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I–Shift generation C
Design and function
FH, FM, FH16
AT2412C, AT2512C, AT2812C,
ATO2512C, ATO3112C
T4021207
88983778
ENG43273 English
Printed in Sweden
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 2(31)
Gearbox, mechanical
I-Shift, Generation C
Contents
• “ General”, page 3
• “ Gear ratio”, page 4
• “ Gearbox construction”, page 4
• “ Synchronisation”, page 6
• “ Range housing”, page 6
• “ Range gear”, page 6
• “ Emergency steering servo pump”, page 7
• “ Oil cooler”, page 7
• “ Control housing”, page 8
• “ Countershaft brake”, page 10
• “ Clutch cylinder”, page 11
• “ Lubrication system”, page 11
• “ Ventilation”, page 14
• “ Electrical system”, page 15
• “ Compressed air system”, page 17
• “ Power train”, page 18
• “ Auxiliary brake lever”, page 24
• “ Gear selector”, page 25
• “ Display”, page 25
• “ Program packages”, page 26
• “ Function description”, page 28
• “ Communication with other control units”, page 29
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 3(31)
General
T4021207
Make VOLVO
AT2412C
AT2512C
Type AT2812C Unsynchronized main gearbox
ATO2512C
ATO3112C
A - Automatic
T - Transmission
O - Overdrive
Symbols ATO2512C
25 - Torque 2500 Nm
12 - Number of forward gears
C - Generation
Gear ratio
Gear engaged AT2412C, AT2512C, AT2812C ATO2512C, ATO3112C
Gearbox construction
The gearbox construction consists of three main parts: and reverse shafts along with a selector unit which is
a clutch housing, a basic housing and a range housing. integrated into the control housing. The range housing
The clutch housing forms the front end plate of the contains the range gear planetary gear and the output
gearbox. The base housing contains the main, counter shaft.
T4021405
1 Clutch housing
2 Main housing
3 Range housing for the retarder
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 5(31)
The main parts in the gearbox are the input shaft, main The range gear incorporates a planetary gear and is
shaft, range gear with selector unit, countershaft, oil integrated with the output shaft.
pump with reverse shaft, as well as the control housing
with selector unit. Gearboxes equipped with a power take-off also have a
drive shaft fitted.
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.
T4021728
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
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 6(31)
Synchronisation
• Split gear (A) is synchronized.
• The main gearbox housing (B) with its gears is not
synchronized.
• Range gear (C) is synchronized.
T4021404
Range housing
Range housing (C) can be combined with: • Emergency steering servo pump
• Power take-off; see option instructions for variants • Retarder unit
Range gear
The range synchronization lies outside the ring gear, a strong range and the helical gears result in a quiet
reducing the unit’s length. The large synchronization area planet gear.
results in short selection time, the wide planet gears give
T4021725
T4021683
Oil cooler
T4021755
The gearbox oil cooler function is not affected by whether the gearbox has a retarder or not.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 8(31)
Control housing
Gears are selected using the gear selector. Once a gear After the gearbox has been put into neutral, the engine
has been selected, the system reduces the engine torque speed is adjusted to accommodate the speed of the
to a suitable level, after which the gears are shifted to selected gear, after which the gear shift takes place.
neutral.
T4018492
A. Split cylinder
B. 1/R cylinder
C. 2/3 cylinder
D. Range cylinder
E. Position sensor for the split cylinder
T4018201
T4057801
GCU
ID Unit Designation
0 The main shaft has a 72 teeth sensor wheel mounted
KBQ
1 The main shaft has a 30 teeth sensor wheel mounted
0 There is a speed-sensor-D1 mounted
KBR
1 There is a speed-sensor-C2 mounted
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.
T4021408
Countershaft brake
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 11(31)
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.
T4021655
A. Clutch cylinder
B. Position sensor
C. Valve unit
D Bleeder nipple for the valve unit.
Lubrication system
T4023570
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 12(31)
The oil is led into the main shaft to lubricate and cool the
range gears as well as the input and main shaft bearings.
T4021729
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.
T4021520
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 13(31)
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).
T4021684
T4033600
Ventilation
Ventilation is via a hose that passes over the control
housing and down behind the valve unit.
T4021686
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 15(31)
Electrical system
Sensors and sockets, for gearboxes without a retarder
T4021412
T4021414
I. Vehicle communication
Cabling from socket II to the valve unit for the
II. Clutch cylinder clutch cylinder.
A. Speed sensor
T4021413
T4021410
T4021409
Cabling from socket II to the retarder.
I. Vehicle communication
II. Retarder
III. Clutch cylinder
A. Speed sensor
T4021418
T4021411
T4021415
T4021417
T4021416
Power train
The following illustrations show the power train for
AT2412C, AT2512C and AT2812C.
T4021693 T4021694
T4021695 T4021696
T4021697 T4021698
T4021699 T4021700
T4021701 T4021702
T4021703 T4021704
T4021691 T4021692
Neutral N1 Neutral N2
T4021687 T4021688
T4021689 T4021690
T4021711 T4021712
T4021713 T4021714
T4021716 T4021715
T4021717 T4021718
T4021719 T4021720
T4021721 T4021722
T4021709 T4021710
Neutral N1 Neutral N2
T4021705 T4021706
T4021707 T4021708
T4022470
Without the brake program, (A) desired rpm for first change
down, (B) area for braking using the auxiliary brake.
T4022471
With the brake program, (B) area for braking using the
auxiliary brake.
