Service Information
Document Title: Function Group: Information Type: Date:
Transfer gearbox, 430 Service Information 3/22/2024
description
Profile:
A60H Volvo
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Transfer gearbox, description
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Valid for option/configuration
Model Option no. Option Configuration
A60H Volvo 22594 Dropbox IL-3 without air damping
Valid for serial numbers
Model Production site Serial number start Serial number stop
A60H Volvo Braås 320001 320241
A60H Volvo Braås 340001 349999
A60H Volvo Braås 350001 350087
The dual range dropbox with its two shafts has the function of distributing the power from the transmission out to the drive
shafts. The dropbox has a differential between the front output shaft and the rear output shaft. There is also a take-off for the
ground-dependent hydraulic pump on the dropbox.
Function description
The power is transmitted from the transmission via a propeller shaft to the dropbox's input shaft. The input shaft is a part of the
longitudinal differential, which distributes the power to the dropbox's both output shafts, enabling rpm variations between the
tractor unit and load unit. An unlocked differential gives a torque distribution of 50% to the front and 50% to the rear. The
dropbox has two ranges, high and low, and shifting can be controlled both manually and automatically.
For more information on gear ratio, see Dropbox, specifications.
Figure 1
Transmission of power
Red – from the transmission to the differential
Blue – from the differential to the front bogie axle
Green – from the differential to the front axle
Differential
The dropbox's differential lock is a dog-clutch with 100% locking. The differential lock is activated by spring force and
deactivated with compressed air. The design of the differential's dog-clutch halves is such that they strive for full engagement at
activation, which enables engagement and disengagement on the move.
Figure 2
Dropbox differential lock
1. SE4607, Monitor, position longitudinal differential lock
2. Shift fork
3. Space for compressed air
4. Piston
5. Spring washers
6. Dog-clutch
The differential lock's position (engaged or disengaged) is monitored by SE4607, Monitor, position longitudinal differential lock.
A range of sensors control engagement and disengagement of the differential lock. The sensors sense rpm differences and
thereby any slipping in the drivetrain. In the system there is also a steering angle sensor (SE6403) that considers rpm differences
that depend on how the machine is steered. The machine's standard inclination sensor (SE3801) is used to keep the differential
lock activated if the longitudinal inclination is above a certain value. The pressure sensor SE4608 monitors that there is enough
air pressure in the system to enable correct disengagement of the dog-clutch.
For more information on the dropbox's longitudinal differential lock and the ATC-function, see Power distribution and ATC,
description
The dropbox's lower main gear drives the lubrication oil pump, via a transfer gear, as well as the power take-off for the ground-
dependent pump. The lubrication oil pump is provided with valves that enable circulation of the oil regardless of travel direction.
Shifting
The shifting function of planetary gear type has three ranges (gears); high, low, and neutral. Neutral is only used when shifting
on the move and when restoring when the machine is stationary. Gears are shifted pneumatically with a splined clutch.
Different gear ratios are obtained by the dog-clutch locking planet gears and sun gear on the dropbox in different combinations.
The dog-clutch is moved between different positions by pressurizing three different pistons; depending on which piston is
pressurized, the dog-clutch moves back and forth. The air pressure that applies each piston is controlled by three solenoid
valves.
Figure 3
L = Compressed air connection, low range, controlled by MA4302
N = Compressed air connection, neutral, controlled by MA4304
H = Compressed air connection, high range, controlled by MA4303
Figure 4
Compressed air connections
1. Connection 1
2. Connection 2
3. Connection 3
Shifting diagram
Range (gear) position Connection Combination
1 2 3
Low X sun gear– transmission housing
Neutral X sun gear
High X sun gear– planet stage carrier
The dropbox's range (gear) position is sensed by two sensors.
