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Gearbox, Mechanical, Function Description

The document provides a detailed description of the mechanical gearbox functions and components used in Volvo vehicles, including gear selection, shifting, and driver interfaces. It outlines various software packages that optimize driver control under different conditions, as well as the operation of the Power Take-Off (PTO) system. Additionally, it includes information on the functionality of the instrument cluster and auxiliary brake lever, emphasizing the importance of proper usage and customization options available for the gearbox system.

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0% found this document useful (0 votes)
4 views

Gearbox, Mechanical, Function Description

The document provides a detailed description of the mechanical gearbox functions and components used in Volvo vehicles, including gear selection, shifting, and driver interfaces. It outlines various software packages that optimize driver control under different conditions, as well as the operation of the Power Take-Off (PTO) system. Additionally, it includes information on the functionality of the instrument cluster and auxiliary brake lever, emphasizing the importance of proper usage and customization options available for the gearbox system.

Uploaded by

Muhammad Syarif
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 18

IMPACT 4.04.

00 25/03/2025

Chassis ID Path
A 880815 43/Description, Design and function//Gearbox, mechanical, function description

Model Identity
FM (4) 163961325

Publish date ID/Operation


24/05/2022

Gearbox, mechanical, function description


Gearbox, mechanical, function description
Component location
Function behaviour
Driver interface
Gearbox software packages
Gear selection
Gear shifting

Related information

Gearbox, mechanical, function description


Component location

Dashboard

1 Instrument cluster (A03H)

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.

1 / 18
IMPACT 4.04.00 25/03/2025

2 Stalk switch (S275)

3 VMCU (Vehicle Master Control Unit)2 (A187(2))

4A Gear selector switch module (S295)

4B GLU (Gear Lever Unit) (S171)

Chassis

1 ECM (Engine Control Module) (A14)

2 TECU (Transmission Electronic Control Unit) (A13A)

3 CCIOM (Centre Chassis I/O Module)2 (A163(2))

4 APM (Air Production Modulator) (A177)

5 EBS (Electronically controlled Brake System) control unit (A21)

6 ACM (Aftertreatment Control Module)2 (A174B)

7 Clutch cylinder

8 CVU (Clutch Valve Unit)

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

10 Valve unit (crawler gear)

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.

2 / 18
IMPACT 4.04.00 25/03/2025

Function behaviour
Driver interface

Instrument cluster

The DID (Driver Information Display) in the instrument cluster shows the following driving modes:

Economy

Standard

1 Drive mode Performance

Off road

Heavy duty

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

N Neutral (N1 low, N2 high)

Automatic 1–12 and crawler gears C/C1, C2 (ASO-C/ULC


Selector A
2 only)
position
Manual 1–12 and crawler gears C/C1, C2 (ASO-C/ULC
M
only)

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

3 Available gears for up or down

4 Active gear

Gear selector, GLU (GSS-AGS)

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.

3 / 18
IMPACT 4.04.00 25/03/2025

The gear selector is attached to the driver's seat.

1 Gear step button (+/-): Spring-loaded switch for manual up and down shifting.

2 Gear selector inhibitor: It prevents unintentional gear engagement from neutral (N) to any gear.

3 E/P button:
E = Economy mode
P = Performance mode.

4 Gear selector position:


R = Reverse
N = Neutral
A = Automatic gear selection mode
M = Manual gear selection mode.

Note
For vehicles installed with heavy duty mode: The heavy duty mode can be activated by
pressing the E button for three seconds. The heavy duty mode gets deactivated by a short
press of the E button on the gear selector. Once the heavy duty mode is deactivated, the
economy mode gets activated automatically.

Gear selector, shift buttons (GSS-4BS)

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.

4 / 18
IMPACT 4.04.00 25/03/2025

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. It locks the current gear and prevents gear changes from up
and down shifts.

5 Gear step button (+/-) = Gear change.

Note
There is no manual gear selection mode. Gear changing is fully automatic, but if necessary,
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.

Note
Hold mode cannot be activated above 55 km/h. If the hold mode is active, it gets deactivated
automatically when the vehicle speed reaches above 60 km/h.

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.

5 / 18
IMPACT 4.04.00 25/03/2025

Auxiliary brake lever (brake mode)

The auxiliary brake lever has many variants. The auxiliary brake lever with a brake programme is
shown in the below illustration.

