Twin countershaft transmission, all synchronized
Contents
1. 90 SL HAEE E Ja cua 1203021 1703051 51607 1703052 5160 1702095 1245 1248 12 15 1245 1 MAS vent plug 290 ESEIA 90 degree bend pipe connecter 3 air pipe assembly air pipe assembly air pipe assembly 90 ERMA 90 degree quick shift connecter 790 ESEA 90 degree bend pipe connecter 8 HH Single H valve 9 H 5 Single H pedestal Section 15 Parts list of 16 speed transmission aT a Clutch housing and transmission housing assembly GB amp 9080M16X15 nylon locking tinnu e 01421032 Hex bolt amp spring washer combination e _ Q141225M Pre gumming hex bolt amp spring washer combination TE Qoi Te 78 Input shaft assembly LU No PatNo Description 6 16182007 1701040 Synchronizer assembly Aux case Fon 1 7 D GJS200T4701034 Spine washer shatt gear 2 remm Gear inputshat In 9 51257170106 Guide sleeve mainshat A 16462001 1701030 TT N main shaft assembly No PartNo Description o wewrwons sg 4 16 82001 1701178 3 4 synchronizer assembly 1 162001701122 Washer main shaftgear2. 12 TERY 64 13 14 15 ie s 16 HFE ARAS uN ee HE 17 18 19 20 hex bolt and spring gasket small hex bolt M10 x 50 hex bolt and spring gasket bearing cover gasket for countershaft aux case cover for lengthened countershaft bolt assembly bearing cover of countershaft aux case taper roll bearing bearing cover gasket of main shaft aux case drive gear bush of odometer drive gear of odometer rear bearing cover of output shaft passive gear bush of odometer passive gear of odometer gasket shim connector of odometer odometer lag 21 KAKAA TTE hex bolt and spring gasket 22 23 WARE s Pk 24 E HH 25 26 Bite 27 hex bolt and spring gasket bolt assembly oil seal of main shaft rear nearing oil seal dust proof output flange Section 13 air filtration adjuster assembly E A H wvIDELSI 8 d d e JOELSPB H vIODLSTS d D Ye E FE 098130 390251 81073 FEEL 70 CANA Wid ds air filtration adjuster 90 E 7 WAS 90 degree pipe connecter 3 CA 3 Fr bowl shape shim 4 AA Bal ZH r F hex bolt and spring gasket 5 hex taper bolt Section 14 Single H valve assembly
3. 58 7 Shift Bar assembly EE EES EE 60 8 Drive gear assembly of auxiliary case 5 9 shaft assembly of auxiliary case 44 Ee ee ee 3 10 Countershaft assembly of auxiliary case 04 11 Shifting cylinder assembly of auxiliary case 5 12 Rear cover assembly D I 13 Air filtration adjuster assembly 55 9 68 14 Single H assembly ee e e 60 15 Spare parts of 16 speeds transmissions 99999 9 9 70 1 parameters of Twin countershaft transmission all synchronized 1 1 Main section picture of the twin countershaft transmission all synchronized K high speed low speed e I E I m 2 a 5 2 Ces p ii Pp ER 4 TK 12 um
4. 3 Take off the interlocking nut of cylinder piston get down sealing ring from piston 4 Piston of shifting cylinder and sealing ring L j k k k p k 4 3 3 Assemble and disassemble synchronizer of auxiliary case 2 Put low speed ring of synchronizer on desk with the pin 1 High low speeds cone ring 3 springs and sliding bush side upward fit into sliding bush 4 Add high speed ring rotating to make 11 to proper position ET 4 3 3 Assemble the auxiliary case 1 Put the synchronizer low speed ring on a wooden 2 Fit into gasket ring of main shaft of auxiliary block 50mm insert input shaft case with the groove side downward 3 Put reduction gear onto output shaft with the flat side upward mand a then pub year press plate of aus case 4 Install the compounding bearing onto output shaft Note Lubricant oil should be basted on the gear pressing plate mark on the reduction gear of auxiliary case 5 f the inner bearing ring of countershaft is disassembled 6 Mark the countershaft which should be consistent install it on with the mark on the gear 99 7 Mesh the two countershafts with the reduction gear 8 Install onto ear case housing note the lengthened countershaft marked teeth should be against each other for should be installed at the right down part of the rear housin
5. GO MOLL ROL ST x ril 1021 1051 ST 10 15 8 d i clSTg d vlDOlSIm 1001518 9 16115 6 50 TIE 011101 1 AAN 1 511101 19 5 21 OO 1 51110 1885 8 St A RON RON ILEI E D I gi EL ste LOOL SP 11021 18115 85111041 156157 Sdt LOS gi ELS ET IELEST SLILIOAL ISELST pe H VIOELSIB 8 1061588 d VIDOLSI8 8 1 5 8 18115 6 H ISELSPG 1081518 10068101 Ti bd stop ring 1 2 HE sliding bush sliding bush of low reverse sliding bush IRERE E 51 13 14 15 16 17 18 19 hex key of shaft Hed BESA spline gasket of shaft gear gasket of shaft gear gasket for reverse gear of shaft 1 2 speed synchronizer main shaft reverse gear of shaft ik 1 gear of shaft 2 gear of shaft 3 gear of shaft over speed gear of shaft ahn bi UE 4 gear of
6. ct Zb AU SL aE Fl lel Dt 6 18 9 t the E _ 48 2065 Pat Part Name Quantity MED EA gasket for PTO window 2 GTZ gasket of bearing cover of input shaft 3 round magnet 4 80277 E Hf window cover of bottom 5 DIV II Us window gasket of bottom PTO 6 gasket for clutch housing 7 ESRB spring gasket 8 transmission housing 9 brand plate bi head bolt 11 o hex nylon fastening bolt 12 WET ff FG side PTO window cover 13 Baas clutch housing 14 hand hole cover 15 hand hole 16 groove taper bolt 17 2 bearing cover of input shaft 18 bi head bolt 19 FN FG KATE RISE A 2 hex bolt and spring gasket 21 PX KRE hex bolt 22 NAIRE hex bolt 23 hex bolt 24 hex bolt 25 hex bolt with hole on head 26 cross groove tapping bolt 27 flat end bolt 28 1 AYN FARES hex nut of 1 type 29 PE flat gasket 30 p 3 8 flat gasket 31 spring gasket 32 HA spring gasket 33 frame oil sealing 6 2 Main shaft assembly 49 EL AAA MELLOL Biel eL
7. Ec L eN H ET BS IU ILI OTI m 1 GEE i 1 EJ A Figure 1 Main section picture of the twin countershaft transmission all synchronized 1 1 2 parameters of Twin countershaft transmission all synchronized Performance parameter Transmission rating input power rating input torque max speed weighr quantity Mm mm ALI 16JS200TA 355 2000 2600 350 9835 19 16JS240TA mu e 19 12J8160TA 285 1600 2600 350 9685 17 12J8180TA 31 1800 2600 _ 98340 ms 12JS200TA 331 2000 2600 380 98340 185 12JS240TA 400 2400 2600 380 98340 185 8JS100TA B 199 1000 2600 323 82130 150 m cu 4 m 835118TA B 220 1180 2600 420 9398 15 BJS118TC B en 1 180 2600 939 8 15 8JS130TA B 243 1300 2600 323 9530 155 amp JS8180TA B 331 1800 2500 3 0 945 30 15 5 9S135TA 243 1350 2600 280 94530 13 SJSI5OTA B 2600 280 998 4 3452007 355 2000 2600 350 94333 16 SJ5200TC 355 2000 2600 350 933 3 16 _ t A cg A A A AA A A cl DM A 656 tt EE 65 Eb 6S EEE EE LL cv El St Ll ev El KLL cv tl 0611 9661 GO FL ae El FL EL Ge el eS LL 99 zL 99 cl 808 9c UL 808 9c 01 6 LL 808 9c
