1Volvo I-Shift Transmission AMT-D, EPA’10 Engines Presented By:Jeff Denny, Volvo Trucks North AmericaChris Sanderson, TEC EquipmentCompany, Department, Nameday month year
2Volvo I-Shift 12 Speed, 2 Pedal Automated Mechanical Transmission Overall Reduction 15.04:1 for OD, 14.94:1 for DirectHaving the right ratio for the right speed at the right time is what a Truck Transmission is all about . And the Volvo I-Shift is still “the” state of the art in Truck Transmissions today.Since introduction, I-Shift has grown to be the world’s most popular automated transmission, and is used with about one out of three Volvo engines sold here in North America.28% Gear StepsSingle CountershaftLight Weight597 to 611 lbs.High Torque CapacityCompany, Department, Nameday month year
3I-Shift Objectives Provide a transmission that offers the following: Fuel economy - intelligent software, Performance - optimized shifting programReliability – fourth generation of Volvo AMTSmooth operationCustom tailored to customer preferences with feature packagesLight weight / increased payloadEase of operation / driver retentionMany features that are exclusive to Volvo!KEY FEATURESIt’s a very reliable and mature productI-Shift can help improve fuel economy through intelligent software and complete integration. It makes every driver to shift like the most fuel efficient driver or better, which leads to improved fuel economy.It features very smooth shifting putting less stress on the driveline and tires.More features and greater flexibility than any other automated manual transmission due to six feature packages that gives you the flexibility needed to tailor the transmission to everybody’s needs. Can easily be recalibrated if the operation changes or for resale. Light weight improves payload.Easy operation helps with driver retention by reducing the time and cost of driver training. It allows new drivers to drive safe and efficient. At the end of the day this transmission can make a difference and improve the bottom line.Company, Department, Nameday month year
4Volvo I-Shift Specifications for EPA’10 AT2612DATO2612DATO3112DUsed WithD11 / D13D16Torque CapacityAny D11 / D13 Torque1900 lb-ftAny D16 Torque2350 lb-ftTop RatioDirect1.00:1Overdrive0.78:1OperationTwo PedalForward Speeds12Overall Ratio14.94:115.04:1Weight, lbs (kg)597 (275)610 (281)Let’s take a brief look at the specifications:We’ll be talking about three different models of I-Shift. All have 12 forward speeds. For EPA’10, these transmissions will be the “D” versionSo the way we define it as shown here is that the first two models are matched to the Volvo D11 and D13, while the third model on the right is matched to the D16.The Volvo I-Shift transmission has the highest input torque capacity of any transmission sold in North America today. In addition, it’s the only transmission which can be used behind Volvo’s 700 HP D16 Euro V engine, with 2323 lb-ft (3150 N-m) torque rating. No matter the model of the I-Shift transmission, the same robust internal gears are used and the transmission will always meet or exceed the torque rating of the engine with which it is paired.The overall ratio is ample for all conditions. And all I-Shifts are extremely lightweight, as you see here, even less than 600 pounds for the D11/D13 models..Company, Department, Nameday month year
5I-Shift Weight Benefits D13 + I-Shift = 3262 lbsISX + Ultrashift PLUS = 3879 lbsSpeaking of weight – did you know that compared to the lightest Ultrashift PLUS LAS, I-Shift is lbs. lighter, including the weight for clutch packages.This is extremely important in today’s market, especially with installation of the additional EPA’10 components.D13 + I-Shift = 3262 lbsISX + Ultrashift PLUS = 3879 lbsThat’s a 600+ lb weight savings! An additional 600 lbs of cargo on each trip can add pretty quickly to a company’s bottom line.712 – 726 lbs.915 – 995 lbs.