Position A: Automatic mode (E+ will be an indicator that is shown in the instrument cluster depending
on vehicle configuration). It is also possible to operate the freewheel (I-Roll).
Position 0: Off.
Position 1–3: Manual mode with predefined levels for auxiliary braking.
Position B: This activates the brake program. The TECU selects the appropriate gear for maximum
deceleration.
While braking, the gear selection depends on the position of the auxiliary brake lever and brake
program.

PTO (Power Take-Off)

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.

6 / 18
IMPACT 4.04.00 25/03/2025

The PTO is activated or deactivated by pressing the switch on the dashboard.

PTO, activation
The PTO activates when the vehicle speed is below 10 km/h in any gear up to sixth gear.
1 The TECU disengages the clutch.

2 The TECU stops the countershaft.

3 The TECU activates the PTO.

4 The TECU engages the clutch.

After activating the PTO, it is possible to increase the vehicle speed above 10 km/h, but it is not
possible to change the gear.

PTO, deactivation
The PTO deactivates at any speed and in any gear.
1 The TECU disengages the clutch.

2 The TECU deactivates the PTO.

3 The TECU engages the clutch.

Gearbox software packages


The software packages have several functions that optimise the driver control in different driving
conditions. Several software packages are available with different functions.
The software packages are further customised with optional functions and customer parameters. For
example, the starting gear can be optimised according to the transport conditions. The PTO operation
can also be customised to fit the needs of the customer by setting parameters.
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.

7 / 18
IMPACT 4.04.00 25/03/2025

The software packages and parameters are easily installed and changed by authorised dealers and
workshops using Tech Tool (Volvo Tech Tool).

Software package

I-Shift drive modes and software functions

DRM-E DRM-BE DRM-BE DRM-BE


AVO-BAS AVO-BAS AVO-ENH AVO-HD

Economy S S S S

Standard N/A S S S

Performance N/A S or O S or O S

Off-road N/A N/A S S

Heavy duty N/A N/A N/A S

I-Shift standard functions

TPM-AUTR N/A S S S

AMSO-BAS S S S S

APF-BAS S S S S

I-Shift option functions

TPM-MAN N/A O O O

AMSO-AUT N/A O O O

APF-ENH O O O O

Software package function


S = Standard
O = Optional
N/A = Not Available

DRM-E DRM-BE DRM-BE DRM-BE


Function
AVO-BAS AVO-BAS AVO-ENH AVO-HD

Change direction N/A N/A S S

Auto return to ECO (TPM-AUTR) N/A S S S

Enable manual switch (TPM-MAN) N/A O O O

Basic gear selection adjustment


S S S S
(AMSO-BAS)

Enhanced gear selection adjustment


N/A O O O
including kickdown (AMSO-AUT)

Basic PTO functions (APF-BAS) S S S S

Enhanced PTO functions (APF-ENH) O O O O

Performance shift S S S S
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.

8 / 18
IMPACT 4.04.00 25/03/2025

Gearbox oil temperature monitor S S S S

Heavy start engagement N/A S S S

Freewheel (I-Roll) S S S S

Smart cruise control S S S S

Downhill cruise control S S S S

Launch control S S S S

Enhanced shift strategy (GCW (Gross


S S S S
Combination Weight) ≤ 85 t)

Heavy duty GCW control N/A N/A N/A S

Seat mounted gear selector


O S S S
(GSS-AGS)

Dashboard mounted gear selector


S N/A N/A N/A
(GSS-4BS)

I-Shift drive mode economy (DRM-E)

This mode is designed for low fuel consumption and fleet utilisation in situations where driver
influence is limited. Predictive cruise control (I-See) functionality is available in PVT-MAP variant.
This mode limits the ability to switch between drive modes and locks the mode in economy mode.

I-Shift drive mode balanced economy (DRM-BE)

This is the base which gives the ideal selection for all applications. To optimise further toward a
particular vocation, DRM-BE is selected with AVO-BAS, AVO-ENH or AVO-HD.
Customers with frequent starts and stops, like garbage collection, a potential to save fuel is to remove
the possibility to access performance driving mode.

Transmission performance mode auto return (TPM-AUTR)

When the driver selects performance mode, the transmission will be in performance mode for a
predefined time. After a predefined time, the transmission automatically returns to economic mode.

