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Issue 1.1 en

Comfort Shift, CS

Function description

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Scania CV AB 2007, Sweden
1 710 497
Contents

Contents
General ...................................................................................3

CS system components ...................................................................................5

Gearbox.....................................................................6
Longitudinal stroke cylinder .....................................6
Lateral stroke cylinder ..............................................7
Control cylinders for the range unit ..........................7
Position sensor ..........................................................8
Speed sensing..........................................................10
Solenoid valves .......................................................11
Clutch pedal switches .............................................11
Gear lever carrier.....................................................12
Gear indicator with buzzer......................................14
Control unit .............................................................15
Diagnostic switch for test programme ....................16
Diagnostic socket ....................................................16
Delay relay ..............................................................16

Gear changing pattern .................................................................................17

Location of components on the

gearbox .................................................................................18

Built-in safety features .................................................................................20

Location of controls .................................................................................23

Driving .................................................................................24

Signal routes .................................................................................28

Emergency gear changing .................................................................................29

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 General

General

The CS system's control unit and functions are

Comfort Shift
the same as the CS2 for the 3 series. The
Comfort Shift, CS, is an electro-pneumatic gear gearbox and gear selector housing are the same
change system produced and developed by as for Opticruise.
Scania to facilitate gear changing and increase
comfort. The CS lever is similar to the gear
lever on a car and is just as easy to change
gears with. In addition gears can be pre-
selected.

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General

The CS system has a manual Control unit

gearbox The control unit detects the vehicle speed and
The CS system supplements the manual gearbox the gear that is engaged. When the driver selects
in that the gear change mechanism has been a gear with the CS lever and depresses the
replaced by control cylinders for engaging and clutch, the control unit changes gear to that gear
disengaging gears. using compressed air cylinders on the gearbox.

For changing gear in the main gearbox, two The control unit program is adapted to the
control cylinders have been added, longitudinal vehicle engine and gearbox. Either the
and lateral stroke. The ordinary GR801 gearbox integrated troubleshooting program or external
control cylinders are used for the gearbox range test equipment can be used for troubleshooting.
unit, high and low range. The control cylinders
on the main gearbox work in the directions
corresponding to the gear selector pattern.
The longitudinal and lateral stroke control
cylinders have been adapted to provide reliable
and rapid gear changing. The longitudinal stroke
movement has a damping device which adapts
the operation of the gearbox to the synchromesh.
A number of position sensors on the gearbox
inform the control unit when each gear changing
sub-movement has been completed and indicate
which gear is engaged.
The CS system has seven solenoid valves. Five
of these are used for longitudinal and lateral
stroke on the main gearbox. The two solenoid
valves for the standard version of the gearbox
are used for the high and low range of the range
unit.

103 571

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 Components

CS system components

2 3 6 4

103 702
5 7 1 5
13
11
14 8 10 9

12
103 574

1 Manual gearbox 8 Clutch pedal switches

2 Longitudinal stroke cylinder 9 Gear lever carrier
3 Lateral stroke cylinder 10 Gear indicator with buzzer
4 Control cylinders for the range unit 11 Control unit with code plug
5 Position sensor 12 Diagnostic switch for test programme.
6 Speed sensing 13 Diagnostic socket
7 Solenoid valves 14 Delay relay

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Components

1. Gearbox
The gearbox is a manual gearbox, the gearshift
housing of which is fitted with compressed air
cylinders.

103 572
Gearbox GR801

2. Longitudinal stroke
cylinder
The longitudinal stroke cylinder performs the
longitudinal gear changing movements. It is
fitted with a double-acting piston and has three
compressed air connectors for:
• Forward longitudinal stroke
• Backward longitudinal stroke
• Neutral position Longitudinal stroke cylinder
To obtain soft gear engagement, the front and
rear longitudinal stroke cylinder air inlets are
fitted with restrictors.
The stroke damper, built into the longitudinal
stroke cylinder, adapts the movement to the
synchromesh when engaging gears. Damping
only takes place from neutral to either forwards
or reverse.

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 Components

3. Lateral stroke cylinder

The lateral stroke cylinder performs lateral gear
changing movements:
• Right lateral stroke
• Left lateral stroke
Lateral neutral position is obtained using a
spring mechanism located in the cover of the
lateral stroke cylinder.

