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431–03
Repair Manual
152 pgs11.02 Mb0

Volvo 431–03 Service Manual

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Page 1
ServiceBulletin
VolvoTrucksNorthAmerica
Greensboro,NCUSA
Transmission,DesignandFunction
Trucks
DateGroupNo.ReleasePage
4.2010
43103
DesignandFunction
I-ShiftTransmission
1(38 )
T4021207
TheI-Shifttransmissionisatechnologicallyadvancedautomatedmechanicaltransmission, designedspecicallytoworkinconjunctionwithVolvo’snewfamilyofheavy-dutydiesel engines.Inordertoworkasatotalpackage,theI-Shiftisprogrammedwitheachengines’ efciencymapandisofferedwithdifferentsoftwareoptionstofullleachoperatorsneeds.
•“Transmission,Mechanical”,page2
PV776-88949834
USA39152
Page 2
VolvoTrucksNorthAmerica ServiceBulletin
Transmission,Mechanical
General
AllvariantsoftheVolvoI-Shifthave12forwardspeeds andupto4reversespeedsdependingonprogramming. Itisasinglecountershafttransmissionbuiltupwitha splittersection,amainsectionwiththreeforwardandone reversegear,andarangegearsection.Itisanautomated mechanicaltransmissionandusessynchronizersinits splitterandrangegearsbutnotinthemainsection.The mainsectionutilizesacountershaftbraketomeshgears andequalizeshaftspeedsasneeded.Asingledisc automatedclutchsystemisutilizedinplaceofatorque converter.TheI-Shiftisa"twopedal"transmissionand doesnotrequireaclutchpedal.
TheI-Shiftusescompressedairandelectricalsolenoids toperformshiftfunctions,clutchcontrolandcountershaft
Date
4.2010
brakefunctions.Allofthesefunctionsaretimedand controlledbythetransmissioncontrolmodule(TCM).A dedicatedairtankisneededonthevehicletosupplyairfor thesecomponents.Theairisplumbedtothetransmission viaasupplylineandisdistributedtotheothercomponents internally.Theaircontrolsolenoidsarehousedinthe transmissioncontrolhousingandintheclutchcontrolvalve assembly.
AllVolvoTruckmodelswillbeavailablewiththis transmissionincludingtheVT ,VNSeries&VHDvocational trucks.MultipleI-Shiftmodelswillbeofferedtosupportthe powerrangesoftheenginesaswellasofferingdifferent geararrangements.
Group
43103
No.Release
Page
2( 38 )
AT2512CATO2512CAT2812CATO3112C
Operation
ForwardSpeeds
EnginesAvailable
OverallRatio
TopRatioDirect1.00:1
Weightlbs(kg)597(275)597(275)610(281)610(281)
Operation
ForwardSpeeds
EnginesAvailable
OverallRatio
TopRatioDirect1.00:1
Weightlbs(kg)614(279)614(279)627(285)
TwoPedalTwoPedalTwoPedalTwoPedal
12121212
D11/D13D11/D13
14.94:115.04:114.94:115.04:1
Overdrive0.78:1
AT2612D
TwoPedalTwoPedalTwoPedal
121212
D11/D13D11/D13
14.94:115.04:115.04:1
ATO2612DATO3112D
Overdrive0.78:1Overdrive0.78:1
D16D16
Direct1.00:1
Overdrive0.78:1
D16
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VolvoTrucksNorthAmerica ServiceBulletin
TransmissionIdentication
Eachtransmissionhastwoidenticationtags.Oneisfound onthetopoftheclutchhousingandtheotherisfoundonthe
MakeVolvo
Type
Transmission NomenclatureA—Automatic
AT2512C,ATO2512C,AT2612D,ATO2612D,AT2812C,ATO3112C,andATO31 12D
T—Transmission O—Overdrive 25—TorqueCapacity2500Nm(1850ft-lb) 26—TorqueCapacity2600Nm(1900ft-lb) 28—TorqueCapacity2800Nm(2050ft-lb) 31—TorqueCapacity3100Nm(2300ft-lb) 12—Numberofforwardgears CorD—DesignLevel
Date
4.2010
backoftherangehousing.Thetransmissionversioncan bereadilyidentiedbythefollowingnomenclaturetable.
Group
43103
No.Release
Page
3( 38 )
GearRatio
GearratiosforAT2512C,A T2612D,AT2812C,ATO2512C, ATO2612D,ATO31 12C,andATO31 12Dareasshownin thetable:
12gearedAT2512C,A T2612D,
Gearselection
1st
2nd
3rd
4th
5th
6th
7th3.44:12.70:1
8th2.70:12.12:1
9th2.08:11.63:1
10th1.63:11.28:1
11th1.27:11.00:1
12th1.00:10.78:1
ReversegearR1
ReversegearR2
ReversegearR3
ReversegearR4
AT2812C
14.94:111.73:1
11.73:19.21:1
9.04:17.09:1
7.09:15.57:1
5.54:14.35:1
4.35:13.41:1
17.48:113.73:1
13.73:110.78:1
4.02:13.16:1
3.16:12.48:1
12gearedATO2512C,ATO2612D, ATO3112C,ATO3112D
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VolvoTrucksNorthAmerica ServiceBulletin
TransmissionConstruction
Thetransmissionhasthreemainparts:aclutchhousing, mainhousingandrangehousing.Theclutchhousing(1) alsoformsthefrontwallofthetransmissionhousing.The mainhousing(2)containsthemain,counterandreverse
Date
4.2010
shaftsalongwiththeselectorassemblywhichisintegrated intothetransmissioncontrolhousing.Therangehousing (3)containstherangeplanetarygearassemblyandoutput shaft.