8. 14 4 2 Assemble and disassemble the shift bar eeeeeeeeeeececccccceccccececeecccccccee 7 4 3 Assemble and disassemble auxiliary Case 4 4 Assemble and disassemble the main case en 5 Typical structure and working theory of 16 speeds transmission 5 1 Typical structure of the 16 speed transmission 9999 9 9 38 5 2 Working theory of 16 speeds transmission air path 30 5 3 points for assembling and disassembling 16 speed transmission 42 6 Catalogue of service parts 6 1 Clutch housing and housing of transmission eeeeeeeecccccccccccceeececee 5 6 2 Main shaft assembly oooooocccncccccncccccccccccccrccccrsccccss 52 6 3 Countershaft assembly e eeeeeeeecccceeccccceececcssssssesooseeecoseecso 54 6 4 Input shaft assembly OG OG 56 5 Reverse countershaft assembly 57 6 Controlling device assembly
9. 10 HRX 11 X 12 13 14 BPR XH 15 HR SCR 16 PUR X HH 17 18 HARTA bi head bolt shift bar guide block of reverse speed guide block of 5 6 speed reverse yoke low reverse yoke yoke of 1 2 speed yoke of 3 4 speed yoke of 5 6 speed shifting block of 5 6 speed yoke shaft of reverse speed yoke shaft of 1 2 3 4 yoke shaft of 1 2 speed yoke shaft of 5 6 speed yoke shaft of 3 4 speed compressed spring compressed spring 19 hex nylon fastening nut 20 21 22 23 2 AYN FAR EE 24 25 26 27 28 X MERET 29 30 swing block supporting shaft pin hex thin nut hex nut of 2 type flat gasket spring gasket spring cylinder pin hex nut fixing bolt of shift yoke gasket of shift bar cylinder pin Section 8 Assembly of drive gear in auxiliary case 65 1 BK SCIRE 2 3 4 BITE BIKE TL it 5 6 zl e 1191 135T JS B 8451001 8 B JS100TA B amp IS130T B amp IS130TA B A a 2 T K UM d M Wen 5 A Ny AA 1 d 12 d i in d a 1 bearing pedestal centripetal
10. shaft 5 gear of main shaft 6 gear of input shaft 3 4 speed synchronizer assembly spring cylinder pin ul gasket of shaft gears clamp ring of reverse gear AMR Ate low speed gear of main shaft Section 3 countershaft assembly 52 53 eee Ee 301041 1815 BISDLOLL LEL LST D T P dl Wi d Sa _ 54 stop ring of countershaft baffle sleeve countershaft 3 gear of counter shaft over speed gear of countershaft over speed gear of countershaft Pins DU FS Ar 6 4th gear of countershaft drive gear of countershaft Sth gear of countershaft square key of countershaft spring cylinder pin 10 semi cylinder key 11 HIRE short cylinder bearing 12 157 stop ring 13 short cylinder bearing 14 FH HETE F spring baffle plate for shafts N 0 1 Section 4 input shaft assembly 55 a 10 15 8 shaft 1 nut of input 2 stop ring 3 centripetal bearing 4 gasket of gears 56
11. weld assembly of countershaft aux case 4 roll bearing of short cylinder 5 stop ring 6 120 129 7 stop 120 129 7 Section 11 shift cylinder assembly of auxiliary case 270 1 15 2 O 4 5 6 AYER a amp IS130T B A BJS100TA 5 Ul a m I 2 cu cylinder piston of range speed O sealing ring O sealing ring sealing gasket of cylinder cover O sealing ring steel ball e BJ5130TA 8 cw 7 Yu 8 9 zu d Si 10 CE 11 AF JE 2 12 FEDL 13 14 15 16 RX 17 Section 12 rear cover assembly cylinder piston of range speed bolt yoke shaft of range speed shift cylinder cover of aux case hex nylon fastening bolt locate spring hex bolt pressure switch bronze gasket yoke of auxiliary case hex bolt with hole on head 73 74 1 2 JEn rear cover gasket rear cover housing 3 hex bolt and spring gasket MIO x 50 hex bolt M10 x 50 4 INIA ALA zH fF gasket of hex bolt and flat ring 5 MIO x 50 6 FV FG HARE 7 BITE rn ep nid 38 8 JIKE 9 10 11
12. 5 stop ring HEE guide sleeve of shaft 7 input shaft Section 3 countershaft assembly of reverse Speed SE LELE 07001 8 SS 0018 ER 01221 5 9 280101 1 0018 21021 161 15 dEBOLOZL 0515 ELI Emm A BERE 22 Baolori eesr 2 SIXSIN 0 9 ALEA 38 06699 1 544 sy 58 1 M20 x 1 5 nut M20 1 5 7 FA REE M16 x 1 5 nut M16 1 5 2 81 FF gasket of reverse countershaft 3 thrust gasket ring of reverse speed 4 roller bearing 5 FP a 76 countershaft gears of reverse gear 6 gasket ring of reverse speed 7 reverse countershaft 8 flat bolt Section 6 assembly of control device 59 60 1 4 1 1 J 1 en d LT gt i 1 D 8 lI 7 x Da m 1 61s 3 ALN 4 5 HL 6 90 Ehm 7 Pe ug 8 RME 9 HR 5 air pipe pipe assembly housing of control device horizontal shift lever shifting block 90 degree shift connecter air r
13. 1 Take out two countershafts assemblies and disassemble reverse idler gear 4 4 5 Assemble and disassemble main shaft assembly It s not necessary to adjust the gears backlash to avoid adjustment referring to 12 speeds transmissions 1 Disassemble the baffle plate at front part of main shaft 2 Demount the clamp which is used to fix 5 6 synchronizer take off gear of input shaft and 5 6 speed synchronizer dismantle 5 6 synchronizer compound ing 4 Assemble Put main shaft on desktop with the small end upward fit gasket of reverse gear rotate for one tooth distance then insert long key 3 Take out the spring pin of main shaft extract long key dismantle gears and gaskets of main shaft 28 9 Assemble the reverse sliding bush of main shaft the etch 6 Assemble gasket of gear of main shaft rotate for one should aim at the Eu of main shaft with hole tooth distance and insert a long key T Fit input gear into main shaft mount spline gasket 8 Put 1 2 speed synchronizer compounding fit a clamp With the flange side upward rotate for one tooth distance the aperture should be aiming at the groove of main then insert a long key shaft with a hole on it 9 Mount gear hub of 1 2 speed synchronizer 10 Mount another compounding of 1 2 speed synchronizer then mount a clamp the aperture aiming then mount main shaft spline with the flange side at the groove of main shaft with a hole on it
