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I-Shift Generation C Design and Function

I-shift

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2K views31 pages

I-Shift Generation C Design and Function

I-shift

Uploaded by

petrica_velvet
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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VOLVO Service Bulletin Volvo Truck Corporation Gteberg,Sueden Trucks Date Group No. Release Page 122010 431 228 10 161) |-Shift generation C Design and function FH, FM, FH16 AT2412C, AT2512C, AT2812C, ATO2512C, ATO3112C I-Shift generation C, design and function ‘The service information describes the design and function of AT gearboxes. 88983778 exoaszr3 Erglsh Printed in Sweden Volvo Truck Corporation Date Group Service Bulletin ve200 «434 No. 228 Release 10 Page 289 Gearbox, mechanical |-Shift, Generation C Contents * © General’, page 3 © © Gearratio”, page 4 * © Gearbox construction’, page 4 ‘+ © synchronisation’, page 6 * © Range housing’, page 6 ‘* + Range gear’, page 6 * “Emergency steering servo pump’, page 7 * *Oilcooler’, page 7 © © Control! housing”, page 8 * © Countershaft brake”, page 10 * © Clutch cylinder", page 14 * Lubrication system’, page 11 © © Ventilation’, page 14 * “Electrical system’, page 15 * “Compressed air system’, page 17 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 Volvo Truck Corporation Date Group No Release Page Service Bulletin 200 431 228 10 380 General Make vowvo AT2H126 AT26126 Type AT28126 Unsynchronized main gearbox ATO25126 ATO31126 ‘A- Autornatc ‘T- Transmission 0- Overdhive Same ATO28126 25- Torque 2500 Nm 12- Number of forward gears G- Generation Range gear Synchronised Split gear Synchronised Forwards 12 Number of gears Reverse 4 ‘AT2412C, AT2512C, ATO2512C ‘AT2812C, ATO3112C Weight without oi 271 kg 277 kg Length 891 mm 909 mm Volvo Truck Corporation Date Group No, Release Page Service Bulletin 2010 © 431 228 10 “39 Gear rat Gear engaged ‘AT2412C, AT2512C, AT2B12C ATO2512C, ATOS1IZC 1st 14.981 11,734 2nd 14,734 92a ard 9,041 7,091 ath 7,091 557A sth 5,581 4,354 eth 4,354 3,4tct Tth 3,481 2,701 ih 2,701 2A2t sth 2,08:1 4,631 40th 1,631 4,284 with 4274 4,001 12th 4,001 0794 Reverse gear (1) 17,481 13,734 Reverse gear (R2) 13,734 10,784 Reverse gear (R3) 4,021 3,161 Reverse gear (RA) 31641 2,48:1 Gearbox construction ‘The gearbox construction consists of three main parts and reverse shafts along with a selector unit which is 2 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. 1. Clutch housing 2. Main housing 3. Range housing for the retarder Volvo Truck Corporation Service Bulletin ‘The main parts in the gearbox are the input shaft, main shaft, range gear with selector unit, countershaft, oll ump with reverse shaft, as well as the control housing with selector unit 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 countershatt has fixed gears. Date 122010 Group 431 Release 10 No. Page 228 sen ‘The range gear incorporates a planetary gear and is integrated with the output shaft Gearboxes equipped with a power take-off also have a drive shaft fitted, Input shaft Main shaft Range gear with selector unit and retarder drive ountershat il pump with reverse shaft Control housing with selector unit Drive shaf for power take-off Volvo Truck Corporation Date Group No, Release Page Service Bulletin 2010 © 431 228 10 ee) Synchronisation * Split gear (A) is synchronized. * The main gearbox housing (B) with its gears is not synchronized © Range gear (C) is synchronized. 