Note: The effect of the auxiliary brake may be reduced For more information on auxiliary brake component parts,
by the I-shift control unit, MID 130, to make the ride as see group 21, Description, Design and Function, “Engine”.
comfortable as possible. The effect reduction is regulated
by the selected gear, vehicle weight and road surface
inclination.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 25(31)
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.
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
T3014422
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 26(31)
Program packages
General notes on the program packages
The gearbox has different functions depending on which Display Program VDA variants
program package is installed in the gearbox. packages
The following program packages are available: B Basic TP-BAS
• Basic is the standard gearbox program DC Distribution & TP-DICON
• Distribution & Construction include functions that Construction
make the truck lighter to manoeuvre. FE Long Haul Fuel TP-FUEC
• Long Haul Fuel & Economy include functions that & Economy
partly improve fuel consumption and partly make the HD Heavy Duty TP-HD
truck lighter to manoeuvre. GCM Control
• Heavy Duty GCM Control is designed for heavy
trucks. This program also contains functions that help Change program package
to improve fuel consumption and make the truck easier When a program package is replaced, the “Central system
to manoeuvre. (VDA)” must be updated before it can be downloaded
Which program package is installed in the vehicle? to the vehicle. This is done by entering the “Converting
When the gear selector is in neutral position (N) and the set number” in the computer tool which is stated in “ Part
“FOLD ” button is pressed in, the lever can be folded information, accessory”.
forwards. The display then shows the program variant
After replacement, reprogramming must be carried out
the gearbox has.
using the TECU control unit (MID 130), and the gearbox
must be recalibrated.
I-Roll X X
Possible optional functions Distribution & Long Haul Fuel & Heavy Duty GCM
Basic
Construction Economy Control
Gear Selection Adjustment in
X X X
Auto including Kickdown
Enhanced Power Take Off
X X X X
Functions
Customer parameters
Customer parameters in the gearbox control unit: Note: The default value can vary depending on the
program package selected.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 27(31)
Function description
Standard functions
The following standard functions are available in the • A display that shows the gearbox oil temperature and
gearbox: a warning system that informs the driver when the oil
temperature is too high.
• Automatic choice of start gear.
• Possibility to change automatically selected gears
when the accelerator pedal is released.
Optional functions
• I-Roll (VEB or retarder required) Automatically selects the lowest possible gear when
This function automatically engages and disengages the air suspension is in manual mode in order to obtain
the freewheel to reduce fuel consumption. When optimal manoeuvrability. ECS required.
you release the accelerator, the transmission shifts
Improves engine brake performance by selecting gears
to neutral, so that the vehicle can roll freely and the
that increase engine speed.
engine goes down to idle.
Temporarily applies the wheel brakes when changing
• Smart Cruise Control
gear to compensate for the engine brake when
The function is only active when cruise control is
the brake program is active. This function requires
activated. Saves fuel by deactivating the auxiliary
ABS-EBS. If a trailer without ABS is hitched up, the
brakes under certain conditions. The function releases
function is deactivated.
the auxiliary brakes after a downhill stretch, which
improves cruise control performance. • Heavy Duty GCM Control
This function makes it possible to adjust the gearing
• Launch Control
strategy to suit the rolling weight - up to 180 tonne.
Allows driving with the engine idling without slipping
the clutch. • Gear Selection Adjustment in Auto including
Kickdown
Regulates engine torque when pulling away for The function makes it possible to adjust automatically
optimum gear changing and avoid high engine speed. selected gears even when the accelerator pedal is
depressed. There is also a Kick Down function for
The following functions in “Launch control” require maximising the acceleration of the vehicle.
EBS: • Enhanced Power Take Off Functions
Improved comfort when pulling-up through smoother Optional functions that support power take-off
disengagement when pressing lightly on the brake operations, e.g. “Auto Neutral” and splitbox. Optional
pedal. functions:
Automatic application of the brakes when the vehicle Makes it possible to determine software parameters
rolls in the wrong direction, in relation to the selected that limit engine speed when power take-off is used.
gear. The function forms a gear selection strategy to suit
engine speed limitations.
Automatic application of the brakes to stop the vehicle
and change from a forward to a reverse gear or vice Disengages the transmission at the request of the
versa. options module, irrespective of the gear lever position,
when “Auto Neutral” is activated.
HSA, “Hill Start Aid”, which is only active on inclines.
See also the description of “Hill Start Aid”: Function Blocks reverse gear when the options module requests
group 593, Information type Description “Electronically “ reverse inhibit”.
controlled braking system (EBS)”.
Makes it possible to use the splitbox for driving the
• Enhanced Shift Strategy power take-off at high capacity.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 29(31)
T4058439
Component list
Component Description
A13 (MID 130) Control unit, TECU (transmission electronic control unit)
A14 (MID 128) Control unit, EECU (engine electronic control unit)
A16 (MID 150) Control unit, ECS (electronically controlled suspension)
A17 (MID 144) Control unit, VECU (vehicle electronic control unit)
A21 (MID 136) Control unit, EBS (electronically-controlled brake system)
A27 (MID 216) Control unit, LCM (external lighting)
A33 (MID 220) Tachograph
A36 (MID 249) Control unit, BBM (body builder module)
• Wheel spin information; the vehicle does not change • In “Launch Control” the gearbox can control the
gear. brakes. For more detailed information, see “ Function
description”, page 28 for “ Launch Control”.
• ABS system active, the vehicle does not change gear.
• Information from ESP, the vehicle does not change
gear.
Communication with control unit ECS (A16), MID 150
Signals / information to TECU: • ECS control unit status. Always start in 1st gear if
the manoeuvre control unit for the air suspension is in
• Vehicle weight.
manual mode.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 12.2010 431 228 10 31(31)