6What Makes I-Shift So Intelligent? Exclusive FeatureI-ShiftWhat Makes I-Shift So Intelligent?Teamwork. Integration. Information.I-Shift knows the engines’ efficiency map for each engine ratingOnly Volvo can integrate so well.Higher level of informationResult: Maximum intelligence and efficiencyWE TRUST THE TRANSMISSION TO CONTROL THE ENGINE!I mentioned intelligence in one of the earlier slides......so, what Makes I-Shift so intelligent? – Teamwork. Integration. Information.Volvo I-Shift transmissions have been fully designed and engineered by Volvo – by the same overall Engineering Department that engineers Volvo engines. Thus the engine and transmission can be truly designed together as one. They speak the same language, using proprietary protocols, are designed to meet the same project goals and timing, and are designed with mutually agreed upon engineering concepts and strategies. For example, the I-Shift transmission is given significant authority to control the engine under various conditions.I-Shift takes customer values to an unprecedented level. It features very smooth operation together with many features that improve drivability, safety and fuel economy. Only Volvo is so well positioned to integrate the engine, transmission, and vehicle together.Result: Maximum intelligence and efficiencyThis integration allows Volvo to put the customer first, in a way that no other Powertrain can!Company, Department, Nameday month year
7I-Shift Exclusive Features Innovative Shifting StrategySix (6) Software Feature PackagesTwo Shifter Control Styles Available – Basic, PremiumEconomy / Performance Operating Modes w/ Premium ShifterIntegrated Engine Brake InterfaceVolvo Driver Information Display InterfaceAccelerator Pedal With Kick-Down SwitchProprietary Engine-Transmission ProtocolTransmission Enabled to Control the EngineUpgradeability to higher engine ratings at resaleThere has been another AMT (Eaton Ultrashift Plus) which has recently entered the market and attempted to copy the I-Shift in many ways. But, there are still features exclusive to the I-Shift which makes it the leader in AMT technology.Here’s a list of some of these exclusive features, which we will discuss in more detail in the following slides.
8Six (6) Software Feature Packages Exclusive FeatureI-ShiftHere is the overall I-Shift Software Features package chart –We won’t go into detail here, but…“Gentle-Shift” is a new software package that has been added for 2010 with the D-Series I-Shift.While not for everybody, “Gentle-Shift” emphasizes very gentle starts and gearchanges over performance.It will be useful in tankers, livestock hauling, motorcoaches, team drivers, etc.Also available “unpublished” are the Basic and Enhanced Basic offering. Using the Fuel Economy package offers more flexibility based of the selectable parameters and allows us to simplify the offering a little. However, they are still available if desired.More features and greater flexibility than any other automated manual transmission due to these six feature packages that gives you the flexibility needed to tailor the transmission to every need. Can easily be recalibrated if the operation changes or for resale.Company, Department, Nameday month year
9Volvo I-Shift Two Control Styles Available Exclusive FeatureI-ShiftVolvo I-Shift Two Control Styles AvailableBasic ShifterNo E/P or Up/Down ButtonsMinimum driver interventionPremium ShifterFull driver ControlInside the truck, there’s no clutch pedal, as we said.The I-Shift transmission is equipped with an ergonomic lever type shifter which is available in either a Basic or Premium level, depending on the software feature package selected. The shifter is mounted to the side of the driver’s seat. Operating modes are:ReverseNeutralDrive – Economy or Performance (Premium Shifter)ManualLimp Home – can be activated if a serious fault occursThe E/P button is part of the “Premium” feature packages and switch between Economy and Performance mode, and there are two buttons on the left side of the lever for manual up- and down-shifting.Company, Department, Nameday month year
10Volvo I-Shift Controls (Basic Shifter) ReverseNeutralDriveManualPistol Grip ShifterBest for Max Fuel EconomyThe Basic shifter is used for the Basic, Enhanced Basic and Fuel Economy software packages.This shifter limits the amount of driver interface with the transmission, allowing it to remain in Economy mode and operate in the most efficient manner at all times.I-Shift can be trusted to provide the right gear for the right conditions every time. The Basic shifter has no +/- buttons and prevents the driver from operating the vehicle in the way he is used to “hearing it sound”.“Limp” Function(Button at Rear on both style shifters)
