Gearbox, Mechanical, Function Description
Gearbox, Mechanical, Function Description
00 25/03/2025
Chassis ID Path
A 880815 43/Description, Design and function//Gearbox, mechanical, function description
Model Identity
FM (4) 163961325
Related information
Dashboard
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
Chassis
7 Clutch cylinder
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
Off road
Heavy duty
4 Active 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.
3 / 18
IMPACT 4.04.00 25/03/2025
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.
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.
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
2 N = Neutral
4 HOLD = Hold the present gear. It locks the current gear and prevents gear changes from up
and down shifts.
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
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.
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
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.
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.
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
Economy S S S S
Standard N/A S S S
Performance N/A S or O S or O S
TPM-AUTR N/A S S S
AMSO-BAS S S S S
APF-BAS S S S S
TPM-MAN N/A O O O
AMSO-AUT N/A O O O
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
Freewheel (I-Roll) S S S S
Launch control S S S S
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.
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.
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.
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.
● 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.
This function continuously shows the gearbox oil temperature in the DID.
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.
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
● 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.
Launch control
● 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
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.
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.
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.
● 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
Note
For more information, refer to the input shaft section in chapter Shaft, gearwheels and
engaging sleeves in the Gearbox, mechanical component description.
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.
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.
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.
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
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
● 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).
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.
14 / 18
IMPACT 4.04.00 25/03/2025
● 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.
● Any step lower than the gear the TECU would have selected in automatic mode.
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
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.
● 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.
● When the engine speed is almost the same as the input shaft speed, the clutch starts to engage.
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.
16 / 18
IMPACT 4.04.00 25/03/2025
Number of reverse
P1ARH gears with or without 1–4/RC, R1–5 Setting the number of reverse gears available.
ASRO–MSR
17 / 18
IMPACT 4.04.00 25/03/2025
Refer Volvo
Gear 12 splitbox Bodybuilder Sets the maximum engine torque that can be used
P1KCL
torque limit instructions in gear 12 splitbox.
(VBI)
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