Group
43103
No.Release
Page
4( 38 )
1Clutchhousing
2Mainhousing
3Rangehousing
W4002905
Page 5
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
5( 38 )
Themaininternalpartsinthetransmissionaretheinput shaft(1),mainshaft(2),rangegearwithselectorunit(3), countershaft(4),oilpumpwithreverseshaft(5),control housingwithselectorunit(6)andifequipped,apower takeoff(PTO)driveshaft(7).
Thetrailingwheelforthereversegear,themaingearsand therangesectionssungeararelocatedonthemainshaft. Therangesectionalsoincorporatesplanetarygearsthat areintegratedwiththeoutputshaft.Thecountershafthas xedgears.
1Inputshaft
2Mainshaft
3Rangegearwithselectorunit
4Countershaft
5Oilpumpwithreverseshaft
6Controlhousingwithselectorunit
7DriveshaftforPTO
T4021728
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VolvoTrucksNorthAmerica ServiceBulletin
Synchronization
•Thesplitgear(A)issynchronized.
•Themaintransmissionhousinggears(B)are
non—synchronized,butinsteadutilizeacountershaft braketoequalizeshaftspeedsandmeshthegears.For moreinformationsee,
page11.
•Therangegear(C)issynchronized.
Date
4.2010
Group
43103
No.Release
Page
6( 38 )
T4021404
RangeGear
Therangegearssynchronizationliesoutsidetheringgear, reducingtheunit’slength.Thelargesynchronizationarea resultsinshortselectiontime;thewideplanetarygearsoffer strengthandthehelicalgearsresultinaquietplanetary gearoperation.
Rangegearassemblywithselectorunit
W4002906
Page 7
VolvoTrucksNorthAmerica ServiceBulletin
ControlHousingAssembly
Thecontrolhousingassemblycontainsthetransmission controlmodule(TCM),shiftsolenoids,countershaftbrake solenoid,gearpositionsensors,oiltemperaturesensor, shaftspeedsensors,theshiftforksandtheirshiftcylinders. Whenagearisselectedusingthegearselector,these componentsworkinconjunctionwiththeenginecontrol module(ECM)toreducetheenginetorquetoasuitable level,beforethecontrolhousingshiftsthetransmissionto neutralandthentotheselectedgear.Thesolenoidsare usedtocontrolpressurizedairtocylinders,thatperform theactionofchangingthegears.Thecontrolhousingalso containsandcontrolsthecountershaftbrakesolenoid.This solenoidcontrolsairpressuretothebrakeassemblywhich aidsinsynchronizingtheshaftspeedstomeshthemain gears.Afterthetransmissionhasbeenputintoneutral,the ECMbeginstoadjustenginespeed(RPM)toaccommodate theselectedgearaftertheshifttakesplace.
Date
4.2010
Group
43103
No.Release
W4002915
Page
7( 38 )
Thecontrolhousingcoverhastwoelectricalsockets andalsocontainstheTCM.
1Vehiclecommunication
2Clutchcylinder
W4002936
Page 8
VolvoTrucksNorthAmerica ServiceBulletin
Thecontrolhousingcovercontainsninesolenoid valvesthatcontrolthepathofpressurizedair:
2.
Solenoidvalve2ndgear
LR.
Solenoidvalve,lowrange
3.
Solenoidvalve3rdgear
HR.
Solenoidvalve,highrange
B.
Solenoidvalve,brake
LS.Solenoidvalve,lowsplit
R.
Solenoidvalve,reverse
HS.Solenoidvalve,highsplit
1.
Solenoidvalve1stgear
Page
8( 38 )
OverdriveTransmissions
Group
43103
No.Release
W4002918
Date
4.2010
2.
Solenoidvalve2ndgear
LR.
Solenoidvalve,lowrange
3.
Solenoidvalve3rdgear
HR.
Solenoidvalve,highrange
B.
Solenoidvalve,brake
HS.Solenoidvalve,highsplit
R.
Solenoidvalve,reverse
LS.Solenoidvalve,lowsplit
1.
Solenoidvalve1stgear
T4018189
DirectDriveTranmission
Page 9
VolvoTrucksNorthAmerica ServiceBulletin
Thefollowingshowsthelocationsofthefourparallel cylindersandoneofthecylinderpositionsensors.
A.Splitcylinder
B.1/Rcylinder
C.2/3cylinder
D.Rangecylinder
E.Splitcylinderpositionsensor
Date
4.2010
Group
43103
No.Release
Page
9( 38 )
T4018494
Thefollowingshowsthelocationsoftheotherthree cylinderpositionsensorsandthespeedsensors.
A.Rangecylinderpositionsensor
B.Countershaftspeedsensor
C.Mainshaftspeedsensor
D.2nd/3rdgearcylinderpositionsensor
E.1st/reversecylinderpositionsensor
T4018201
Page 10
VolvoTrucksNorthAmerica ServiceBulletin
Thefollowingshowsthelocationsoftheotherthree shiftforks.
1.1st-Reversegearshiftfork
2.2nd-3rdgearshiftfork
3.Splittergearshiftfork
Date
4.2010
Group
43103
No.Release
W4002920
Page
10( 38 )
Page 11
VolvoTrucksNorthAmerica ServiceBulletin
CountershaftBrake
Thecountershaftbrakeislocatedatthefrontofthe countershaftwithintheclutchhousing.Itisusedtostop therotatingpartsinthetransmissionwhenastartinggear isselected,whicheliminatestransmissionwearandnoise. Thebrakeisalsousedwhenchanginggears,toaidin synchronizingtheshaftspeedsforquickergearchanges.It isactivatedbyasolenoidcontainedinthecontrolhousing. Thesolenoidcontrolspressurizedairowtothebrakes integratedpneumaticcylinderwhichappliespressureto frictionandsteeldiscplates.