11Volvo I-Shift Controls (Premium Shifter) ReverseNeutralDriveManualEconomy / PerformanceMode ButtonThe Premium shifter is used for the Performance, Comprehensive and Gentle Shift software packages.When equipped with the Premium shifter, I-Shift comes with two selectable personalities - Economy and Performance/P+ modes.The shifter also adds the feature of manual shifting capabilities to the transmission and is recommended for Owner Operators, Vocational and Heavy Duty applications where additional driver interaction may be desired.“Limp” Function(Button at Rear on both style shifters)Manual Shift ButtonsUp / DownCompany, Department, Nameday month year
12Exclusive Feature I-Shift E / P Operating Modes Fuel Economy Mode In “E” mode, the transmission will select shift points and command engine parameters that maximize FUEL ECONOMY. Shift points are at low RPMs and gears are skipped to reduce languishing in lower gears.Performance ModeIn “P/P+” mode, GRADABILITY is maximized. RPM in each gear is increased, more gears are taken, and more power is available. The “P” mode will default back to “E” after a while when no longer used.Even when the Premium Shifter is used, the E/P switch can be programmed out, if desired, and re-enabled at resale.In “E” mode, the transmission will select shift-points and command engine parameters maximizing FUEL ECONOMY. The vehicle will actually achieve cruising speed faster because of the skipped shifts!In “P/P+” mode, GRADABILITY is maximized. NOTE: The P+ mode is only available with the Performance software package.In “KD” (kick-down) mode, ACCELERATION is maximized.Only Volvo has Fuel Economy, Performance and KD in the same Transmission.This enhances residual value when the truck enters it’s second life.Company, Department, Nameday month year
13Performance/P+ Additional Features Exclusive FeatureI-ShiftPerformance/P+ Additional FeaturesAbility to Rock FreeThe I-Shift has the ability to rock the vehicle back and forth to maneuver out of a stuck situation.In most instances, the shifter doesn’t need to be changed between forward and reverse – simply pump the accelerator.As mentioned in the previous slide, Performance/P+ mode maximizes power and gradeability. Here are a few other features that are unique to the Volvo I-Shift transmission.Ability to Rock Free - A combination of carefully pressing and releasing the accelerator, to ease the vehicle forward or backwards, will produce the rocking motion to elongate the wheel tracks which have caused the vehicle to become stuck. To utilize this feature, take the following steps:Engage differential locksTurn off traction controlSelect Performance/P+ mode of the I-ShiftMove the gear selector to the M-Manual position, 1st gear, or the 1st reverse gearCarefully press accelerator pedal up and down with a smooth pumping action
14P+ Additional Features Exclusive FeatureI-ShiftP+ Additional FeaturesPower LaunchIf the vehicle becomes “really stuck” in sand or very soft soil and is equipped with the Performance software package, the I-Shift has the ability to use extra engine torque to get the vehicle moving once again.I know this vehicle pictured is an exaggeration, but let’s say you get the vehicle “really stuck” and are unable to get it moving again by trying to rock it free. That’s where the Power Launch feature comes in. Selection of this feature allows you to use full engine torque to get the vehicle moving again.Engage as follows:Engage differential locksSelect P+ mode of the I-ShiftMove the gear selector to the D or M position, 1st gear, or the 1st reverse gearPush and hold the minus (-) button on the gear selectorCompletely depress the accelerator – the engine will rise to 1300 rpmRelease the minus (-) button and the clutch is engaged, launching the vehicle free
15Premium Shifter Additional Features Exclusive FeatureI-ShiftPremium Shifter Additional FeaturesAvoid Shifts in Drive ModeDelay a downshift by pushing the plus (+) button on the shifter while the engine rpms are very low – useful when approaching the top of a hill when a downshift is not desired.Delay an upshift by pushing the plus (-) button on the shifter – useful when driving uphill with poor traction or when approaching a hill where higher engine rpms are needed for more efficient operation.To avoid the I-Shift transmission downshifting when in Drive (D) mode, push the plus (+) button on the gear selector while the engine rpms are very low. This could be used approaching the top of a hill when a downshift is not desired by the driver.To avoid the I-Shift transmission up-shifting when in Drive (D) mode, push the minus (-) button on the gear selector. This could be when driving uphill with poor traction or when approaching a hill where higher engine rpms are needed for more efficient operation.
