°–1.5° at low idling. This is because the backlash in the gear drive for the
injection pump disappears under load.
See the curve in [Invalid linktarget] .

Press the key twice to begin measuring again if required.

15. Restore by removing the electronic control unit, the service display unit and the two sensors. Swing in the radiator.
Install the plate plug and the rubber plug in the flywheel housing and close the engine hood.
 Service Information

Document Title: Function Group: Information Type: Date:

Low and high 236 Service Information 2014/6/26
idling speed, checking and
adjusting using service
dispaly unit
Profile:

Low and high idling speed, checking and adjusting using service
dispaly unit
Op nbr 23603

999 3721 Service display unit

Before checking the engine speeds, the engine, the transmission and the hydraulic system should have reached
normal working temperature.

When checking, units which use a lot of electricity and the AC unit, if applicable, should be turned off.

1. Connect the Service Display Unit to the socket to the left under the instrument panel, see [Invalid linktarget] .

Figure 1

2. Select figure 4.11 on the Service Display Unit, see [Invalid linktarget] .

Figure 2
Service Display Unit, figure 4.11

3. Check the engine speeds when the engine, the transmission and the hydraulic system have reached normal
working temperature.

4. Run the engine at low idling.

Read off the Service Display Unit, figure 4.11.
The speed should be 670 30 rpm.
Low idling speed

5. Adjusting:

 Loosen the nut on the adjusting screw.

 Adjust the speed with adjusting screw (1), see [Invalid linktarget] .
 Lock the nut and check the speed.

Figure 3

A. Governor control arm

1. Adjusting screw, low idling

2. Adjusting screw, high idling

CAUTION
Changes to locked/sealed items may only be carried out by workshops authorised by Volvo or Bosch.

High idling speed, checking and adjusting

6. Run the engine at high idling speed.

Read off the Service Display Unit, figure 4.11.
The speed should be 2400 60 rpm.

CAUTION
Stoppskruven under gaspedalen ska avlasta vajerreglaget i fullgasläge, see [Invalid linktarget]

Figure 4
Accelerator pedal

1. Stop screw
 Service Information

Document Title: Function Group: Information Type: Date:

Stall speed, checking using 236 Service Information 2014/6/26
Service Display Unit
Profile:

Stall speed, checking using Service Display Unit

Op nbr 23604

999 3721 Service display unit

Before checking the engine speeds, the engine, the transmission and the hydraulic system should have reached normal
working temperature.

When checking, units which use a lot of electricity and the AC unit, if applicable, should be turned off.

Figure 1

CAUTION
Changes to locked/sealed items may only be carried out by workshops authorised by Volvo or Bosch.

1. Connect the Service Display Unit to the socket to the left under the instrument panel, see [Invalid linktarget] .

2. Select figure 4.11 on the Service Display Unit, see [Invalid linktarget] .

Figure 2
Service Display Unit, figure 4.11

3. Check the engine speeds when the engine, the transmission and the hydraulic system have reached normal
working temperature.

4. Place the gear selector in position D.

 Apply the brakes.
Apply the parking brake.
Run the engine at maximum speed.
The stall speed should be at least 1690 +80/–90 rpm.

CAUTION
The engine must not be stalled for more than 30 seconds.

If another check is required, move the gear selector control to neutral and run the engine at idling speed for at
least 2 minutes at 1200–1500 rpm to allow the oil temperature to drop.
A deviating stall speed is not necessarily a fault in itself which requires to be corrected, but should be used as an
aid during trouble-shooting.

Speed Probable cause (action)

200 rpm below min. stall speed Freewheel, torque converter
200 rpm below min. stall speed Check the condition of the engine
According to the specifications Normal
200 rpm above min. stall speed Check the oil pressure in the torque converter. If these
values are according to the specifications, the fault is
probably wear in the torque converter.

Table, trouble-shooting
 Service Information

Document Title: Function Group: Information Type: Date:

Injectors, replacing all 237 Service Information 2014/6/26
Profile:

Injectors, replacing all

Op nbr 23702

999 6643 Extractor

981 2546 Cleaning brush

Hand drill, (10 mm (0.40 in))

Torque wrench

CAUTION
Observe the greatest possible cleanliness when working on the fuel system.

