Transmission

Gearbox
SR 1700 / 1900 - VT 2014 / 2514
Preface Content
SR 1700 / 1900 Gearbox - General Information 3
This training module introduces the SR1700 / 1900
and VT2014 / 2514 gearboxes. The training module is Torque transmission in the gearbox 4
part of a series of modules designed for the Introduction 5
Transmission Basic Training Program.
Selector-shaft housing 6
This module should studied right after all other modules Idle speed inhibitor 7
from the Transmission Basic Training Program.
Lubrication system 8
While studying this module, you will have the Oil pump 9
opportunity to learn the specific components of
Compressed air system 10
SR1700 / 1900 and VT2014 / 2514 gearboxes, as
well as the function and operation of these Air filters 11
components.
Range cylinder relay valve 12
Inhibitor cylinder in the selector-shaft housing (1) 13
Inhibitor valve in the selector-shaft housing 14
Splitter cylinder 16
Splitter cylinder relay valve 17
Splitter inhibitor valve 18
Splitter gears 19
Electrical system 20
VT2014 / 2514 Gearboxes 21
Introduction 22
Synchronisation 23
Oil pump and oil filter 24
Gearbox cooling system 25
Inhibitor cylinder in the selector-shaft housing 26
Electrical components 27
SR 1700 / 1900 Gearbox - General Information

SR 1700 / 1900 gearboxes are provided with 14 speeds (2 idle speeds + 12 speeds), being the
12 highest speeds synchronised. The 4 reverse gears are not synchronised.

The basic gearbox contains 3 speeds and 1 idle speed, as well as a reverse gear. The basic
gearbox is equipped with a splitter controlled by a pneumatic cylinder. The gearbox is divided into
high and low gears, where the speeds in the basic gearbox and in the splitter are doubled.

* S - S means the the gearbox is equipped with a split gear mounted in the front of the basic
speed box.
* R - R means the the gearbox contains a high and a low shift, and that it is directly connected
to the basic gearbox output.
* C - idle
* R - reverse gear
* LS - low speed in the splitter
* HS - high speed in the splitter

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Torque transmission in the gearbox

The pictures show the route taken by the power within the SR 1700 / 1900 gearbox in each one
of its speeds.

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Introduction

The basic design of a mechanical gearbox has been studied in the basic module on gearboxes.
In this module, only the specific components of SR 1700 / 1900 and VT 2014 / 2514 gearboxes
will be studied.
The components of a SR 1700 / 1900 gearbox are as follows:

- Selector-shaft housing
- idle speed inhibitor
- torque transmission in the gearbox
- lubrication system
- oil pump
- oil radiator
- compressed air system
- air filter
- range cylinder
- range cylinder relay valve
- inhibitor valve in the selector-shaft housing
- inhibitor cylinder in the selector-shaft housing
- range gear inhibitor
- splitter control cylinder
- splitter cylinder relay valve
- splitter inhibitor valve
- splitter gear shifting electrical system

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Selector-shaft housing

As we have seen in the basic module, the selector-shaft housing is installed on the gearbox-
housing top. We have also seen that its function is to transmit the gear lever motion to the
gearbox gearshift attachment.

The selector-shaft housing is made up by:

A control shaft (1) to which the gearshift control is attached. A gearshift control bar (2) that
operates the gearshift attachments is installed in the control shaft (1).

The selector-shaft housing contains equipment called ”Gear selector inhibitor” that prevents the
two attachments from being operated at the same time.

The gear selector inhibitor is equipped with a gear selector attachment (4) that helps keep the
gears engaged. The reverse gear inhibitor (5) sticks the gear lever by creating a resistance
when displacing the gear lever to reverse gear / idle speed.

The position of the selector-shaft housing may be accurately adjusted by means of two adjusting
screws.

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Idle speed inhibitor

The purpose of the idle speed inhibitor is to prevent the vehicle from driving in high gears when in
idle speed, which would mean an excessive load in the planetary gears.