16Premium Shifter Additional Features Exclusive FeatureI-ShiftPremium Shifter Additional FeaturesGreatest Possible DownshiftTo evoke one large downshift instead of several smaller ones – useful when approaching a steep hill in off-road conditions when a higher engine speed is needed.The I-Shift uses its grade sensor and GCW calculations to determine the best gear to select.Push and hold the minus (-) button and change the gear selector from Drive (D) to Manual (M) mode.Release the minus (-) button.This gives a large downshift for the purpose of immediately getting a high engine speed in the vehicle, for instance when approaching a steep hill in off-road conditions.The I-Shift uses its grade sensor and GCW calculations to determine the best gear to select.
17Exclusive Feature I-Shift Driver Interface Volvo “DID” Selector PositionPresent GearPossible Gears Up & DownEconomy / Performance ModeIf Eco-Roll is enabledEngine Brake SelectionThe I-Shift transmission communicates through the Driver Information Display (DID) in the instrument cluster. All of the needed information is right in front of the driver in an easily readable format. Information displayed is as follows:Gear selector positionPresent gearAvailable gears – up or downEconomy or Performance modeEngine Brake positionIf Eco-Roll enabledThe I-Shift lets the driver know the number of steps that can be taken up or down based on present conditions, BEFORE the shift is attempted, not an audible signal to indicate the shift has failed AFTER it has been attempted as with Eaton automated transmissionsVolvo “DID”Company, Department, Nameday month year
18Integrated Engine Brake Interface Exclusive FeatureI-ShiftEngine Cruise Control, Engine Brake, & Transmission Integrated Together for Seamless PerformanceOff“A” – AutomaticBrake Cruise Control Enabled1,2,3 – Manual I-VEB Engine Brake Control“B” – I-Shift Brake Program Shifts Down for Maximum RetardationPlus / Minus switch on end for Brake Cruise Control functionI-Shift is perfectly integrated into the Volvo Intelligent Engine Brake (I-VEB) control.In the ‘A’ position, ‘Brake Blending’ occurs as the I-VEB is operated at 50% level with the application of the footbrake.Positions 1, 2, and 3 operate the I-VEB at 40%, 70%, or 100%.When the Brake Mode (B) is activated, the I-VEB comes on 100% and the transmission automatically downshifts to maximize the performance of the engine brake. I-Shift will continuously downshift in Brake mode as the speed decreases in order to maintain maximum retardation. The function then becomes less aggressive in the lower six gears to protect the driveline and improve comfort.Company, Department, Nameday month year
19Exclusive Feature I-Shift Upgradeability I-Shift can accommodate upgrades to anyavailable engine rating without requiring clutch ortransmission changes.I-Shift can be upgraded from Basic to Premium Shifter at trade-in for higher residual value.I-Shift can be re-rated to any software package.Upgradeability and flexibilityWith I-Shift you avoid all the fuss when it’s time to upgrade Power and Torque.The clutch and transmission can handle any of the available engine ratings from the lowest to the highest in any engine displacement.Whether you have Volvo D11, D13, or D16, you can upgrade the engine to its highest rating without needing to modify clutch or transmission.You can upgrade from Basic to Premium version within the same gearbox. This gives maximum flexibility and resale value for any vehicle and application.It makes I-Shift a perfect option for dealer stock vehicles.Company, Department, Nameday month year
20I-Shift Clutch Package Exclusive FeatureI-Shift17” Organic Faced Spring Dampened ClutchSmooth Clutch EngagementClutch – The Volvo Sachs 17” clutch assembly is designed for and precisely matched to the Volvo I-Shift application. Critical to the functionality of an automated mechanical transmission, it features a single-plate design with spring-cushioned organic friction facings that ensures drag-free synchronization during gear shifts and the smoothest possible clutch engagement. The combination of these non-aggressive facings and I-Shift’s ability to minimize heat during clutch engagement results in excellent clutch life and reduced Flywheel wear compared to cerametallic facing clutches.Clutch Actuator – The ZF Sachs “ConAct” clutch actuator provides the Volvo I-Shift with numerous advantages over competitor AMT’s. The lighter-weight and maintenance free actuator is a completely pneumatic device which is electronically controlled by the I-Shift. Combining the functions of numerous components of alternative release systems into a single integrated unit, the wear points and resulting inaccuracies of operation are virtually eliminated. The result is smooth automated transmission shifts over the entire lifetime of I-Shift.**Anyone who has driven an I-Shift equipped vehicle can attest to the smooth clutch engagement.Clutch WarrantyNormal Duty = 3 years / 300,000 miles / 7,500 hoursHeavy Duty = 3 years / 250,000 miles / 6,250 hoursSevere Duty = 1 year / 100,000 miles / 3,250 hours