Lateral stroke cylinder

4. Control cylinders for the

range unit
The range unit control cylinders switch between
the high and low ranges of the gearbox. The
cylinders, which are the ordinary gearbox
cylinders, work in parallel.

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Components

5. Position sensor
Position sensors inform the control unit when
the gear changing movement is complete. A
gear change in the main gearbox can consist of
a maximum of three gear changing movements:
• Neutral position - Confirmation
• Lateral stroke, right/left - Confirmation
Longitudinal stroke, forwards/backwards -

103 682
•
Confirmation
In addition there is the gear changing Location of position sensors
movement and confirmation when changing
between high and low range in the range unit.
The gearbox has two different types of position
sensor:
• Magnetic sensor
• Confirmation contacts for the high and low
range in the range unit.

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 Components

Magnetic sensor
The magnetic sensor provides contact-free gear
change confirmation for the gear changing
movements of the main gearbox. The
confirmation unit reacts to and is controlled by a
magnetic field. It consists of 2 sections:
• a magnet housing
• a sensor housing
The magnet housing is under the gear selector
shaft. The sensor electronics are cast into the
sensor housing. The location of the sensors
means that the control unit can detect the
movement of the gear selector in the gearbox.
See also "Gear changing pattern" in this booklet.
During gear changing movements the sensors
are activated and the signal cable becomes live. Magnetic sensor
The sensor circuit has five signal cables, which
gives nine combinations of signal that the
control unit can detect: N, NL, NR, F, FL, FR,
B, BL and BR. The movement is divided into
lateral strokes e.g. N to NL and longitudinal
strokes e.g. NL to BL.

Note: On the GR801 the gear selector has no

backward stroke in the right position, BR. See
figure.

L = Left
R = Right
F = Forward
B = Backward
Gear selector movement pattern GR801

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Components

Confirmation switches
The electrical movement detection confirmation
switches on the gearbox range unit are closed
when they are not actuated.

Confirmation switch

Confirmation switches on the range unit

A = High
B = Low

6. Speed sensing
Speed sensing consists of a speed sensor which
detects the rotation of a pulse wheel. The signal
informs the control unit of the current speed.

Speed sensing, speed sensor

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 Components

7. Solenoid valves
The solenoid valves are controlled by signals
from the control unit and regulate the air flow to
the various control cylinders.
When gear changing is complete the control unit
is informed via the position sensors. Then
activation is stopped and the control cylinder is
vented through the solenoid valve.
The CS system uses seven solenoid valves. Five

103 704
of these are used for longitudinal and lateral
stroke on the main gearbox. Two solenoid valves
are used for the high and low range of the range
unit.

8. Clutch pedal switches

The clutch pedal position is detected by two
switches, one upper and one lower:
• The upper switch detects whether the clutch
pedal is released and the control unit can
check that the speed sensor is operating.
When the pedal is depressed the switch
earths a relay which in turn transmits a
+24 V signal to the control unit.
• The lower clutch pedal switch closes when
the clutch pedal is fully depressed. The
control unit detects this and energises the
relevant solenoid valves.
Both switches must be closed and the pedal
must be depressed for a gear change to be
possible.
Clutch pedal switch
A = Upper switch
B = Lower switch

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Components

9. Gear lever carrier

The gear lever carrier consists of
• CS lever
• Micro switches
• Interlock valve
• Rotary control for emergency gear change

103 589
Gear lever carrier
CS lever
The CS lever is used to request the desired gear.
There are seven forward gears and one reverse
gear. To engage 1st and reverse gear a
mechanical detent on the CS lever must be
lifted.
The movement of the CS lever has four lateral
positions and five longitudinal positions. Refer
to the illustration.
When the driver moves the lever towards the
desired gear the CS lever stops in the gear
changing position. When the gear change has
been carried out the driver moves the CS lever to
the drive position and the gear change is
complete.

Micro switches R 2 4 6
Z
Seven micro-switches are activated by the CS Y
lever, four laterally, A-D, and three
longitudinally, X-Z. Refer to the illustration.
A B C D X
The micro-switches detect the position of the CS
lever and provide the control unit with
information about the desired gear change. Y
1 3 5 7
103 590

A - D. Lateral positions
X. Neutral position
Y. Gear changing position
Z. Drive position

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 Components

Interlock valve
The interlock valve stops the CS lever in the
gear changing position until the gear change has
been carried out in the gearbox. When the gear
change is complete the interlock is released and
the driver can move the lever to the drive
position.
If the driver moves the CS lever rapidly so that
the interlock valve cannot lock it, a mechanical
wedge in the gear lever carrier prevents the CS
lever from going into the next drive position
before the gearbox has completed the gear
change.