The reverse gear shifting fork (idle speed) is equipped with an arm (1). When the piston rod in
the shifting cylinder is its forward position (high speed) it prevents the gearbox from being put
into idle speed.

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Lubrication system

All gearboxes are partly splash lubricated and partly spray lubricated.

The lubrication system is carried out as follows:

Right after the oil pump, there is a retaining valve adjusting the oil pressure to stop it from
reaching an excessive value.

The oil passes after the oil filter, which is a paper filter similar to the ones used in Volvo engines.

Then, the pump forces the oil to the main shaft back cover. A controlled escape through the
retainers permits the lubrication of the main shaft rear bearing.

Part of the oil (70%) is pressed to the lubrication of a planetary gear set. The rest (30%) is
impelled under pressure to the oil delivery pipe that is supplied with holes through which the
pressurised oil comes out to the box shafts. These shafts are also supplied with a hole that
carries the oil to the bearings and synchronisers.

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Oil pump

The oil pump is an eccentric pump driven by an intermediate shaft gear through its own gear (4)
installed in the reverse shaft.

Oil radiator

The oil radiator is an extra component in the gearbox. It is made up by a support (1) and a heat
exchanger (2) coiling up in the gearbox where it is usually located the oil filter.

The oil filter cover (3) is later screwed to the support.

The oil impelled by the oil pump passes first through the oil radiator, the oil filter and then,
through the oil circulation galleries in the gearbox.

The oil cooling, through the heat exchanger, is carried out with the help of the engine cooling
system that carries cooling water up to the heat exchanger through metallic pipes and hoses.

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Compressed air system

The purpose of the compressed air system is to provide air pressure to the range cylinder and to
the splitter cylinder.

The compressed air system also provides pressure to control the gearshifts so that these do not
happen simultaneously in the basic gearbox and in the splitter.

The range shifting control is located on the gear lever knob (5). It consists of a valve that opens
and closes the air passage, for the gearshifts, to the relay valve for the range cylinder.

The gear lever knob (4) receives the compressed air through the connection (1). When you shift
into the low range gear, the air comes out through the connection (21) and, when you shift into
the high range gear, the air comes out through the exhaust outlet (3). Connection (22) supplies
gear shift air to the splitter relay valve.

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Air filters

The compressed air system in the gearbox is supplied with an air filter.

This filter (1) is installed in the compressed air distributor bolted to the chassis crossmember. Its
function is to retain any impurities in the air supply the gearbox.

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Range cylinder relay valve

The function of the relay valve (7) is to control the air passage to the cylinder piston’s backside
according to the selected gearshift. The relay valve also serves as a cylinder back cap.

The relay valve is provided with a load spring that keeps the control piston in the high range gear.
When you shift into the low range gear, the gear shift air passes through the relay valve, the
spring force is overcome by the air pressure and the control piston is displaced to the low range
gear. The cylinder air discharge is carried out through the relay valve.

Range cylinder

The range cylinder is a double action pneumatic cylinder bolted to the gearbox back end. The
piston is also bolted to the back of the gearbox via the piston rod. It is sealed by a rubber ring (1).
The other sealers are the piston sealer (2), the piston rod sealer (3), the rubber ring that seals
against the gearbox house (4) and the rubber seal rings on the cap (relay valve) (5).

The cylinder should be adjusted back and forth in relation to the range gear so that the fork
eccentric rollers are kept in a proper position in relation to the synchronisers coupling ring. The
adjustment is carried out with shim (6) installed between the cylinder and the range gear.

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Inhibitor cylinder in the selector-shaft housing (1)

The inhibitor cylinder is installed in the selector-shaft housing. Its function is to inhibit the manual
shifts in the basic gearbox while a range gear shifting is being carried out.

The inhibitor cylinder consists of a single action spring loaded cylinder whose piston is provided
with an inhibitor dowel.