Date
4.2010
Group
43103
No.Release
Page
11( 38 )
Countershaftbrakelocation
Countershaftbrakediscs
T4021408
T4022010
Page 12
VolvoTrucksNorthAmerica ServiceBulletin
Clutch
AllI-Shiftequippedvehicleshaveasingledisc,drytype clutch.Thepressureplateusedinthevehicleswillvary dependingontheenginethatthevehicleisbuiltwith. VehiclesequippedwiththeD11orD13engines,willuse anonadjustablepressureplatewhiletheD16equipped vehicleswilluseaselfadjustingpressureplate.Dueto theselfadjustingnatureoftheD16’spressureplate,it’s necessarytocagetheadjustingsystempriortopressure plateremoval.Theadjustercannotberesetifnotcaged properly.Allclutchandpressureplatesarereplacedin matchedsets. TheI-Shiftclutchisfullyautomatedandisactuatedbya clutchcylindermountedbehindthepressureplate.This automationincludesclutchprotectionthatisprogrammed intothetransmissioncontrolmodule(TCM)software.Ifa vehicleisheldstationaryonagradeusingtheaccelerator ortoohighgearisselectedwhichallowsexcessiveclutch slippageorload,a“clutchprotectionactive”warningor“high clutchload”warningwillappearinthedriverinformation display(DID)andanaudiblewarning.Ifthesewarnings areignoredtheclutchwillslowlyengagetoprotectthe clutch.Iftheacceleratorpedal(AP)isreleasedtheclutch willimmediatelydisengage.
Date
4.2010
Group
43103
No.Release
Page
12( 38 )
T4012799
ClutchCylinder
Theclutchcylinderislocatedinsidetheclutchhousing. Thisfullyautomatedcylinderencirclestheinputshaftand isresponsiblefortheactuationoftheclutch.Compressed airisusedtomovethecylinderasneededtoactuatethe clutch.Thepressurizedair,isregulatedbytheclutch controlvalvelocatedontheoutsideoftheclutchhousing. Theclutchcylinderalsohousesthereleasebearing.In situationswheretheI-Shiftisunintentionallyleftingear andtheparkingbrakehasbeenapplied,thetransmission controlmodule(TCM)willautomaticallygointoneutralafter aperiodoffourminutes.Thisprovidesprotectionagainst releasebearingdamageaswellascrankshaftthrust bearingwearanddamage. Aclutchcylinderpositionsensorismountedtotheoutside ofthecylinder.Itisusedtomonitorclutchpositionand clutchengagementpoint.Asasecondaryresponsibility itisusedtocalculateclutchwear.Therearetwoclutch positionreferencevaluesthatarenecessaryinmonitoring theclutch.
1X1Value—Thisisthebaselinevaluesetwhenevera
newclutchisinstalled.Thisisdoneusingthescantool byperformingthe“ClutchEngagementPointCalibration”.
T4021527
2X2V alue—Thisisthevaluethatrepresentsthepresent
positionoftheclutch.
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VolvoTrucksNorthAmerica ServiceBulletin
ClutchControlValve
Theclutchcontrolvalveislocatedontheoutsideofthe clutchhousing.Itcontrolsthesupplyofcompressedair totheclutchcylindertocontrolclutchengagementand disengagement.Thecontrolvalvecontainsfoursolenoid valves.Therearetwoengagementvalves,oneslowand onefast.Therearealsotwodisengagementvalves,one slowandonefast.Thesevalvescanbeusedaloneor togetherasneededtoachievethedesiredengagement ordisengagementspeed.Thevalvealsocontainsa serviceableltertopreventcontaminantsfromenteringthe clutchcylinderthroughtheairsupply.
Date
4.2010
Group
43103
No.Release
W4002898
Page
13( 38 )
Page 14
VolvoTrucksNorthAmerica ServiceBulletin
LubricationSystem
CAUTION
NeverreusedrainedI-Shiftoil.Theoilmustbereplaced alongwiththeoillter.Reusingdrainedoilcanresultin damagetotransmissioncomponents.
Thetransmissionislubricatedthroughacombinationof pressurefromanoilpumpandsplashing.Theoilisled
Date
4.2010
Group
43103
No.Release
Page
14( 38 )
intothemainshafttolubricateandcooltherangegears, theinputshaftandmainshaftbearings.Thecountershaft brakeandoutputshaftbearings,arealsolubricated.The lubricationsystemhastwooverowvalves.Onevalve ensuresthatthetransmissionislubricatediftheltergets blockedwhiletheotherpreventsexcessivepressureinthe system,e.g.duringcoldstart.Thevalvesaremadeupofa compressionspringandavalvepeg.
Overowvalvetoensurethatthetransmissionislubricated.
T4021401
T4021730
T4021729
Overowvalvetopreventexcessiveoilpressure.
Page 15
VolvoTrucksNorthAmerica ServiceBulletin
OilPump
Theoilpumpisaneccentricpump.Itisdrivenoffofthe reversegear.Theoilislteredbyacartridgestylelteron thepressuresideofthepump.
OilFilter
Thetransmissionoillterislocatedinalterhousingthatis boltedtotheoutsideofthemainhousing.Itisacartridge stylelter.Altersupporttubeisintegratedinthecoverto preventthelterfromcollapsing.Thetopportionofthe housingcontainstheinletandoutletportsfortheoilcooler lines.
Date
4.2010
Group
43103
No.Release
Page
15( 38 )
OilCooler
Thetransmissionoilcoolerisofaliquidtoliquiddesignand islocatedinsidethelowertankoftheradiator.Transmission oilispumpedtothecoolerwherethetransmissionoilcan transferitsheat,andthenbacktothetransmission.
W4002908
W4002917
W4002919
TransmissionCoolerInlet/OutletHousing
Page 16
VolvoTrucksNorthAmerica ServiceBulletin
OilLevel
Theoilisdrainedviaaplugatthebottom(1A)and/oraplug ontherightside(1B)ofthetransmission..
Note:Therearetwooildrainplugs.
Theoilllplug(3),isontherightside.Checktheoillevel throughthesightglass(2).
Date
4.2010
Group
No.Release
43103
1A.Drainplugatthebottomofthetransmission,1B.Drain
plugontherightsideofthetransmission,2.Sightglass,3.