Rotary control for emergency gear

change
There is a cover behind the CS lever. Under the
cover is an emergency gear change rotary
control and a switch for reverse gear.

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Components

10. Gear indicator with buzzer

The gear indicator is part of the instrument

cluster and consists of four components:
• A window with eight character positions

108377
• Buzzer
• Background lighting Gear indicator
• Indicator lamp (does not affect the function
of the CS system)
When driving the gear indicator has two
functions:

Acoustic signals via the buzzer

Indicating gear selections
The buzzer is controlled directly from the
A lit numeral or letter in the middle of the control unit. The function of the buzzer is to
indicator shows which gear is engaged. inform the driver with different acoustic signals
that the control unit has detected a fault in the
system or that the driver is making a mistake,
Displays malfunctions with a e.g. selecting too low a gear.
character code
See also the section Integrated safety features in
See also the section Integrated safety features in this booklet.
this booklet.

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 Components

Background lighting
The gear indicator has background lighting to
make the gear indicator visible. When the light
switch is in position 0 the background lighting is
at full brightness. When the light switch is in the
parking or main and dipped beam position, the
background lighting follows the rheostat for the
instrument lighting.

Note: The background lighting bulb must be

intact in order for the gear indicator to operate.

11. Control unit Control Unit Gearbox

xyzzxy xxyy zz
xx11xyzzxy xxyy zz
xyzzxy xxyy zz
xx11xyzzxy xxyy zz
The control unit receives information from the xx11xyzzxy xxyy zz xyzzxy xxyy zz
xyzzxy xxyy zz
xx11xyzzxy xxyy zz
CS lever and checks the gear selection. It also
controls the gear change sequence in the
gearbox via solenoid valves and position
sensors.
Adaptation to the various power trains is carried
out with a code plug, which programs the
control unit for the relevant combination of
engine and gearbox. See table in Specifications A
103 592

in the work description. On the control unit is a B

55-pin connector which connects the various CS
system components. The control unit has a built- Control unit
in test programme. A = Code plug
B = Connector

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Components

12. Diagnostic switch for

test programme
There is a test programme integrated in the
control unit, activated with a switch in the
central electric unit. The vehicle must be
stationary. Using this test programme any faults
can be quickly located.

Switch for built-in test programme

13. Diagnostic socket

At present there is no diagnostic program
available for CS in the 4 series bus.

Diagnostic socket

14. Delay relay

If a gear is engaged when the engine is switched
off using the starter key, the delay relay
maintains supply voltage for 10 seconds. The
delay is so that the control unit can warn about a
gear being engaged and so that the gear can be
disengaged without switching on the voltage
again.

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 Gear changing pattern

Gear changing
pattern

Because vehicles with CS systems are fitted

with a manual gearbox, the positions of the
gears are in the gear selector movement pattern.

L = Left
R = Right
F = Forward
B = Backward
Gear selector movement pattern GR801

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Location of components

Location of components on the gearbox

Solenoid valves

Designation Function Connection

V20 Lateral stroke, right A4
V21 Lateral stroke, left A5
V22 Longitudinal stroke, neutral A2
V23 Longitudinal stroke, backwards A3
V24 Longitudinal stroke, forwards A1
V63 Low range A6
V78 High range A7

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 Location of components

Switches Position sensor

Designation Function Designation Function
B16 Reversing lights E6 Right hand
B500 Neutral position - gearbox Left hand
Backwards
Connectors Neutral
Designation Function Forwards
C97 7-pin B41 Range, high
C99 10-pin B42 Range, low
C142 7-pin Speed sensing
C202 2-pin Designation Function
C203 2-pin T17 Speed sensor

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Built-in safety features

Built-in safety features

Overspeed protection Clutch pedal switches

Overspeed protection is to prevent the selection There are two switches by the clutch pedal, an
of too low a gear in relation to the vehicle speed. upper and a lower. They provide a signal to the
control unit to indicate whether the clutch pedal
If the requested gear would result in an engine is released or depressed.
speed above 3,000 rpm the gear change is not
carried out and a buzzer sounds. The buzzer For a gear change to be permitted, both switches
stops when neutral is engaged or the speed is must be functioning correctly. If one of the
lowered. switches gives an incorrect signal, only gear
changing to neutral and a higher gear is
permitted.

