FAST Training Meterial(approved)1 HANVAN XCMG.ppt

FAST Training Meterial(approved)1 HANVAN XCMG

2. Twin countershaft TransmissionTwin countershaft Transmission
双中间轴变速器 双中间轴变速器

Structure & PrincipleStructure & Principle
结构及结构及
原理原理

3. Function & Purpose of TransmissionFunction & Purpose of Transmission
变速器的功能和用途变速器的功能和用途
Transmission can make transfer system change speed and
torque—reduce speed and increase torque, the speed ratio is
represented by “i”. “i” is in direct ratio with drive force,
while it is in reverse ratio with speed.能使传动系“变速变扭” ，即 “降
速增扭” 。“降速增扭”的程度用 i（速比）表示。 i与驱动力成正比，与车速成反
比。
• Can make automobile run on the reverse.能使车辆倒向行驶。
• Has proper max.and min.transfer ratio.具有合适的最大和最小传动
比。
• Has “neutral” speed.具有“空档”
• Can provide power “interface” for additional equipments
attached to the vehicle.能为车辆的附加装置提供动力“接口”。
• The more speed shifts,the more helpful for engine’s work,
better for automobile drive performance and economy of fuel.
档位愈多，对发动机的工作愈有利，车辆的动力性和燃油经济性愈好。

4. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器 双中间轴变速器
FeaturesFeatures
特点特点

5. Adopt the design of combination of main and auxiliary transmission,
manual operation in the main section, gas operation in the auxiliary
section, 9 forward speeds.主副箱组合设计，主箱手操纵，副箱气操纵。多个前进档。
The main and auxiliary transmissions both adopt twin countershaft drive.
The main shaft and its gears are in floating condition, without needle
bearings on main shaft gears.主副箱均为双中间轴传动，主轴和主轴齿轮浮动，取消
了所有主轴齿轮上的滚针轴承。
Double H or single H operating, single lever or double lever, left or right,
double directions remote operating are available.双H或单H操纵，可单、
双杆操纵或左、右操纵、双向远距离操纵。
Can be equipped with full-power PTO, side PTO, bottom PTO or rear
PTO.可配置前置全功率取力器、侧取力器、底取力器和后取力器。
Short in axial dimension, small in weight, large capacity of bearing load,
high reliability and easy to maintain.轴向尺寸小、重量轻、承载力大，使用
可靠，维修方便。
Features of Twin Countershaft TransmissionFeatures of Twin Countershaft Transmission
双中间轴变速器特点双中间轴变速器特点

6. Structure of Main & Auxiliary Transmission
---Twin countershaft is not mystic
主、副箱结合 ---双中间轴不神秘

7. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器 双中间轴变速器
Rules of Serial NumberRules of Serial Number

编号规则编号规则

8. 8JS100、8JS130T、9JS180 SERIES（系列）
9　J S 150 A ( T )
Fully
synchronized
Mechanical
Twin countershaft Nominal input
torque（×10N·m）
Forward
speeds
Code of speed

9. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器 双中间轴变速器
Typical StructureTypical Structure
典型结构典型结构

10. Auxiliary Transmission
Main Transmission
1.1.Basic Structure of Twin Countershaft TransmissionBasic Structure of Twin Countershaft Transmission
双中间轴变速器基本结构双中间轴变速器基本结构

11. 2. Basic Structure of Main Transmission2. Basic Structure of Main Transmission
主箱基本结构主箱基本结构
Input shaft
Constant
engaging gear
PTO gear
3/7 speed gear
2/6 speed gear
1/5 speed gear
Climbing gear
Reverse gear
Gear of input shaft
Brake gear
Reverse
medium gear
Sliding bush
Output shift

12. 3. Basic Structure of Auxiliary Transmission3. Basic Structure of Auxiliary Transmission
副箱基本结构副箱基本结构
Air filtrating
regulator
Shift cylinder
Output joint of
speedodometer
Output shaft
High speed and
low speed fork
Auxiliary
countershaft

13. 4. Twin Countershaft transmission Power Transfer Path4. Twin Countershaft transmission Power Transfer Path
双中间轴变速器动力传递路线双中间轴变速器动力传递路线

24. 5. Main Transmission Power Transfer Path
副箱动力传递路线

25. 6. Auxiliary Transmission Power Transfer Path
副箱动力传递路线
High Speed Low Speed

26. Figure: Double H Shifting
Mechanism Pneumatic Path
Exhaust
Air pressure
after adjusted
High speed
air pressure
Low speed
air pressure
1. Double H valve 2. Range cylinder
3. Air filtrating regulator

27. High Speed SectionLow Speed Section
Figure: Auxiliary Transmission Operating Device
副箱工作示意图

28. FIGURE: Auxiliary Transmission Operating Device
副箱工作示意图
Exhaust
 
Air
pressure
adjusted
 
High
speed air
pressure
 
Low
speed air
pressure
 
Low Speed Section High Speed Section

29. Low Speed Section
低档区
Double H Valve Plunger
at Compressive Position
双H阀触头处于压缩位置
High Speed Section
高档区
Double H Valve Plunger
at Protrusive Position
双H阀触头处于伸出位置
7. Double H Operating Device双H操纵机构

