IVECO B.U.H.

(Heavy Business Unit)

Volumes 2002 IVECO B.U.H.(Heavy Business Unit) Madrid & Ulm
Units

30,000

25,000

20,000

15,000 Today

10,000

5,000

0
2000 2001 2002 2003 2004 2005 2006 2007
ECOMAT 161 147 138 144 140 130 130 130
ASTRONIC2 173 2,044 5,999 7,032 9,114 11,260 14,600 16,100
ASTRONIC 1 3,584 2,468 331 30 0 0 0 0
ECOSPLIT 19,501 20,134 19,067 18,107 17,380 16,180 14,600 12,850
ECOMID* 2,583 2,185 2,254 2,332 2,454 2,080 600 560

EuroTronic and Synchro Transmisisons 3

EuroTronic II
The Automatic Choice.

Full automated

Release 4.50 - 1/Nov/02

Focus on the EuroTronic.ppt

EuroTronic and Synchro Transmisisons 4

 General characteristics
• Designed from the ground up to be an automated box
- optimised, not a conversion or after thought
• Main Section - Mechanical constant mesh 3 or 4-speed
gearbox, twin counter shaft, includes a transmission brake,
helical cut gears & serrate output flange for torque transfer.
• Single point connections for air and power
• Aluminium case with integral bell housing
• "conventional" dry single plate clutch, no torque convertor
• No clutch pedal, clutch and gear shifting is actuated
electro-pneumatic
• The driver gets information about the gear,
shifting possibilities and problems via the
display in the Instrument Panel.

EuroTronic and Synchro Transmisisons 7

 General characteristics
• Wabco “D” ABS is mandatory to work all the benefits
This also includes EBL (Electronic Brake Limiting) function
to replace the old LSPV (Load Sensing Proportion Valve) on
EuroTech’s.
• Permanent data exchange with other electronic control
systems (engine, braking system, Intarder etc.) via the
CAN BUS to communicate for shifting and engine brake
operation
CAN BUS is a simple 2 wire twisted pair.
“D” Plug<->ABS ECU<->Engine ECU<->Trans. ECU.
• The ECU is adaptive - senses loads, gradients,
acceleration etc and adjusts to use different shift patterns
and points (skip and progressive) as required
• It’s easy to drive in the fully automatic mode with manual
operations available at any time.
• Multi. function "Joy-stick" and accelerator pedal

EuroTronic and Synchro Transmisisons 8

 Typical Drivers
Comments - Perceptions

• “Does not go, lacks grunt, accelerates slowly” - Not True.

This perception is a result of the driver having much less to do

(ie occupy his left arm, foot and mind), shifts are smoother
and combined with the lower cab noise levels creates a very
strong impression.
APG testing has shown this is a perception only, but if not
corrected could lead to more use of the manual mode with the
resultant higher fuel consumption.
The issue is similar to a Manual Vs Automatic car.
• “Corners sneak up on you” - True.
Here again, with the driver doing much less, he can lose an
understanding of the vehicles speed.

EuroTronic and Synchro Transmisisons 9

 "visible“ Display

components
Accelerator Gear lever
Pedal with ("joy-stick")
kick down
de-tent. Transmission
ECU & Shift
Module

No Clutch Gearbox
Pedal Constant Mesh
Main Section

Clutch Actuator

EuroTronic and Synchro Transmisisons 10

 Display
Flow of electric signals
IMMOB

EBL

INT

ABS

ECUs
speed / eng.revs
"Joy-stick"
engine brake

"open door" switch -

Buzzer sounds if
door is opened.

PTO switch

Reversing lights
Clutch actuator
EuroTronic and Synchro Transmisisons 11
Basic Construction for the 12 or 16 speed versions.