Fillplugandlevel.
Page
16( 38 )
W4002904
Ventilation
FordesignlevelCtransmissions,caseventilationis providedviaahosethatpassesoverthecontrolhousing anddownbehindtheclutchcontrolvalveunit.Thevent ttinginthesideofthetransmissionisinstalledata45 degreeupwardangletopreventoilleakage.
T4021684
Sightglassforcheckingtheoillevel.
W4002937
Page 17
VolvoTrucksNorthAmerica ServiceBulletin
FordesignlevelDtransmissions,caseventilationis enhancedtoaddinternalcaseventing.Thisextendsoillife andmaintenanceintervals.
Date
4.2010
Group
43103
No.Release
W4054739
Page
17( 38 )
1.Pluggedvent.
1.Ventholes.
W4054740
Page 18
VolvoTrucksNorthAmerica ServiceBulletin
ElectricalSystem
SensorsandElectricalConnections
Date
4.2010
Group
43103
No.Release
Page
18( 38 )
1.Vehiclecommunication
2.Clutchcontrolvalve
3.Speedsensor
W4002910
W4002911
Wiringharnessconnector2totheclutchcontrol valve.
Generalwiringharnessrouting
W4002939
Page 19
VolvoTrucksNorthAmerica ServiceBulletin
PneumaticSystem
CompressedAirConnections
Compressedairisusedtoperformtheshifting,clutch disengagementandcountershaftbrakeengagement. Thecompressedairiscontrolledbysolenoidvalves.A dedicatedairtankmountedtotheframeisneededto supplytheairforthetransmission.Airissuppliedtothe
Date
4.2010
Group
43103
No.Release
transmissionviaasupplylinetotheleftsideofcontrol housing.Thetankispressurizedbytheenginemounted aircompressorandcontainsacheckvalve,topreventair pressureloseifaleakispresentinthemainairsystem.
Page
19( 38 )
W4002913
Compressedairconnectionbetweenthecontrolhousingand
theclutchcontrolvalve.
W4002938
Compressedairconnectionbetweenthetankandthecontrol
housing.
T4021417
Airconnectionbetweencontrolhousingandcountershaft
brake(hardline).Airconnectionfromtheclutchcontrolvalve
totheclutchcylinder(hose).
Page 20
VolvoTrucksNorthAmerica ServiceBulletin
PowerPath
Thefollowingillustrationsshowthepowerpathfor AT2512C,AT2612D,andAT2812C.
Date
4.2010
Group
43103
No.Release
Page
20( 38 )
T4021695
1stgear(planetarysectionengaged,lowrange)
2ndgear(planetarysectionengaged,lowrange)
T4021693
3rdgear(planetarysectionengaged,lowrange)
T4021696
4thgear(planetarysectionengaged,lowrange)
T4021694
5thgear(planetarysectionengaged,lowrange)
T4021697
Page 21
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
21( 38 )
6thgear(planetarysectionengaged,lowrange)
7thgear(directdrivethroughrangesection,highrange)
T4021698
9thgear(directdrivethroughrangesection,highrange)
T4021699
10thgear(directdrivethroughrangesection,highrange)
T4021701
T4021702
8thgear(directdrivethroughrangesection,highrange)
T4021700
11thgear(directdrivethroughrangesection,highrange)
T4021703
Page 22
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
22( 38 )
12thgear(directdrivethroughrangesection,highrange)
NeutralN1
T4021704
ReversegearR1(planetarysectionengaged,lowrange)
T4021691
ReversegearR2(planetarysectionengaged,lowrange)
T4021687
T4021688
NeutralN2
T4021692
ReversegearR3(directdrivethroughrangesection,high
range)
T4021689
Page 23
VolvoTrucksNorthAmerica ServiceBulletin
ReversegearR4(directdrivethroughrangesection,high
range)
Date
4.2010
T4021690
Group
43103
No.Release
Page
23( 38 )
Page 24
VolvoTrucksNorthAmerica ServiceBulletin
Thefollowingillustrationsshowthepowerpathfor ATO2512C,A TO2612D,ATO31 12C,andATO3112D.
Date
4.2010
Group
43103
No.Release
Page
24( 38 )
T4021713
1stgear(planetarysectionengaged,lowrange)
2ndgear(planetarysectionengaged,lowrange)
T4021711
T4021712
3rdgear(planetarysectionengaged,lowrange)
T4021714
4thgear(planetarysectionengaged,lowrange)
5thgear(planetarysectionengaged,lowrange)
T4021716
Page 25
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
25( 38 )
6thgear(planetarysectionengaged,lowrange)
7thgear(directdrivethroughrangesection,highrange)
T4021715
9thgear(directdrivethroughrangesection,highrange)
T4021717
10thgear(directdrivethroughrangesection,highrange)
T4021719
T4021720
8thgear(directdrivethroughrangesection,highrange)
T4021718
11thgear(directdrivethroughrangesection,highrange)
T4021721
Page 26
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
26( 38 )
12thgear(directdrivethroughrangesection,highrange)
NeutralN1
T4021722
ReversegearR1(planetarysectionengaged,lowrange)
T4021709
ReversegearR2(planetarysectionengaged,lowrange)
T4021705
T4021706
NeutralN2
T4021710
ReversegearR3(directdrivethroughrangesection,high
range)
T4021707
Page 27
VolvoTrucksNorthAmerica ServiceBulletin
ReversegearR4(directdrivethroughrangesection,high
range)
Date
4.2010
T4021708
Group
43103
No.Release
Page
27( 38 )
Page 28
VolvoTrucksNorthAmerica ServiceBulletin
VolvoEngineBrake
Note:ForbasicoperatorinformationabouttheVolvo enginebrake,refertotheOperator’sManual.