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, 2 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 Range gear with selector unit and retarder drive Volvo Truck Corporation Date Group No Release Page Service Bulletin 200 431 228 10 789 Emergency steering servo pump The emergency steering servo pump is located on the gearbox and is driven by the gearbox output shaft. The emergency steering servo pump is activated when for some reason the normal power steering circut fails. Emergency steeting serve pump, PSS-DUAL Oil cooler URETARD RET-TH UTCOOL UTCOOL + TC -MWO TC - MWO. + TC - MWOH2 TC - MWOH2 < TC - MAOH2 TC - MAOH2 + ” ay ae : ‘The gearbox ol cooler function fs not affected by whether the gearbox has a retarder or not Volvo Truck Corporation Service Bulletin Date Group Release Page 200 = 431 228 10 sen Control housing Gears are selected using the gear selector. Once a gear has been selected, the system reduces the engine torque to a suitable level, after which the gears are shifted to neutral ‘The contro! housing cover has two or sometimes three electrical sockets. When there ismo retarder, the following applies: Vehicle communication 1 Clutch eylinger m— The following applies with retarder Vehicle communication W Retarder Gluten cylinder The contro! housing incorporates nine solenoid valves: 2. Solenoid valve 2nd gear LR. Solenoid valve, low range 3. Solenoid valve 3rd gear HR. Solenoid valve, high range B. Solenoid valve, brake HS. Solenoid vaive, high spit R. Solenoid valve, reverse LS. Solenoid vaive, low spit 1. Solenoid valve tst gear LHS and LS have reversed imctions on Over Drive gearboxes After the gearbox has been put into neutral, the engine ‘speed is adjusted to accommodate the speed of the selected gear, after which the gear shift takes place. Volvo Truck Corporation Date Group No Release Page Service Bulletin 200 431 228 10 20 The control housing incorporates the following components: * Four parallel cylinders, split, 1/R and 2/3 and range. A * Four inductive sensors for the postioning of the 6 pistons * Two speed sensors, one for the main shaft and one =e for the countershaft. The input shaft speed is set by OLO the countershaft sensor. © An oil temperature sensor, selector forks for split gears and main gearbox. The oll temperature sensor is located on the cabling for the rpm sensor. * A pressure sensor * Control unit for transmission, TECU. Locations of cylinders and position sensor A. Split cylinder B. 1/R cylinder €. 213 cylinder D. Range cylinder E. Position sensor for the split eylinder Location of position sensor and speed sensor A. Position sensor range cylinder B. Speed sensor, countershaft C. Speed sensor, main shaft D. Position sensor, 2nd and 3rd cylinders E. Position sensor 1st and reverse eylinder Volvo Truck Corporation Service Bulletin Date Group Release Page 200 = 431 228 10 1089 Parameter settings for installation of GCU-D (GCU-D: Gear Control Unit for /Shift generation D) For more information regarding GCU-D and these Parameters, see Function Group 4318, Information type Diagnostics MID 130 PID 160 Parametersetting. Soe eB Sires Wea MAH (ie ecu D Unit Designation KBQ 0 The main shaft has a 72 teeth sensor wheel mounted The main shaft has a 30 teeth sensor wheel mounted KBR 0 There is @ speed-sensor-D' mounted 1 There is a speed-sensor-C? mounted 1 Speed sensor for Tsht gearbox gmeratin D 2 Speed sensor for Tshit gearbox gmeratin C 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. Countershaft brake Volvo Truck Corporation Date Group No. Release Page Service Bulletin 200 431 228 10 ne Clutch cylinder The cluteh 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 cluteh cylinder and is located on the outside of the clutch housing, ‘A.Clutch eyinder 8. Postion sensor Vale unit D Bleeder nipple forthe valve unit Lubrication system —_—_—_———* A! Volvo Truck Corporation Date Group Service Bulletin ve200 «434 No. 228 Release Page 10 1289 ‘The gearbox is lubricated through a combination of pressure and splashing, ‘The oil is led into the main shaft to lubricate and cool the range gears as well as the input and main shaft bearings. ‘The countershaft brake, output shaft bearings, emergency steering servo pump drive, retarder gear and power take-off are also lubricated, ‘The lubrication system has two overflow valves. One valve ensures that the gearbox is lubricated if the fitter gets blocked while the other prevents excessive pressuresin the system, e.g. during cold start. The valves. are