When the compressed air reaches the cylinder, the spring is compressed and the piston dowel
is pushed so that it can move down into the gear lever groove. Thus, the basic gearbox is locked
in neutral.

Range gear inhibitor (2)

The range gear inhibitor makes it impossible to shift into low range when the output shaft
revolutions in the gearbox are higher than 700 rpm (30 km/h).

A relay valve is controlled by the speedometer that activates an electric signal, that in it’s turn
closes the air passage to the relay valve of the range cylinder, thus preventing, the low range
gear from being engaged.

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Inhibitor valve in the selector-shaft housing

The basic gearbox shifting is locked (3) while the range gear is being shifted by means of an
inhibitor cylinder installed in the selector-shaft housing.

The inhibitor valve (1) that, in its turn, is controlled by the piston rod (2) in the gear-shifting
cylinder adjusts the feed air for the inhibitor cylinder. The mechanism is as follows:

The piston rod is provided with two holes. The inhibitor valves dowel is housed in one of these
holes while a range gearshift is engaged. There is one hole for the low range gear and another
one for the high range gear. The valve closes the air passage for the inhibitor cylinder in the
selector-shaft housing.

When you shift range gears, the inhibitor valve piston is pushed up and comes out of its
inhibiting position and, as a consequence, opens the airflow for the inhibitor cylinder.

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Inhibitor valve in the selector-shaft housing - continuation

It is not possible to shift a _ range gear while one of the basic gearbox gears is engaged. This is
controlled by another inhibitor valve working in a reverse way than the one installed in the range
gear.

A - when the gear lever is in neutral (1), the inhibitor valve is open and the feed air passes to the
range cylinder.

B - when the gear lever is engaged in a basic gearbox gear (2), the gear lever pushes the valve
piston in and closes the air passage to the range cylinder.

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Splitter cylinder

The splitter cylinder is a double action pneumatic cylinder installed next to the range gear. The
cylinder is an assembly made up by a piston, a piston rod and an inhibiting device.

This unit is bolted to the gearbox.

The piston is installed in a separator bolted to the piston rod. This way, the piston rod may be
safely displaced up and down and provide the required play for the splitter synchronisers. The
cylinder position does not require adjustment.

Two attachment balls help keep the cut-out switch lights up a control lamp that indicates a
splitter high gear is engaged.

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Splitter cylinder relay valve

The splitter cylinder (1) relay valve operation is similar to that of the range cylinder relay valve.
The relay valve is kept in the low splitter by the force of a spring. When you switch to high
splitter, the air passage to the relay valve is open. The air overcomes the spring force and the
valve cursor is displacing to the high splitter.

REMEMBER:
The splitter switch is located on the gear lever knob.

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Splitter inhibitor valve

Shifting gears in the splitter gear should not take place without pressing the clutch pedal down.
For this reason, an inhibitor valve controls the feed air passage for the splitter cylinder.

With the clutch pedal depressed, a lever pushes the inhibitor valve piston in and opens the valve
that, this way, closes the passage of the feed air of the splitter cylinder.

1. disengaged valve
2. engaged valve

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Splitter gears

Let’s know how the airflow is performed and what happens to the many components while
switching from low splitter into high splitter:

Shifting gears in the splitter may only be carried out when the clutch pedal is fully depressed,
regardless of the basic gearbox being engaged or not.

A. Low splitter, that is, the relay valve is receiving the shifting air.

B. To shift the splitter from low to high, press the clutch pedal down so that the inhibitor valve
opens the feed air passage to the splitter cylinder. The cylinder switches to high splitter. The
cylinder piston side that is not being used discharges the air pressure through the relay valve
and, at the same time, a control lamp in the instrument panel lights up.