Monitoring speed Because the upper clutch pedal switch registers

whether the clutch is slightly depressed, false
measurement information can be provided to the control unit
if the driver keeps his foot on the clutch pedal
when driving.
Road speed sensor
If there is an open-circuit in either of the clutch
A check function in the control unit monitors pedal switches, no gear changing is permitted.
speed measurement. If the clutch is released and
a gear with a gear ratio of less than 8:1 is To restart the control unit:
engaged, e.g. GR801 gears 2 to 7, the control
unit expects that a speed will be registered by • Switch off the engine.
the speed sensor. • Start the engine.
If the measurement is not correct or is perceived
to be zero for 10 seconds by the control unit, the
buzzer goes off and only a higher gear or neutral
can be selected. The fault may be a short-circuit
or open-circuit.

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 Built-in safety features

Time delay for reverse gear

When the driver selects reverse gear, there is a
time delay of 3 seconds before the gear is
engaged in order to protect the gearbox.

Gear shift interlock

An interlock valve in the gear lever carrier locks
the CS lever in the drive position if the engine is
stopped with a gear engaged. To engage neutral
in the gearbox the driver must depress the clutch
and put the CS lever in the neutral position.
Otherwise low air pressure can result in the
clutch pedal being very heavy when the engine
is started again.

Protection against
emergency gear changing
when driving normally
If emergency gear changing is used when
driving normally the control unit will request
neutral while the vehicle is moving. Then the
control unit will disconnect itself and it will only
be possible to use emergency gear changing. For
the control unit to start functioning again the
voltage to the control unit must be switched off
and the switch must be turned to the D position.

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Built-in safety features

Buzzer signals
Short acoustic signals warn the driver about
leaving the vehicle with a gear engaged and the
engine shut-off. Because the clutch is operated
using compressed air, the pedal would be very
heavy if the vehicle stood for long enough for
the compressed air system to depressurise. The
signal sounds for 10 seconds.

Short steady signals warn that speed

measurement is not correct.

Steady acoustic signals warn that overspeed

protection has been engaged.

Fault messages
Certain fault messages are displayed directly on
the gear indicator whilst driving.

108 379
"CODEPLUG" The code plug is faulty, absent or not
defined. 1)
"BLACKBOX" Internal fault in the control unit. 1)
"ERROR1" The indicator is receiving an
incorrect signal from the control unit.
2)
"ERROR2" The indicator is receiving no signal
from the control unit. 2)

1) The vehicle cannot be driven without using

emergency gear changing.
2) The control unit is functioning normally but
the driver receives no information about the gear
engaged.

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 Location of controls

Location of controls

2
3

103 594
1 Gear indicator with buzzer
2 CS lever
3 Emergency gear change rotary control

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Driving

Driving

Starting the engine

1 Starter key in drive position.

2 Depress the clutch if the gear indicator does

not display N. Put the gear lever in neutral
position.
This puts the gearbox in neutral if there is
sufficient air pressure.
If there is insufficient air pressure, keep the
clutch pedal depressed when the engine is
started. It will be very heavy if there is no
pressure at all.

3 The gear indicator displays N.

108 378
4 Start the engine.

Starting the vehicle

1 Depress the clutch.
2 Select the starting gear with the CS lever.
When the gear change is complete a
confirmation is sent to the control unit,
which in turn sends a signal to the gear
lever. The interlock is released and the CS
lever can be moved to the drive position.
108 380

3 Release the parking brake.

4 Release the clutch and accelerate.

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 Driving

Gear changing

Gear changing without pre-

selection
1 Depress the clutch.
2 Move the gear lever to the desired gear
change position. When the gear change is
complete in the gearbox, move the CS lever

108 380
to the drive position.