Volvo’senhancedenginebrake(I-VEB)isstandardwith I-Shifttransmissions.I-Shiftequippedvehicleswiththis systemoperatewithsomenewfeaturesthatarenow availableduetotheintegratedoperationofthetransmission controlmodule(TCM)andtheenginecontrolmodule (ECM).Thissharingofinformationandintegrationallows foramoreoptimizedenginebrakeperformance.The transmissioncannowdownshifttoincreasetheengine brakingeffect.Asthevehicleslows,thetransmissionmay downshifttokeepbrakingtorquehigh.AllI-Shiftequipped vehicleswillhaveanew6positionbrakestalk.Positions0, A,1,2,and3areofaxedorlockingswitchpositionwhile theBpositionisofamomentarytypeswitch.Thefollowing chartshowsthebrakingeffectineachbrakestalkposition.
Note:WhentheVolvoenginebrakeisactiveandthe transmissionisshiftinggear,therewillbeamomentary interruptionofthebrakingtorque.Thismayleadtoa temporaryincreaseofthespeed.
Date
4.2010
Group
43103
No.Release
Page
28( 38 )
StalkPositionPercentageofAvailableEngine
TorqueUsedForBraking
0(Off)0%
A
1
2
3
B
150%whentheservicebrakeisapplied.0–100%dependingonbrakecruise
request,andbrakingdemandtomaintainvehiclebrakecruisesetting
2+Downshiftsifnecessary
1
50%
40%
70%
100%
2
100%
T5012243
10I-VEBOff
2AAutomaticMode
31–3ManualModes
4BBrakePerformanceMode
Page 29
VolvoTrucksNorthAmerica ServiceBulletin
GearSelector
Note:Forbasicoperatorinformationaboutthegear selector,refertotheOperator’sManual.
Thegearselectorisattachedtothedriversseatandcan befoldedawaytoaidinenteringthecabin.Therearetwo availableselectorcongurations,abasicandapremium. Theselectorinthevehicleisdependantonwhichprogram packagelevelthevehicleisbuiltwith. BothselectorshavegearpositionsofR(Reverse),N (Neutral),D(Drive),andM(Manual).Withtheselectorin thedrivepositionthetransmissionwillshiftasanautomatic, performinggearselectionsandshiftingwithoutdriverinput. Wheninthemanualposition,thedrivereitherselectsthe gearsusingthegearselectorbutton(premiumselector)or willlockthegearthatthetransmissionispresentlyoperating inandholdthatgearuntiltheselectorisplacedinthedrive positionagain(basicselector).Withthebasicselector ,ifthe manualpositionisengagedatastopthevehiclewillstartin rstandholdthatgear.Thebasicselectorisn’tequipped withagearselectorbuttonoraeconomy/performancedrive modebutton. InsituationswheretheI-Shiftisunintentionallyleftingear withtheparkingbrakeapplied,thetransmissioncontrol module(TCM)willautomaticallygotoneutralwhenthe ignitionkeyisturnedtoOFFposition.Thisisdonetoavoid thetransmissiongettingstuckingearduetodriveline “torqueup”. Thereisagearselectorcontrolmodule(GSCM)thatis locatedinthedashboard.TheGSCMreceivessignalsfrom theselectorandinterpretsthesesignalsintocommunication informationthatistransmittedtotheTCM.
Date
4.2010
Group
No.Release
43103
1GearLever
2Economy/PerformanceDriveModeSelectButton
3GearSelectorLock
4GearSelectorButton
5LeverFoldButton
Page
29( 38 )
W4002922
SelectorFolding
Thegearselectoriscapableoffoldingforwardtoaidin cabentryandisalsousedtoidentifywhichsoftwarelevel thatisprogramintheTCM.Withtheselectorintheneutral position(N)pressinthefoldbuttonandthelevercanbe foldedforward.Thedisplaywillthenshowtheprogram packagelevelinplaceofthedrivingmode.Thisisfound justtotherightofthepresentgearwithinthedisplay.
W4002855
FoldingtheSelector
Page 30
VolvoTrucksNorthAmerica ServiceBulletin
LimpHomeMode
Note:LimpHomeModeshouldonlybeusedtogeta
vehicletoasafeorsecurelocation.Itisnotmeantfor drivinganydistance.
Attimeswhenamajorsensorfailureorinternaltransmission damagehasoccurred,“LimpHomeMode”canbeactivated. PressandholdtheLbuttononthegearselectorwhile movingthegearlevertotheDpositiontoactive“Limp HomeMode”.Whenactivated,Lisdisplayedasthedriving modeinthedriverinformationdisplay(DID).In“LimpHome Mode”,onlyforwardgears1,3and5areavailablefor vehicleswiththepremiumselectorandonlyrstgearfor vehicleswiththebasicselector.Nomatterwhichselector thevehiclehas,reversegear1isavailablealso.The vehiclemustbestationarytoshiftgears.The“LimpHome Mode”,willbedeactivatedwhentheignitionkeyisturned toOFFposition.Thismodeisonlymeanttogetavehicle toasafeorsecurelocation.Itisnotmeantfordrivingany typeofdistance.
Date
4.2010
Group
43103
LimpHomeModeButton
No.Release
Page
30( 38 )
W4002856
DriverInformationDisplay(DID)
Note:ForbasicoperatorinformationabouttheDID,referto theOperator’sManual.
TheDIDintheinstrumentclusterprovidescurrentoperating information.
W4002916
1GearSelectorPattern
2GearRange
3AvailableGears(down)
4CurrentGear
5AvailableGears(up)
6DrivingMode(programpackagelevelwithshift
leverinfoldedposition)
Page 31
VolvoTrucksNorthAmerica ServiceBulletin
ProgrammingandFeatures
I-ShiftHillStartAssist
DANGER
HillStartAssistisonlyintendedtotemporarilyholdthe vehicleonagradeduringavehiclelaunch.Thevehicle brakemustbeapplied,independentofHillStartAssist, toholdthevehicleonagradeforanextendedperiodof time.Failuretofollowthisinstructioncanresultinlossof vehiclecontrolandseriouspersonalinjuryordeath.