1. Place the machine on level ground. Apply the parking brake. Open the engine hood.

2. Clean around the injectors, the delivery pipes and the upper part of the injection pump.

Removing

3. Remove the leak-off fuel pipe between the injectors and plug the connections.

WARNING
The fuel delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped.

If a pressure prestressed fuel delivery pipe is bent or deformed, there is a great risk that the pipe will break.

A damaged delivery pipe must always be replaced!

4. Remove the fuel delivery pipes. They are clamped together three and three. Do not loosen the clamping. The fuel
delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped. Plug the
connections.

5. Remove the nuts for the injector retaining yokes and remove the yokes.

6. Remove the rubber seals around the injectors.

7. Turn the injectors and at the same time pull them upward. When necessary use extractor 999 6643. See [Invalid
linktarget] .
 Figure 1

1. 999 6643 Extractor

8. Make sure that the copper washer which is positioned between the injector and the copper sleeve comes out
together with the injector, see [Invalid linktarget] . If it does not come out, use a hook made from a piece of wire to
get it out.

Figure 2

1. Copper washer

9. Clean the contact surface for the injectors in the copper sleeves. Use the cleaning brush.
The brush is packed together with an installation sleeve. Push the installation sleeve down over the brush, before
the brush is inserted down into the copper sleeve, so that the parts keep together. See [Invalid linktarget] .

Figure 3
Cleaning brush

10. Position the installation sleeve over the copper sleeve. See [Invalid linktarget] .
 Figure 4
Installation sleeve over copper sleeve

1. Installation sleeve
2. Copper sleeve

11. Push the brush down into the copper sleeve. Attach a drill to the shaft on the brush and clean the copper sleeve.
See [Invalid linktarget] . Remove the pipe between turbocharger and intercooler when cleaning copper sleeve for
cylinder No. 6.

Figure 5
Drill attached to shaft on brush

12. After the cleaning, blow away any contaminants with compressed air.

13. Re-install the pipe between the turbocharger and the intercooler.

Installing

14. Install the new injectors together with new copper washers.

15. Install new rubber seals around the injectors.

16. Install the retaining yokes and the nuts.

Tightening torque:50 N m (5.0 kgf m) (37 lbf ft).

17. Install the leak-off fuel pipe together with new copper washers.
 WARNING
The fuel delivery pipes are pressure prestressed and must under no circumstances be bent or reshaped.

If a pressure prestressed fuel delivery pipe is bent or deformed, there is a great risk that the pipe will break.
A damaged delivery pipe must always be replaced!

18. Install the fuel delivery pipes. Observe the greatest possible cleanliness and make sure that the pipes are not bent
or deformed. Tighten down the pipe nuts.
Tightening torque:
15–25 N m (1.5–2.5 kgf m) (11–18 lbf ft).

19. Start the engine and check that there are no leaks.
 Service Information

Document Title: Function Group: Information Type: Date:

Description 253 Service Information 2014/6/26
of function
Profile:

Description of function
Exhaust retarder (Optional equipment)
The exhaust retarder is connected to the exhaust system immediately after the turbocharger. The purpose of the exhaust
retarder is to slow down the flow of exhaust gases when the machine is to be retarded and in this way aids the ordinary
service brakes.
The exhaust retarder consists of an compressed/air cylinder, which is connected to a valve (damper). The retarder is engaged
when compressed air is admitted in behind the piston in the cylinder, so that it is pressed to its inner end position and closes
the valve. The valve now blocks the way for most of the exhaust gases. Only a few small holes are open. The pressure in the
engine rises.
At low speeds and small amounts of exhaust gases, there is enough time for the gases to escape through the small holes,
and the rise in counter pressure in the engine caused by the gases is hardly detectable.
At higher engine speeds and larger amounts of exhaust gases the holes cannot let through enough gases and the pressure
rises. The valve opens to a position where there is a balance between the pressure from the exhaust gases and the pressure
from the compressed-air system of the machine. The exhaust retarder is engaged through a solenoid valve.
The exhaust retarder is engaged by the ECU when switch (SW105) is switched on and the accelerator pedal is released. An
inductive sensor (SE53), which is positioned on the accelerator pedal under the floor, senses the position of the accelerator.
[Invalid linktarget] . The sensor gives off a signal to the ECU when the pedal is released. The ECU energises a solenoid valve
(MA49), when it senses an engine speed from sensor SE3 (sensor SE4 indicates output speed) between 18.3 r/s (1100 rpm)
and 40 r/s (2400 rpm), a forward drive gear engaged and a travelling speed exceeding 2 km/h (1.2 mph).
NOTE!
Up to and incl. serial No. 2439 sensor SE53 is positioned on the injection pump.
Figure 1
Exhaust retarder, function
 Service Information