3 Release the clutch.

Gear changing with pre-selection

When a gear is engaged the CS lever can be
moved out of the drive position without
depressing the clutch, and moved to another
gear change position as a pre-selection.
1 Move the CS lever to the desired gear
change position. Hold the lever there or it
will return to the neutral position.
103 596

2 Depress the clutch. Only when the clutch is

depressed is the gear engaged in the
gearbox, and the CS lever should then be
moved to the drive position.

3 Release the clutch.

103 597

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Driving

Reversing

Gear changing without pre- 5s

selection

Note: The order is important. The vehicle must

be stationary, otherwise the gearbox may be
damaged.

1 Depress the clutch and wait five seconds.

103 598
2 Lift the sleeve under the CS lever and move
the CS lever to the reverse gear change
position.

3 When reverse gear is engaged and the

interlock is released, move the CS lever to
the drive position.
4 Release the clutch and accelerate.

Gear changing with pre-selection

The vehicle must be stationary, otherwise the
gearbox may be damaged. The gearbox should
be in the neutral position.
1 Lift the sleeve under the CS lever and move
the CS lever to the reverse gear change
position.

2 Depress the clutch. After a delay of 3

seconds the gear is engaged in the gearbox.
The interlock is released and the CS lever
can be moved to the drive position.

3 Release the clutch and accelerate.

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 Driving

Parking
1 Depress the clutch.

103 599
2 Put the CS lever in the neutral position. The
gear indicator should display N. N

103 595
3 Apply the parking brake.
4 Short acoustic signals warn if the gearbox is
not in neutral when the engine is stopped.
The signal sounds for 10 seconds.

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Signal routes

Signal routes

The control unit receives information from various functions. The CS lever controls gear selection.
When the clutch pedal is depressed, the control unit receives an order to change gear. A signal goes
to the solenoid valves which carry out the gear change using compressed air. An interlock in the CS
lever indicates that the gear change has been completed. A buzzer in the gear indicator warns of
malfunctions.

103 571

Signal to the control unit from: The control unit notes:

Road speed sensor Current speed
Position sensor Gear engaged and gear changing movements
carried out
CS lever The control unit notes the gear selected
Clutch pedal switches, 2 off Clutch pedal position

Signal from the control unit to: Results in:

Gear indicator Fixed lit signal in the middle - gear engaged
Buzzer Warns of malfunctions
Solenoid valves Control the gear change sequence
Interlock valve in the CS lever Indicates a completed gear change

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 Emergency gear changing

Emergency gear
changing

If the CS system is not functioning, emergency

gear changing can be used.
Emergency gear changing can be used if there is
a fault in the CS lever, control unit or position
sensors. However, the compressed air system,
compressed air cylinders and solenoid valves
must be functioning.

Switch to emergency gear changing using a

rotary switch located under a cover in the gear
lever carrier. Reverse gear R and three forward
gears, 2, 4 and 5, corresponding to the same
gears for normal driving, are available.
If emergency gear changing is not functioning
because of a fault in the control unit, the control
unit must be disconnected by disconnecting the
55-pin connector.

Gear indicator
Because emergency gear changing is used in the
event of a fault in the CS system, the gear
indicator may not provide the correct
information about the gear engaged.

Preparations for RP14 RP15 RP16 RP17 RP18 RP19 RP20 RP21 RP22 RP23
RP24 RP25 RP26 RP27 RP28

emergency gear changing RP7 RP8 RP9 RP10 RP11 RP12 RP13
RP29 RP30 RP31 RP32 RP33

46 47 48 49 50 51
RP1 RP2 RP3 RP4 RP5 RP6 RP34

First check fuse numbers 5 and 14 and replace 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

them as necessary.
103 699

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Emergency gear changing

Driving using emergency

gear changing
Unscrew the cover behind the CS lever.

! WARNING!

Emergency gear changing does not have

overspeed protection. Take great care
when changing gear.

Driving forwards
1 Depress the clutch.

2 Turn the rotary switch to position 2.

3 Release the clutch and accelerate.

Select other gears using the emergency gear

change rotary control and depress the clutch
as usual.
103 600

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 Emergency gear changing

Reversing
1 Depress the clutch.
2 Turn the rotary control to position R.
3 Press the switch to the left of the rotary
control and keep it pressed for five seconds.

4 Release the clutch and accelerate.

After driving using emergency

gear changing

IMPORTANT! The rotary control should be in

the D position when emergency gear changing is
not being used.

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