Splitter unit Central section (3 or 4 speed)

Range
change
unit

Lay shaft
brake

EuroTronic and Synchro Transmisisons 12

Transmission Control Module

Under the ECU Cover

Showing the shift solenoids

CAN
management

Clutch control

Gear shifting

Transmission
control

EuroTronic and Synchro Transmisisons 13

Shift Process (Up shift)

EuroTronic and Synchro Transmisisons 14

Shift Process (Downshift)

EuroTronic and Synchro Transmisisons 15

 EuroTronic II
Optimized space, weight and cost!

12 AS 2301 DD

Full automated
12-speed transmission
for vehicles up to 1 900 Nm
(approx. 440 bhp)

16 AS 2601 OD

16-speed transmission
for vehicles up to 2 600 Nm
(approx. 550 bhp)

EuroTronic and Synchro Transmisisons 16

 Operating modes - simply
Automatic mode
No training.
Just drive it!
010832
 The transmission shifts automatically
 Both hands are always on the steering wheel
 Optimum shifts in all situations.
No matter whether driving economically
or for power: the electronics detect the
“driver characteristics” requirements
 If necessary, gear correction using joystick
 The electronics preselect a starting gear,
the driver can adapt this to any particular
situation
Manoeuvring mode and PTO operations are only available in manual mode!
or Manual mode
To pre-empt hills
& obstacles
 The driver makes the shifts
(using the joystick)
 Automatic transmission clutch
engagement / disengagement
 Transmission shifted by tipping joystick:
1 detent = 1 gear, 2 detents = 2 gears
 Manoeuvring mode:
in 1st gear or RL gear
 Incorrect shifts are not possible, however
engine can be used incorrectly.
EuroTronic and Synchro Transmisisons 17
 Operating concept
Console-range selector
Second
detent First detent The display provides
(upshifts 2 (upshifts 1 gear) information to the driver
gears)
 operating displays
Function button F (operating mode,
changeover between present gear selected)
Neutral button N
automatic / manual  warning information

First detent  information relating to

(downshifts system faults
1 gear)
Reverse gear inhibit
and error code inquiry 017581

Second detent
(downshifts
2 gears) 017020
Manoeuvring in Manual mode
in 1st gear and in low reverse gear (RL)

EuroTronic and Synchro Transmisisons 18

 Drive function
Automatic mode - starting.
F Function button

Full automated
Reverse gear
R inhibit (pull up)
 Start the engine
(put your foot on the brake
to clear the EDC lamp) Display
Neutral position
CH is display for the N
system Check. N button
This display is shown
after the system check N F
 Press function key
The starting gear is selected automatically
(if necessary, correct setting off gear: + or -)
R
 Accelerate and release the park brake together
Danger: The vehicle may roll on a hill, as would any other mechanical (manual) transmission!
Change into Neutral, to reduce wear on the clutch release mechanism for periods over about 2 min

EuroTronic and Synchro Transmisisons 19

 Drive function - starting.
 Starting Off
Apply the trailer brakes to prevent rolling on starting,
apply the accelerator, release the brakes as the clutch
engages.
Starting Gear
 Maximum allowable starting gear is
7th for the 16 speed transmission
5th for the 12 speed transmission
only when there is no load, on level ground.
 Typical, automatically selected starting gear,
when on level ground
4th for the 16 speed transmission
3th for the 12 speed transmission
Every time the vehicle is stopped (without stopping
the engine), the last starting gear is automatically
selected or if a lower gear is used on the approach to
the stop, it will become the starting gear.
Note: If the accelerator pedal is not sufficiently depressed, the clutch may not dis-engage fully
Full automated
Warning:
If when starting off, the vehicles
rolls in the direction opposite to
the gear selected - the clutch will
engage and disengage quickly.
Use the brakes to stop it rolling
and start over again, using a lower
gear, more accelerator or the
trailer brakes.
 CL will appear in the display if
the clutch has been over loaded
and this may lead to shut down if
the warning is not heeded
EuroTronic and Synchro Transmisisons 20
 Drive functions The Display