Note:ForbasicoperatorinformationabouttheHillStart Assistfeature,refertotheOperator’sManual.
TheVolvoI-ShiftHillStartAssistfeature(option),provides theoperatorwithanti-rollbackassistanceduringvehicle launchonahill.HillStartAssistworksbyapplyingthe vehiclesbrakeswheninaforwardgearandstartingonan incline,orinareversegearwhenstartingonadecline. Whenenabled,itautomaticallyactivateswhenallofthe followingconditionsaremet:
•IgnitionkeyintheRUNpositionandtheenginespeed
(RPM)ispresent
Date
4.2010
Activationofthesystemistriggeredbythereleaseof theservicebrakepedal.Onceactivated,brakechamber pressureismaintainedforuptothreesecondsoruntil positivetorqueisidentiedinthedriveline(whichever occursrst).Whenactive,thedriverinformationdisplay (DID)willread“HillStartAssistActive”toalerttheoperator ofthefunction. HillStartAssistalwaysdefaultstotheonpositionupon vehiclestartup.Amomentaryswitchislocatedonthedash fortemporarydeactivationofthefeaturebut,willre-enable ifthevehiclebeginsanotherdrivecycle,themomentary switchisdepressedagainorthevehicleexceeds20km/h (12mph).Whentemporarilydisabled,theHillStartAssist telltaleintheinstrumentclusterwillblink.Thistelltaleisalso usedtoalertthedriverofapermanentlydisabledsystem, butthetelltalewillbesolidlyilluminatedinthisinstance.
Thefollowingcomponentsareresponsibleforoperating thisfeature:
Group
43103
No.Release
•HillStartAssistmomentaryswitch
•VehicleElectronicControlUnit(VehicleECU)
Page
31( 38 )
•andthevehiclespeedisequalto0km/h(0mph)
•andvehicleisinaforwardgearonaninclineequaltoor
greaterthen2%,orinareversegearonadeclineequal toorgreaterthen2%
•andtheservicebrakeapplied
•andtheHillStartAssistdisableswitchisnotselected
•andnofailureswithexpectedSAEJ1939datalink
communicationsarepresent
•andthefunctionisnotinadowngradedmode.
Functioninadowngradedmode:
•Whenanexistingfaultorlossofinformationfromother
necessarycontrolmodulessuchasthetransmission controlmodule(TCM)andtheanti-lockbrakesystem controlmodule(ABS).
•Anotherdowngradedmodewouldbeifbrakingwith
activeABS,automatictractioncontrol(ATC)orelectronic stabilityprogram(ESP)isdetected.
•SolenoidstotheABS
Thefollowingcomponentsareusedtosupporttheoperation ofthisfeaturewithinputtotheVehicleECU:
•TCM
•BrakeControlUnit(ABS)
Page 32
VolvoTrucksNorthAmerica ServiceBulletin
ProgramPackages
Note:Forbasicoperatorinformationabouttheprogram
packagesandtherefunctions,refertotheOperator’s Manual.
AsidefromtheI-Shiftbeingprogrammedtocompliment theenginescharacteristics,itisavailablewithdifferent optionalprogrampackages.Thesepackagesofferexibility totailorthetrucktospecicapplicationsoroperator needs.Thetransmissionhasdifferentcharacteristicsor features,dependingonwhichprogrampackagesoftwareis installedinthetransmissioncontrolmodule(TCM).Itisalso dependantonwhichfeaturesareactivewithinthepackage. Somefeatureswithinagivenpackagecanbedeactivated tofurthertailorthesystemifdesired.Thefollowingprogram packagesareavailable.
•Basic
•EnhancedBasic
•Performance
Date
4.2010
Group
43103
No.Release
Page
32( 38 )
•FuelEconomy
•Comprehensive
•Gentle
ProgramPackageIdentication
Toidentifywhichsoftwarelevelthetransmissioncontrol module(TCM)isprogramwith,movethegearselector tothefoldedposition.Withtheselectorintheneutral(N) position,pressinthefoldbuttonandthelevercanbefolded forward.TheDriver’sInformationDisplay(DID)thenshows thesoftwarevariant.
SoftwareVariantDisplay Terms
BBasic
EBEnhancedBasic
P
FEFuelEconomy
COComprehensive
GGentle
ProgramPackages
Performance
ReplacingtheProgramPackage
Whenaprogrampackageisreplaced,anupdateofthe “VehicleDataAdministration(VDA)”,mustbeperformed beforeitcanbedownloadedintothevehicle.Thisisdone byenteringtheappropriate“ConversionKitNumber”into
thescantool.Formoreinformationreferto,“VCADSPRO ConversionKitandAccessoryKitNumbers”infunction group0.Aftercompletionoftheconversion,reprogramming oftheTCM(MID130)mustbecarriedout.
Page 33
VolvoTrucksNorthAmerica ServiceBulletin
PackageFeatures
Programpackagesaremadeupofdifferentfeatures. Somefeaturesarestandardandsomeareoptionalwithin aprogrampackage.Notallfeaturesmaybeactivewithin agivenpackageandsomeparametershaveadjustable values.Thisallowstheoperatorexibilitytotailorthe
Date
4.2010
Group
43103
No.Release
Page
33( 38 )
packagetotheirspecicneedsorliking.Formore informationaboutthesefeaturesandparametersreferto “ParameterProgramming”,foundinfunctiongroup1inthe scantool.
