Gearbox, Mechanical, Function Description

IMPACT 4.07.
03 04/04/2019
Chassis ID Path
A 833957 43/Description, Design and function//Gearbox, mechanical, function description
Model Identity
FM (4) 138610389
Publish date ID/Operation

31/01/2017
Gearbox, mechanical, function description

Component location
Interface to gearbox
Driver interface
Gear selector, gear lever unit GSS-AGS
Gear selector, shift buttons GSS-4BS
Auxiliary brake lever – brake mode
PTO
Gearbox software packages

Gear Selection Adjustment, AMSO-BAS, AMSO-AUT
Power Take-Off, APF-BAS, APF-ENH
Performance mode options, AVO-BAS, AVO-ENH
Launch Control
Enhanced shift strategy
Free wheel
Heavy Duty GCW Control
Crawler gears ASO-C, ASO-ULC
Multi Speed Reverse ARSO-MSR
Predictive Cruise Control
Gear selection
Gear selection in automatic mode
Gear selection in manual mode
Start gear selection
Gear selection in special driving condition and Limp home
Gear shifting
General
Components involved
Parameters
Related information

Component location
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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Interface to gearbox
Note
Placement of components may vary between vehicle variants. For more information, see
wiring diagram.
Inside cab
1 Instrument panel (A03)
2 HMIIOM (Human Machine Interface I/O Module) (A161)
3 VMCU (Vehicle Master Control Unit) (A187)
4 Steering wheel module (S275)
5A Gear selector switch module (S295)
5B GLU (Gear Lever Unit) (S171)
6 Sensor, accelerator pedal (B25)
On chassis
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1 ECM (Engine Control Module) (A14)
2 TECU (Transmission Electronic Control Unit) (A13A)
3 CCIOM (Centre Chassis I/O Module) (A163)
4 APM (Air Production Modulator) (A177)
5 EBS (Electronically controlled Brake System) (A21)
6 ACM (Aftertreatment Control Module) (A174/B)
7 Clutch cylinder
8 CVU (Clutch Valve Unit)
9 Crawler gear housing (ASO-C and ACO-ULC only)
10 Valve unit, crawler gear
Driver interface
Dashboard centre display
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The centre display in the instrument panel shows the following driving modes:
R Reverse R1-R4 with MSR option RC, R1-R5
N Neutral (N1 low, N2 high)
A Automatic 1-12 and crawler gears C/C1, C2 (ASO-C/ULC only)

1 Selector position
M Manual 1-12 and crawler gears C/C1, C2 (ASO-C/ULC only)
F Folded (GSS-AGS only)
H Hold the present gear (GSS-4BS only)
2 Active gear
E Economy
E+ Free wheel (I-Roll) possible
IS Predictive cruise control (I-See) possible
P Performance
3 Driving mode P+ P+ is adapted for heavy construction
B Brake program
HD Heavy duty
L Limp home
Ê Dynamometer mode
4 Available gears up or down (maximum three arrows) from current gear.
Gear selector, gear lever unit GSS-AGS

The gear lever unit is attached to the driver seat.
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1 Gear step button (+/-).

Spring-loaded switch for manual up and down shifting.
2 Gear shift lever fold button.

To fold the lever forward into horizontal position.
3 Gear selector inhibitor.

Prevents unintentional gear engagement from neutral (N) to any gear.
4 Gear selector position:

R = Reverse.
N = Neutral.
A = Automatic gear selection mode.
M = Manual gear selection mode.
5 E/P-button.
E = Economy mode.
P = Performance mode.
If HD-mode (Heavy Duty) is installed, this mode is reached by pushing the button for at least
three seconds. Once in HD mode, a short press is enough to go back to E.
6 L-button (Limp-home).
Note
Limp-home is activated by pressing the Limp-home switch at the same time as moving the
gear lever from N to M. Limp-home is active until the next engine start.
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Gear selector, shift buttons GSS-4BS