14. s _ 116152007 1701113 8 gear main shaft io _ 16 82001 1701112 2 gear main shat wer 1 2 synohronzer i _ QO S 116 52007 1701108 Sling sleeve TT est Reverse gear manst 1 _ 0 16482001 10105 SSS 1 6152001701121 Long nex key manst 1 2 1 EN 7 16JS200T 1701111 1 gear main shaft ll 9 WS EUM EN 80 countershaft assembly Ti 2 16JS200TA 1701052 Differential gear countershat 3 111607 1701087 4 1 amp USROUT70056 Driving gear countershat 1 5 1606200 1701060 39 gear countershaft 6 16520071701056 Squrekoycomteshal 1 7 Tome Emsomdiapin 1 8 XE Sememweky I 9 16 520071701048 Counterst 1 N7 sch 81 Control device assembly g O at P d 81 eu gt Do 4 Sh SF 82 No PartNo Description 6 mees toaionrng _ 8 982176 0000 SmalhexboMBX22 9 GB9376 Springwashers o o o o GB70 76 45 angular pipe union 36 GB85976 Spring washer L 4 737 Bewmrpug 1 38 CO3004 1 39 00935 65 1 arem 1 un 9901271004 Pressure smith oo 83 No Par
15. 2 When low speed there is air at outgoing vent of the pre selector when high speed there is no air at outgoing vent of the pre selector 2 4 Working theory of static Power taking off In order to meet certain demands of special vehicles at rear and down part of 12JS180T transmission between clutch housing and transmission PTO can be installed Power taking off from the lengthened Countershaft of the Aux case it is called rear PTO It s most prevailing nowadays If it s installed between clutch housing and transmission it s called front PTO or all power PTO When the rear PTO applied the Aux Case must be engaged in the neutral position for the purpose of power taking off and stop To deal with this problem it 15 simple to remove the cover of Aux Case cylinder and add a neutral position cylinder Structure of neutral position cylinder is shown in figure 8 and the indicated location is neutral position 10 Hole and Hole B are connected separately with low speed air inlet and high speed air inlet corresponding to the twin air valve with air pressure of 0 57 0 6 Mpa Hole C 15 compressed air inlet with air pressure of 0 7 0 8 Mpa First put the Transmission operating rocker at neutral position of low speed section here the piston 15 will press closely the position ring then operate the cylinder control vale to let compressed air enter the neutral position cylinder 9 via Hole C Owing to pressure difference the neutral po
16. 4 w V 11 Mount another compounding oi synchronizer 12 Install the spline gasket of input shaft then mount a clamp ring 7 E DP A 14 Baste anti oxygen material on the screw of input 13 Assemble input shaft gear and spline gasket shaft nut fix it Mark two opposite teeth then add a clamp ring of differential gear 2 5 3 3 Assemble and disassemble the shift bar assembly 2 Detach bolts on the shift bar 1 Detach the follower valve and parity cylinder s pipe 43 3 Screw off the bolts and take down the shift 4 Take off 3 location spring and steel balls of shift bar housing Detach 1 2 speed voke and yoke shaft take out the interlock steel ball inside the housing Note there is interlock pin inside the hole of 1 2 yoke shaft 1 Detach 3 4 speed yoke shaft guide block and voke 8 Detach the clamp ring inside shifting cylinder on take out interlock steel balls inside the housing shift bar housing 9 Knock yoke shaft of piston take out spring and 10 Y style sealing ring of yoke shaft and 0 style steel ball take out voke shaft of piston sealing ring of side cower 44 12 Baste grease onto the Y sealing ring install yoke 11 Y sealing ring of parity shift cylinder of shift bar shaft onto parity cylinder of shift bar 13 Mount a location steel ball into shift cylinder Note vius hal Noon 14 I
17. The neutral of low speed section 16 at 3 4 speeds the neutral of high speed section is at 9 10 speeds See figure 5 Figure 5 illustration of control hand See figure 6 the operation mechanism is made up of operation mechanism housing outer shifting arm horizontal shifting level reverse switch control block shifting bar compressed spring air plug indicator switch starting pin and so on It is use for choosing a speed hanging a speed and disengage a speed Each side of the shifting bar has a fan shaped convexity and grooves on the convexity control neutral indicator switch and air path control valve The reverse indicator switch is controlled by moving and rotating the reverse switch control block TEL paads 3513431 JO 07 funr gs mo 761 md gengt EAS IO OT mus ST nd FT gings JO El JO Sursnoq zT Suds passaaduio 11 21820 jd apts e US 71101 78 pessapad md 24 EA eed 133330009 SAEM E E 33300109 Us Hob 06 Apquiasse ponas paads jo I041003 T Figure 6 illustration of single device ission will be decreased from 0 7 0 8Mpa to 0 57 0 6Mpa by the air th of 12 speeds transm filtrating regulator then enter main pipe and air entering control pipe
18. so rear auxiliary case chooses lock pin synchronizer This kind of synchronizer switch automatically only when shift between high speed and low speed 36 5 2 Pneumatic path and working theory of 16 speed transmissions 16 speed transmission 15 remote control and it has two kinds of control mechanisms that are single lever double H control and double lever double H control The main transmission adopts manual control and front auxiliary case uses pneumatic control see figure 11 as double H shifting mechanism hand ball position chart and figure 13 as control hand ball chart When the switch of hand ball pre selector valve is at position 1 the hand ball can engage 2 4 6 8 10 12 14 16 and R2 speed when the switch at position 2 the hand ball can engage 1 3 5 7 9 11 13 15 and speed that is position 1 is even number speed AREER RY 3 5 9 3 position 2 is odd number speed Figure 11 Position of shifting hand ball in double H mechanism The auxiliary case of 16JS200T is also pneumatic control but only shift between high speed and low speed ls realized automatically in the double H control mechanism 16JS200T transmission uses plug in type structure so there is whole speed and half speed Usually the transmission runs at odd speeds or even speeds That is when engaging a speed with the control hand ball no need to turn the odd and even shift switch only on the special road conditions as climbing long slop