30. .主轴 一轴 一轴齿轮 副箱驱动齿轮
In order to ensure correct engaging and distribute the load
evenly, the gears of main shaft are in status of axial floating,
and main shaft adopts the floating structure with hinge joint.
为了满足正确的啮合并使载荷尽可能平均分配，主轴齿轮在主轴上呈径向浮动状
态，主轴则采用绞接式浮动结构。
8.8. Floating Structure of Main ProcedureFloating Structure of Main Procedure主轴浮动结构主轴浮动结构
1. Main shaft 主轴
2. Input shaft 输入轴
3. Gears on input shaft
一轴齿轮
4. Auxiliary drive gear
副箱驱动齿轮

31. The floating structure can make some of manufacturing
tolerance and assembly tolerance counteract automatically,
when the gears are engaging. Therefore the engaging becomes
easy to achieve design requirement, which has been confirmed
by operation in practice. This helps to reduce the engaging
noise and improve the durability.浮动的结果 ,使得齿轮在啮合时能自
动抵消一部分制造和装配误差 ,啮合区容易达到设计要求 ,实际使用情况也证实了
这一点。这就有利于降低啮合噪声和提高耐用度。
When it works, the force from gears of two countershafts
impose on the gears of main shaft are equal in intensity, opposite
in direction, so they counteract each other. Therefore main shaft
doesn't bear the bending torque, only bear the torque, which
improve the stress condition of main shaft and its bearings and
the reliableness and durability of transmission greatly.当工作时两
个中间轴齿轮对主轴齿轮所加的径向力大小相等，方向相反，相互抵消，使主轴只
承受扭矩，不承受弯矩，改善了主轴和轴承的受力情况，并大大提高了变速器的使
用可靠性和耐久性。

32. 9. 9. ““TimingTiming””in main boxin main box主箱对齿主箱对齿


“Timing” must be carried on for solving the problem
of engaging between the gears of twin countershaft and
gears of main shaft.为了解决双中间轴齿轮与主轴齿轮的正确啮合，装配
时必须进行对齿
1.gear of left countershaft 2.gear of input shaft
3. gear of right countershaft

33. 10. “Timing”Procedure对齿步奏
Mark gears
of countershaft
Mark
teeth of
input shaft “Timing”in Auxiliary Box
“Timing”

34. 1. Sliding Bush 2. Gears on main shaft
3. Clip spring 4. Spline gasket
4. Adjusting gasket 6. Main shaft
Note: α=35°
11. Gear Shift Mechanism & Location of Gears on Main shaft
换档机构及二轴齿轮定位
16
5
4
3 2
α

35. There is no synchronizer in main transmission of 9JS180(A)
and 9JS150F. The main shaft sliding bush is sleeved on the
main shaft by involute spline, move the sliding bush so as to
engage its joint teeth with the internal teeth of main shaft gear
for transferring the power. 9JS180(A) 和9JS150F变速器主箱内无
同步器。 主轴上的滑套通过渐开线花键套在主轴上，移动滑套使滑套的接合齿与
主轴齿轮的内接合齿啮合传递动力。
The cone angle of joint teeth end for sliding bush and all gears
on main shaft are same : α=35°。Because main shaft and its
gears are at the state of floating, so the two cone face can
function as automatic centering and synchronizing when
engage the gears.滑套和主轴齿轮内接合齿端处于相同大小的锥角
α=35°。由于主轴和主轴齿轮处于浮动状态，所以挂档时，这两个锥
面能
起
到一定的自动定 心和同步作用。

36. The twin countershaft speed-9
transmission are multi-speeds, the ratio
step between each speed is very small,
so the difference of rpm between
adjacent gear is also small, therefore it
is light,free and smooth during the gear
shifting, with low cost and reliable
usage.
双中间轴 9档变速器的档位多，
各档间
速比的
级差小，所以工作时相 邻档位之
间的
转速差也小，使得变速器操纵轻便，
换档机构结构
简单，造价低廉，使用可
靠。

37. 13. Main Box Control Mechanism主箱操纵机构
R、L
shift
yoke
1(5)、
2(6)
shift
yoke
3(7)、
4(8)
shift
yoke
R
L2
1
4
3
6
57
0 0
8

38. When changing “O” ring,
please loose the nut.更
换
O型
圈可松开此螺栓。
14. High Speed & Low Speed Cylinder高低档气
缸

39. 15. Structure of synchronizer同步器构造
1. Friction tape for high speed gear
2. Synchronizing ring
3. Sliding sleeve
4. Friction tape for low speed gear
5. Lock pin for low speed gear
6. Cone ring in low speed
7. Lock pin for high-speed gear
8. Spring