The gear selector is a four-button gear selector located on the dashboard.
1 R = Reverse.
2 N = Neutral.
3 A = Automatic gear selection mode.
4 HOLD = Hold the present gear. Lock the gear to prevent gear up and gear down.
5 Gear step button (+/-) = Change gear up and down.
Note
There is no manual gear selection mode. Gear changing is fully automatic, but if required the
driver can adjust the start gear manually with the gear step button (+/-).
Note
The neutral gear (N) is automatically pre-selected when starting the vehicle.
Auxiliary brake lever – brake mode

The auxiliary brake lever has many variants. This example shows an Auxiliary brake lever with Brake
program:
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A: Automatic mode (Depending on configuration E+ will show in display and Free wheel (I-Roll) is
possible)
0: Auxiliary brake not applied
1–3: Manual mode with predefined levels for auxiliary brake
B: Activating the brake program. TECU selects the best gear for maximum deceleration
When in brake mode, the position of the auxiliary brake lever and the activation/deactivation of the
brake program control the gear selection occurrence.
PTO (Power Take-Off)

PTO can be activated or deactivated by pressing the button.
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Engaging driveline PTO

The PTO can be engaged when the vehicle speed is below 10 km/h, in any gear up to gear 6.
It is not possible to change gear with the PTO engaged.
1 The TECU disengages the clutch
2 The TECU engages the PTO
3 The TECU engages the clutch
After engaging the PTO, the vehicle speed can be increased to above 10 km/h but it is still not
possible to change gear.
Disengaging driveline PTO

The PTO can be disengaged at any speed and in any gear.
1 The TECU disengages the clutch
2 The TECU disengages the PTO
3 The TECU engages the clutch
Gearbox software packages

The software packages have several functions that optimise the driver’s control of the driving
situation.
Several different software packages are available and the packages contain progressively more
functions.
The software packages can be further customised with optional functions and customer parameters.
For example, the starting gear can be optimised according to the transport conditions. The Power
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Take-Off operation can also be customised to fit the customer's needs by setting parameters.
The software packages and parameters can easily be installed and changed by authorised dealers
and workshops using Volvo Tech Tool.
Software packages
Gearbox (I-Shift) basic The standard software package supplied with the gearbox
TP-BAS
software package (I-Shift). Includes the basic functions for all round driving.
Adapts the functions to match the specific conditions in

the distribution segment. Includes functions that aid
Gearbox (I-Shift) distribution
TP-DIST manoeuvring, pulling away and enhanced gear selection.
gear changing software
Possible options are Enhanced power take-off, and
Performance plus (for bad road conditions).
Adapts the functions to the specific conditions in the

Gearbox (I-Shift) construction segment. Includes functions that aid
TP-CON
construction software manoeuvrability, pulling away and slow driving. This
software can handle bad road conditions.
Intelligent functions that minimise fuel consumption. Ideal

for long-haul operations where strong emphasis is placed
Gearbox (I-Shift) long haul on fuel economy. Includes the Free wheel (I-Roll)
TP-LONG
software function. Same possible options as TP-DIST but with the
additional options Predictive cruise control (I-See) and
crawler gears.
Intended for heavy transports. Driveability and comfort

are optimised for heavy weights with Heavy Duty GCW
Heavy duty transport
TP-HD (Gross Combination Weight) Control. Can be deselected
software
for lighter loads to improve fuel consumption. Same
possible options as TP-LONG.
Software package functions

S = Standard
O = Optional
Function TP-BAS TP-DIST TP-CON TP-LONG TP- HD
Basic gear shifting strategy AMSO-BAS S S S S S
Basic power take-off function APF-BAS S S S S S
Basic performance function AVO-BAS S S – S S
Launch control – S S S S
Enhanced shift strategy – S S S S
Free wheel (I-Roll) – – – S S
Heavy duty GCW control – – – – S
Optional function
Enhanced gear selection adjustment

– O O O O
AMSO-AUT
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Enhanced power take-off function APF-ENH – O O O O
Enhanced performance – bad roads

– O S O O
AVO-ENH
Crawler gears ASO-C / ULC – – O O O
Multi speed reverse ARSO-MSR – – O O O
Predictive cruise control (I-See) – – – O O
Gear Selection Adjustment, AMSO-BAS, AMSO-AUT