19. the long hexagonal key to fix axial position and there is no need to conduct axial adjusting On the main shaft there are two sets of double taper face lock ring synchronizers that are large in capacity and flexible in engaging a speed In the rear auxiliary case the auxiliary drive gear connects with the main shaft via spline And the auxiliary countershaft driving gear 1s welded on the auxiliary countershaft The auxiliary main shaft reduction gear is supported on the shaft by spline washer and the gear can radial float The rear auxiliary case adopts the enhanced lock pin synchronizer with non metal friction material and high in reliability Both in the main case and auxiliary case except reverse gear lst gear and rear auxiliary reduction gear the other gears all use fine teeth design with big overlap ratio stable gear engagement and low noise In the main case of 16JS200T twin countershaft transmission there are two completely same countershafts in dimensions and structures so 15 the auxiliary case 1 gear j Igam Ja HS 7 r 1 Agam 2 eeng TT M 4 tose iii f gear 4 54 2 24 Figure power transfer path of 16 speeds transmission 255 5 1 2 Power Transfer Path of 16JS200T Transmission The power transfer path of 16JS200T see figure 9 The engine power 15 transferred to the inpu
20. When the main case 16 at the neutral 2 3 Working theory and pneumatic pa The compressed air from the vehicle position air path stopping valve opens the compressed air enters into the air path commuting valve The compressed air enters into cylinder vent plug through low speed pipe the cylinder s piston moves synchronizing bush of auxiliary case to mesh with reduction gear at this time transmission 15 at all low speed as R1 1 2 3 4 5 6 speeds select High at the preselector there 18 no air in the outgoing pipe the compressed air comes into high speed pipe and then to cylinder s high speed incoming vent plug the cylinder s piston moves synchronizing bush of auxiliary case to mesh with drive gear of auxiliary case at this time the transmission 15 at all high speed as R2 7 8 9 10 11 12 Neutral position of low speed is 3 4 speed Neutral position of highed is 9 10 speed high speed T ee w lt Ll 0 5 0 6MFa Compressed air inlet 1 air filtration adjuster 2 main pipe 3 transition pipe 4 inlet pipe 5 shift handler 6 outlet pipe 7 high speed pipe 8 low speed pipe 9 air path control valve 10 air path shift valve Figure 7 illustration of air path about single H Pay attention 1 The air control valve only opens when it s in neutral position when shifting the air path will be blockaded at the valve That is only when transmission is in neutral position can shifting speeds be realized
21. cone lock ring synchronizer is a newly designed synchronizer device based on similar working theory and structure of the lock ring synchronizer It inherits the advantages of the lock ring synchronizer and makes up the shortage by improving the friction torque Figure 4 18 5 6 speed synchronizer 5th speed and 6th speed are all cone faces 5th speed and 6th speed share the synchronizer gear spacer hub sliding block and spring Both of 5th and 6th have three cone parts 5 6 8 and six single splines on outside cone 5 of synchronizer combines six spline grooves on the inside cone 8 of the synchronizer so both the outside cone 5 and inside cone 8 rotate with the main shaft But six protrudings of cone 6 combine 6 holes of the conjoint ring 7 so the cone 6 rotate with 5th speed gear As a result when the transmission 15 shifting from 4th speed to 5th speed or shifting from 6th speed to 5th speed a relative speed difference will be produced between the 5th speed gear and the mainshaft at this time two sliding friction cones of the 5th speed synchronizer cone mechanism will start work There under the same condition the friction torque made by the axial thrust of the synchronizer gear spacer equals to sum of the friction torque of the two cones that 18 friction torque made while shifting the 5th speed is approximately 2 times that of the single cone so reducing the shifting force for about 5046 Working process When shifting m
22. groove of main shaft with a hole on it 22 Use pressing plate to fix input gear onto main shaft 31 4 4 6 Assemble main case assembly Assemble reversing idler gear with the flange side forward 2 Assemble shaft of reverse idler gear screw interlock nut 3 Mark teeth which is 180 degree opposite of input gear Mesh marked teeth with marked groove of input gear put main shaft in main case install drive bearing to Fix the slate mount rear bearing of countershaft 8 Use same method to assemble the rear front bearing of another countershaft 255 9 Detach pressing plate in front of input gear lubricate hole 5 S e 10 Assemble the clamp of input gear of input shaft insert input shaft into spline of input gear gp 13 Baste mucus on nut of input shaft mount it with special tools PANE 16 Assemble reverse idler gear detach bearing of drive sear pull reverse gear of main shaft backward make it mesh with reverse idler gear 15 Mount front baffle plates for 2 countershafts then assemble input shaft cover 33 17 Mount a gasket of main shaft gear into reverse gear 18 Mount a clamp into inner side of reverse gear of main shaft 19 Mount the bearing of drive gear then mount 20 Assemble drive gear of auxiliary case then mount location plate use steel wire and nut to fix it a clamp on rear part 21 Mount 2