Enable manual switch (TPM-MAN)


When the driver selects performance mode, the transmission will be in performance mode until the
driver presses the mode switch again.

Gear selection adjustment (AMSO-BAS, AMSO-AUT)

Basic gear selection adjustment (AMSO-BAS)


This function allows the driver to adjust gear selection with the gear selector buttons during engine
braking in automatic mode.
Enhanced gear selection adjustment including kickdown (AMSO-AUT)
The enhanced gear selection adjustment function allows both the automatically selected starting gear
and the driving gear in automatic mode to be adjusted by pressing the +/- button on the gear selector.
The arrow symbols in the DID show the gear information at every moment. The gears can also shift
upwards since the engine speed is automatically increased before upshifts.
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.

9 / 18
IMPACT 4.04.00 25/03/2025

The kickdown function selects a gear for maximum acceleration. The kickdown function is activated
by pressing the accelerator pedal all the way to the floor, thus pressing the kickdown switch located
on the accelerator pedal assembly. When the kickdown switch is activated, the system changes the
gear shift strategy to maximise vehicle acceleration. Typically, this results in an immediate gear
downshift. The kickdown is deactivated once the accelerator pedal is lifted, thus releasing the switch.

PTO function (APF-BAS, APF-ENH)

Basic PTO functions (APF-BAS)


This function facilitates PTO operation only. Predefined splitter gear positions determine which splitter
gear should be used when the PTO is engaged.
Enhanced PTO functions (APF-ENH)
Several functions aid PTO operations. The gearbox (I-Shift) mounted PTO functions make it possible
to activate properties by having the customer parameters adjusted at an authorised workshop. Some
of the key properties are:
● Auto Neutral: When auto neutral is activated, the driveline is disconnected from the BBM (Body
Builder Module) control unit, regardless of the gear selector position.

● Reverse Inhibit: When the BBM control unit receives the reverse inhibit command, the reverse
gears are blocked by the transmission system.

● Connection of splitter box: This allows connection of a splitter box for the operation of high
capacity PTOs. When the BBM is in splitter box mode, direct gear is activated. It is possible to
use all the high range gear.

Note
For more details, refer to Volvo Bodybuilder Instructions (VBI).

Performance shift

This function provides faster, gentler gear shifts by utilising the engine compression brakes (VEB
brakes), the vehicle clutch and gearbox brakes. Automatic selection of the correct starting gear
(first–sixth gear) is included. The choice of starting gear is determined by GVW (Gross Vehicle
Weight) and road gradient.

Gearbox oil temperature monitor

This function continuously shows the gearbox oil temperature in the DID.

Heavy start engagement

In performance mode, the engine begins with high rpm in first gear, resulting in more beginning
torque. This function increases the rpm to make heavy starts easier. This is useful, for example, if the
truck is stuck on soft ground.

Performance mode options (AVO-BAS, AVO-ENH or AVO-HD)

Performance mode has three modes such as:

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.

10 / 18
IMPACT 4.04.00 25/03/2025

● Basic vocational (AVO-BAS)

● Enhanced performance (bad roads) (AVO-ENH)

● Enhanced performance (heavy duty) (AVO-HD).

Basic vocational functions


This mode allows the driver to choose between the Economy, Standard and Performance driving
modes.
Enhanced performance (bad roads)
The enhanced performance is specially adapted to the specific conditions, such as construction and
transport segments.
The off-road mode includes various functions that adjust the gear shift and gear selection to poor
driving and hill conditions. During off-road driving, it prevents the wheel from spinning. The functions
included are:
● When starting from a standstill, the engine rpm (Revolutions per Minute) is increased as required
to give more torque.

● Larger margins before upshifts ensure safer driving if the gradient changes.

● The gear selection is adjusted to minimise the number of gear shifts and run at slightly higher
rpm.

● When the accelerator pedal position and road gradient change, this function makes it easier to
keep the same gear.

● Activates multiple downshifts and facilitates gear shifts when driving up steep slopes.

● Speeds up clutch release and makes it easier to rock the vehicle out of trouble if it gets stuck on
a soft surface.

● When moving the gear lever, the driver can choose the gear that provides the highest possible
engine speed.

Enhanced performance (heavy duty)


This mode optimises I-Shift for heavy duty transport with high GCW (> 85 t). Regardless of the GCW,
the driver can always optimise driveability by activating or deactivating the heavy duty mode and
activating long haul mode. The functions in the software package also offer benefits for trucks hauling
multiple trailers.
This mode also includes the enhanced performance mode function (off-road mode). When the heavy
duty mode is inactive, the off-road mode is active.

