FAST Training Meterial(approved)1 HANVAN XCMG

2. Twin countershaft Transmission
Twin countershaft Transmission
双中间轴变速器
双中间轴变速器
Structure & Principle
Structure & Principle
结构及
结构及
原理
原理

3. Function & Purpose of Transmission
Function & 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
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Features
Features
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 Transmission
Features 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
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Rules of Serial Number
Rules 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
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Typical Structure
Typical Structure
典型结构
典型结构

10. Auxiliary Transmission
Main Transmission
1.
1. Basic Structure of Twin Countershaft Transmission
Basic 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 Transmission
2. 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 Transmission
3. 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 Path
4. 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 Section
Low 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 Procedure
Floating 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. “
“Timing
Timing”
”in main box
in 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
1
6
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
L 2
1
4
3
6
5 7
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
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Usage Requirement
Usage Requirement
使用要求
使用要求

48. Usage Requirement
Usage 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 Requirement
Usage Requirement 使用要求
使用要求

50. Usage Requirement
Usage 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 Requirement
Usage 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
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Notes for usage
Notes 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 Usage
Notes for Usage 使用注意事项
使用注意事项

55. Twin countershaft
Twin countershaft
Transmission
Transmission
双中间轴变速器
双中间轴变速器
Mounting the Main
Mounting the Main
Shaft Sub-assembly
Shaft 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 Transmission
Twin countershaft Transmission
双中间轴变速器
双中间轴变速器
Frequent Malfunctions
Frequent Malfunctions
and Solutions
and 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
： RL 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. Thanks
Thanks
谢谢，再见
谢谢，再见