23. or it will impair life of transmission 3 2 5 When hanging a reverse first do stop the vehicle then hang so as to prevent breaking the spare parts inside the transmission When hanging a reverse use bigger force to choose the speed to overcome the resistance of the reverse lock 3 2 6 When shifting from 6th to 7th or from 7th to 6th halt for a movement consciously to insure the Aux Case accomplish the conversion from low speed to high speed or from high speed to low speed Before removing a speed move the operation arm to the aimed position at first then process conversion of high and low speed 3 2 7 Forbidden to change from high to low or from low to high don t skip speed otherwise life of synchronizer in Aux case will be shortened 3 2 8 Regularity Check vent plug if blocked with dirt should be cleaning at any moment 3 2 9 Should be check filter web of air filtrating regulator each running 20 000 Km cleaning filter web and wall of filtrating regulator with subs and make it dry with compressed air 3 2 10 Try to avoid changing from high to low or from low to high when vehicle downhill 3 2 11 If there is abnormal noise you fell heavy in operation stop and check immediately 3 2 12 Operating must strictly accord the operation criterion otherwise may destroy the synchronizer Aux Case 3 2 13 Don t dismantle or assembly a transmission by yourself during the three guarantee period EET
24. speed Gears of Main Shaft are in floating state on Main Shaft thus traditional roller bearing is canceled which make the mainshaft s structure simple When it works force by two Countershaft Gears against to Main Shaft Gears are equal in intensity and opposite in direction therefore they will counteract each other at this moment the main shaft 1s only bearing the torque but not bearing flexural torque so the stress condition on main shaft and bearing 18 improved and the reliability and durability of Transmission are improved greatly 2 1 Shifting structure 1 hushofsvnchronizer 2 locatering 3 spring 4 hubofsynchronizer 5 thrustofsvnchronizer 6 double cone of synchronizer 7 contact teeth of synchronizer 8 inner taper of synchronizer Figure 4 twin cone faces synchronizer assembly of main case The synchronizer in transmission make shifting easier and more convenient low collision and noise so the gears life 18 prolonged performance can be enhanced so except the reverse speed gear other gears are equipped with synchronizers Inertia synchronizer ensures that it can shift to gears stably and smoothly It consists of two kinds inertia locking stop style and inertia force style The most prevailing is locking stop style The lock ring synchronizer has compact structure good performance high reliability and low cost so it is widely used currently The only shortage 18 that its friction torque 18 a little lower The twin
25. the compressed air will push the piston move to the left so that main air pipe 5 connects with odd number speed that is half speed air pipe 4 which is connecting with the cylinder in the front auxiliary case so the synchronizer in the auxiliary case of the transmission will be at odd number speed region position There are two interfaces on the shifting cylinder in front auxiliary case which are relatively connecting with odd or even number speed air pipe so by moving the piston to left or right to control the front auxiliary case be at odd number speed or even number speed that is at half speed or whole speed position 2004 5 3 Points when assemble and disassemble 16 speed transmissions 5 3 1 Assemble main shaft of 16 speed transmission 1 Put main shaft vertically on working table 2 Mount reverse gear onto main shaft with meshing mount reverse gasket rotate for one tooth teeth upsard mount reverse sliding bush the aperture distance and put the long key through aiming at the groove of main shaft with a hole on it 4 Mount 151 gear onto main shaft with the meshing tooth distance push the long key upward then push the long key upward 5 Mount a compounding of 1 2 speed synchronizer 6 Mount a hub of 1 2 speed synchronizer then mount a clamp then mount a clamp 40 7 Mount another compounding of 1 2 speed synchronizer 8 Mount 2nd gear onto main shaft with meshing teeth then spling gas
26. 0074112 152007 1 1 ini TTT TT 111111 1 1 1 P 1 11 im R1 R1 7 R21R2 Figure 3 illustration of power path 2 Typical structure of twin countershaft transmission all synchronized The and Aux Case are all adopt two countershafts with same structure alternate with180 the power is input from input shaft and then it can be distributed to the two countershafts finally influx to the shaft for output so 16 the Aux Case As theoretically each countershaft can only transfer 1 2 torque so using the twin countershaft can reduce the center distance of transmission the width of gears 1s less axial size 15 shorter and weight 15 lighter After using two countershafts each speed gears on Main shaft must be mesh with two gears on counter shafts at the same time For meeting the correct meshing and distributing the load evenly the gears of main shaft are in floating status on Main Shaft The Main shaft adopts the floating structure with hinge joint The front neck of Main Shaft insert into the hole of Input Shaft the guide sleeve with oil 18 pressed into hole there is enough radial clearance between the neck of Main Shaft and Guide Sleeve The back end of Main Shaft insert into 1nner hole of Drive Gear in Aux Case by involute spline the shaft neck of Drive Gear in Aux Case is supported on hole of the ball bearing Owing to each
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29. 4 Assemble and disassemble twin countershaft transmission all synchronized Take 12 5200 transmission as example 4 1 assemble and disassemble shifting mechanism single H valve 1 single left control transmission of 12 speeds 2 detach the inner hex bolt of air pipe from sing assembly 4 detach supporting bolt from air pipe comutatira valve 4 detach the 4 locating bolts of single H assembly at right side of shift bar B detach 2 bolts off the side plate take out spacing valve then take cut circlip pliers off horizontal shifting shaft 1 turn double H housing take out bowl shape shin and wires 10 Take out the cylinder pin off the shifting block 11 Take out spring cylinder pin off reverse control block 2 assemble if the oil seal already detached showing horizontal shifting shaft fit it into the single H valve 13 install horizontal shifting shaft then spring cylinder pin to reverse control block 14 fit cylinder pin into shifting block and fix with steel wires fit into spacing sleeve install side plate 1 install starter pin and switches for reverse 18 install dust proof and shifting yoke and neutral position make sure the yoke amd block are in line 4 2 Assemble and disassemble shift bar 2 Detach the four bi head bolts from 1 Detach bolts from shift bar shifting bar housing with tools 3 Knock shift bar with bronze stick detach it from gasket 1 off the sh
