I-Shift, Design and Function
I-Shift, Design and Function
I-Shift, Design and Function
Chassis ID Path
43/Diagnostics/FH, ATO2512C/MID 130 PID 160 Parameter setting
Model Identity
FH 131707418
Gearbox, mechanical
Contents
General
Gear ratio
Gearbox construction
Synchronisation
Range housing
Range gear
Emergency steering servo pump
Oil cooler
Control housing
Countershaft brake
Clutch cylinder
Lubrication system
Gearbox ventilation
Ventilation
Electrical system
Compressed air system
Power train
Auxiliary brake lever
Gear selector
Display
Program packages
Function description
Communication with other control units
General
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Make VOLVO
Reverse 4
Gear ratio
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Gearbox construction
The gearbox construction consists of three main parts: a clutch housing, a basic housing and a range housing. The
clutch housing forms the front end plate of the gearbox. The base housing contains the main, counter and reverse
shafts along with a selector unit which is integrated into the control housing. The range housing contains the range
gear planetary gear and the output shaft.
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1. Clutch housing
2. Main housing
3. Range housing for the retarder
The main parts in the gearbox are the input shaft, main shaft, range gear with selector unit, countershaft, oil pump with
reverse shaft, as well as the control housing with selector unit.
The trailing wheels for the reverse gear and basic gears are located on the main shaft. The range gear's sun gear is
also integrated with the main shaft. The countershaft has fixed gears.
The range gear incorporates a planetary gear and is integrated with the output shaft.
Gearboxes equipped with a power take-off also have a drive shaft fitted.
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1. Input shaft
2. Main shaft
3. Range gear with selector unit and retarder drive
4. Countershaft
5. Oil pump with reverse shaft
6. Control housing with selector unit
7. Drive shaft for power take-off
Synchronisation
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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Range housing
Range housing (C) can be combined with:
Range gear
The range synchronization lies outside the ring gear, reducing the unit's length. The large synchronization area results
in short selection time, the wide planet gears give a strong range and the helical gears result in a quiet planet gear.
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Oil cooler
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The gearbox oil cooler function is not affected by whether the gearbox has a retarder or not.
Control housing
Gears are selected using the gear selector. Once a gear has been selected, the system reduces the engine torque to a
suitable level, after which the gears are shifted to neutral.
After the gearbox has been put into neutral, the engine speed is adjusted to accommodate the speed of the selected
gear, after which the gear shift takes place.
The control housing cover has two or sometimes three electrical sockets.
I Vehicle communication
II Clutch cylinder
III
I Vehicle communication
II Retarder
III Clutch cylinder
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1
HS and LS have reversed functions on Over Drive gearboxes.
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A. Split cylinder
B. 1/R cylinder
C. 2/3 cylinder
D. Range cylinder
E. Position sensor for the split cylinder
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For more information regarding GCU-D and these parameters, see - MID 130 PID 160 Parametersetting .
GCU
ID Unit Designation
1
Speed sensor for I-shift gearbox generation D
2
Speed sensor for I-shift gearbox generation C
Countershaft brake
The counter shaft brake is located at the front of the counter shaft and brakes the rotating parts the gearbox when a
start gear is selected, which eliminates gearbox wear, deposits and noise. The brake is also sometimes used during
changing up to give quicker gear changes. It is activated using an integrated pneumatic cylinder.
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Countershaft brake
Clutch cylinder
The clutch cylinder is located in the clutch housing, concentrically round the input shaft with a position sensor which
measures clutch wear. A valve unit controls the clutch cylinder and is located on the outside of the clutch housing.
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A. Clutch cylinder
B. Position sensor
C. Valve unit
D Bleeder nipple for the valve unit.
Lubrication system
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The oil is led into the main shaft to lubricate and cool the range gears as well as the input and main shaft bearings.
The countershaft brake, output shaft bearings, emergency steering servo pump drive, retarder gear and power take-off
are also lubricated.