Launch control

Full functionality with launch control requires EBS.


Launch control includes the following functions, such as:
● Idle speed driving

● Faster change of direction between forward and reverse, using the EBS system.

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.

11 / 18
IMPACT 4.04.00 25/03/2025

● 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 +/- button 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

This function includes a brake mode that maximises auxiliary brake power by automatically selecting
the appropriate gear. This function compensates for the engine brake when changing gears in the
brake mode.
When changing gears during engine braking, the service brakes activate to compensate for the
auxiliary brake torque loss when the clutch is disengaged. This increases braking power and provides
smoother gearshifts.
When brake mode is activated, the truck is prevented from accelerating during gearshifts on steep
slopes.

Freewheel (I-Roll)

This function activates or deactivates automatically to save fuel consumption while the auxiliary brake
lever is in position A. When engine power or engine braking is required, such as on flat roads,
freewheel (I-Roll) is used.
When driving with CC (Cruise Control), the freewheel (I-Roll) runs at a low speed and saves fuel.

Heavy duty GCW control

This function optimises gear selection for high GCW (> 85 t). The heavy duty GCW control enables
the heavy duty driving mode.
In heavy duty mode, first gear or crawler gear is used as starting gear and gear selection is adapted
for heavier GCWs. The gear shift occurs at higher engine speeds. The heavy duty mode is activated
by pressing the E/P button on the gear selector for about three seconds and can be deactivated by a
short press. If the heavy duty mode is selected when the engine is not running, it applies from the
next engine start.
While driving with low GCWs or no load conditions, it is recommended to run the vehicle in economy
mode.

Crawler gears (ASO-C, ASO-ULC)

There are two crawler gear options available:


● ASO-C (crawler) with one crawler gear (C)

● ASO-ULC (ultra-low crawler) with two crawler gears (C1 and C2).

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
first 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 a Tech tool (Volvo Tech Tool). The
overdrive gearboxes cannot be upgraded using a software update because a different gearwheel and
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.

12 / 18
IMPACT 4.04.00 25/03/2025

input shaft set are needed.

Note
For more information, refer to the input shaft section in chapter Shaft, gearwheels and
engaging sleeves in the Gearbox, mechanical component description.

Multi-speed reverse (ARSO-MSR)

The multi-speed reverse is an optional function with ASO-C or ASO-ULC and is installed using a
Tech tool (Volvo Tech Tool). This function provides two extra reverse gears (six reverse gears in
total) 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
multi-speed reverse.
The multi-speed reverse is designed for improved pulling away ability and low-speed manoeuvrability
in reverse and improves the optimal gear ratio. It is not possible to change between the high and low
range while reversing. Pulling away in high range gear is facilitated by the crawler gear in high range.

Predictive cruise control (I-See)

The Predictive cruise control (I-See) is a fuel-saving function. The vehicle system uses stored
information about approaching road topography to select a gear shifting strategy, engine torque and
vehicle speed for enhanced driving comfort and fuel efficiency. The Predictive cruise control (I-See)
uses map data with the variant PVT-MAP.

Note
For more information refer to Predictive cruise control (I-See), function description.

Smart cruise control

This function interacts with the vehicle brake cruise and ensures that the auxiliary brakes are not
activated unnecessarily. The auxiliary brakes are deactivated on downhill stretches to save fuel. This
allows increased use of the freewheel (I-Roll) function, resulting in improved fuel efficiency.

Downhill cruise control

This function prevents the truck from exceeding the speed set by the driver. The maximum speed is
easily set by the driver. This function primarily uses the auxiliary brakes, such as the Volvo engine
brake or the retarder, to ensure that the set speed is not exceeded. Only when required, the wheel
brakes are applied. The driver can still use the brake pedal to further reduce the speed without
deactivating the system.

Gear selection

Gear selection in automatic mode


The TECU calculates which gear to engage based on the following criteria:
● Speed of gearbox shafts and gears

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.

13 / 18
IMPACT 4.04.00 25/03/2025

● Clutch status

● Engine speed

● Engine torque

● Vehicle speed

● Vehicle weight

● Vehicle inclination

● Accelerator pedal status

● Gear selector status

● Driver settings.