21Exclusive Feature I-Shift Accelerator Pedal With Kick-Down Switch Firm Detent Near BottomIn “Kickdown” mode, downshifts occur when possible and ACCELERATION is maximizedThe accelerator pedal with I-shift features a Kick-Down Mode, with an appropriate detent. Pressing it causes the I-Shift to aim for MAXIMUM ACCELERATION.Using Kick-Down Mode will:- Change down a gear if it improves acceleration- Make the engine operate in it’s peak power window- Start in a lower gearThe Kick-Down Mode is enabled with some of the premium software packages, as we will describe.ONLY I-SHIFT COMES WITH A KICKDOWN SWITCHCompany, Department, Nameday month year
22Idle Driving Mode Facilitates driving slowly Lets the driver drive at engine idle speed in any of the lower range gears (1-6)A touch of the throttle (or + button on the Premium shifter) Increases to the next higher gearA slight press on the brake pedal (or – button on the Premium shifter) will downshift to a lower gearThe clutch is not slipped and is only opened when the vehicle stopsWorks well in reverse backing a trailerIdle Driving ModeWhen traffic jams up on the Interstate, there’s nothing to do but move along slowly in line when you can.The I-Shift utilizes the Idle Driving mode, which is engaged by the driver removing their foot from the accelerator and allowing the vehicle to idle along. The transmission automatically selects the gear which best suits the speed. The vehicle speed can be adjusted without the accelerator by using the plus (+) or minus (-) buttons on the Premium shifter (if equipped) which slightly raises the engine speed for the transmission to shift up, or slows the vehicle down with a downshift. When the Basic shifter is utilized, slightly pressing the accelerator or brake pedal will change engine speed to facilitate an upshift or downshift.The Idle Governor also works in reverse and comes very handy when backing a trailer for example.Company, Department, Nameday month year
23Grade Sensor Allows I-Shift To “See” What’s Ahead Informed TechnologyI-Shift has a Grade Sensor, so it knows how steep the grade is and if it’s changingI-Shift continuously monitors the grade, vehicle speed, acceleration, torque demand, weight, rolling and air resistanceI-Shift continuously predicts and selects the most efficient utilization of the engine over the next rolling 30 second period.How Can I-Shift See Into the Future? Intelligent TechnologyThe transmission knows the engines’ efficiency map for each engine rating - and by continuously monitoring the not just the vehicle speed, acceleration, torque demand, weight, but the GRADE, and the rolling and air resistance, it predicts and selects the most efficient utilization of the engine for the next 30 seconds.I-Shift has a sensor that tells it what grade it’s on. That helps I-shift determine what gear to start in, where to put the shift points and whether it can skip-shift or not.Even more: I-Shift looks at how the Grade is changing.So it can actually predict what the vehicle performance will be in the future. **This is one of the features that the Ultrashift Plus has copied.Company, Department, Nameday month year
24Hill Start Assist – OPTIONAL (Must also spec air ride suspension & Electronic Stability Control) Brake Pedal EngagedHill Start EngagedAccelerator PressedHill Start ReleasedHill Start Assist is a “Nice-To-Have” option for safety and reduction of wear on drivetrain components by eliminating roll-back with I-Shift.The brakes will remain on for three seconds. During this time, when the driver steps on the accelerator, the truck will begin to move forward with no rollback. It also works when in reverse on a downgrade and allows reversing without any roll-forward.**This is a feature that the Ultrashift Plus has copied.