40. 15. Structure of synchronizer同步器构造
A lock pin synchronizer is installed in the auxiliary transmission box and
the shift cylinder of auxiliary transmission operates it only in case of shift
from high-speed section or vice verse.在双中间轴
九档变速器的副变速箱内装
有
锁销式惯性同步器。 它由副箱换档气 缸来操纵，仅在高低档位 段变化时才使用。
High-speed synchronizing ring and low speed cone ring is made of
sintered iron with powder metallurgy. Nonmetallic material with super
anti-friction performance applied to inner cone face of high-speed
synchronizing ring and outer cone face of low speed cone ring.高档同步
环和
低档同步锥
环基体为铁基粉末冶金锻 造烧结而成，在高档同步 环的内锥面和低档
锥
环的外锥面上分别粘有高摩擦性能的非金属材料 。

41. FIG11 structure of countershaft brake
16. Countershaft Brake中间轴制动器
取力齿轮外圆面
摩擦轮
壳体取力窗口面
压缩空气入口
制动活塞
图 中间轴制动 器结构图
Case PTO window
7·8 bar inlet of
compressed air
Brake piston
External radial
of PTO gear
(friction wheel)

42. It only can be used in case the vehicle starts running, to
make countershaft speed drop immediately and the
vehicle start running steadily.仅
用于起步挂档时，使中间轴 转速
很快
降低，便于车辆平 稳挂档起步。

43. PTO shaft
17. PTO Mechanism取力机构
Twin countershaft transmission usually take off power from the lengthened
countershaft of the auxiliary case in the rear of transmission.双中间轴变速
器
普遍都
采用在变速器后端副箱加
长轴处取力。

44. 18. Back PTO Control Mechanism后取力
控制机构
The auxiliary transmission must be engaged in neutral position for the purpose
of stop and power taking-off. To solve this problem, it is simple to remove the
cover of speed section cylinder and add neutral position cylinder.为实
现停车取力，
必须
将副变速器处于空档位置。为解决这一 问题，将范围档气缸盖去掉 ，装一个空档位置
气
缸即可。
Hole A is the compressed air inlet with air pressure of 0.41bar，Hole C is
0.7bar. For stop and power taking-off, put the transmission operating rocker at
the low speed section firstly, then open the neutral position cylinder control valve.
At this time, the transmission speed section is at the neutral position. A口接
0.41mpa气压，C口接0.7mpa气压，
停车取力时， 先将变速器手 柄低档区，使 打开空
档气
缸控制阀，此时变速器 范围档处于空档位置。
Locating ring
定位
环

45. Gas storage
barrel
Valve of Electro
-magnetism
air filtrating
regulator
Double
H valve
3
5
1
2
4
Middle position
cylinder
High and low
speed cylinder
PTO cylinder
7---8bar
Low speed gas pipe
4.1-4.4bar
4.1
4.4
bar
7---8bar 7
8
bar
High speed
Low speed
QH50 PTO Pneumatic Path Figure

46. QH70 PTO Pneumatic Path Figure
Gas storage
barrel
Valve of Electro
-magnetism
air filtrating
regulator
Double
H valve
3
5
1
2
4
Middle position
cylinder
High and low
speed cylinder
PTO cylinder
7---8bar
Low speed gas pipe
4.1-4.4bar
4.1
4.4
bar
7
8
bar
High speed
Low speed
Common pressure
4.1-4.4bar
QH70取力器气路工作示意图

47. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器双中间轴变速器
Usage RequirementUsage Requirement

使用要求使用要求

48. Usage RequirementUsage Requirement使用要求使用要求
Proper and correct operation and maintenance of transmission are of
great significance to the vehicle’s safety and reliability and also the useful life
of transmission. The following items should be well observed:正确合理
地操作使
用变速器，定
期进行维护保养，对于保证汽车安全可靠的行驶和 延长变速器的使用 寿
命十
分重要， 请遵循下面 使用要求 ：
1.
 Grade of lubricant
Transmission should be filled with high quality gear
lubricant oil, not inferior to 85W/90GL-5 vehicle gear oil. 润
滑油牌号
变速器内
须加
注优质齿轮润滑油，其性能不得低于
85W/90GL-5车辆齿轮油。
2. Oil level The oil level can be inspected through the conic view hole on the side
of transmission case. The oil level should be equal with the low edge of peep
hole, not lower 5mm than the position. Over charging will result in
temperature increase or oil leakage, while inadequate oiling will cause to
lubricate parts deficiently, even to fire the transmission. 油
面位置
油
面高度由变
速器
壳体侧面的锥形油面观察孔 进行检查，油面高度应与油面观察孔下沿 平齐，过多
的加油量
将会导致 变速器温度升高和漏油；过少的加油量 将会导致零件润 滑不良，严
重
者将会发生烧箱事故。
The oil should be
filled with about
13L.

49.  
 
