bruder Volvo A60H Manual

Also See for Volvo A60H:

Instructions manual (39 pages)

Table of Contents

Contents

1 Skill Level
2 Recommended Tools
3 Parts List
4 Instructions
5 Controls (RTR version)
6 Dismantling
7 Part List
8 Documents / Resources
- 8.1 Download manual

bruder Volvo A60H Manual

Skill Level

This conversion kit for the Bruder Volvo A60H is recommended to users with medium and above competence.
The following instructions are deemed a guide to "how to do the conversion" not a concise step by step procedure.

Caution Note

Carefully read and fully understand the instructions before commencing assembly. A supervising adult should also read and understand the instructions if a child assembles the model.
When assembling this kit, tools including knives and heat gun are used. Extra care should always be taken to avoid personal injury and damage to the kit.
All instructions relating to tools, glues, etc (not included in the kit) must be always adhered to.
Keep out of reach of small children. Kit contains small parts and plastic bags which are harmful to children if swallowed.

Recommended Tools

Philips screwdriver
Allen keys
Hex socket
HSS drill bits 2mm, 3mm, 3.5mm, 4mm, 5mm, 6mm, 10mm
File
Pliers
Soldering Iron
Side cutters
Hot glue gun
Knife
G clamp (for pushing motors into 3D printed parts)

Parts not included in kit

Heat shrink
Glue
Steering horn
Steering rods

Parts List

Note depending on the kit purchased you may not have all the listed parts supplied.
Parts List

Instructions

Disassemble Bruder model. (See Appendix A)
Cut front chassis to accept part number #A01.

Insert motors and steering servo into part number #A01. Note. one side you will need to flip the polarity to the motor.

Place the front axle (part number A#01) into the front chassis. Drill 4 fixing holes of 3.5mm diameter. Fix in place using M3x20mm bolts and nuts.

Cut and clear the area behind the cab to take the M10 bolt and nut.

Install the M6 x 30mm bolt into the swivel knuckle part #A02

Clear plastic around knuckle area to accept part #A02

Cut away plastic to allow more space for steering rods.
Install servo, servo horn and steering rods.

Remove the grey/silver plastic bit and install supplied part #A13 as shown. These work from 6v supply so can be connected to the receiver or other control mean.

Insert the motors into the rear axle arm part #A10

For ease of identification mount the motors so red dot is top on one axle and at bottom of the other axle.

Cut two pieces of wire, 1 @ 10cm, 1 @ 15cm. Solder both to one motor.
Put a motor cap #A11 over the wires and onto the motor.

Put another cap over the 15cm wire as shown.

Solder the 15cm wire to the other motor.

Place the motor cap on the motor.

Repeat for the other side but flip the polarity over.

Screw the M6x30mm bolts into parts #A07 and #A09. Make sure the bolts are square when put in. This action will form a thread ready for later installation process.
Predrill parts #A05 & #A06 with 2.5mm drill bit.

Lay the rear chassis parts #A04, #A05 & #A06 upside down on a flat surface. Place a 5.5mm drill piece (or Allen key, screwdriver) between all 3 parts to assist alignment. Add the rear axle sleeve #A07 and secure with the M6 bolts.
Using a 2mm drill bit drill pilot holes (2 per side), and screw in the self-tapping screws

Once secured with the self-tapping screws, remove the securing drill bit and fasten with M6 x 16mm bolts and M6 nuts.
Turn chassis right way up and align the rear axles. Briefly connect to a battery to determine the rotation of shafts is correct for each side.

Remove the rear axle sleeve and place the two completed rear axle arms into the chassis slots, making sure the cables go through the split cable way as shown.

Insert the rear axle sleeve back and tighten up but not too tight the rear axle arms cannot move.

Position part number #A08 at the rear of the chassis. Using 2mm drill bit, drill pilot holes 12mm deep into the chassis at the top and back. Secure with 4 self-tapping screws.
Turn the chassis upside down. Position the front half of the truck so to place part number #A02 at the front and place part number #A03 over it. Hold in place and secure with M3x20mm socket head bolts and M3 nuts. Note the nuts will not spin in the hole so once the bolt starts it will self-tighten.

From the underneath drill 2 x 2mm holes and secure with self-tapping screws.

Feed a length of cable through the chassis from the rear motors to the front cab. Leave enough slack at the articulation point. Do the same for the actuator cables.

Attach the linear actuators using the M4 nut and bolts. Make sure the cable comes off at the bottom. Note the actuator stickers can be peeled off easily.

Join the motor wires together.
Insert the metal hub (with out the grub screws) into the wheel part number #A12 making sure the holes line up. This can be achieved by putting a small screwdriver or Allen key through both parts. Turn upside down, drill 2 pilot holes (2mm) and fix in place using selftapping screws. Then put in the grub screw.

Push part number #A12 onto the 6 motor shafts noting the flat side on the shaft needs to align with one of the M3 grub screws mentioned in last step. Once pushed on, tighten the grub screws.
Using the Bruder wheels, drill 5mm hole in the Bruder wheel from the inside tube (this allows for perfect centering of the hole)

Using the supplied wheel cutting template part number #A14, cut away the internal plastic to leave a flat surface on the inside. Now enlarge the hole with a 6mm drill bit.

Using M6x25mm bolt attached Bruder wheel over supplied re-enforced wheel #A12. Repeat for all 6 wheels.

Add the Bruder dump body to the hinge and secure using a M6x30mm bolt in each side of the hinge sleeve part #A09. Note. A screwdriver can assist to hold the sleeve whilst screwing in the bolt.

It is easier to extend the linear actuators to allow connection to the tub.
Secure the top of the linear actuator to the tub using the M4 bolt and M4 nuts. Note do not over tighten as need some flexibility at the joint.

Install battery, ESC's, receiver and connect to the motors and receiver.
Test operation.

Controls (RTR version)

Left stick up/down	Drive forward/reverse
Right stick up/down	Bucket tilt up/down
Right stick left/right	Steer left/right
Switch A	Lights if installed
Switch D	Orange beacon if installed

Notes

If sound unit is installed the sound will automatically start when drive forward/reverse is activated, engine sound will idle for 15 seconds then stop if no further input is detected.
If orange beacon is installed, when powered on the unit will do fast rotation effect, to cycle through different effects move switch D down then up to move along one sequence.
Sequences are
Fast rotation
Slow rotation
Fast flash
Slow flash
Off

Dismantling

Dismantling the Bruder model can be difficult as are bult not to come apart as intended for 3 year + children. The following is given to assist in the dismantling of the model ready to be modified for the conversion. Remove the dump tub plastic cylinders. A flat headed screwdriver or similar can be used to prise the cylinder from the dump tub. It is not necessary to remove the end attached to the chassis but can be for easier access later on removing the wheels.
Dismantling - Step 1

Remove the dump tub by prising the lugs over the hinge.
Dismantling - Step 2

Remove the lower part of the access ladders to the cab the front to rear umbilical attachment.
Dismantling - Step 3

Turn upside down and release or snap off the 7 clips under the cab. You should now be able to separate the front lower and top section which will also disconnect the rear chassis.
Dismantling - Step 4

Separate the front middle and top section by releasing the indicated clips.
Dismantling - Step 5

To remove the wheels from the metal axle. 2 options.
Dismantling - Step 6

Brute force hold one wheel in a vice or something and pull on the other. Note considerable force is needed so be careful not to injure yourself, others or property.
Using a sharp knife cut a slot down the plastic wheel shaft, then twist the wheel and it should come away from the shaft.