IMPACT 4.08.

02 01/10/2024

Printed by:Myint Htun

Service

Chassis ID Path
4311/Description, Design and function//Gearbox, mechanical, component description

Model Identity
FM (4) 150202516

Publish date ID/Operation

18/12/2019

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.

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IMPACT 4.08.02 01/10/2024

Gearbox, mechanical, component description

Contents

General
Gearbox construction
Synchronisation
Range housing
Range gear
Control housing
Countershaft brake
Clutch cylinder
Lubrication system
Ventilation
Electrical system
Compressed air system
Power flow
Emergency steering servo pump (optional)
Oil cooler (optional)
Customer parameters

General

The gearbox is a 12 speed overdrive/direct drive gearbox. The gear shifting system is electronically controlled by the
TECU (Transmission Electronic Control Unit). This provides fully automatic gear shifting with the possibility of manual
shifting.

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.

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The gearbox has three basic gears, an integrated split gear (high and low) and a range gear (high and low). The split
and range gears are mechanically synchronized whereas the basic gears are electronically synchronized by using the
engine and the countershaft brake to control the input shaft speed.

An oil cooler, PTO (Power Take-Off), compact retarder and emergency power steering pump can be optionally fitted to
the gearbox. (The available optional components can be different in different markets)

Gearbox construction
The gearbox construction consists of three main parts: a clutch housing, a basic housing and a range housing. The
clutch housing forms the front end plate of the gearbox. The base housing contains the main, counter and reverse
shafts along with a selector unit which is integrated into the control housing. The range housing contains the range
gear planetary gear and the output shaft.

1. Clutch housing
2. Main housing
3. Range housing for the retarder

The main parts in the gearbox are the input shaft, main shaft, range gear with selector unit, countershaft, oil pump 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 countershaft has fixed gears.

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.

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
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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.

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IMPACT 4.08.02 01/10/2024

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

Synchronisation
Split gear (A) is synchronized.
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
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IMPACT 4.08.02 01/10/2024

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:

Power take-off; see option instructions for variants

Emergency steering servo pump
Retarder unit

Range gear
The range synchronising is located outside the ring gear which reduces the unit's length. The large synchronising area
makes for short gear-shift times and the wide planet gears with their helical teeth contribute to a robust and silent
planet 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.

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IMPACT 4.08.02 01/10/2024

Range gear with selector unit and retarder drive

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.

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.

The control housing cover has two or sometimes three electrical sockets.

When there is no retarder, the following applies:

I Vehicle communication
II Clutch cylinder
III —

The following applies with retarder:

I Vehicle communication
II Retarder
III 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.

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IMPACT 4.08.02 01/10/2024

The control 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 valve, high split1
R. Solenoid valve, reverse
LS. Solenoid valve, low split1
1. Solenoid valve 1st gear

1
HS and LS have reversed functions on Over Drive gearboxes.

The control housing incorporates the following components:

Four parallel cylinders, split, 1/R and 2/3 and range.

Four inductive sensors for the positioning of the pistons.
Two speed sensors, one for the main shaft and one for the countershaft. The input shaft speed is set by the
countershaft sensor.
An oil temperature sensor, selector forks for split gears and main gearbox. The oil temperature sensor is located on
the cabling for the rpm sensor.
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
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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.

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IMPACT 4.08.02 01/10/2024

A pressure sensor.
Control unit for transmission, TECU.

Locations of cylinders and position sensor

A. Split cylinder
B. 1/R cylinder
C. 2/3 cylinder
D. Range cylinder
E. Position sensor for the split cylinder

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 cylinder

Countershaft brake

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
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IMPACT 4.08.02 01/10/2024

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

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.

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
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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.

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IMPACT 4.08.02 01/10/2024

A. Clutch cylinder
B. Position sensor
C. Valve unit
D Bleeder nipple for the valve unit.

Lubrication system

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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.

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IMPACT 4.08.02 01/10/2024

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 filter gets
blocked while the other prevents excessive pressures in the system, e.g. during cold start. The valves are made up of
a compression spring and a valve peg.

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.

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IMPACT 4.08.02 01/10/2024

The overflow valve which ensures the gearbox is lubricated if the filter gets blocked.

Overflow valve which prevents excessive pressure.

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.

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.

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IMPACT 4.08.02 01/10/2024

Oil level
The oil level is checked using a level glass (2) and is adjusted through two drain plugs (1A and 1B) and two filler plugs
(3 and 4).

Overfilled oil is also adjusted with a level plug (3).

Read more about oil quality and oil change volumes in - Preventive maintenance intervals .

Level glass to check oil level

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
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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.

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IMPACT 4.08.02 01/10/2024

The previous version

1A. Drain plug

1B. Drain plug
2. Sight glass
3. Filler plug/level plug
4. Filler plug/air valve

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
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IMPACT 4.08.02 01/10/2024

The later version

1A. Drain plug

1B. Drain plug
2. Sight glass
3. Filler plug/level plug
4. Filler plug

Ventilation
The ventilation in the previous version runs through a hose that goes past the control housing and down behind the
valve assembly.
In this previous version, the main shaft cover is not involved in the gearbox ventilation.

The previous version

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
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IMPACT 4.08.02 01/10/2024

The ventilation in the later version runs through a built-in air duct with two valve holes on the main housing.
The later version of ventilation also has a different design of the main shaft cover (as well as the basic housing).
The complete gearbox is ventilated through its main shaft cover and further through the air duct with two valve holes.

The later version

Electrical system

Sensors and sockets, for gearboxes without a retarder

I. Vehicle communication
II. Clutch cylinder
A. Speed sensor

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.