25Forced Lubrication Gear type oil pump (Similar to engine oil pump)Pumps lubricant through drilled passageways for superior lubricationLube Oil Filter will remove any contaminants500,000 mile oil change intervals with on-highwayI-Shift, like all Volvo mechanical transmissions, features a lube oil pump. Like an engine oil pump, it pumps lubricant around through drilled passageways to get it where it’s needed, unlike common splash lubricant designs where all the gears are immersed in the lubricant. The pump also lets us offer a filter. It’s there on the side of the transmission. The filter catches any dirt that may get in to ensure clean lube for long life.Company, Department, Nameday month year
26PTO’s **Enhanced PTO Features or Multiple PTO’s – Needs a BBM Clutch dependent PTOs on the Volvo I-Shift are available with multiple power outputs. They can be specified in a variety of configurations with up to three outputs, accommodating direct mount hydraulic pumps (DIN) and flange drive connections. The design is simple and robust, requiring a minimum amount of maintenance. Since the PTO has limited ability for being turned on when the vehicle is moving, due to the clutch being engaged, it may also be an advantage from a safety point of view.Clutch dependent PTOs are the obvious choice where the vehicle has a manual or AMT transmission and there is no need to use the PTO when the vehicle is in motion.**Enhanced PTO Features or Multiple PTO’s – Needs a BBM
27I-Shift PTO Functions Basic – always included with I-Shift Pre-defined split positions – Low, HighStalk controlEnhanced – optional, includes Basic functionalityAbility to select split position when equipped with Premium ShifterLimit engine speed when PTO is engaged, additional rpm controlsAuto neutralReverse inhibitPark brake setting*Requires a Body Builder Module* - see BB Manual for additional infoEnhanced – optional, includes Basic functionalityAbility to select split position when equipped with Premium ShifterGear selection adaptation to engine speed limits- possible to set parameters that will limit engine speed when PTO engagedAuto neutral- driveline will be disengaged on request from the BBM regardless of the gear lever position when activeReverse inhibit- reverse gears are blocked when PTO engagedRequires a Body Builder Module
28I-Shift Application Guidelines MAKE TOUGH STARTS IN “P”On-Highway to 143,000 pounds beginning NOW (D16).VHD flat or partly hilly on-off highway to 110,000 beginning NOW.Strictly off-road (severe mining, etc.) still should use AllisonAs before, no mixers, no refuse. However, 6x4, 8x4, 10x4, 12x4 dump trucks, 105,500 chip trucks, 105,500 transfer dumps, block trucks, fire trucks, snowplows, line stripers, vac trucks, etc.
29What Does Volvo I-Shift NOT Do? I-Shift doesn’t get locked in gear if you shut it off in gear by mistake and the air pressure bleeds down.Instead, when you turn off the key with the selector in gear, the transmission shifts to neutral before it turns off the engine.I-Shift doesn’t tear up your dock or your ICC bumper backing up.Instead, when you back up and touch the brake, it de-clutches rapidly.I-Shift doesn’t “beep” at you to tell you it won’t shift.Instead I-Shift tells you if it CAN shift with arrows in the DID before you try.I-Shift doesn’t just sit there if you stop while in Manual Mode and try to take off in too high a gear.Instead, a pop-up message tells you to downshift or to put it in “D”.I-Shift doesn’t get locked in gear if you shut it off in gear by mistake and the air pressure bleeds down.Instead, when you turn off the key with the selector in gear, the transmission shifts to neutral before it turns off the engine.I-Shift doesn’t tear up your dock or your ICC bumper backing up.Instead, when you back up and touch the brake, it de-clutches rapidly.I-Shift doesn’t “beep” at you to tell you it won’t shift.Instead I-Shift tells you if it CAN shift before you try.I-Shift doesn’t just sit there if you stop while in Manual Mode and try to take off in too high a gear.Instead, a pop-up message tells you to downshift or to put it in “D”.
30Questions?Company, Department, Nameday month year