Full automated

Each

3 5 bar
stands
for one
10
gear

Automatic mode Manual mode Manual mode

- 3rd gear display - 5th gear display - 10 th gear selected
- downshift by 2
gears is possible

EuroTronic and Synchro Transmisisons 21

 Drive functions
+1 -1 Setting off (16 spd.) Upshifts on the move
+2 -2 from Stationary
First programmed + 1 gear
setting off gear - 1st gear

Second programmed + 2 gears

setting off gear - 4th gear
F H automatic gear search
014575
Third programmed (alternative)
setting off gear - 7th gear F H
to max. engine torque
N F
Downshifts on the move

- 1 gear Reverse from Stationary

R RL low
Press function
F key - 2 gears RH high

R Reverse gear to max. engine power H F

inhibit (pull up) rating for acceleration.
Press neutral
Maneuvering
N position key to max. engine speed F only in 1st & 2nd gear or RL/RH
for max. ITB operation
H Hold Button In! (engine braking) Neutral N

EuroTronic and Synchro Transmisisons 22

 Driving with EuroTronic
Tip 1

 Drive in automatic mode

 Only use manual mode to:
Ÿ prevent “gear hunting”
on uphill inclines
Ÿ to restrict “upshifts”
3
on downhill inclines
Automatic mode
Ÿ be Pro-Active with the road conditions - 3rd gear display

The transmission can’t see the road ahead, but

the driver can.
Warning: The transmission does not upshift when coasting in manual mode.
Therefore brake the vehicle before excessive engine speeds are reached.

EuroTronic and Synchro Transmisisons 23

 Driving with EuroTronic
Tip 2

 Driving with anticipation

Ÿ Detect obstacles in good time
to prevent unnecessary stops/accelerations
Ÿ Take advantage of momentum
Ÿ Take advantage of “green wave”
(synchronized traffic light sequences)
and move with the flow of traffic
Note: In cruise mode, the ITB will activate, if
the road speed is above the set speed, this may
limit the over run and reduce the momentum
to attack the next hill.

Warning: Continuous acceleration and braking uses a lot more fuel!

EuroTronic and Synchro Transmisisons 24

 Driving with EuroTronic
Tip 3 - for coupling/uncoupling trailers, moving into a loading dock.

In Manual Mode, there is a +1

1
Manoeuvring / picking up trailer
feature
Ÿ only in 1st gear
-1
R
Ÿ & RL N

This mode “Slips” the clutch, reduces engine

torque and increases the throttle pedal’s sensitivity.
Only while up to 70% throttle position, but not 70%
RL
of engine speed.

EuroTronic and Synchro Transmisisons 25

 Driving with EuroTronic
Tip 4

Switch the engine off, when parking

and even briefly leaving the cab N

Ÿ Put the park brake on and 017922

press neutral button N

When stationary for more than 2 min’s
Ÿ If ignition is switched off, the
transmission automatically shifts
into neutral
N
Danger: Ignition cannot be switched off when a gear is selected! and to use the
battery isolation switch will lead to ECU faults.
When the ignition is turned off, the ECU’s are
still active to write data to memory.
EuroTronic and Synchro Transmisisons 26
 Driving with EuroTronic
Tip 5
Automatic Mode
EuroTronic is an automated manual transmission
and unlike torque converter automatics, will roll on hills

3
as would any other manual transmission. N
 Starting off on a slope, in manual or automatic
modes, may require the driver to move his right foot
quickly from the brake to the accelerator, however on Manual Mode
steeper slopes the following is advised:-

2
Ÿ the use of the trailer brake controller to prevent
the truck from rolling, which is then released as the
EuroTronic engages the clutch
Ÿ Or by the gradual application of the accelerator
pedal while releasing the brake pedal, ie use both feet.

Danger: Do not the truck’s park brake controller, as it will not release quickly!.