FeaturesBasic
Enhanced
Basic
Fuel
Economy
Perfor­mance
ComprehensiveGentle
AutomaticGear ShiftinginDrive
XXXXXX
Mode
ManualGear ShiftinginDrive
XXX
Mode
ManualGear ShiftinginManual
HoldOnlyHoldOnlyHoldOnly
XXX
Mode
ManualSelectionof StartGear
IdleGovernor DrivingMode
XXXXX
XXX
EconomyModeXXXXXX
PerformanceMode
Kick-DownX
1
Eco-RollX
ExtraEngineBrake PerformanceMode
Dynamometer Mode
StandardPTO Features
EnhancedPTO Features
1Featurecanbeenabledordisabledpercustomerpreference
2Limitedfunctionality.
2
X
XXXXX
XXXXXX
XXXXXX
OptionalOptionalOptionalOptionalOptionalOptional
1
X
1
X
1
1
X
1
X
1
X
1
X
1
X
1
X
1
X
1
Page 34
VolvoTrucksNorthAmerica ServiceBulletin
FeatureDescriptionandFunction
•AutomaticGearShiftinginDriveMode
Thismodeisthedefaultmodeandshouldbeused inmostdrivingsituations.Whennecessaryorable, thisautomatedmodewilltakefulladvantageofother I-ShiftfeatureswhetheritsEngineBraking,Eco-Roll, Kick-Down,PerformanceModeorEconomyMode.The startinggearwillbeselectedbasedontheenginepower rating,loadandslopeoftheroad.T ypicallythestartgear is1or2withatrailerconnectedand4whenbob-tailing. Thetransmissionwillperformallgearchangesto optimizefueleconomyorperformance,dependingon themodeselected.
•ManualShiftinginDriveandManualMode
Thedrivercanmanuallyselectgearsusingtheup/down buttonslocatedonthehandleofthepremiumselector. Thedriverinformationdisplay(DID)willindicatehow manyup/downgearsareavailablebythemeansof up/downarrows.
•ManualSelectionofStartingGear
In"Manualmode"thedrivercanselectstartinggears withintherangefrom1-6withouttrailerand1–3witha trailerconnected.In“DriveMode”thestartinggearwill beselectedbasedontheenginepowerratingandslope oftheroad.However ,thedrivercanadjusttheselected gearbyuptotwogearsabovethecalculatedaslongas itdoesnotexceed"Highestavailablestartgear".The highestavailablestartgearisacustomerprogrammable parameterintherangefrom1-6withadefaultvalueof6.
•IdleGovernorDrivingMode
Theidledrivemodeallowsdrivingincongestedtrafc withouttheneedtoconstantlydepressorrelease theacceleratorpedal(AP).Thetransmissioncontrol module(TCM)fullyengagestheclutchandutilizes theenginecontrolmodule(ECM)tocontrolengine speed(RPM)bymeansoftheengineidlegovernor. Althoughtheengineloadmayvary,theidlegovernorwill adjustthetorquetomaintainidlespeedandconstant vehiclespeed.Sincetheclutchremainsfullyengaged iteliminateswearandoverheatingoftheclutch.In ordertoenabletheidle-drivemode,thevehiclespeed isincreasedtoadesiredgearandthenthepedalisfully released.T ypicallytherearetwomethodsofselecting aloweridle-driverspeed.Thiscanbeaccomplished bydepressingthedown-arrowonthegearleverorby slightlyapplyingtheservicebrake.Bothwillcausethe transmissiontodownshifttoalowergear.
Date
4.2010
Group
43103
No.Release
•EconomyMode
Whenthekeyswitchisturnedon,thetransmissionisin Economymode.AnEisdisplayedasthedrivingmode intheDID.Thetransmissionautomaticallyselectsshift pointsandengineparameterstooptimizefueleconomy. Economymodeshouldbeusedastheprimarydriving modeundernormalconditions.
•PerformanceMode
InPerformancemode,aPisdisplayedasthedriving modeintheDID.Thetransmissionstrategychanges tooptimizegradeability.TheTCMisable(basedon customerparameters)torevertbacktoEconomyMode ifitdeterminesthatPerformanceModeisnolonger necessary.
•Kick-Down
ThisfeatureisactivatedbydepressingtheAPallthe waytotheoor,thusdepressingthekickdownswitch locatedontheAPassembly.Thesystemchangesthe gearselectionstrategytomaximizevehicleacceleration. Typicallythisresultsinanimmediategeardownshift. Insomesituationsdependingontheavailableengine power,theTCMwillnotdownshift.Thekick-downis deactivatedoncetheAPislifted,thusreleasingthe kickdownswitch.
•Eco-Roll
Twoversionsofthisfeatureexist.Thebasicversionis activatedwhenthebrakestalkswitchisintheAposition whereasthesecondversionisactivatedwiththebrake stalkinthe0positionaswellastheApositions.This featureoptimizesthetopology(downgrades)byopening thedrivelineviathesplittergears,thuscontributingtofuel savings.Withthesplittergearsbeingsynchronizedthey areabletore-engageataninstantifthedrivertouches thebrake,AP,oriftheenginebrakeengages.Themain sectionofthetransmissionstaysingearduringthis free-rolling.ItoperateswhendrivingwiththeAPorwith thecruisecontrolset.Withthecruisecontrolsetandthe brakestalkintheAposition,ifthevehicleisfree-rolling andtheoverspeedsettingofthecruisecontrolismet, theenginebrakewillengageautomaticallytokeepthe vehicleatthedesiredmaxspeed.Whenengaged,an E+alongwiththetext“Eco-Roll”isdisplayedinthe drivingmodewindowaswellasanNinthecurrentgear windowwithintheDIDwhenthevehicleisfree-rolling. Thesecondversioniseasilyidentiedbyamomentary switchonthedashboard.Theswitchcanbeusedtoturn thefeatureoffbutthesystemdefaultstoonwhenever thevehicleisstarted.