AMSO-BAS:
Possible to select gears in Manual mode.
Possible to change start gear in Automatic mode.
AMSO-AUT:
All functions in AMSO-BAS and:
Possible to select gears when driving in Automatic mode.
Kick-down.
Power Take-Off, APF-BAS, APF-ENH

APF-BAS
Basic PTO facilitates Power Take-Off operation. Predefined splitter gear positions determine which
splitter gear is used when one or two gearbox Power Take-Offs are engaged. No customer
parameters are available.
APF-ENH
Several functions that aid Power Take-Off operation. gearbox (I-Shift) Power Take-Off functions
make it possible to activate properties by having the customer parameters adjusted at an authorized
workshop. Some of the key properties are:
● Auto Neutral
● Reverse Inhibit
● Connection of splitter box
See Volvo body builder instructions (VBI) for more details.
Performance mode options, AVO-BAS, AVO-ENH

There are two performance mode options, AVO-BAS and AVO-ENH
AVO-BAS
Toggle between E (Economy mode) and P (Performance mode) by pressing the P button on the gear
lever. Performance focus on higher power output from the engine.
AVO-ENH
Same as AVO-BAS with the addition of P+. P+ is adapted to poor driving surfaces and hilly conditions
by implementing higher engine speed and fewer gear changes. Also facilitates pulling away in poor
driving conditions. Toggle between E (Economy mode), P (Performance mode) and P+ (Enhanced
performance mode) by pressing the E/P button on the gear lever.
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Launch Control
Full functionality with Launch Control requires EBS.
Launch Control entails:
● Idle speed driving
● Faster change of direction between forward and reverse, using the EBS system
● Smart Hill Start Aid
Low speed manoeuvring makes it possible to drive the vehicle forward with the idle control.
AMSO-AUT allows vehicle speed adjustment by changing gear using the +/- switch on the gear lever,
for instance when driving in traffic queues.
The Smart Hill Start Aid function is only activated on inclines and uses EBS to hold the vehicle until it
pulls away.
Enhanced shift strategy

Enhanced shift strategy includes a brake function that maximises auxiliary brake power by
automatically selecting the appropriate gear. This may entail a downshift.
When changing gear during engine braking, the service brakes are activated to compensate for loss
of auxiliary brake torque when the clutch is disengaged.
When the air suspension is set in manual mode for height adjustment, starting gear 1, C2 or C, if
available, is selected automatically for slow and smooth manoeuvring.
Free wheel (I-Roll)

Free wheel (I-Roll) (requires VEB/VEB+ or retarder).
Automatic engagement and disengagement of the Free wheel function, when the auxiliary brake lever
is in A position, for the purpose of reducing fuel consumption.
When the accelerator pedal is released and road decline allows the truck to maintain almost constant
speed, the driveline is disconnected so that the vehicle can roll freely, and the engine is idling.
Heavy Duty GCW Control

The Heavy Duty GCW Control optimises gear selection for high gross combination weights (GCW >
85 t). Heavy Duty GCW Control enables the HD (Heavy Duty) driving mode. In HD mode, 1st gear or
crawler gear is used as the starting gear and gear selection is adapted to heavier gross combination
weights. The gear shifts generally occur at higher engine speeds. HD is activated by pressing and
holding the E/P button on the gear selector for about 3 seconds; a short press is enough to
deactivate. If HD is selected when the engine is not running, it will be applied at the next engine start.
When driving with low gross combination weights or without a load, it is recommended to return to
Economy mode.
Crawler gears ASO-C, ASO-ULC

There are two Crawler gear options:
● ASO-C (crawler) with one Crawler gear (C)
● ASO-ULC (Ultra Low Crawler) with two Crawler gears (C1 and C2)
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The Crawler gears are used, both in automatic and manual mode, for good pulling away capability
and low speed manoeuvrability. As crawler gears extend the total gear ratio, it is possible to use a
fast rear axle for good fuel economy and retain good pulling away capability with heavy loads. The
input shaft on ASO-C and ASO-ULC in the direct drive gearboxes is the same. Therefore upgrading
from ASO-C to ASO-ULC is possible with a software update using Tech Tool. The overdrive
gearboxes cannot be upgraded using a software update because a different gearwheel and input
shaft set is needed. For more information, see the input shaft section in chapter "Shaft, gear wheels
and engaging sleeves" in the Gearbox, mechanical component description.
Multi Speed Reverse ARSO-MSR