made up of a compression spring and a valve peg, ‘The overtow valve which ensures that the gearbox & lubricates Overtow valve which prevents excessive pressure il pump The oll 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 low oil fiter of the insert fiter type on the pressure side of the pump. It is located in the oi fiter housing in the main housing. A support pipe is fitted in a cover that is fastened to the bottom of the oil fiter housing. The support pipe prevents the fitter, which sits ‘on the outside, from collapsing, Volvo Truck Corporation Service Bulletin Date Group No. Release Page v22010 431 228 10 "a0 Oil level The oll level is checked with a level glass (2) and adjusted Using two drain plugs (1A and 1B) and two filer plugs (Gand 4), Overfilled oil can also be adjusted using level plug (3) Read more about oil quality and oil change volumes inF unction Group 1750, Information type Service and maintenance Preventive maintenance intervals. 1A. Drain plug 1B. Drain plug 2. Level glass 3. Filler pluglevel plug 4. Filler plug / Vent valve Level glass for checking ot level Volvo Truck Corporation Date Group No, Release Page Service Bulletin 2010 © 431 228 10 89 Ventilation \Ventiiation is via a hose that passes over the control housing and down behind the valve unit Volvo Truck Corporation Date Group No Release Page Service Bulletin 200 431 228 10 109 Electrical system Sensors and sockets, for gearboxes without a retarder |. Vehicle communication Cabling from socket It to the valve unit for the IL Clutch cylinder clutch cylinder. A, Speed sensor Cabling from socket I to the speed sensor and chassis cabling, Volvo Truck Corporation Date Group No, Release Page Service Bulletin 2010 © 431 228 10 1869 Sensors and sockets, for gearboxes with a retarder Cabling from socket Il to the retarder |. Vehicle communication 1 Retarder ie IL. Cluten cylinder A. Speed sensor Cabling from socket Il to the valve unit for the cluteh cylinder. Cabling from socket I to the speed sensor and chassis cabling, Volvo Truck Corporation Date Group No. tease Service Bulletin 200 431 228 10 ren Compressed air system Compressed air connections ection between the conto! housing the clutch cylinder. between the contal housing and the Volvo Truck Corporation Date Group No, Release Page Service Bulletin ve200 434 228 10 1869 Power train ‘The following illustrations show the power train for AT2412C, AT2612G and AT2812C. Ast gear 2nd gear rd gear 4th gear Sth gear oth gear Volvo Truck Corporation Date Group No. Release Page Service Bulletin 200 431 228 10 1989 7th gear 8th gear oth gear ‘0tn gear ‘1th gear 12th gear Volvo Truck Corporation Date Group No, Release Page Service Bulletin ve200 434 228 10 208) ou Neutral Na Neva N2 Reverse gear (Rt) Reverse gear (R2) Reverse gear (R9) Reverse gear (R4) Volvo Truck Corporation Date Group No. Release = Page Service Bulletin 200 431 228 10 2169 The following ilustrations show the power train for ATO2512C and ATO31126. ‘st gear 2nd gear 31d gear 4th gear sth gear th gear Volvo Truck Corporation Date Group No. Relesse Page Service Bulletin ve200 434 228 10 28) 7th gear 8th gear oth gear ‘tn gear ‘th gear 12th gear Volvo Truck Corporation Date Group No. Release Page Service Bulletin 200 431 228 10 28) ou Neva a Newt 2 Reverse gear (R1) Reverse gear (R2) Reverse gear (R3) Reverse gear (RA) Volvo Truck Corporation Service Bulletin Date Group No. Release Page 200 = 431 228 10 2480 Auxiliary brake lever On all vehicles with a retarder and on vehicles with an ‘automatic gearbox and engine brake (VEB) the auxiliary brake is applied using a lever on the steering shaft 0 Auxiliary brake not applied A Automatic mode 4-3 Manual mode B Position for activating the brake program. Spring return to position 3, ‘The illustration shows a vehicle fitted with the “Basic program set, which has no brake program. When the ‘auxiliary brake lever is moved to position B, the gearbox will select a gear giving an engine speed of just over 1500 tpm. Ifthe