Document Title: Function Group: Information Type: Date:

Sensor 253 Service Information 2014/6/26
exhaust retarder, adjusting
Profile:

Sensor exhaust retarder, adjusting

Op nbr 27123

Applies to serial No. 2440–

1. Place the machine on level ground in the service position.

2. Expose the accelerator pedal together with the inductive sensor according to [Invalid linktarget] , Op. No. 27122.

3. Adjust the distance (3 ±1 mm = 0.118 ±0.0397 in) between the sensor and setting indicator plate, see [Invalid
linktarget] and [Invalid linktarget] .

Figure 1
Accelerator pedal with inductive sensor, side view

4. Adjust the distance (4 ±1 mm = 0.157 ±0.040 in) between the setting indicator plate and the centre line of the
sensor, see [Invalid linktarget] and [Invalid linktarget] .
NOTE!
The light-emitting diode of the sensor lights up when the ignition key is in the starting position and the distances
are correctly adjusted. See [Invalid linktarget] , item 1.
 Figure 2
Accelerator pedal with inductive sensor, setting measurement

1. Light-emitting diode

5. Install the exposed accelerator pedal according to [Invalid linktarget] .

 Service Information

Document Title: Function Group: Information Type: Date:

Sensor, 253 Service Information 2014/6/26
exhaust retarder, replacing
Profile:

Sensor, exhaust retarder, replacing

Op nbr 27122

Applies to serial No. 2440–

The work can be carried out from inside the cab, or alternatively from underneath the cab. Both alternatives are described in
the following text.
Alternative 1, working from inside the cab
Removing

1. Place the machine on level ground in the service position.

2. Switch off the current supply from the battery with the battery disconnect switch.

3. Lift the front and rear floor mats out of the cab.

4. Remove the operator seat and place it against the rear wall.

5. Remove the bolts retaining the steering column boot.

6. Remove the bolts from the two front floor plates.

7. Lift up one side of the right floor plate and support it with a block, see [Invalid linktarget] .

Figure 1
Floor plate with brake pedal and accelerator pedal

8. Remove the three bolts retaining the brake pedal and put the pedal down through the hole.

9. Lift up the front end of the plate so that its underside with the lower part of the accelerator pedal becomes
accessible, see [Invalid linktarget] .
 Figure 2
Floor plate, underside with accelerator pedal

10. Disconnect the connector from the inductive sensor.

11. Remove the inductive sensor, see [Invalid linktarget] .

Figure 3

1. Inductive sensor

Installing

12. Install the new inductive sensor, [Invalid linktarget] .

13. Adjust the sensor according to [Invalid linktarget] .

14. Connect the connector to the inductive sensor.

15. Switch on the electric power from the batteries with the battery disconnect switch.

16. Let down the right floor plate and install the brake pedal.

17. Install the floor plates and the steering column boot.

18. Install the operator seat.

19. Put the floor mats back into the cab.

20. Connect the service display unit. Select ”Setup, Exhaust Retarder”, see [Invalid linktarget] . Activate the exhaust

retarder by pressing .
 Figure 4
Contronic service display unit, setup, exhaust retarder

21. Disconnect the service display unit.

22. Test-run the machine.

The service engineer is working at the front right wheel housing, lying on the frame, [Invalid linktarget] .

Alternative 2, working from under the cab

Removing

23. Place the machine on level ground in the service position.

Figure 5
Working from under the cab

24. Switch off the current supply from the battery with the battery disconnect switch.

25. Remove the inner mudflap by the right front wheel.

26. Disconnect the connector from the inductive sensor.

27. Remove the inductive sensor, see [Invalid linktarget] .

Figure 6

1. Inductive sensor

Installing
28. Install the new inductive sensor, [Invalid linktarget] .

29. Adjust the sensor according to [Invalid linktarget] .

30. Connect the connector to the inductive sensor.

31. Switch on the electric power from the batteries with the battery disconnect switch.

32. Connect the service display unit. Select ”Setup, Exhaust Retarder”, [Invalid linktarget] .

Activate the exhaust retarder by pressing .