The MSR (Multi Speed Reverse) is an optional function with ASO-C or ASO-ULC and is installed
using Tech Tool. MSR provides two extra reverse gears (6 reverse gear in total) in order to handle
slow and fast reverse speeds. With these additional reverse gears, the lowest gear is lower and the
step between low and high range is smaller compared to gearboxes without MSR. This provides
better pulling away capability for reversing and improves the likelihood of finding the optimal gear
ratio. It is not possible to change between high and low range while reversing. Pulling away in high
range gear is facilitated by a crawler gear in high range.
Predictive Cruise Control (I-See)

Predictive Cruise Control (I-See) is a set of fuel saving functions. The system uses stored information
about approaching road topography to select gear shifting strategy, engine torque and vehicle speed
for enhanced driving comfort and fuel efficiency.
See Predictive Cruise Control (I-See), function description.
Gear selection
Gear selection in automatic mode
TECU calculates which gear to engage on the basis of the below criteria:
● speed of gearbox shafts and gears
● clutch status
● engine speed
● engine torque
● vehicle speed
● vehicle weight
● vehicle inclination
● accelerator pedal status
● gear selector status
● driver settings
The TECU may omit one or several gears during both up- and downshifting. The driver can manually
prevent an up shift by pressing the gear step (-) or hold button, and a down shift by pressing the gear
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step (+) or hold button. The most appropriate starting gear is always selected when entering
automatic mode (A).
Gear selection in manual mode

More gears are available in manual mode than in automatic mode. The available gears are shown by
up and down arrows in the display.
If the engine speed becomes too low, the clutch disengages to prevent stalling.
When moving the gear shift lever from automatic (A) to manual (M), the automatically selected gear
remains. The gear is "locked". When moving the gear shift lever from neutral (N) to manual (M) with
the gear step (+) button pressed and when the vehicle is moving, a gear resulting in a low engine
speed is selected. When moving the gear shift lever from neutral (N) to manual gear selection mode
(M) with the gear step (-) button pressed and when the vehicle is moving, the lowest possible gear for
high mobility is selected.
Note
The TECU determines the available gears and shows them with up (^) or down (v) arrows in
the instrument panel. The gears are changed using gear step button (+/-).
Note
The vehicle must be stationary to change between the low and high range reverse gears.
Start gear selection

The start gear selection is a compromise between high comfort and low clutch wear. To obtain high
comfort and fewer gear shifts, a high start gear is normally selected. To cause as little clutch wear as
possible, a low start gear is selected. The start gear can be one of the crawler gears or one of the
gears 1-6. The possible start gears can be limited by customer parameters.
Automatic start gear selection

The choice of start gear depends on:
● Gross combination weight
● Road inclination
● Engine rating
● Driving mode
● Trailer just disconnected
● When the air suspension is set in manual mode for height adjustment.
It is also possible to manually change the start gear, up to 2 steps higher than the automatically
selected gear, when in automatic mode. The start gears that can be selected are one of the crawler
gears or one of the gears 1–6.
Manual start gear selection

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The start gear can be a crawler gear or one of the gears 1–6.
The available start gears may be limited by the load and other physical conditions. In this situation the
driver can select a start gear:
● up to 2 steps higher than the gear the TECU would have selected in automatic mode
● any step lower than the gear the TECU would have selected in automatic mode.
Gear selection in special driving condition and Limp home