30. 7181250 Hex bolt with hole of head 2 1819 Iron wire requirements 6 089876 00000 Springwasmerto 8 7 082176 SmalhxtotMIOX32 a _ 8 1445 Oring seal LI 9 JS220 1707061 Yoke shaft range speed 1 10 144 Piston air cylinder range speed 1 1 12 14344 Oring seal 001 18 GB890 80 HexnyonlcckmgihinmuMI6X18 1 _ 14 14349 Seal gasket air cylinder cover 1 15 F99857 Shifting speed air cylinder cover Aux case 1 16 095 Tee union NPT1 8 J 1 17 068801 Square head cone plug NPT 1 8 1 18 1280 4 anguarpipeunon J 1 _ mamen Folding copperwasher 4 _ 20 79100710069 01 91 rear cover housing assembly 92 Ti 1461050 Spring washer of hex bolt amp plain washer combination JS180 1707156 Gasket rear bearing cover mainshaft Aux case 7 20 21 C09033 Hex bolt with hole of head amp spring washer combination 2 23 24 25 26 27 93 Air filtrating regulator 8 plug screw assembly Air inlet 7 5 pressure 4 Connect with air tank of auto screw 3 8 CS High pressure 6 7 7 1 pressure Connect with rear Aux case screw 1 6 94
31. Twin countershaft transmission all synchronized Catalogue 1 Main parameters of Twin countershaft transmission all synchronized 1 1 Main section picture of the twin countershaft transmission synchronized 1 2 parameters of Twin countershaft transmission all synchronized 2 1 3 Numbering of Twin countershaft transmission all synchronized 4 4 1 4 Power transfer illustration of 12 speeds transmlsSlOnS 5 2 The structure of Twin countershaft transmission all synchronized 2 1 Shifting structure illustration seess seess ee ef 2 2 Controlling structure illustration ooooccnsrcccrrrccccrrccccssss g 2 3 Working theory of 12 speeds transmission air path H 2 4 Working theory of static power taking Off 9 9 9 9 3 Maintenance awareness for using Twin countershaft transmission all synchronized 3 1 Use and maintenance 3 2 Pay attention 12 4 assemble and disassemble the Twin countershaft transmission all synchronized 4 1 Assemble and disassemble the shifting structure single H valve
32. ars and shafts can provide enough lubricating oil for transmission When the rear wheels of the vehicle is being towed countershaft gears and main shaft gears of the main case don t rotate but the main shaft driven by the rear wheels rotate at high speed the adjusting gaskets driven by mainshaft also rotate at high speed which will destroy the transmission badly due to speed difference and lack of lubricating oil Warnings When the engine is going out neutral sliding will also cause the same evil consequence If the vehicle needs towing you can draw out the half shaft or off the drive shaft or tow with the drive shaft part from the earth So any towing without preventive measures are prohibited 3 2 Pay attention to those points 3 2 1 Before vehicle starting brake should be released If your automobile adopts the pneumatic brake only after turn on brake valve and wait until air pressure goes up to required pressure you can hang shift for starting 3 2 2 Adopt 3rd speed or 4th speed to start according to highway condition De 3 2 3 Shifting level have neutral at both high speed section and low speed section that is at 9th 10th neutral position at high speed section and 3rd 4th neutral position at low speed section When stopping the vehicle transmission should be set at low speed position and the conversion switch on the operation arm 1s at the low position 3 2 4 Before shifting clutch should be release entirely
33. ball bearing with a stop groove stop ring locate panel of auxiliary bearing drive gear of auxiliary case stop ring 66 JL Wa FE hex bolt with a hole in head 8 steel wire Section 9 Assembly of main shaft of auxiliary case 67 SLL LOM STE 10 15 8 8 1061SP8 g vioo0isre LOLS 10 15 6 89 15156 Ch 105156 Deo HISP xz 212015 DOT Fee e 68 main shaft of auxiliary case MEER high low speed synchronizer gasket for main shaft of auxiliary case reduction gear of main shaft auxiliary case press slate for main shaft auxiliary case flange nut U BW WN Section 10 Assembly of countershaft auxiliary case amp IS119T B EJ5130T B 4 51307A B 845135 iF Uu 22 X E cl zc z 69 1 roll bearing of short cylinder 2 weld assembly of lengthened countershaft aux case 3
34. downward rotate for one tooth distance insert a long key 220 11 Mount 2nd speed gear onto main shaft mount gasket 12 Mount 3rd speed gear onto main shaft mount E M Cm spline with flange side upward rotate for SES for one tooth di stance sert a long key pte tooth distance insert lang key 13 Put into one of 3 4 speed synchronizer 14 Mount gear hub of 3 4 speed synchronizer then mount mount a clamp the aperture aiming at the groove of clamp the aperture aiming at the groove of main main shaft with a hole on it shaft with a hole on it 1 D S B NA 15 Mount another compound ing of 3 4 speed synchronizer 16 Mount 4th speed gear onto main shaft mount gasket then mount main shaft spl with the f lange side downward rotate for one tooth distance insert a long key rotate for one tooth distance insert a long key 30 17 Mount 5th speed gear onto main shaft mount spline with flange side upward rotate for one tooth distance insert a long key 18 Put into one compounding of 5 6 speed synchronizer mount a clamp the aperture aiming at the groove of main shaft with a hole on it 19 Mount spring pin of main shaft put the long key to a proper position E 21 Put into another compounding of 5 6 speed synchronizer mount input shaft gear 20 Mount gear hub of 5 8 speed synchronizer then mount a clamp the aperture averting the