Figure 7
Contronic service display unit, setup, exhaust retarder

33. Disconnect the service display unit.

34. Install the inner mudflap by the right front wheel.

35. Test-run the machine.

 Service Information

Document Title: Function Group: Information Type: Date:

Description 260 Service Information 2014/6/26
Profile:

Description
The cooling system consists of two parallel cooling circuits which both are connected to the main radiator:

1. Engine cooling circuit

2. Intercooler circuit

Engine cooling circuit

The coolant pump for this circuit is positioned on the timing gear casing cover.
intercooler circuit
The coolant pump for this circuit is mounted in tandem with the engine cooling circuit coolant pump.
Cooling system, checking
See Section 9, Hydraulic system, fan drive.

Figure 1
Cooling system, principle diagram

A Expansion tank, 0,5 bar

P1 Coolant pump
P2 Coolant pump, intercooler
1 Radiator
2 Converter cooler
3 Retarder cooler
4 Cab heat
5 Engine oil cooler
6 Compressor, cooling
7 Coolant filter (optional)
8 Intercooler
9 Thermostat
10 Engine block
 Service Information

Document Title: Function Group: Information Type: Date:

Coolant, 261 Service Information 2014/6/26
changing
Profile:

Coolant, changing

Figure 1

A. Cap for expansion tank

Op nbr 26104

Draining coolant
Remove the expansion tank cap (A). See [Invalid linktarget] .
The following points refer to the items in [Invalid linktarget] , [Invalid linktarget] and [Invalid linktarget] .

1. Open draining (1) valve on the cylinder block.

 Figure 2

2. Swing out the radiator and bend down hose (2) by the radiator. Drain the coolant by pressing in the clamp in the
quick-action coupling.

3. Let down the belly plate.

Open the quick-action coupling by pressing in the clamp in the quick-action coupling (4). The quick-action
coupling is positioned on the longitudinal pipe under the transmission oil cooler.

4. Remove plug (3) from the transmission oil cooler.

5. Remove plug (5) from the underside of the engine oil cooler (positioned in front of the oil filters).
 Figure 3

Figure 4

Fill coolant through the expansion tank.

Use clean water in the radiator, with the addition of anti-corrosion agents and anti-freeze. If the coolant is rusty,
rinse the system thoroughly before filling with new coolant.

Filling coolant in an empty system

6. The engine should be stationary and the heater control set to warm.

7. Bleeder valve (1), [Invalid linktarget] , above the radiator should be open while filling.

Figure 5

1. Bleeder valve

8. Fill coolant until the expansion tank is 2/3rds full.

9. Run the engine until it is warm and top up so that the cooling system becomes completely full and all air has been
removed.

10. The level should be checked after the engine has been run warm and then allowed to cool.

CAUTION
Never fill cold coolant when the engine is warm, it can cause crack formation in cylinder block and cylinder head.
 WARNING
If the engine is started with the radiator in the swung out position, no person may be on or near the right
fender.
 Service Information

Document Title: Function Group: Information Type: Date:

Radiator, adjusting 261 Service Information 2014/6/26
Profile:

Radiator, adjusting
Op nbr 26110

The radiator must be correctly adjusted vertically and horizontally so that it is not exposed to abnormal strains.

1. Place the machine on level ground in the service position. Open the engine hood.

Figure 1

2. Swing out the radiator.

3. Swing in the radiator and check its vertical position. The cooler is correctly adjusted vertically, when one has to lift it
10 mm (0.4 in) to enter the locked position.

4. If the radiator has to be lifted more or less than 10 mm (0.4 in), the height must be adjusted.
Loosen the lock nut for the vertical adjustment screw.
Screw the vertical adjustment screw clockwise to raise the rear edge of the radiator or counter-clockwise to lower
the rear edge of the radiator See [Invalid linktarget] .

5. When the correct height has been adjusted, the radiator stop should be checked. Adjust the radiator stop so that a
pre-tension of 10 mm (0.4 in) is obtained when the radiator is locked. See [Invalid linktarget] .

Figure 2
6. When the radiator rests against the stop there should be a clearance of 10 mm (0.4 in), see [Invalid linktarget] .