Examples:
Change driving direction

When manoeuvring below 10 km/h, the driver can change direction from forwards to reverse simply
by changing the gear lever from forward (A or M) to reverse (R) or vice versa. The accelerator pedal
can be held down and there is no need to apply the brakes. Once the gear lever is changed, the EBS
automatically slows down the vehicle. When it is almost at a standstill, the TECU changes the gear to
change the direction of travel. When this gear is engaged, the engine delivers torque again.
Trailer disconnection/connection
After a trailer has been disconnected (electrically) from the tractor, the lowest start gear is engaged
until the truck has been driven forward a few metres in order to provide precise manoeuvring.
When the air suspension is set in manual mode for height adjustment, such as for marshalling, start
gear 1 is selected automatically to provide a slow and smooth start.
Overheated clutch
The TECU calculates the energy, in the form of heat, that is generated during clutch engagement and
disengagement. If the clutch overheats, a warning to protect the clutch is shown in the control panel.
If the accelerator pedal is pressed or other systems request pulling away, the clutch is engaged
smoothly but quickly, even if this causes the engine to stall.
If the clutch overheats when a crawler gear is engaged, the clutch disengages in order not to
overload the propeller shaft.
Limp home
If a major fault occurs in the gearbox, Limp home mode can be activated, allowing the truck to be
driven but with very limited functionality.
In Limp home mode only gears 1, 3 and 5 forward and 1 reverse are used. It is only possible to
change gear when the truck is stationary.
The Limp home mode is deactivated when the ignition is switched off.
Gear shifting
General
When shifting gear, the TECU controls the speed and torque of the engine. Details available in
TechTool test 43194.
The gear shifting sequence started by the TECU is:
● “Engine Torque Mode” signal is changed to value = 6.
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● Engine torque is limited.
● Clutch is disengaged.
● Engine and the gearbox speeds are controlled. At this point the VCB (Volvo Compression Brake)
may be used momentarily to reduce the engine speed, and the countershaft brake may be used
to reduce the gearbox speed, in order to facilitate rapid gear shifting.
● The shift forks are activated to implement the gear change.
● When the engine speed is almost the same as the input shaft speed the clutch starts to engage.
● The engine torque is applied again.
The use of VCB requires an engine temperature above 60°C.
Components involved
EBR-EPGC
Exhaust pressure governor with VCB
EBR-VEB
Volvo Engine Brake = EPG + VCB
EBR-VEB+
Volvo Engine Brake = EPG + VCB plus
VCB
Volvo Compression Brake
Countershaft brake
Parameters
Parameters
Customer parameters in the gearbox control unit:
Note
The default value can vary depending on the program package selected.
Parameter Caption Value Description
Split gear used when gearbox PTO 1 is engaged.

Low split has priority over high split if PTO 1 and
PTO 2 are both engaged and have conflicting (split
Split Gear for gearbox gear) settings.
P1A05 0-2
PTO 1 0 = Split selected by driver, low split as default
1 = use low split
2 = use high split
Split gear used when gearbox PTO 2 is engaged.

Low split has priority over high split if PTO 1 and
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PTO 2 are both engaged and have conflicting (split

Split Gear for gearbox gear) settings.
P1A06 0-2
PTO 2
0 = Split selected by driver, low split as default
1 = use low split
2 = use high split
Specifies if the clutch is used to disengage the

P1A07 Autoneutral via clutch 0-1
driveline during auto neutral.
The gearbox will automatically return to Economy

mode when the engine is no longer operating under
high load when set to auto.
Gearbox performance
P1AP3 0-2 0 = Manual
mode
1 = Auto
2 = Disable
Number of reverse
1-4 / RC,
P1ARH gears without MSR / Setting the numbers of reverse gears available.
R1-5
with MSR
Enables free wheel 0 = Free wheel (I-Roll) is always available.

(I-Roll) only when
P1FP2 0-1 1 = Free wheel (I-Roll) is only active when cruise
cruise control is
active control is active.
Start gear with

P1ISL 7-12 Specifies start gear for engaging the splitbox.
splitbox
Allows gear 12 with

FALSE / Specifies if it is allowed to use gear 12 or not on
P1ISM splitbox on an
TRUE overdrive gearbox when splitbox is active.
overdrive gearbox
0 = The selected start gear is not lowered during

ECS control mode.
Start gear depends
1 = The selected start gear is lowered during ECS
on ECS
control mode.
(Electronically
P1JZ7 0-2 2 = The selected start gear is lowered both during
controlled
suspension) manual and after ECS control mode. Use this setting to
control mode prevent starting in a high gear before the air
suspension has been raised from the bump stops
during manual control mode.
FALSE = Do not use Slope condition, allow Hill