Figure 5
Cut-away view, sun gear and shift fork
1. Sensor SE4305 Low range
2. Sensor SE4306 High range
3. Ball with spring holding shift fork in neutral range position
Shifting in the dropbox is affected by various factors:
¡ the machine's current gear and gear selection, engine oil temperature, any alarms
¡ engine rpm and torque use
¡ transmission shifting, oil temperature, and output rpm
¡ dropbox's output rpm and range (gear) position
¡ signals to the gear selector valves for high and low range
¡ parking brake
¡ load and dump brake
When the dropbox shall change range position from Low to High while driving, the input and output speeds are synchronised by
requesting engine braking[1]. To avoid activating the anti-stall function of the transmission (the anti-stall function disengages
lock-up in the event of rapid reduction of engine speed), relay RE4213 is activated, which closes an input on the transmission
control unit and thereby deactivates the anti-stall function.
For more information on the gearshifting strategy between transmission and dropbox, see Gear shifting strategy
Shifting diagram, dropbox
The dropbox has two ranges (gears); low and high. The switch on the instrument panel enables selecting if shifting is to be
controlled automatically between high and low (AUTO), or manually, then only low (L)
Figure 6
Shifting diagram dropbox
Figure 7
Switches
Switch in position Auto
Stationary machine Loaded Range position Low requested
Unloaded Range position High requested
Machine moving Loaded Maintains range position Low.
Depending on the rolling resistance of the machine or
inclination of the road, range position High can be activated.
To change from High range to Low range, the machine must
be stopped.(a)
Unloaded Requests and maintains High range
At any time the switch can be moved between positions Auto and Low, but the conditions must be fulfilled for shifting to take
place, see 'Conditions for shifting' below.
Switch On/in position Low
Stationary machine Loaded Range position Low requested
Unloaded
Machine moving Loaded Range position Low requested
Unloaded To change from High range to Low range, the machine must
be stopped.[T1]i
At any time the switch can be moved between positions Auto and Low, but the conditions must be fulfilled for shifting to take
place, see 'Conditions for shifting' below.
[T1]Older version: also changes from range position High to Low while driving, depending on the rolling resistance of the
machine or inclination of the road.
Figure 8
Low range requested
Figure 9
Low range active
Conditions for shifting of stationary machine:
¡ transmission in range (gear) position N (neutral) for 7 seconds
¡ engine speed below 780 rpm (13 r/s)
¡ transmission oil temperature above 30 °C (86° F)
¡ engine oil temperature above 55 °C (131° F)
¡ compressed air above 650 kPa (6.5 bar)
In addition, one of the following conditions must also be fulfilled:
¡ parking brake activated
¡ load and dump brake activated with button
¡ load and dump brake activated by pressing down brake pedal.
The load and dump brake is activated automatically by the software by pressing down brake pedal briefly after the
transmission has been in neutral range for more than 7 seconds.
Conditions for shifting of machine on the move:
¡ gear position F6
¡ Lock-up activated
¡ transmission oil temperature above 30 °C (86° F)
¡ engine oil temperature above 55 °C (131° F)
The engine's overspeed protection prevents the dropbox from shifting when operating downhill.
For more information about the gearshifting strategy between transmission and dropbox, see Gear shifting strategy
Software description
Alarm conditions Alarm function
Dropbox shifting defective Red central warning
Dropbox locked in neutral Amber central warning
Figure 10
1. Check
2. Restart the engine
3. Dropbox. Stuck in neutral
Dropbox shifting defective Amber central warning
Function check
Basic setting and adjustment of the longitudinal differential lock takes place on a loose component, any additional adjusting is
normally not needed. Incorrectly adjusted differential lock can lead to wear when the differential lock is engaged.
Function checks
¡ Dropbox function, checking
¡ Differential lock dropbox sender unit, adjustment
Supplementary information
¡ Dropbox, specifications
¡ Dropbox, component location
¡ Compressed air diagram
¡ Power distribution and ATC, description
Diagnostics
Detailed information regarding appropriate warnings and error codes for the components can be found under the Diagnostics
tab in PROSIS.
¡ MID249 PSID58 / MA4604
¡ MID249 PPID1409 / SE4309
¡ MID249 PPID1205 / SE4311
¡ MID187 PPID1087 / MA4303
¡ MID187 PPID1088 / MA4302
¡ MID187 PPID1112 / MA4304
[1]In certain cases, older version software also allows changing range position from High to Low while driving.