Figure 3

7. Lock the cooler and lower the engine hood.

 Service Information

Document Title: Function Group: Information Type: Date:

Radiator, replacing 261 Service Information 2014/6/26
Profile:

Radiator, replacing
Op nbr 26108

WARNING
Carefully remove the expansion tank cap. There are risks of burns because of excess pressure in the cooling system.

Removing

1. Switch battery disconnect switch to the off position.

2. Open up the engine hood, remove the radiator casing and lower the front guard plate.

3. Swing out the cooler and fold down the draining hose. Press in the clamp in the quick-action coupling so that
coolant flows out, see [Invalid linktarget] .

CAUTION
The cooling system will not be safe from freezing after draining.

Figure 1

1. Bleeder valve
2. Quick-action coupling

4. On machines equipped with air conditioning:

Loosen the attachment for the condenser and swing it to one side.

CAUTION
Do not disconnect any AC hoses.
 5. Remove the radiator side plates, upper casing and radiator grille.

6. Loosen the draining hose and the breather hose from the radiator. Remove the nipples.

7. Detach the fan unit from its brackets and move it to one side.

8. Disconnect the lower and upper hoses from the radiator.

9. Remove the rubber cloth secured with two profiled bars. Detach the fan shroud from the radiator and move it to
one side. See [Invalid linktarget] .

Figure 2
Detaching fan shroud

10. Remove the lower attaching bracket. The radiator is now free and may be lifted away. See [Invalid linktarget] .

Figure 3
The radiator is free

Installing

11. Position the new radiator and install the lower bracket.

12. Install the fan shroud.

13. Connect the coolant hoses.

14. Install the nipples for the draining hose and the breather hose. Lock with thread tape. Connect the hoses to the
 nipples.

15. Install the fan unit and the bracket.

16. Install the radiator side plates, the upper plate and the radiator grille.

17. Fill coolant. The bleeder valve must be open when filling.

18. Run the engine at idling speed a few minutes to purge the system of air.

19. Check the coolant level in the expansion tank and top up with coolant if required. Run the engine until it has
reached normal working temperature and check that there are no leaks.
 Service Information

Document Title: Function Group: Information Type: Date:

Coolant 262 Service Information 2014/6/26
pump removed,
reconditioning
Profile:

Coolant pump removed, reconditioning

Op nbr 26271

999 3756 Fixture

999 3805 Drift
999 8361 Drift

699 9007 Drift handle

699 9015 Drift plate

699 9020 Drift plate

699 9028 Drift plate

699 9038 Drift plate

Drift 14x100 mm (0.55x3.937 in)

Figure 1

A. The upper edge of the seal should be under the chamfered edge on the pump housing.
 B. 24.5 ±0.2 mm (0.965 0.008 in)
C. 3 ±0.2 mm (0.118 0.008 in)

1 Gear 11 Screw
2 Screw 12 Intermediate housing
3 Lock plate 13 Impeller
4 Lock plate 14 Seal ring
5 Pump housing 15 Ball bearing
6 Washer 16 Oil seal ring
7 Screw 17 Seal ring
8 Cover 18 Shaft
9 Impeller 19 Ball bearing
10 O-rings 20 Bearing journal

Dismantling
All numbers within brackets refer to items in [Invalid linktarget] .

1. Mark the coolant pump externally with a line, see [Invalid linktarget] .

Figure 2
External marking of coolant pump

2. Remove cover (8) from the coolant pump.

3. Turn the coolant pump, remove bolts (2) and lock plates
(3 and 4).

4. Secure the coolant pump in a press.

CAUTION
Position the counterholds under the pump housing so that the impeller (13) does not snag against anything when
pressing it out. See [Invalid linktarget] .
 Figure 3
Pressing out pump shaft

1. Drift 14x100 mm (0.55x3.937 in)

5. Press shaft (18) out of bearing journal (20). Remove any remnants of seal (14).

6. Position the coolant pump turned the right way round in a press and press out, gear (1), ball bearing (15, 19) and
oil seal ring (16). See [Invalid linktarget] .
NOTE!
The bearings and the oil seal ring must be pressed out against the drive side.