     
3. Oil level inspection油
面检查
The oil level should be inspected periodically. During the check, the vehicle should
stop on a flat road, and not allow to be checked immediately just after working
because hot oil may expand. Only after the oil level becomes steady and the
temperature decreases, the check can be done.油
面高度应定期进行检查。检查油面高
度时
汽车应停在水平的路面上。由于 热油的体积膨胀 ，为了防止测量不准，行驶后的车辆
不能
立刻检查，只有在油 面稳定和稍微冷一些时才可进行。
4. Oil replenishment补充润
滑油
The type of lubricant to be replenished should be identical with that of the
previous one to prevent chemical reaction between different lubes.为了
防止不同型
号的
润滑油发生化学反应，在补充润滑油时应保证与原来的润滑油型号相同。
5. Circle of oil change换油
周期
The remnant oil must be drained off before oil change.更
换润滑油时， 首先将原有的
润
滑油排放干净。
Oil must be changed after 2000~5000Km run of new transmission.新
变速器在行
驶2000~5000Km时，必须
更换润滑油。
Check the oil level after every 10000Km run, replenish if necessary.每
行 驶
10000Km应随
时检查，进行补充。
The oil should be changed after every 20000~30000Km run. 每
行 驶
20000~30000Km应更
换润滑油。
Usage RequirementUsage Requirement使用要求使用要求

50. Usage RequirementUsage Requirement使用要求使用要求
6．Working temperature工作
温度
The temperature of transmission when working continuously should be no
more than 120 , but no less than -40 . If the working temperature exceeds
℃ ℃
120 , the lube may decompose and the useful life of the transmission be
℃
shortened.变速器在
连续工作期间的最高 温度不得超过
120℃，最低
温度不得低于
-
40℃ ，工作
温度超过
120℃时，
会使润滑油分解并缩 短变速器的寿命。

Each of the following cases will cause the working temperature of
transmission to exceed 120
℃
：下
列情况中的 任何一种都能引起变速器的工作 温度
超
过
120℃：
a) 
Continuously working at the speed less than 32km/h.
连续
时速
＜32km/h
的情况
下工作。
b) 
High engine Rev.
发动机
转速高
c) High environment temperature. 环境温
度高
d) Vortex encircles the transmission.涡流环绕
变速器
e) Exhaust system is equipped quite near the transmission.排
气系统太靠近变速
器
f) Over large power or overrun.大功率
超速运转

51. 7. Working lean angle工作
倾角
When the transmission working lean angle is over 12°，the lubrication may be
inadequate. The working lean angle is equal to installing angle plus slope angle. If
the angle is over 12°，the transmission should be equipped with lube pump or
cooling means to assure well lubrication.变速器工作
倾斜角超过
12°时，
润滑可
能不
充分。工作 倾斜角等于变速器在底 盘上的安装角加上 坡度角。如果长时间超
过12°工作时，变速器
应安装润滑油泵或冷却装置，以 保证良好的润滑。
8. Running by tow or sliding拖
行或滑行
When the transmission works, its shafts and gears keep rotating to provide
sufficient lubrication. However, when a vehicle runs by tow with rear wheels on
ground and driving system connected, the countershaft gears and main shaft gears
don’t rotate while the main shaft rotates rapidly driven by rear wheels, which will
cause severe damage of transmission due to inadequate lubrication.变速器在工作
时，变速器的轴和齿轮不
停地转动，可以为变速器提供 充分的润滑。但当车辆在
后轮
着地，传动系 连接的情况 下被拖行时，主箱的中间轴齿轮和主轴齿轮并不 旋
转
，而主轴却被后轮带动着高速旋转，这样将会因缺乏润 滑而引起变速器的 严重
损坏
。


Usage RequirementUsage Requirement使用要求使用要求

52. The following items must be observed to prevent above incidents:
为了
防止这类现象发生，应注意以下几点：
Prohibit a vehicle sliding in case of clutch disconnected;切勿踩下
离合器
踏板使车辆长时间空档滑行 ；
When a vehicle needs towing, draw out the half shaft, disconnect
drive shaft or keep drive wheel away from the ground.当车辆
需
要拖行时，可 抽出半轴或脱开传动轴，也可使驱动轮离 地拖
行。

53. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器 双中间轴变速器
Notes for usageNotes for usage
使用
注
使用
注
意
事项
意
事项