EuroTronic and Synchro Transmisisons 27

 Displays
Operating displays

CH System self check

(with ignition on) 1 Manoeuvring mode
forwards gear

N Transmission in
neutral 10 Gear selected,
downshifts possible

Automatic operations
display RL Manoeuvring mode
low reverse gear

5 Setting off or driving gear

selected (in this instance RH High reverse gear
selected
5th gear)

PN PTO 1 is active (P),

transmission neutral (N)
PTOs 1 and 2 are activated
P3 (P), setting off gear 3
selected (3)

EuroTronic and Synchro Transmisisons 28

 Displays - Warning information / system errors

Warning information System errors

Vehicle can still be driven in a
AL Insufficient air pressure
(Airless), will not start!
restricted manner, visit specialist
workshop as soon as possible.

S Vehicle can be driven to the

FP Remove foot from accelerator!
(accelerator test)
T
O
P
nearest parking area in the gear
selected, ignition off for approx.
5 sec.and then on again.

CL Clutch overloaded,
select lower gear
Visit service centre
if error is still present.

EE Communication with display

error 53 Example, error code: 153
(bars signify “1”)

CW Clutch worn display

Replace
20 Example, error code: 220
(arrows and bars signify “2”)

EuroTronic and Synchro Transmisisons 29

 Recalling System Errors
Error message call up

 Lift reverse gear inhibit (R) upwards and

do not press the foot-operated brake Reverse R
gear inhibit
 The figures shown in the display correspond
to the error number

Examples:

Ÿ Error code 53 53
Ÿ Error code 153
(bars signify “1”) 53
Ÿ Error code 220
(arrows and bars signify “2”) 20

EuroTronic and Synchro Transmisisons 30

special functions in automatic mode:
• "kick-down" function of the accelerator
pedal changes the shift patterns and has the
engine operating at the maximum power -
when the driver pushes the pedal through
the de-tent.
Note: the pedal records 100% throttle at the
de-tent.
• The driver can stay in Automatic mode and
temporally select a gear by moving gear
lever in either direction. This will result in a
gear shift, but the transmission will remain
in the automatic mode, until the EuroTronic
thinks conditions require another gear and
will revert to automatic mode.
ie manual shifts in automatic mode.

EuroTronic and Synchro Transmisisons 31

4 Modes of Engine Brake Operation
By the 3 position switch
- Foot off the accelerator pedal
- Foot on the brake pedal
- Foot on the Floor Button (EuroTech) or
- While in Cruise Control Mode
• The engine brake must be turned “OFF” to activate
cruise control mode. When in cruise mode, the engine
brake will operate automatically if the truck’s speed
exceeds the set cruise speed by 2 km/hr
• The ECU’s manages the transmission, engine brake
and VGT to maintain the set speed and will change
gears to operate the engine brake at maximum rpm’s
up to the red line when above set speed by 4km/hr.

EuroTronic and Synchro Transmisisons 32

 Clutch Wear (Long Distance) Field Testing
The European Expereince
100 ic
on

ion
r
roT

is s
u
rE

m
o

ns
t f
e

ra
rg
Ta
lT
ua
Clutch wear [%]

an
-M
lu e

50
Va
al

Test Data:
p ic
Ty

Six trucks in Field Test:

16 AS 2200
Experience with EuroTronic 345 kW (470PS)
40t GVM Axle Ratio = 3,07

0
0 200 400 600 800 1 000

Distance x 1 000 km

EuroTronic and Synchro Transmisisons 35

 Fuel Consumption Comparisons
The European Experience

+ 1. Variation min/max
(good driver/bad driver)
with EuroTronic
with Ecosplit
3.0L/100 km
around 5.0L/100 km

+ 2. Fleet consumption reduction:

(using EuroTronic v Ecosplit)
minimum 0.6L/100 km
up to 1.3L/100 km

+ 3. The bad driver (fuel consumption) improves

EuroTronic and Synchro Transmisisons 36

EuroTronic and Synchro Transmisisons  37