Figure 4

1. Drift handle, part No. 699 9007

2. Drift plate 699 9038
3. Drift plate 699 9020

7. Press bearing journal (20) out of gear (1) and ball bearing (19). Use a piece of pipe as counterhold. See [Invalid
linktarget] .
 Figure 5
Pressing out bearing journal

1. Drift handle, part No. 699 9007

2. Drift plate 699 9028
3. Drift plate 699 9015
4. Pipe, inside diameter 40 mm (1.57 in), length 50 mm (1.969 in)

8. Clean all parts. Replace damaged or worn parts.

Assembling

9. Press bearing journal (20) into ball bearing (19) and gear (1), [Invalid linktarget] .

Figure 6
Pressing in bearing journal in ball bearing and gear

1. Pipe, inside diameter 20 mm (0.787 in), length 110 mm (4.331 in)

10. Position drift 999 3805 in the pump housing and position the pump housing in a press. See [Invalid linktarget] .
Press in the inner ball bearing (15) with drift 999 8361 until the bearing bottoms against drift 999 3805.
 Figure 7
Pressing in inner ball bearing

1. Drift part No. 999 8361

2. Drift 999 3805
3. Fixture 999 3756

11. Lubricate seal ring (16) with oil and press it into the pump housing until the upper edge of the seal ring is below
the chamfered edge of the pump housing. See item A in [Invalid linktarget] .

CAUTION
The lip of the seal should be turned towards the gear wheel side.

NOTE!
Make sure that the centre stud in fixture 999 3756 has been removed so that the pump shaft bottoms in the guide.

12. Press gear (1), ball bearing (19) and shaft (18) into the pump housing. Use drift 999 3805 as a counterhold for the
inner bearing. See [Invalid linktarget] .

CAUTION
Stop pressing when the outer bearing race on the bearing journal bottoms in the pump housing. Check that the
shaft rotates easily.

Figure 8
Pressing in ball bearing and shaft

1. Drift part No. 999 3805

2. Fixture 999 3756
13. Install lock plates (3 and 4) and bolts (2). Tighten down the bolts and lock with lock plate (3).

14. Apply locking fluid (strong) 116 1053 externally on seal ring (14). Press in the seal ring in the housing with drift
999 8361. See [Invalid linktarget] .

CAUTION
Use locking fluid (strong) 116 1053 between the seal ring (14) and the pump housing. Make sure that the
counterhold fits up against the pump housing.

Figure 9
Installing seal ring

1. Drift part No. 999 8361

15. Position impeller (9) on fixture 999 3756.

Position the pump housing on the impeller. Press in the shaft in the impeller using a drift. See [Invalid linktarget] .

CAUTION
Press until the shaft reaches to the bottom of the tool.

Figure 10
Pressing in impeller.

1. Drift 14x100 mm (0.55x3.937 in)

2. Impeller
3. Fixture part No. 999 3756

16. Check that impeller (9) is pressed-in to the correct measurement (24.5 ±0.2 mm) (0.965 ±0.008 in). See item B in
[Invalid linktarget] .
17. Install seal (17) in intermediate housing (12).
NOTE!
The seal should be installed with the lip of the seal turned towards the outer impeller (9).

18. Install intermediate housing (12) on the pump housing together with new O-rings (10).

19. Press in the impeller. Check that the impeller has been pressed in to the correct measurement (3 ±0.2 mm)
(0.118 ±0.008 in), item C in [Invalid linktarget] .

20. Install cover (8) on the pump housing togehter with a new O-ring (10). Make sure that the marking aligns.
 Service Information

Document Title: Function Group: Information Type: Date:

Thermostat valve 262 Service Information 2014/6/26
Profile:

Thermostat valve
The thermostat valve is positioned on the coolant pipe leading to the transmission oil cooler on the right side of the engine.
Checking function

Op nbr

NOTE!
Incorrect measuring result as under the heading "Fan motor, checking working pressure", with Op. No. 26304, may be
caused by a faulty thermostat valve. In order to determine whether the valve functions, check as follows:

Figure 1

1. Thermostat valve

1. Run the engine until it has reached a temperature above 90 °C (194 °F).

2. Disconnect the outlet line from the thermostat valve or at the collecting pipe for leak-off oil. Remove any
restrictions in the line between pump and thermostat valve.
Measure the amount of oil flowing out. Correct amount is max. 30 cm3 (1.8 in3) per minute. At a coolant
temperature below 90 °C (194 °F) the flow increases to reach a maximum at 60 °C (140 °F).

3. Incorrect function according to point 2 may be caused by needle (3) or sleeve (4) binding or that the valve should
be adjusted, see [Invalid linktarget] .