The lubrication system has two overflow valves. One valve ensures that the gearbox is lubricated if the filter gets
blocked while the other prevents excessive pressures in the system, e.g. during cold start. The valves are made up of a
compression spring and a valve peg.
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Oil pump
The oil pump is an eccentric pump driven by the countershaft via a gear. The pump is mounted in two needle bearings
in the reverse shaft.
There is a full flow oil filter of the insert filter type on the pressure side of the pump. It is located in the oil filter housing
in the main housing. A support pipe is fitted in a cover that is fastened to the bottom of the oil filter housing. The
support pipe prevents the filter, which sits on the outside, from collapsing.
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Oil level
The oil level is checked with a level glass (2) and adjusted using two drain plugs (1A and 1B) and two filler plugs (3 and
4), see picture below.
Read more about oil quality and oil change volumes in- Preventive maintenance intervals .
Gearbox ventilation
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Ventilation
There are two version of gearbox housing, the later version was introduced week 0907
A 693152
B 553957
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The ventilation (breathing) of the gearbox goes via the main shaft cover(1) through a chamber (2) and a hole up to the
Gear Control Unit, GCU (3). The air passes different chambers (4) and (5) before it goes out to the ambient air through
the channels (6), in the gearbox housing. Ventilation air from the gear shift cylinders also passes one of the chambers (
5) and then out to the ambient air through channels (6), in the gearbox housing. This gives clean air into the gearbox
COPYRIGHT Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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as well as ventilation of the gearbox to the ambient air without oil moisture.
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Possible combinations
It is possible to combine parts from previous and later version of ventilation. If there should be any uncertainty after old
and new parts have been combined, to make sure that the gearbox get a correct ventilation, the valve and hose (D)
from previous version of ventilation can always be retrofitted.
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Caution
The later version of the main cover (G) can not be used at the previous gearbox housing .
Gearbox ventilation
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Electrical system
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I. Vehicle communication
II. Clutch cylinder
A. Speed sensor
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Cabling from socket II to the valve unit for the clutch cylinder.
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I. Vehicle communication
II. Retarder
III. Clutch cylinder
A. Speed sensor
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Cabling from socket III to the valve unit for the clutch cylinder.
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Compressed air connection between the control housing and the valve unit for the clutch cylinder.
For the high pressure system, compressed air connection between the control housing and the four-circuit valve. For
the low pressure system, compressed air connection between the control housing and the pneumatic tank.
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Pneumatic connection between the control housing and the countershaft brake.
Power train
The following illustrations show the power train for AT2412C, AT2512C and AT2812C.
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1st gear
2nd gear
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3rd gear
4th gear
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5th gear
6th gear
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7th gear
8th gear
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9th gear
10th gear
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11th gear
12th gear
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Neutral N1
Neutral N2
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The following illustrations show the power train for ATO2512C and ATO3112C.
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1st gear
2nd gear
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3rd gear
4th gear
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5th gear
6th gear
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7th gear
8th gear
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9th gear
10th gear
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11th gear
12th gear
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Neutral N1
Neutral N2
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13 Manual mode
B Position for activating the brake program. Spring return to position 3.
The illustration shows a vehicle fitted with the Basic program set, which has no brake program. When the auxiliary
brake lever is moved to position B, the gearbox will select a gear giving an engine speed of just over 1500 rpm. If the
speed in reduced, the gearbox will then select gears to maintain an engine speed between 1000-1500 rpm (B). The
driver can also change down further by moving the auxiliary brake lever to position B.
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Without the brake program, (A) desired rpm for first change down, (B) area for braking using the auxiliary brake.
The vehicle in the illustration is fitted with one of the program sets Distribution & Construction, Long Haul Fuel &
Economy or Heavy Duty GCM Control, which include the braking program. When the auxiliary brake lever is moved to
position B, the gearbox will select a gear giving an engine speed above 1500 rpm. The gearbox will then select gears
to maintain an engine speed above 1500 rpm (B).
With the brake program, (B) area for braking using the auxiliary brake.