speed in reduced, the gearbox will hen select gears to maintain an engine speed between 1000-1500 1pm (B). The driver can also change down further by moving the auxiliary brake lever to posttion B. ‘The vehicle in the illustration is fitted with one of the program sets Distribution & Construction’, “Long Haul Fuel & Economy” or“ Heavy Duty GCM Control, which include the braking program. When the auxiliary brake lever is moved to position B, the gearbox will select a gear giving an engine speed above 1500 rpm. The gearbox will then select gears to maintain an engine speed above 1500 rpm (B). Note: The effect of the auxiliary brake may be reduced by the I-shift control unit, MID 130, to make the ride as comfortable as possible. The effect reduction is regulated by the selected gear, vehicle weight and road surface inclination, Without the brake program. (A) desired rpm for frst change down, (8) atea for braking using the auxiliary brake With the brake program. (B) area for braking using the alary brake For more information on auxiliary brake component parts, ‘see group 21, Description, Design and Function, “Engine” Volvo Truck Corporation Date Service Bulletin 122010 Group No. 431 228 10 Release Page 250 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 ‘The gear selector incorporates the following functions: 1. Three position switch with spring return for up and down changing Button for lowering the lever into a horizontal position, 3. Gear selector inhibitor preventing the vehicle from being put in gear unintentionally. 4 Gear selector positio R= reverse gear N= neutral ‘A= automatic M = manual 5. Button EP for economy/performance position. 6 Button L “Limp Home’ Note: The * Limp Home" function is intended for moving the vehicle short distances in order to get off the road and to a workshop. Only one gear can be used and the driving may be jerky. For information on how to engage and use this function, see driver instructions, Display The display provides information on the gear currently selected and which gears ate available The display is divided into smaller fields showing 1. Driving program Selected gear Available gears (downlup) Lever position Volvo Truck Corporation Service Bulletin Date Group No. Release Page e210 431 228 10 2069 Program packages General notes on the program packages ‘The geathox has different functions depending on which program package is installed in the gearbox. ‘The following program packages are available: * Basic is the standard gearbox program * Distribution & Construction include functions that, make the truck lighter to manoeuvre. * Long Haul Fuel & Economy include functions that partly improve fuel consumption and partly make the truck lighter to manoewvre. ‘* Heavy Duty GCM Control is designed for heavy trucks. This program also contains functions that help to improve fuel consumption and make the truck easier to manoeuvre. Which program package is installed in the vehicle? When the gear selector is in neutral position (N) and the “FOLD " button is pressed in, the lever can be folded forwards. The display then shows the program variant the gearbox has, Functions in every program package Display Program | VDA variants packages 5 Basic TP-BAS De Distribution & | TP-DICON Construction FE Long Haul Fuel | TP-FUEC & Economy HD Heavy Duty TP-HD GCM Control Change program package When a program package is replaced, the “Central system (VDA)" must be updated before it can be downloaded to the vehicle. This is done by entering the “Converting ‘set number" in the computer tool which is stated in" Part information, accessory’. After replacement, reprogramming must be carried out using the TECU control unit (MID 130), and the gearbox must be recalibrated Distribution & Long Haul Fuel & | Heavy Duty GCM Function Basic Construction | Economy Control -Rol x x Smart Cruise Control x x Launch Control x x x Enhanced Shif Strategy (GCM x = 607) , Heavy Duty GGM Control (60 T

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