54. Twin countershaft transmission has two neutral positions: high-speed section and low-speed
section. Automobile is not allowed to stop at high-speed neutral position (5/6 speed), but only at
low-speed neutral position (3/4 speed).双中间轴变速器有两个空档区
：高档空档区及低档空档区。
不能在高档空档区
停车（
5/6档），只
允许在低档空档区（
3/4档）
停车。
When shifting gear from 4 speed to 5 speed(or inversely), the clutch should be disengaged
thoroughly. Stop for a while to ensure the conversion of auxiliary synchronizer. Prohibit skipping
shift between low-speed and high-speed.四
档换五档（或五档换四档）应将离合器彻底分离。
稍停
片刻
，以使副箱同步器 完成转换。
高低档区
转换时不允许跳档。
The shift between low-speed and high-speed should be avoided in case that the vehicle runs on a
downhill road.在
下坡路面尽量减少高低档区的 转换。
Prohibit sliding at the neutral position or running by tow without any measure.禁止
空档长时间的
滑行或无
任何措施的拖行。
Please adopt bipod clutch operation.最好采用两
脚离合。
Prohibit operating countershaft brake during shift gears. If no countershaft brake, one should wait
for 3~5 minutes after engaging clutch to engage gears for starting.带
有中间轴制动器的车辆， 禁止
在车辆行驶换档时使用中间轴制动器。
未装中间轴制动器的车辆， 起步挂档前踩下离合器后， 应
有意
停顿
3至5秒
。
Prohibit driving automobiles at speed of 32km/h or less continuously without any measure.严禁
车
辆在无
任何措施下 的连继在
32km/h以
下速度行驶。
Properly maintain constantly.通
常正确的维护保养。
Notes for UsageNotes for Usage使用
注意事项
使用
注意事项

55. Twin countershaft Twin countershaft
TransmissionTransmission
双中间轴变速器 双中间轴变速器
Mounting the Main Mounting the Main

Shaft Sub-assemblyShaft Sub-assembly
二轴装配二轴装配

56. Put main shaft on the
edge of working table
将
二轴直立于工作台上
Mounting adjusting
shim of first-speed gear
装入
调整垫及一档齿轮
Mounting main shaft sub-assembly
二轴装配
Components of main
shaft sub-assembly
二轴
零件

57. Mounting main shaft sub-assembly
二轴装配
Mounting hex key
装入
六角键
Spring pin hole
弹
性销孔

58. Mounting sliding clutch of
reverse and low-speed gears
装入倒档滑套及
爬档轮
Gap of the sliding clutch
滑套的
缺口
Gap is matching hex key of main shaft
缺
口对正二轴 六角键
Mounting main shaft sub-assembly
二轴装配

59. Mounting adjusting shim
of 1-speed gear
装入1档齿轮
调整垫
Mounting spline shim of
1-speed gear
装入1档齿轮花键
垫
Mounting 1-speed gear
装入2档齿轮
Mounting main shaft sub-assembly
二轴装配

60. mounting 2-speed gear
装入2档齿轮
Fixing adjusting shim
Mounting adjusting shim of
2-speed gear
装入2档齿轮
调整垫
clearance should be
between 0.13 and 0.30mm
前进档
之间间隙
0.13MM~0.30MM。
Mounting main shaft sub-assembly
二轴装配
固
定调整垫

61. Make hex key pass through so as to fix the adjusting shim
推送六
角键固定调整垫
Mounting main shaft sub-assembly
二轴装配

62. Mounting sliding clutch of 2,3-speed gears
装入2/3档齿轮滑套
Mounting main shaft sub-assembly
二轴装配

63. Mounting adjusting and spline shim of 2-speed gear
装入2档齿轮
调整垫及花键垫
Mounting main shaft sub-assembly
二轴装配

64. Mounting 2-speed gear
装入2档齿轮
Mounting main shaft sub-assembly
二轴装配

65. Mounting 3-speed gear and spline shim
装入3档齿轮及花键
垫
Mounting main shaft sub-assembly
二轴装配

66. Mounting adjusting shim
装入
调整垫
Mounting main shaft sub-assembly
二轴装配

67. Mounting 3-speed adjusting shim and fix it
装入3档
调整垫并固定
Mounting main shaft sub-assembly
二轴装配

68. Mounting adjusting and spline shim of
reverse gear
装入倒档齿轮
调整垫及花键垫
Mounting main shaft sub-assembly
二轴装配

69. Put hex key through and fix it with
snap ring
推
入六角键并用卡环固定
Don’t mount rabbet on snap ring over against hex key
卡环
开口要错过六角键
Mounting main shaft sub-assembly
二轴装配

70. Fit spring pin
安
装弹性销
Mounting main shaft sub-assembly
二轴装配

71. Mounting sliding clutch of
3,4-speed gears
装入3/4档滑套
Mounting reverse gear
装入倒档齿轮
Mounting main shaft sub-assembly
二轴装配

72. Main shaft assembly
二轴
总成
Clearance is between
0.30 to 0.90mm
倒
挡间隙应为
0.30~0.90MM
Clearance between
1speed and crawl
gears should be 0.13
to 0.30mm,so is that
between 2,3 speed
gears
前进档
之间间隙为
0.13~0.30MM。
Mounting main shaft sub-assembly
二轴装配

73. Difference between 8JS118 and 8JS130T
8JS118与8JS130T间的差
异
Main transmission without synchronizer
主箱无同步器
Main shaft assembly of two types of 8-speeds transmissions
8档变速器的两
种二轴总成
Main transmission with fully-synchronized
主箱全同步器