Hill Start Aid Start Aid for both inclines and declines.
FALSE /
P1K8G auto-neutral Slope
TRUE TRUE = Use Slope condition, allow Hill Start Aid
condition
only for inclines.
Gear 12 splitbox Sets the maximum engine torque that can be used
P1KCL See VBI
torque limit in gear 12 splitbox.
If the torque protection function is enabled and the

Torque protection
P1KCM – torque from the engine exceeds this value, the
limit gearbox PTO
clutch will disengage.
Highest start gear in The start gear in manual mode is set equal to or
P1LCL 1-6
manual mode below this value.
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Highest start gear in The start gear in automatic mode is set equal to or
P1LCM 1-6
automatic mode below this value.
Related information
Component description
➠ Clutch, component description
➠ Gearbox, mechanical, component description
➠ Hydraulic retarder, component description
➠ APM, component description
Function description
➠ Predictive cruise control, function description
System descriptions
➠ Vehicle electronics overview, system description
➠ Air supply, system description
➠ Electronic brake system (EBS), system description
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Gearbox, Mechanical, Function Description

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IMPACT 4.07.

Publish date ID/Operation

Gearbox, mechanical, function description

Gearbox software packages

Gearbox, mechanical, function description

1 Instrument panel (A03)

2 HMIIOM (Human Machine Interface I/O Module) (A161)

3 VMCU (Vehicle Master Control Unit) (A187)

4 Steering wheel module (S275)

5A Gear selector switch module (S295)

5B GLU (Gear Lever Unit) (S171)

6 Sensor, accelerator pedal (B25)

1 ECM (Engine Control Module) (A14)

2 TECU (Transmission Electronic Control Unit) (A13A)

3 CCIOM (Centre Chassis I/O Module) (A163)

4 APM (Air Production Modulator) (A177)

5 EBS (Electronically controlled Brake System) (A21)

6 ACM (Aftertreatment Control Module) (A174/B)

8 CVU (Clutch Valve Unit)

9 Crawler gear housing (ASO-C and ACO-ULC only)

10 Valve unit, crawler gear

Dashboard centre display

R Reverse R1-R4 with MSR option RC, R1-R5

N Neutral (N1 low, N2 high)

A Automatic 1-12 and crawler gears C/C1, C2 (ASO-C/ULC only)

F Folded (GSS-AGS only)

H Hold the present gear (GSS-4BS only)

E+ Free wheel (I-Roll) possible

IS Predictive cruise control (I-See) possible

3 Driving mode P+ P+ is adapted for heavy construction

4 Available gears up or down (maximum three arrows) from current gear.

Gear selector, gear lever unit GSS-AGS

1 Gear step button (+/-).

2 Gear shift lever fold button.

3 Gear selector inhibitor.

4 Gear selector position:

Gear selector, shift buttons GSS-4BS

3 A = Automatic gear selection mode.

5 Gear step button (+/-) = Change gear up and down.

Auxiliary brake lever – brake mode

PTO (Power Take-Off)

Engaging driveline PTO

2 The TECU engages the PTO

3 The TECU engages the clutch

Disengaging driveline PTO

2 The TECU disengages the PTO

3 The TECU engages the clutch

Gearbox software packages

Adapts the functions to match the specific conditions in

Adapts the functions to the specific conditions in the

Intelligent functions that minimise fuel consumption. Ideal

Intended for heavy transports. Driveability and comfort

Software package functions

Function TP-BAS TP-DIST TP-CON TP-LONG TP- HD

Basic gear shifting strategy AMSO-BAS S S S S S

Basic power take-off function APF-BAS S S S S S

Basic performance function AVO-BAS S S – S S

Enhanced shift strategy – S S S S

Free wheel (I-Roll) – – – S S

Heavy duty GCW control – – – – S

Enhanced gear selection adjustment

Enhanced power take-off function APF-ENH – O O O O

Enhanced performance – bad roads