35. e 5 are air exhausting And the result is connecting the high speed region or low speed region The working theory of single H double H and pre selector valve will be described in detail below 37 high speed Tw Jow speed Compressed niet 7 bar aec CERPUNWE OE jom arr tank E xA XB l double H 2 range speed cylinder 3 air filtrating regulator 4 air valve 5 clutch pedal single H valve Figure 12 Pneumatic path illustration of the transmission even number speed half speed odd number speed whole speed S Figure 13 Working theory of pre selector valve Working theory of pre selector valve as see figure 13 the switch on the hand lever has up and down two states If turning upwards the transmission 15 at half speed that 15 even number speed 1f turning downwards the transmission 15 at whole speed that is odd number speed To realize shift between half speed and whole speed the driver only need to turn the switch of the pre selector valve on the shift lever In figure 13 air pipe 5 always connects with the main inlet pipe on the follow up valve single H valve When the switch at odd number speed air pipe 5 connects with air pipe P through hole 1 when the switch at even number speed air pipe S can t connect with air pipe P at this time the high pressure air in pipe P gets through with outside air via hole 2 but the high pressure air in air pipe 5 15 plug
36. eshing bush 15 taking sliding block and pushing outer cone move forward because there is aperture after installing synchronizer cone pushes gear ring and make it close to gear The friction moment produced by speed difference make out cone rotate a certain angle and fixed by sliding block At this time the gear sleeve moves interface of gear sleeve contacts with that of out cone s outer spline The shifting force further pushes outer cone through lock stop slant face friction happens consequently the synchronizing forward shifting can be stopped When the friction moment counteracts with inertia moment of the part being combined speed difference and friction moment disappear Ring moment force the outer cone back to position the lock stop slant face disengaged meshing sleeve meshes with synchronizing gear ensuring a smooth shifting Shifting process The vehicle driving each part of transmission position as figure 3 after the driver remove speeds At this moment the power from Motor and Clutch transferred to the Input Shaft through involute spline transfer to Input Shaft Gear the Input Shaft Gear and Countershaft Drive Gear are meshed each other The power transferred to the Countershaft owing to each speed gears on Countershaft and countershaft connecting together so rotate together Each speed gears on Countershaft makes each speed gears on Main Shaft rotate together Because Sliding Clutch of each synchronizer in neutral position so eac
37. f synchronizer to equip with 16 speed transmission As the figure shows a is a parity synchronizer It has small rotation difference so it uses single taper face and friction face 1 adopts carbon fibre material Because front auxiliary 18 pneumatic control the structure of the synchronizer is uni direction design b is main case synchronizer which is double taper face There are two sets of this synchronizer one is between 1st speed and 2nd speed the other is between 3rd speed and 4th speed Because there are two assistant frictions 1 and 2 the synchronizing capacity 18 1 greatly improved and shifting is more 427 flexible The assistant frictions with steel ring and brass material and there 18 middle position in the synchronizer to meet the demand of neutral speed The above two kinds of synchronizer are lock ring inertial synchronizer c 1s rear auxiliary case synchronizer which 15 lock pin inertial synchronizer It 15 pneumatic control so the structure of the E gt SE synchronizer is also uni direction design and with carbon fibre material Because the ratio difference 18 big in the rear Figure 10 structure of synchronizer auxiliary case about 4 55 large synchronizer capacity is required and cylinder thrust force is big then the impact force will be big when engaging a speed It is testified that lock pin synchronizer is more resistant to impact force than lock ring synchronizer
38. front bearings for lengthened countershafts clutch housihz assembly then mount clamps at the rear part of countershafts in main case The 12 speeds transmissions of twin countershafts with synchronizers can be assembled according to the above instructions For 16 speeds transmission above instructions can be used 24 5 Typical structure and working theory of 16 speed transmissions 5 1 The typical structure of 16 speed transmissions 5 1 1 Main structure of 16JS200T transmissions 16JS200T transmission is in 2x4x2 structure The gears on the input shaft main shaft and main shaft in auxiliary case are in radial floating condition Input shaft gears are freely set on the input shaft using the spline washer and snap ring to fix axial position which is simple in structure convenient in assembly and also gets rid of the adjusting shim the input shaft differential gear is also freely set on the input shaft between the input shaft gear and differential gear equipped a single taper face lock ring inertial synchronizer which is pneumatic operation and engaging a speed through yoke of shift bar cylinder The Ist gear 2nd gear and reverse gear of countershaft are integrated with the countershaft other gears on the countershaft match and joint with the countershaft via given magnitude of interference and semicircular key or long key The main shaft gears is freely set on the main shaft using the spline washer snap ring and