74. Main shaft assembly of 9JS150T
9JS150T主轴
总成
2-speed gear is fine teeth
二轴二档为
细齿
Lock ring synchronizer of 3,4 speed gears
¾档
锁销式同步器
Lock pin synchronizer of 1,2 speed gears
½档
锁销式同步器
Main shaft
Sliding clutch is a bit narrow
倒
爬档滑套窄一些

75. Twin countershaft TransmissionTwin countershaft Transmission
双中间轴变速器 双中间轴变速器

Frequent Malfunctions Frequent Malfunctions
and Solutionsand Solutions
常见故障
及分析
常见故障
及分析

76. When synchronizer teeth groove is meshing with main shaft gears, they
should be parallel. If the engaged teeth are tapered or worn out, it has a
detaching momentum when gyrating, possibly the transmission is going to be
out of gear.（当同步器齿套与主轴齿轮啮合时，啮合的齿
之间必须平行。
若
啮合齿之间有锥度或 磨损，旋转时将分离，这 样变速器在 运转时便会脱
档）
1) 
 
input shaft is not concentric with the directional bearing in the engine一轴与发动
机
导向轴承不同 心
2)
  fierce collision among gears when shifting speeds, cause abrasion of meshing gears
挂档时齿轮间的
猛烈碰撞 ，引起结合齿的 磨损。
3)
  the engaged gears is worn and tapered
啮合齿
磨损和有锥度。
1. Main transmission is out of gear主箱
脱档

77. 4)
  lock spring is weak or damaged, the force on locating steel ball is not
enough因锁止弹
簧变软或损坏造成定位 钢球上的压力不 够。
5)
  locating slot of yoke shaft is worn out
拨叉
轴定位槽严重磨损。
6)
  improper adjustment of link drive mechanism
，the gears can not
mesh well with sliding clutch操纵装置
连杆调整不当，使啮合
齿与滑套不能
充分啮合。
7)
  transmission will be out of gear when the vehicle is draught by full-
power engine or burden当车辆以全功率
牵引或在有负荷推动的情况
下减
速时常会发生脱档。
8)
 when vehicle is driving on a cragged road, long heavy gearlever will
oscillate, which would work against lock spring, cause out of gear当
车辆行驶在
崎岖路面时，又长又重的连杆像钟摆一样摆动，会克服
锁止弹
簧的锁止力，引起脱档。

78. Wear or have taper or incomplete engagement of Aux. drive gear, reduction
gear and synchronizer engaged tooth（副箱
脱档可能是由于副箱驱动齿轮， 减速
齿轮和同步器滑套接合齿
磨损、有锥度或 非全长啮合而引起的。
）
Causes for this malfunction is collision when shifting speeds and abrasion after
long time use.（这
故障的原因是由于换档时的 撞击和长期使用后的 磨损造成
的）
Defects of pressure regulating valve and vibrating caused by improperly
mounted transfer shaft（由于气压阀的气压
故障或传动轴装配不当造成。）
Excessive abrasion of engaged teeth
啮合齿
严重磨损
2. Aux. transmission is out of gear 副箱
脱档

79. Forces for speed shifting are different according to various condition, it
is abnormal when it requires too much（
根据各档的情况，换档的力量 是
不同的，
如果力量太大，就不正 常了。）
Difficulty in speed-shifting often happens in the distant controlling
device of a heavy duty truck. First check the link lever of the distant
controlling device, problems in link lever are caused by abrasion and
improper meshing and alignment of linking fork and bush or by some
mechanism which obstacles the free movement of link lever.（换档
困难，
大多
数发生在重型车所用的远距离操纵装置上。 首先检查 远距离操纵系
统
的连杆，而连杆上的问题又是由于连接叉或衬套磨损、 不适当的啮合
以及机
械障碍限制杠杆自由运动等原因造成。）
3. Difficulty in speed-shifting换档
困难

80. To ascertain whether the difficulty is caused by transmission
itself, we need to dismantle gearlever or linking lever, move
guide matrix, mesh it with gears of all speeds. If yoke can
slide smoothly, the problem is without the transmission, if
not, it’s the transmission‘s problem.（为了确定换档
困难是
否
变速器本 身所引起的，就需要把变速杆或 连接杆从变速
器上
边拆掉，然后用撬杠或起子移动换档 导块，使其啮合
入
各个档位。 如果拨叉轴能轻松地滑动，说明故障存在于
变速器
外部，反之故障存在于变速器内部。 ）

81. If the problem is within transmission, it maybe caused by
following aspects：如
果问题在变速器内部， 那么可能是下
列原
因
1) sliding clutch is tangled with sliding sleeve 。This maybe caused by
tweak of main shaft or warp of yoke or spline.二轴滑套或同步齿套的花
键
咬在主轴上。这 是由于主轴扭 曲，拨叉弯曲或主轴花键弯 曲所造成的。