4. A reduction of the flow at a temperature above 90 °C (194 °F), is done by turning valve seat (2) clockwise,
see [Invalid linktarget] .

CAUTION
Minimum through flow means maximum fan speed.
Figure 2
Thermostat valve

A Checking point 7 Spring

1 Valve housing 8 O-ring
2 Valve seat 9 Sleeve
3 Needle 10 O-ring
4 Sleeve 11 O-ring
5 Lock ring 12 O-ring
6 Wax body
 Service Information

Document Title: Function Group: Information Type: Date:

Thermostat valve removed, 262 Service Information 2014/6/26
checking
Profile:

Thermostat valve removed, checking

Op nbr

1. Measure distance (A) and make a note of it, see [Invalid linktarget] .

2. Screw the valve seat out of the thermostat valve (item 2).

3. Place the thermostat valve together with the wax body fully under water and then heat the water to 96 °C (205 °F).

4. Then check that the wax body pin protrudes approx. 10 mm (0.40 in) outside the face of the wax body, that is, the
valve would then be fully closed.

5. Check that the needle (item 3) runs easily in the valve seat.

6. Assemble the valve and make sure that distance (A), measured in point 1, is obtained when assembling.

Figure 1
Thermostat valve

A Checking point 7 Spring

1 Valve housing 8 O-ring
2 Valve seat 9 Sleeve
3 Needle 10 O-ring
4 Sleeve 11 O-ring
5 Lock ring 12 O-ring
6 Wax body
 Service Information

Document Title: Function Group: Information Type: Date:

Cooling fan motor, 263 Service Information 2014/6/26
adjusting speed
Profile:

Cooling fan motor, adjusting speed

Adjusting the low speed of the fan motor
Adjust the control pressure for the low speed of the fan motor (23–35 bar) (334–508 psi) by screwing on the compensator
valve on the pump, see [Invalid linktarget] . The fan speed should be between 700 and 900 rpm. Do not forget to fit a new
security seal to the pressure control valve.

Figure 1
Pump

1. Adjusting screw, pressure compensator (maximum pressure)

2. Pressure-limiting valve

Adjusting the high speed of the fan motor

Adjust with the solenoid valve adjusting screw, see [Invalid linktarget] . Turning clockwise will increase the fan speed, while
turning counter-clockwise will reduce the speed. The high speed of the fan should be 1400 ±50 rpm when the engine speed
exceeds 1520 ±50 rpm.
Figure 2
Adjusting relay valve

1. Adjusting nut
 Service Information

Document Title: Function Group: Information Type: Date:

Fan motor, 263 Service Information 2014/6/26
changing piston rings
Profile:

Fan motor, changing piston rings

Op nbr 26302

Puller Kukko 20-20

Torque wrench

Removing

1. Turn off the current with the battery disconnect switch.

2. Swing out the radiator and unscrew the hydraulic motor bracket.

3. Remove the fan and the fan hub and the hydraulic motor (mark the hydraulic hoses). See [Invalid linktarget] .
NOTE!
The fan hub centre bolt is locked with locking fluid.

Figure 1
Removing hub with the aid of Kukko 20-20

Dismantling

4. Remove the key with a suitable pair of pliers.

5. Mark the pump housing halves relative to each other with punch marks.

6. Turn the pump with the shaft downward and loosen the four hexagon socket head bolts (8 mm).

7. Turn the pump with the shaft upward and pull the pump housing halves apart with a puller (Kukko 20-20). Then lift
out the shaft complete with pistons. Remove the guide sleeve and the shim halves.

8. Carefully remove the cylinder drum and tap out the valve disc. See [Invalid linktarget] .
 Figure 2
Removing valve disc

9. Remove the pistons, one at a time, by holding them in line with the shaft and lifting them straight up. See [Invalid
linktarget] .

Figure 3
Removing and installing pistons

10. Remove the piston rings from the respective pistons – three piston rings on each piston. Insert a finger nail in the
piston ring opening, open the piston ring and press the rings off the piston.

11. Check that the piston ring grooves are not worn. Test with three new piston rings. See [Invalid linktarget] . If there is
a clearance between the rings and the groove in the piston, the piston must be replaced with a new one.
 Figure 4
Testing piston ring groove

12. Install new piston rings on all pistons.

13. Remove the attaching ring from the cylinder drum. Wash all parts.

Assembling

14. Position the lower housing (see [Invalid linktarget] , item 20) together with shaft (11) vertically. Lubricate valve disc
(2) with petroleum jelly on the side which has an oil groove. Install the valve disc in the lower housing half with the
oil groove turned downward, see [Invalid linktarget] . Make sure that the guide groove aligns with the lock pin.