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Electrical system

SR 1700 / 1900 gearboxes are provided with some electrical components, such as:

1. An electric valve that acts on the range gear inhibitor operation.

2. A speedometer sensor that helps the range gear inhibitor operation.

3. A cut-out switch that shows a splitter gear is engaged.

4. A cut-out switch that shows a reverse gear is engaged. (reverse lamp lights up).

Components:
1 = 614
2 = 7052
3 = 214
4 = 217

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VT2014 / 2514 Gearboxes

The gear configuration in the VT2014 / 2514 gearboxes is similar to those in the SR 1700 / 1900
gearboxes, that is:

14 speeds
- 2 idle speeds
- 12 synchronised high speeds

The 4 reverse gears are not synchronised.

* VT - Volvo transmission
* 20 or 25 - gearbox maximum torque, 2050 Nm or 2450 Nm.
* 14 - number of gears in the gearbox.

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Introduction

VT2014 / 2514 gearboxes are based on the SR 1900 gearboxes.

The differences between these two gearboxes are as follows:

- in the synchronisation mechanism

- in the oil pump and oil filter
- in the gearbox cooling system
- in the function of some of the electrical components
- in the inhibitor cylinder in the selector-shaft housing

These alterations will be detailed in the following pages.

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Synchronisation

VT2014 / 2514 gearboxes are provided with a new synchronisation mechanism.

This new mechanism considerably reduced the gearbox effort during gearshifting.

This new system consists of a gear ring (1), an inner ring (2), a washer (3), an outer ring (4), a
synchroniser ring (5), a plate spring (6), a engaging body (7), a coupling sleeve(8), 4 spring pins
(9), and 2 spring pins for the neutral (10).

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Oil pump and oil filter

The oil pump and the oil filter in the VT2014 / 2514 gearboxes present some advantages over the
oil pump and oil filter in the SR gearboxes.

The relief valve (1), set in motion when the filter is clogged, is now installed in the pump
(previously, it was installed in the filter). The pump relief valve (2), is still located in the pump it
self.

Like the old system, 70% of the oil is pressed to lubricate the range gear and 30% to the other
gearbox components.

The supply hole, the level display and the drain are installed on the gearbox side in separate
holes; the oil level can be checked through a glass.

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Gearbox cooling system

VT2014 / 2514 gearboxes may be equipped with a heat exchanger installed in the gearbox itself.

Thus, the oil coming from the pump passes through a pipe (1) in the heat exchanger before
being sent to the gearbox.

The oil is always kept in a constant temperature to properly lubricate the gearbox components.

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Inhibitor cylinder in the selector-shaft housing

The inhibitor cylinder in the selector-shaft housing is provided with a new function:

When the gear lever is in neutral and the clutch pedal is released, the cylinder (2) locks the
gearshifting through the spring force. When the clutch pedal is applied, the air passes through
the splitter inhibitor valve (1) to the inhibitor cylinder bottom and overcomes the spring force,
making it possible for the gears to be shifted.

This function makes it impossible to shift a gear before pressing the clutch pedal.

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Electrical components

VT 2014 / 2514 gearboxes are equipped with electrical components that are the same from the
ones in the SR gearboxes. They are as follows:
214 - a splitter contact. It activates the splitter lamp in the instrument panel when the splitter low
gears are in use.
217 - a reverse gear contact. It activates the reverse lamp and a sound signal when the reverse
gear is engaged.
614 - an electric valve that helps the range gear inhibitor operation (makes it impossible to shift
to low range when the speed is higher than 30 km/h).
7052 - a speed sensor. It sends speed signals to the tachograph speedometer.
2074 - a range gear position sensor. It sends information to the vehicle central control unit on the
range gear shifting. Its purpose is to activate the electric valve (614) that prevents gears from
being incorrectly shifted.
6050 - an electric valve that inhibits the 1st gear engagement. Its purpose is to avoid damage to
the coupling synchronising system.
XXX - a control sensor. It informs the control unit the gear lever is in neutral.
762 -an oil temperature sensor. It shows the temperature of the gearbox lubrication oil.

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