2)
 Yoke shaft is tangled in the housing of top cover. This is caused by
warp of the yoke shaft and abrasion on its surface.拨叉
轴在上盖壳体内
咬住
。这是由于壳体破裂、换档轴上 锁止螺钉拧紧力矩过大，造成 拨叉
轴弯
曲以及拨叉轴表面磕碰等引起的。
3)
  The lock bolt on the shifting shaft looses.
换档轴上
锁止螺钉松动。

82. Working temperature of Transmission is below 120 ,
℃
too much time
above this will cause lubricating oil to deteriorate, shortening useful life of
the transmission.变速器工作
温度必须低于
120 ℃，温
度过高会是润滑油分
解变
质，缩短变速器的 寿命。
Transmission generates some heat due to the friction of the moving
components. The normal working temperature is 38
℃
higher than that of
the environment. Heat throws off through the housing of transmission.
There will be overheat if the exhaust does not work well.变速器
产生一定的
热
量是由于运动件的摩擦。正常工作温度比环境温度约高
38 ℃。
热量通过
变速器
壳体散发出去。如果散热不正常，就会引起变速器过 热。
Before searching for the cause of overheat, you should check the oil-
thermometer to make sure the reading data is right.在
查找变速器过 热原因
之
前，你必须检查油温表已确定读出的数据正确无误。
4. Overheat of the transmission变速器过
热

83. Overheat usually originates due to following causes:过
热的原因
1)
  Lubrication is not done well. Oil level is too high or too low, the brand of
lubricating oil is incorrect. Transmission slope angle is more than 12°（
润
滑油不好，油
面太高或太低，润滑油牌号不适当，变速器工作 倾角超过
12 °）
2)
  Driving speed is usually below 32km/h.
（
长时间
低于32km/h行驶。）
3)
  RPM of engine is too high.
（发动机
转速过高）
4) Transmission is surrounded by framework, chassis fuel-box and a large
bumper assembly, ventilation is bad.（变速器
被车架、油箱、 保险杠环绕，
空气
流通性不好。）
5)
  Exhaust system is too near the transmission.
（
排系统太靠近变速器。）
6)
  The environment temperature is very high.
（
外界温度太高）
7)
  Overload or over-speed driving.
（
超载、超速驾驶）

84. You can hear some noise even though the transmission is working properly. If
the noise is too big or abnormal, such as screaming or roaring, probably
something’s wrong with the transmission. These noises maybe generated by
transmission itself, or they are produced by other parts, then magnified by
transmission when they go by it. （在变速器正
常运转下 ，你可以听到一定的
噪
音。但如果声音过大，例如尖叫声、轰鸣声
\等，
都表示变速器自 身有
问题
。这声音可能是由变速器 产生的。也可能 是由整车的其它零部件产
生
的，它们的声音经由变速器 被放大了。）

5. Big noise within transmission
（变速器内部大的
异响）

85. (1)
 It is generated by friction among inner gears of transmission, which can be
distinguished by the shining point after hard pressure. Generally speaking,
the noise is bigger when the gears are bearing overload. If the noise
happens once you shift to a certain speed, it’s the gear’s problem. The
friction can be solved by grinding wheel or whetstone. （这
是由变速器内
的齿轮
摩擦碰撞产生，可由齿 面猛烈碰撞 后造成的 亮点来鉴别。一般来说
，当齿轮承载过度，这
种声音就更显著了。一旦你挂上某一档位就 产生噪
音
时，说明这一档的齿轮有 问题。用油石或砂轮打磨便可解决。）
(2)
  If the grinder or roller of bearing is damaged, or sliding path become
cragged, there will be noise when RPM is low at various speeds.（
如果轴
承的滚轮或滚
子坏了，滑道内磨损，在各档低转速都会产生噪音。）
(3)
  If the gears are overloaded or there is crack when mounting, it will knock
at low speeds, scream at high speeds.（
如果齿轮受到承载 负荷过多或在装
配时齿轮出
现裂纹，变速器在低档 会产生敲击声，高档 产生尖叫声。）
A
  sound of knocking
（
敲击声）

86. B sound of scream（
尖叫声）
(1) The usual friction between gears and the burn after long-term use, can cause
screaming before collapsing.（一
般是由齿轮长期使用后正 常磨损，如齿轮出现烧
灼
，损坏前会产生尖叫。
）
(2) The gears do not mesh well, which can be discriminated by the unevenness of
friction on gears. （齿轮啮合不当造成，可由齿轮表
面的不均匀摩擦来判断。）
C sound of roaring（
轰鸣声）
Improper “timing” when remount the transmission or incorrectness of “timing”
caused by gears pirating on the aux. shaft, these will contribute to roaring.（由“对
齿”误差所造成。变速器重
新装配时“对齿”不正确，或由于齿轮在副轴上 转动所造成
的“对齿”不正确
都会产生轰鸣声。 ）
D sound of creak（
吱吱声）
Because of the excessive axial clearance between bearings of main shaft and
countershaft, it creaks when the torque change its direction. If there is an excessive
clearance in the radial direction between bearing and countershafts, it will cause a
larger center distance, consequently the pressure effects on tops of the teeth. This
will damage the teeth.（
因为主轴轴承和中间轴轴向间 隙过大，当扭矩变换方向时
会
产生吱吱声。中间轴轴承的径向间 隙过大，从此会产生压力效果作用在齿轮的齿
顶
上，这样会造成打齿。）