Figure 5
Installing valve disc

1. Oil groove
2. Guide groove

15. Install a new attaching ring (see [Invalid linktarget] , item 5) on cylinder drum (6). Install the attaching ring with the
chamfer towards the tooth side on the drum and the recess towards the valve disc. Turn the cylinder drum so that
the marking will be facing you. Mark the tooth tips on either side of the punch mark with white marking paint, see
[Invalid linktarget] . (This is because the punch mark on the cylinder drum will not be visible once the guide sleeve
has been installed.) Tilt the housing downward 45.
 Figure 6

1. Tooth markings
2. Tooth markings

16. Replace the two O-rings on the guide sleeve (see [Invalid linktarget] , item 10). Lubricate the sleeve with petroleum
jelly and install it. Install the half-moon shaped shims (9) before the guide sleeve is pressed right down.

17. Lubricate pistons (7) with petroleum jelly so that they can be fixed in position when assembling. Push the pistons so
that they snap into position in the ball sockets. Lubricate the new piston rings and the cylinders.

18. Install the shaft together with the pistons. Check that the marking on the gear ring is placed between the two
colour marked tooth tips on the cylinder drum. Turn the shaft round a few times. The shaft should turn easily and
silently.

19. Replace the shaft seal, see [Invalid linktarget] .

Figure 7
Installing seal ring

1. Seal ring
2. Support washer
3. Circlip

20. Re-install the lower pump housing half. Make sure that the markings on the housing halves agree (punch marks).
Pull the housing halves together with the four hexagon socket head bolts (see [Invalid linktarget] , items 27 and 26).
Torque-tighten the bolts to 48 N m (4.8 kgf m) (35 lbf ft).

Installing
21. Install key (13). Install the hydraulic motor, the fan hub and the fan. Apply locking fluid to the threads on the fan
hub centre bolt, install the bolt and tighten it to a torque of 100 N m (10.0 kgf m) (74 lbf ft).

Figure 8

1 Pump housing, upper half 15 Taper roller bearing

2 Valve disc 16 Taper roller bearing
3 Plug 17 Lock washer
4 Plane gasket 18 Spacer ring
5 Attaching ring 19 Round nut
6 Cylinder drum 20 Pump housing, lower half
7 Piston 21 O-ring
8 Piston ring 22 O-ring
9 Shims 23 Seal ring
10 Guide sleeve 24 Circlip
11 Shaft 25 Support washer
12 Cylindrical pin 26 Hexagon socket head bolt
13 Key 27 Hexagon socket head bolt
14 Ring gear
 Service Information

Document Title: Function Group: Information Type: Date:

Fan motor, checking 263 Service Information 2014/6/26
working pressure
Profile:

Fan motor, checking working pressure

Op nbr 26304

494 0506 Cap plug, 2 pcs, (9/16 UNF)

929312 Nipple (9/16 UNF)

11 666 020 Pressure gauge, 0–25 MPa (0–250 bar)

11 666 035 Hose, 1 pc

(0–3626 psi)

Figure 1
Connecting pressure gauge

Connect a pressure gauge (0–250 bar) to the hydraulic pump checking point, see [Invalid linktarget] . Then start the engine.
Low speed
Run the engine at low idling and check that the speed of the fan motor is between 700 and 900 rpm at the same time as the
hydraulic pump oil pressure is between 23 and 35 bar (334 and 508 psi).
High speed
Increase the engine speed to just above 1500 rpm and check that the speed of the fan motor is 400 ±50 rpm and that at the
same time the hydraulic pump oil pressure is between 60 and 75 bar (870 and 1088 psi).
Maximum speed
Figure 2
Thermostat valve

1. Output hydraulic line

2. Plug

Plug the hydraulic output line from the thermostat valve, see [Invalid linktarget] .
Check that the fan motor speed is 1900 rpm when the engine speed exceeds 1400 ±50 rpm.

CAUTION
This is no check of the thermostat valve function.
 Thank you for your purchase.
Have a nice day.

file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/26 10:49:16]