Page
34( 38 )
Page 35
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
Page
35( 38 )
•ExtraEngineBrakePerformanceMode
TheEngineBrakePerformanceModeisactivatedby movingthe6-positionenginebrakestalkswitchtotheB position,whichisamomentaryswitchposition.When activated,Bisdrivingmodeinthedriversdisplay.When theExtraEngineBrakePerformancemodeisrequested, thetransmissionmonitorstheRPMsandhelpsthe engineprovidemaximumbrakingtorquebyautomatically selectingalowergear(s)inordertokeeptheengine speedashighaspossible.Thisfunctionisonlyavailable inthehighrangegears(7–12)andwillautomatically disableoncealowrangegearisattained.
•DynamometerMode
ADynamometermodeispartofallvehiclessoftwarefor timeswhenthevehicleisrunonadynamometer.The I-Shifttransmission,willnotupshiftifthefrontwheels arenotmovingatornearthesamespeedastherear wheels.Duetothis,whenonadynamometer,placethe gearselectorintheDpositionanddepresstheAPallthe waytotheoor.Thevehiclewillholditspresentgear for10secondatwhichtime,thedynamometermode willengageandthetransmissionwillbegintoshift.T o disengagedynamometermode,releasetheAP .When thetransmissionisoperatedinDynamometerMode,E^ isdisplayedasthedrivingmodeintheDID.
•EnhancedPTOFeatures
TheEnhancedPTOFunctionsoptionforI-Shiftmakeit possibletoactivatePTOfeaturesbysettingsoftware parameters.Thefollowinglistshowthefeaturesand requirethatabodybuildersmodule(BBM)isinstalledin thevehicle.
1GearSelectionadaptationtoRPMlimitsItis
possibletosetsoftwareparametersthatwilllimitthe RPMswhenengineortransmissionPTO(s)areused. Thisfeaturewilladaptthegearselectionstrategyto thesespeedlimitations.
2AutoNeutralThe“AutoNeutral”functionprovides
thetransmissiontheabilitytogotoneutralandback intogearbasedonanexternalinput(e.g.parking brakestatus),regardlessofthegearleverposition.
3ReverseInhibitThe“ReverseInhibit”function
providesnecessaryapplicationstheabilitytoblock thereversegeareventhoughtheoperatorhasmoved thegearlevertoreverse.
4SplitBoxEngagementTheuseofachassismounted
splitterboxforrunninghighcapacityPTO(s),is supportedbythesoftware.Thedirectgearisengaged whentheBodyBuilderModuleengagesthesplitbox.
•StandardPowerTakeoff(PTO)Features
TheBasicPTOFunctionisstandardwiththeI-Shift transmissionandisalwaysavailable.Predenedsplitter positionsareincludedintheBasicfunction.Itispossible tosetsoftwareparametersthatdenewhichsplitter geartoengagewhentransmissionPTO1and/or2are engaged.
Page 36
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
CommunicationWithOtherElectronicControlUnits(ECUs)
Summary,Components(signalsummary)
Group
43103
No.Release
Page
36( 38 )
W4055714
Page 37
VolvoTrucksNorthAmerica ServiceBulletin
Componentlist
SA0/MID128/ECM
MID223/GSCM
MID144/VehicleECU
MID140/Central
InstrumentCluster
Date
4.2010
MID
MID130/TCM
MID136/ABS
MID216/LCM
Component
A109
S171Gearselector
S08/S09Switch,differentiallock/wheellock
B13-20
S43CPressureSwitch,Trailerparkingbrake
Description
A14
ECM(enginecontrolmodule)
B04
Sensor,crankshaftposition(CKP)
Y39
Solenoidvalve,VCB(Volvocompressionbrake)
A13
TCM(transmissioncontrolmodule)
GSCM(gearselectorcontrolmodule)
A17
VehicleECU(vehicleelectroniccontrolunit)
Positionswitch,brakepedal
S59
B25
Sensor,acceleratorpedal(withkickdown)
B12
Sensor,outputshaftspeed(roadspeed)
Pressureswitch,parkingbrake
S43
S28Switch,powertakeoff
S25Stalkswitch,cruisecontrol
S24Stalkswitch,enginebrake
A3Instrumentcluster
A12
ABScontrolunit(anti-lockbrakesystemcontrolmodule)
Sensor,wheelspeed
A27
LCM(lampcontrolmodule),externallighting
Group
43103
No.Release
Page
37( 38 )
Page 38
VolvoTrucksNorthAmerica ServiceBulletin
Date
4.2010
Group
43103
No.Release
CommunicationwithEngineControlModule(ECM),SA0/MID128
Signals/information:
•Enginesignalssuchas;enginespeed(RPM)andtorque
monitoring
CommunicationwithGearSelectorControlModule(GSCM),MID223
Signals/information:
•Gearselectorinput
CommunicationwithVehicleECU,MID144
Signals/information:
•Acceleratorpedal(AP)position,including“kickdown”.
•Cruisecontrol.
•Powertakeoff(PTO)control
•Brakepedalstatus
•Parkingbrakestatus
Page
38( 38 )
•Enginebrakestalkswitch
•Hillstartassist(HSA)
CommunicationwithInstrumentClusterMID140
Signals/information:
•Gearselectordisplayinformation
•Driverinformationdisplay(DID)warnings
•Onboarddiagnosticstroublecodes(DTCs)fortheTCM
andGSCM
CommunicationwithAnti-LockBrakeSystem(ABS)ControlModule,MID136
Signals/information:
•Wheelspeedsensorinformation
•ABSstatusinformation
•Tractioncontrolstatusinformation
•Volvoenhancedstabilitytechnology(VEST)information
•Hillstartassist(HSA)
CommunicationwithLightingControlModule(LCM),MID216
Signals/information:
•Trailerparkingbrakeswitchstatus,(trailerconnected)
•Thetransmissioncontrolmodule(TCM)willselectthe
wrongstartinggearandwronggearsiftheparameterID “ANI”isnotenabled.SincetheTCMcannotdetectifa trailerisconnected,theTCMwilldefaulttothelowest possiblestartinggear.
•Reverselights(lightsareilluminatedoncethereverse
gearisphysicallyattained)
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