The TECU may ignore 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 downshift by pressing
the gear 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 instrument cluster.
If the engine speed is 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 (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 in the instrument cluster. The
gears are changed using the 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 minimise clutch wear, 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


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.

14 / 18
IMPACT 4.04.00 25/03/2025

The choice of start gear depends on:


● GCW

● Road inclination

● Engine rating

● Driving mode

● Trailer disconnected

● When the air suspension is set in manual mode for height adjustment.

When in automatic mode, it is also possible to manually change the start gear, up to two steps higher
than the automatically selected gear. The start gears that can be selected are one of the crawler
gears or one of the gears 1–6.

Manual start gear selection


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 two 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


Examples:

Change driving direction


When driving below 10 km/h to 20 km/h, the driver can adjust the gear lever from forward (A or M) to
reverse (R) or the opposite way to change the vehicle direction from forward to reverse. The gear
change process can be completed by releasing the accelerator pedal and without the application of
brakes. Once the gear lever changes, 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. After the new
gear engages, the engine starts delivering torque again.

Trailer connection/disconnection
After the trailer disconnects (electrically) from the tractor, the lowest start gear engages until the truck
has driven forward a few metres 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 temperature that is generated during clutch engagement and
disengagement. If the clutch gets overheated, 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.
When a crawler gear is engaged and the clutch overheats, the clutch disengages to avoid
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.

15 / 18
IMPACT 4.04.00 25/03/2025

overloading the propeller shaft.

Gear shifting

General
When shifting gears, the TECU controls the speed and torque of the engine. Details are available in
Tech Tool test 43194.
The gear shifting sequence started by the TECU is:
● Engine torque mode signal is changed to value = 6.

● Engine torque is limited.

● Clutch is disengaged.

● Engine and gearbox speeds are controlled. At this point, the VCB (Volvo Compression Brake)
may be used momentarily to reduce the engine speed. Also the countershaft brake may be used
to reduce the gearbox speed to facilitate rapid gear shifting.

● The selector 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 (Exhaust Pressure Governor) + VCB
EBR-VEB+
Volvo Engine Brake = EPG + VCB plus
VCB
Volvo Compression Brake
Countershaft brake

Parameters
Customer parameters in the gearbox control unit:

Note
The default value can vary depending on the program package selected.

Parameter Caption Value Description

Spilt gear is used when gear box PTO1 is


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.

16 / 18
IMPACT 4.04.00 25/03/2025

engaged. If PTO1 and PTO2 are both engaged


and have conflicting (split gear) settings, low split
Split gear for gearbox
P1A05 0–2 has priority over high split.
PTO1
0 = Split selected by the driver, low split as default
1 = Use low split
2 = Use high split

Spilt gear is used when gear box PTO2 is


engaged. If PTO1 and PTO2 are both engaged
and have conflicting (split gear) settings, low split
Split gear for gearbox has priority over high split.
P1A06 0–2
PTO2 0 = Split selected by the driver, low split as default
1 = Use low split
2 = Use high split

Auto neutral through Specifies if the clutch is used to disengage the


P1A07 0–1
clutch 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
P1AP3 0–2 0 = Manual
performance mode
1 = Auto
2 = Disable

Number of reverse
P1ARH gears with or without 1–4/RC, R1–5 Setting the number of reverse gears available.
ASRO–MSR

Enables freewheel 0 = Freewheel (I-Roll) is always available.


(I-Roll) only when
P1FP2 0–1 1 = Freewheel (I-Roll) is only active when cruise
cruise control is
active control is active.

Start gear with


P1ISL 7–12 Specifies the start gear for engaging the splitbox.
splitbox

Allows gear 12 with


Specifies if it is allowed to use gear 12 or not in
P1ISM splitbox on an False/true
the overdrive gearbox when the 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 during and
Controlled
Suspension) manual after the 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 Start


Hill Start Aid Aid for both inclines and declines.
P1K8G auto-neutral slope False/true
True = Use slope condition, allow Hill Start Aid
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.

17 / 18
IMPACT 4.04.00 25/03/2025

condition only for inclines.

Refer Volvo
Gear 12 splitbox Bodybuilder Sets the maximum engine torque that can be used
P1KCL
torque limit instructions in gear 12 splitbox.
(VBI)

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.

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 braking system (EBS), system description

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.

18 / 18

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