Gearbox

Fact Sheet R800

R800 is a 9-speed range-change gearbox designed for and
matched to Volvo's medium-duty truck models.
This gearbox has a wide gear ratio span that gives very high
initial tractive force, at the same time as it has the capacity
to achieve high average speeds. This is possible as a result
of the gear ratios being matched exactly to the characte-
ristics of the engine.
The R800 is dimensioned for an engine torque of 825 Nm,
and also for transport operations involving gross combina-
tion weights of up to 32 tonnes.
The gearbox is divided into a forward basic unit and a rear
range-change unit. The basic unit contains 4 basic speeds,
and the range housing contains a planetary type of range-
change gear. The basic unit, range housing, and clutch
casing are all made of aluminium, which means that the
gearbox has low weight. All gears in the gearbox are made
of special steel that is case-hardened to give high strength
and long service life.
The idler gears in the basic unit and the reverse idler gear
for the reverse gear are journalled in needle bearings to give
low friction.
The following product features are characteristic of the
R800:
• Robustly dimensioned bearings, shafts and gears.
• Planetary type of range-change gear with five planet
gears and a range inhibitor that prevents incorrect gear
changing.
• Crawler gear that gives high initial tractive force.
• Non-adjusting control cylinder for the clutch.

13.16

8.91

Specification 6.50

Type designation .................................................. R800

4.67
Weight without oil ............................................. 125 kg
3.50
Oil change capacity ............................................... 9.5 l
2.55
Maximum torque ............................................ 825 Nm 1.86
Maximum combination weight ...................... 32000 kg 1.33
1.00
Type ..................... Synchronised range-change gearbox
No.of forward gears ................................................... 8 C HR LR
crawler gears .................................................... 1
reverse gears ..................................................... 2
Gear/Gear ratios:
3.35
Crawler gear, low-range ................................... 13.16:1 R
1st ....................................................................... 8.91:1
2nd ...................................................................... 6.50:1
3rd ...................................................................... 4.67:1
4th ...................................................................... 3.50:1
5th ...................................................................... 2.55:1
6th ...................................................................... 1.86:1
7th ...................................................................... 1.33:1
8th ...................................................................... 1.00:1
Reverse gear, low-range ................................... 11.74:1
11.74
Reverse gear, high-range .................................... 3.35:1 R

RSP 403319.02.00. Eng. Printed in Sweden.


Fact Sheet
Robust internal
components for long
service life
All gears in the gearbox are made of
case-hardened special steel. After har-
dening, the gears are ground thorough-
ly to reduce wear and noise.
The gears in the basic unit are bevel
gears, which means that several gears
can be in mesh with each other at the
same time.
All shafts and planet gears in the range-
change gear are journalled in roller
bearings, with the exception of the
low-loaded output shaft that is jour-
nalled in a ball bearing.
The R800 is adapted for lubrication
with a thin-bodied gearbox or motor
oil, which gives low resistance to gear
shifting when the gearbox is cold.
Crawler gear gives high
initial tractive force and
low fuel consumption
In order to provide the vehicle with
high initial tractive force when star-
ting with a heavy load on the trailer,
the gearbox is fitted with a crawler
gear.
The high ratio of the crawler gear
(13.16:1) creates the necessary condi-
tions for selecting a fast rear axle ratio.
This makes i possible to match the
cruising speed exactly to the engine's
economy band.
Compact and strong
planetary type of range
gear gives high level of
operational reliability
The range gear consists of a robustly
dimensioned planetary gear fitted be-
hind the basic unit.
The planetary gear consists of a sun
gear (1), 5 planet gears (2), a planet
gear carrier (3), and the outer ring gear
(4).
When the range gear's high-range
position is engaged, the mainshaft's
rear ring (sun gear) is driven around
the entire planetary gear so that the
ratio will be 1:1.
In the low-range position, the outer
ring gear is locked in the range hous-
ing and forces the planet gears to
rotate towards the ring gear. This
means that the output shaft will have
a lower speed (rpm) at a ratio 3.50:1.
2
4 3
1 reliable power take-offs,
High-range position
2 The power take-offs are driven direct-
4 3
Low-range position
Gearbox
R800
Gear control that
permits fast and easy
gear changing
The movements of the gear lever are
transmitted to the gearbox by means
of a telescopic gear selector rod jour-
nalled in the gear lever by needle bea-
rings.
The telescopic tube in the gear selec-
tor rod has an inhibitor mechanism
that opens automatically when the cab
is tilted. When the cab is lowered back
into position, the gear lever only needs
to be moved forward to ensure that the
telescopic tubes are secured by the
inhibitor mechanism.
The gear shift movements are then
transferred from the gear selector rod
to the gear selectors and synchronisa-
tion mechanism by means of the shift
axle in the shift axle housing.
Catch mechanism in gear selector rod
Prepared for fitting
which gives higher vehicle
productivity
A range of power take-offs are avail-
able for the R800, and these are fitted
as separate units on the rear end wall
of the gearbox.
ly by via the gearbox countershaft and
constitute part of a complete hydrau-
lic system, which can be tailored to
match most applications.