87. Diagnosis and resolutions to frequent malfunctions常见故障
诊断及排除
1:symptom----reversing light is always on or never on.（
故障现象： 倒车灯常亮或
不
亮。）
analysis: first, make sure there is a electric power supply, then check up if the
switch-controlling pin of reverse gear is blocked, or the switch is always on or never
on. Replace the corresponding components if it’s transmission’s problem.（
故障分
析：首先应
确定整车电源有电，其次应当检查倒档开关控制销有无卡死，开关常
通或
常不通。如果是变速器的原 因则更换相应的零件。）
2:symptom----the engine can not be started especially that with a harness.（
故障现
象：
发动机打不着火尤其是带线束的。）
analysis: first, make sure there is a electric power supply, then check up if the
switch of neutral gear works well. If it is with a harness, check its quality and
contact. （原
因分析：首先应 确定整车电源有电，其次检查空档开关是否工作正常
。
如果带线束应当检查其质 量以及接触 是否良好。）
Frequent Malfunction of a New Vehicle
新
车常见故障

88. 3:symptom----you can not shift to R,L speed or 7,8 speed.（
故障现象
：R\L档或7、8档无
法挂入。）
analysis: first, check if the gear shifting lever is well adjusted, to see if
you can shift to R,L gear or 7,8 gear. If it’s the transmission’s
problem, you should check the lumen of double H controlling
system, to see whether it’s intervened inside.（
故障分析：首先检
查
换档杆调整是否到位，看是否能挂上
R、L档或7、8档。
如
果
是变速器自 身原因应当检查双
H操纵机构内
腔有无干涉。）
4:symptom---shifting location isn’t clear, it turn off when shifting gear,
location of neutral gear is not clear.（
故障现象： 档位不清晰，换
档
拐弯，空档位置不 清。）
analysis: first, check the whole lever system, to see if it intervene. If it’s
the transmission’s problem, you should check yoke shaft and guide
block of 1,2 speed gears; then check the same components of 3,4
speed gears. Replace corresponding components to solve problems.
（
故障分析：首先应 当检查整车杆系是否有干涉。如果是变速器自
身
原因，应检查
1/2档
拔叉轴及
1/2档
导块或
3/4档
拔叉轴及
3/4档
导块是否有问题，可更换相应零件解决问题。
）

89. 5:symptom----cannot shift between high and low speeds, reversing speed is high.
（
故障现象： 不能在高低档间 转换，倒档速度 快。）
analysis: first, check up whether the housing of double H valve is intact. If double H valve
is OK, dismantle it and shift speeds manually. If it works well, take off gasket for double H
valve and retry. severe friction of the valve’s touching tip would cause “no high speed”; if
the touching tip retracts or gets stuck, it would cause “no low speed”.（原
因分析：第一，
检查
双
H阀
是否完好。如果双
H气阀
完好，拆下双
H阀用手
转换。若工作正常，取下双
H阀
衬垫装上再试。双
H阀触头
严重磨损会导致 “无高挡”；双
H阀触头
收回卡死，会导致
“无低档”。）
6:symptom----a certain speed is hard to lodge or dislodge，feel heavy when shift
speeds.（
故障想象：某一档位难挂难摘，挂挡手感重。）
analysis: check the gear-shifting plug, if it’s immoderately big, grind its two sides, not
curves at two sides. Then check if the guide block intervenes.（原
因分析：检查 挂档拨头是
否
过大，若是，可修磨拨头两侧， 但不能打磨拨头两侧圆弧。其次应当检查导块是否干涉
。）
7:symptom----there’s noise when starting and running the vehicle.（
故障分析：
车辆
起步挂挡及跑车挂挡都有异响。）
analysis: tell the driver right operating procedures. Put into gears after several seconds’
tramp on the clutch pedal when start vehicle. You can shift into a suitable (adjacent) gear
according to current speed, never exceed. （原
因分析：告知驾驶员正确的操作程 序。车辆
起
步时可踏下离合器踏板几秒 钟再挂档。跑车时应选择合适的档位挂 挡，但不能越挡操作
。）

90. Damaged pieces and analysis of causes
损坏零件
及原因

91. Transmission Escutcheon
变速器
标牌
When you need
service or fittings, find
out the assembly
model, customer serial
NO. and outlet serial
NO. on the brand
plate which is pasted
on the housing
Customer serial NO.
Assembly model
Outlet serial NO.
当
您服务或装配时， 应
当
察看壳体表面上标牌
的
总成型号、用 户编号
、出
厂编号。

92. ThanksThanks
谢谢，再见谢谢，再见