Service Information

Document Title: Function Group: Information Type: Date:

Dropbox, removing 434 Service Information 3/22/2024
Profile:
A60H Volvo

Dropbox, removing
Showing Selected Profile

Valid for serial numbers

Model Production site Serial number start Serial number stop
A60H Volvo

Op nbr 434-074

Total procedure time (hr): 4.00

Tools:
88830508 Standard Jack Single
88830509 Adapter
88830510 Support
88830512 Pump

This operation also includes required tools and times for applicable parts of the following operations:

¡ Service positions
¡ Dropbox quick drain valve, replacing
¡ Dropbox oil, changing

NOTE!
When replacing the dropbox, the quick-drain valve must also be replaced, see Dropbox quick drain valve, replacing.

NOTE!
The dropbox weighs approx. 580 kg (1279 lbs). Always make sure that the dropbox is secured adequately.

1. Place the machine in service position 3, see Service positions, which means that axle stand 88830509 Adapter should be
used. Extend the axle stands with 88830510 Support.
 Figure 1

1. Axle stand88830509 Adapter together with 88830510 Support

WARNING
Risk of burns! Use protective work gloves.

2. Drain the oil from the dropbox in a container that holds approx.15 litres (4.0 US gal), see Dropbox oil, changing.

Figure 2

1. Drain plug

3. Start the machine and make sure that the machine's brake system and compressed air system have full working
pressure.

4. Release the parking brake and check on the information display that all differential locks are disengaged. The machine
always starts with disengaged differential lock in the dropbox and drive to the rear bogie axle.
 5. Turn off the engine with the emergency stop but keep the ignition in position I, operating position.

WARNING
Risk of crushing!

Machine could start moving and cause serious crushing injury.

Secure wheels with chocks.

6. Raise a wheel on the front axle. Use 11668007 Standard Jack Single and 88830512 Pump.

Figure 3

1. 88830508 Standard Jack Single

2. 88830512 Pump

Figure 4
Overview of dropbox propeller shafts positions

1. Input propeller shaft

2. Rear output propeller shaft
3. Front output propeller shaft

WARNING
Do not work under a hanging or suspended load!
 7. Place a fabric strap around the front output shaft (pos. 3 in overview figure) so that the prop shaft cannot part. Secure
the prop shaft with a tensioning strap around the dropbox. Loosen and lower the prop shaft with the tensioning strap.
Weight: approx. 45 kg (99 lbs)

Figure 5

1. Fabric strap
2. Retaining strap

8. Secure the prop shaft for the rear output shaft with a tensioning strap around the hitch. Loosen and remove the bolted
joint between the prop shaft and the drive flange for the rear output shaft on the dropbox (pos. 2 in overview figure).
Push in ("telescope") the propeller shaft and let it down.
Weight: approx. 55 kg (121.2 lbs)

Figure 6

1. Propeller shaft, rear output shaft on dropbox

2. Retaining strap

9. Turn off the ignition.

NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.

10. Disconnect the ground-dependent pump from the dropbox.

Weight: approx. 35 kg (77 lbs).
 Figure 7

1. Bolts holding ground-dependent pump to dropbox (2 pcs.)

11. Remove and discard the O-ring.

Pull the pump forward and secure with a fabric strap to the axle
NOTE!
Oil may drain when the pump is removed.

Figure 8

1. Fabric strap
2. O–ring

12. Install a cover over the power take-off.

 Figure 9

1. Cover

13. Disconnect the hoses for the breather and oil fill point.

Figure 10

1. Oil fill point

2. Air bleeder
3. Air hose differential lock
4. SE4607 Monitor, position longitudinal differential lock
5. Bolts for bracket for solenoid valves
6. SE4309 Sensor, front output rpm, dropbox

14. Disconnect the air hose for the differential lock from the dropbox.

15. Unplug the connector for position sensor SE4607.

16. Remove the two bottom bolts for the bracket for the solenoid valves.

17. Unplug the connector for rpm sensor SE4309.

18. Remove the bolt that holds the cooler. Remove the seal ring and the O-ring. Move aside the cooler.

Figure 11

1. Bolt
2. O–ring
3. Heat exchanger
4. Seal ring

19. Install a cover over the hole on the dropbox where the cooler was installed.
 Figure 12

1. Cover

20. Disconnect the right sensor unit for level control from the bracket on the frame and move it aside.

Figure 13

1. Sensor unit for level control

21. Remove the rear and middle floor mats from the cab.
 Figure 14

1. Front floor mat

2. Middle floor mat
3. Rear floor mat

22. Remove the operator's seat and lift it out of the cab, see Operator's seat, removal

Figure 15

23. Remove the service cover as well as the rear and middle floor plate.

Figure 16

1. Floor plate, front

2. Floor plate, middle
3. Floor plate, rear, with operator's seat bracket
4. Service hatch

24. Remove the two upper bolts for the bracket for the solenoid valves. Push aside the valve unit and secure with a cable
tie.
 Figure 17

1. Bolts for bracket

2. Sensor SE4305 Low range
3. Sensor SE4306 High range

25. Unplug the connectors for position sensor SE4306 and SE4305 from the dropbox.

26. Mark up and disconnect the air connections for low, neutral, and high from the dropbox.

Figure 18
 1. Low
2. Neutral
3. High

27. Place a fabric strap around the input propeller shaft in the dropbox so that it cannot come apart. Remove the bolted
joint between the propeller shaft and dropbox (pos. 1 in overview figure).
Push in ("telescope") the propeller shaft and move it aside.

Figure 19

1. Fabric strap

28. Secure the dropbox with a tensioning strap around the dropbox and frame, so that it cannot tilt forward when the
upper mount is removed.

Figure 20

1. Securing the dropbox

 Figure 21

1. Securing the dropbox

29. Remove the upper mount for the dropbox.

Figure 22

1. Bolts for front part of dropbox upper mount

2. Nuts for rear part of dropbox upper mount
3. Bolts for rear part of dropbox upper mount

30. Install the lifting device, which is included in 88830384 Lifting tool, in the upper mount for the dropbox. Use existing
bolts.
NOTE!
The lifting yoke should be positioned at the rear of the attachment.
 Figure 23

1. Lifting device

31. Remove the two upper bolts for the spill guard's brackets. Loosen but do not remove the bolt and nut for the lower
brackets for the spill guard. Tilt back the spill guard.

Figure 24

1. Upper bracket
2. Lower bracket

32. Connect a ratchet block rated for at least 750 kg (1653 lbs) to suitable lifting equipment. Connect a lifting sling rated for
at least 750 kg (1653 lbs) to the ratchet block. Route the sling down between the cab and spill guard, and connect the
sling to the lifting device. Tighten up the lifting sling so that the dropbox does not fall down when the bolts for the
mounts are removed.
 33. Remove the tensioning strap that straightened up the dropbox.

34. Remove the two lower mounts for the dropbox.

Figure 25

1. Nut plate
2. Bracket
3. Spacer
4. Bolts
5. Washer

WARNING
Do not work under a hanging or suspended load!

35. Lower the dropbox with the ratchet block. For easier lowering, the front end of the dropbox can be angled to the right
when there is space. Lower the dropbox onto a pallet forklift and pull it out from under the machine.
Weight: 580 kg (1279 lbs)
NOTE!
The easiest way to do this is two persons working together. The time for this method step is calculated for two persons.

Figure 26