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IMPACT 4.08.02 01/10/2024

Cabling from socket I to the speed sensor and chassis cabling.

Cabling from socket II to the valve unit for the 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.

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IMPACT 4.08.02 01/10/2024

Sensors and sockets, for gearboxes with a retarder

I. Vehicle communication
II. Retarder
III. Clutch cylinder
A. Speed sensor

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
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IMPACT 4.08.02 01/10/2024

Cabling from socket I to the speed sensor and chassis cabling.

Cabling from socket II to the retarder.

Cabling from socket III to the valve unit for the clutch cylinder.

Compressed air system

Compressed air connections

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
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Compressed air connection between the control housing and the valve unit for the clutch cylinder.

For the high pressure system, compressed air connection between the control housing and the four-circuit valve. For
the low pressure system, compressed air connection between the control housing and the pneumatic tank.
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
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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.

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Pneumatic connection between the control housing and the countershaft brake.

Power flow
The following illustrations show the direct drive gearboxes.

1st 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
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2nd gear

3rd 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
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4th gear

5th 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
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6th gear

7th 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
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8th gear

9th 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
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10th gear

11th 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
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12th gear

Neutral N1

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Neutral N2

Reverse gear (R1)

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Reverse gear (R2)

Reverse gear (R3)

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
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Reverse gear (R4)

The following illustrations show the power train for ATO2612D, ATO3112Dand ATO3512D.

1st gear

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2nd gear

3rd gear

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4th gear

5th gear

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6th gear

7th 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
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8th gear

9th 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.

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10th gear

11th 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
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12th gear

Neutral N1

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IMPACT 4.08.02 01/10/2024

Neutral N2

Reverse gear (R1)

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IMPACT 4.08.02 01/10/2024

Reverse gear (R2)

Reverse gear (R3)

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IMPACT 4.08.02 01/10/2024

Reverse gear (R4)

Emergency steering servo pump (optional)

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 circuit fails.

The available optional components can be different in different markets.

Emergency steering servo pump, PSS-DUAL

Oil cooler (optional)

The gearbox can be equipped with an oil cooler to ensure sufficient cooling.

The available optional components can be different in different markets.

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.

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IMPACT 4.08.02 01/10/2024

The gearbox oil cooler function is not affected by whether the gearbox has a retarder or not.

Customer parameters
Customer parameters in the gearbox control unit:

Note: The available parameters and default values are different in different markets and truck models. The default
value can also vary depending on the program package selected.

ID Designation Default Value Unit

GJJ States that the engine's power take-off can be loaded even No Yes / No
when it is inactivated.
By setting this parameter to "Yes" the gear change quality
problem is solved as the engine's rear power take-off is
always activated.
GJI1 Auto Neutral via the clutch. No Yes / No
The clutch is used to inactivate the gearbox under Auto
Neutral.
GJG States how the split gear behaves when power take-off 1 is Selectable LS / HS / Selectable
activated.
Low split has priority over high split if both power take-offs 1
and 2 are activated and have conflicting split gear settings.
GJH States how the split gear behaves when power take-off 2 is Selectable LS / HS / Selectable
connected for the gearbox.
Low split has priority over high split if both power take-offs 1
and 2 are activated and have conflicting split gear settings.
IEO States how the gearbox power mode is handled. AVO-ENH = Manual / Auto /
Manual = Power mode available. Inactivated Inactivated
Auto = Power mode available. The gearbox returns AVO-BAS = Auto
automatically to economy mode when the engine is no longer
under heavy load.
Inactivate = Power mode is not available.
IEH States when the kick-down function is available. AMSO-BAS = not Not available /
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
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available Always available /

AMSO-AUT = Available in economy
always available mode
AVO-ENH =
available in
economy mode
IPA States number of reverse gears available (1–4). Not applicable 4
LAQ States highest starting gear in manual mode (1–6). Not applicable 6
The setting of the starting gear in manual mode is limited to
gears equal to or lower than this value.
LAR States highest starting gear in automatic mode (1–6). 6 Not applicable
The choice and setting of the starting gear in automatic mode
is limited to gears equal to or lower than this value.
LAP Start gear selection dependence on ECS manual control AVO-BAS = During No influence / During
mode. AVO-ENH = During / During and after
No influence =The selected start gear is not lowered during and after
ECS control mode.
During = The selected start gear is lowered during ECS
control mode.
During and after = The selected start gear is lowered both
during and after ECS control mode. Use this setting to avoid
to high start gear before the air suspension have been raised
from the beam stops during manual control mode.
NUN Enable cruise underspeed during I-Roll Depend on variant Yes / No
No = Use this setting to ensure that I-Roll not will stay active
below the cruise set speed.
Yes = When cruise control is active a small underspeed
below the cruise control set speed is allowed before I-Roll is
deactivated. Will only work on supported variants.
(VTC Eu5)
NUO Enable I-Roll only when CC active. No Yes / No
Yes = I-Roll will only be allowed when cruise control is active.
No = I-Roll allowed both for pedal- and cruise control driving.
NXK2 Enable Splitbox Start with Accelerator Pedal. No Yes / No
No = Splitbox is started when the gear lever is moved from
Neutral to Automatic or Manual.
Yes = Splitbox is not started until the accelerator pedal is
fully depressed. The accelerator pedal must be fully
depressed within 10 seconds from when the gear lever is
moved from Neutral to Automatic or Manual and held
depressed during the complete start-up phase. This will
achieve high engine torque.

1
GJI only used at APF-ENH; the others are always included.

2
If parameter NXK is missing, reprogramming of MID 130 is required.

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.

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