Note: The effect of the auxiliary brake may be reduced by the I-shift control unit, MID 130, to make the ride as
comfortable as possible. The effect reduction is regulated by the selected gear, vehicle weight and road surface
inclination.
For more information on auxiliary brake component parts, see group 21, Description, Design and Function, Engine.
Gear selector
Gear selector (GLU) is attached to the driver's seat and can be folded away to ease passage inside the cab. The gear
selector control unit is in the dashboard.
1. Three position switch with spring return for up and down changing.
2. Button for lowering the lever into a horizontal position.
3. Gear selector inhibitor preventing the vehicle from being put in gear unintentionally.
4. Gear selector position:
R = reverse gear
N = neutral
A = automatic
M = manual
5. Button E/P for economy/performance position.
6. Button L Limp Home.
Note: The Limp Home function is intended for moving the vehicle short distances in order to get off the road and to a
COPYRIGHT Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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workshop. Only one gear can be used and the driving may be jerky. For information on how to engage and use this
function, see driver instructions.
Display
The display provides information on the gear currently selected and which gears are available.
The display is divided into smaller fields showing:
1. Driving program
2. Selected gear
3. Available gears (down/up)
4. Lever position
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Program packages
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The display then shows the program variant the gearbox has.
B Basic TP-BAS
When a program package is replaced, the Central system (VDA) must be updated before it can be downloaded to the
vehicle. This is done by entering the Converting set number in the computer tool which is stated in Part information,
accessory .
After replacement, reprogramming must be carried out using the TECU control unit (MID 130), and the gearbox must
be recalibrated.
Launch Control X X X
Possible optional functions Basic Distribution & Long Haul Fuel & Heavy Duty GCM
Construction Economy Control
AMSO-BAS X
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APF-BAS X
Customer parameters
Customer parameters in the gearbox control unit:
Note: The default value can vary depending on the program package selected.
GJG Determines how the split gear performs when PTO 1 is Selectable LS/HS/Selectable
1
connected for the gearbox.
GJH Determines how the split gear performs when PTO 2 is Selectable LS/HS/Selectable
1
connected for the gearbox.
1
For further information, see options instructions.
2
GJI only used at APF-ENH; the others are always included.
Function description
Standard functions
The following standard functions are available in the gearbox:
Optional functions
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down to idle.
Smart Cruise Control
The function is only active when cruise control is activated. Saves fuel by deactivating the auxiliary brakes under
certain conditions. The function releases the auxiliary brakes after a downhill stretch, which improves cruise
control performance.
Launch Control
Allows driving with the engine idling without slipping the clutch.
Regulates engine torque when pulling away for optimum gear changing and avoid high engine speed.
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Component list
Component Description
A13 (MID 130) Control unit, TECU (transmission electronic control unit)
A14 (MID 128) Control unit, EECU (engine electronic control unit)
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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A17 (MID 144) Control unit, VECU (vehicle electronic control unit)
A109 (MID 223) Control unit, GSECU (gear selection electronic control unit)
The vehicle control unit parameters MG, MH and AQ must have the same values. Check the parameter settings
in the VDA.
Accelerator pedal position, including kick-down.
Cruise control.
Retarder control. For further fault tracing see the PC-tool, function group 5.
Power take-off control, see options instructions.
Brake pedal position.
Parking brake applied or not.
The VECU K-factor must be the same as the tachograph K-factor.
COPYRIGHT Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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Vehicle weight information on leaf suspension vehicles ( RADD-BR and RADD-TR), used for gear selection.
Communication with the control unit Central instruments (A03), MID 140
Signals / information from TECU:
Engine speed.
Engine configuration
Engine torque
If the engine is not running smoothly, this will adversely affect gear shifting.
Vehicle weight.
ECS control unit status. Always start in 1st gear if the manoeuvre control unit for the air suspension is in manual
mode.
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Trailer coupled.
The gearbox can select the wrong start gear and wrong gears if the parameter ANI is not active. The gearbox
then assumes that a trailer is hitched up.
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