39. g ID Install the clamp ring onto the countershaft bearing Kg r 12 Install out put shaft cover install odometer passive and active gear and connector u 19 Insert shifting yoke into sliding bush of synchronizer 2 mount bolt to connect yoke and cylinder fix them 14 Mount shifting cylinder of auxiliary case with steel wire 7F D 15 Fasten flange nut with special tools 16 Put synchronizer of auxiliary case at low speed position a L Tm 17 Baste oil evenly onto the 2 bearing holes at the rear part of main case 1t s important pn 18 Assemble auxiliary case with special crane 19 Fix the bolts which connect the rear cover and main case housing 4 4 Assemble and disassemble assembly of main case 4 4 1 Disassemble input shaft this method can be used to change input shaft without disassembling the main case 1 Demount the bolts on the clutch housing 2 Demount the bolts on input shaft cover slightly take down the clutch housing knock to take out the input cover pos 4 Demount the pressing plate at the front end of 3 Mesh the synchronizer with two groups of gears countershaftof main case then demount the nut of input shaft 8 Knock the input shaft right and left to make it fall out from the hole of housing 1 Take off the gasket of input shaft gears 8 Take out the clamp circle
40. ge nut of output shaft with special wrench m d 3 off 3 from auxiliary Cylinder 4 Take off the connecting bolts between rear and take off 2 bolts from air filtration housing and main case 18 5 Screw out the 4 bolts of auxiliary case for about 10 mm 6 Take off auxiliary case with tools 8 Take off 2 output bearing cover get down the clasp 1 Take off flange nut and flange panel from auxiliary shaft with tools 3 Knock the output shaft rearward depart it from bearing take down bearing of countershaft 11 Take off the bolt which connects shifting cylinder of auxiliary 12 Take off the 4 bolts of auxiliary shifting cylinder get case and shifting yoke of auxiliary case down the cylinder assembly 19 13 Take off synchronizer from output shaft 14 Knock the output shaft rearward to make it fall from the bearing hole 15 Brace the output shaft assembly knock down the bearing 16 The components of output shaft assembly 17 off the bolts of bearing cover of output shaft zet down the bearing cover disassemble connector of 18 Take out the outer ring of bearing from the rear odometer drive gear and driven gear cover housing 20 4 3 2 Disassemble shifting cylinder of auxiliary case 2 Screw down the bolts of cylinder housing and take out steel ball spring Ku 1 shifting cylinder of auxiliary case f
41. ged up 38 2 Working theory of single H valve also follow up valve see figure 14 gh t gen even number speed o 1 half speed 5 odd numberspeed 277 whole soeed if MET low speed air pipe high speed air la Sch 1 pre selector valve 2 air pipe P 3 high speed air pipe 4 low speed air pipe 5 main inlet pipe 6 air ppe S 7 follow up valve assembly Figure 14 Working theory of single H valve When the clutch has been completely released continue to tread the clutch pedal the control valve under the clutch pedal will be open then the compressed air about 2 8 3 2 Pa from the transmission air filtrating regulator will enter into main air pipe 5 see figure 14 a then from main air pipe 5 enters into follow up valve assembly 7 If the odd and even shift switch of pre selector 1 18 at even number speed region air pipe S will get through with air pipe 5 see figure 14 b and the compressed air will push the piston move to the right so that main air pipe 5 connects with even number speed that 1s half speed air pipe 3 which 15 connecting with the shifting cylinder in the front auxiliary case so the synchronizer in the auxiliary case of the transmission will be at even number speed region position If the If the odd and even shift switch of pre selector 1 18 at odd number speed region air pipe S6 will get through with air pipe P2 see figure 14 c and
42. h speed gears on Main Shaft racing the Main Shaft no power output When the driver operate shifting lever for hangs 5th Speed in cab Through drive Mechanism of shifting lever the Yoke Bar 5th amp 6th speed makes Yoke 5th amp 6th speed move to right the foot of Yoke push Sliding Clutch move to axial direction now two sliding friction cones of the 5th speed synchronizer cone mechanism will start work When the relative angular velocity of 5th gear and main shaft 18 zero inner spline of synchronizer will mesh the outer spline of 5th gear slightly So far entirely hang speed have completed After the power from Motor and Clutch transferred to Input Shaft through the spline transferred to Input Shaft Gear and transferred to symmetrical two Countershaft Drive Gears and through symmetrical two Countershaft Gears Sth Speed transferred to synchronizer sliding Main Shaft through Spline meshed and then the power through Drive Gear of Aux Case input Aux Case Finally the output flange of Transmission output the power through Aux Case u Analysis of inertia synchronizer s defects Lock ring synchronizer single cone face synchronizer multi face synchronizer 1 inactive at a early stage Under usual condition within warranty period allowance of synchronizer disappear make lock and synchronizing effect of synchronizer inactive it maybe caused by the following factors 1 The disengagement of synchronizer is not thorough enough so whe
43. ift bar take out the springs and steel balls Note use hand to ward the spring holes preventing spring from dropping into holes J Turn the shift bar detach the reverse yoke Detach spring cylinder pin off the 1 2 speed yoke yoke shaft and guide block take off yoke and shaft inter lock pin and steel ball 1 Detach spring cylinder off 3 4 speed yoke 8 Detach locate bolts off 5 8 speed yoke shaft take off yoke and shaft inter lock pin and steel ball take off yoke shaft 5 6 speed yoke and guide block 3 Mount low reverse speed guide block and yoke onto yoke shaft fix it with taper bolts 10 Install 1 2 speed yoke shaft fit into spring cylinder pin fasten wires and fit into a inter lock steel bal me interlock pin of 1 2 speed yoke shaft should not be missed 11 Fit into one inter lock steel ball 12 Install 3 4 speeds yoke shaft install spring cylinder pin on yoke and inter locking pin and interlocking ball 13 Install 5 6 speeds yoke shaft then install 5 8 speed guide block and yoke fasten the wires with bolts 14 Install the shift bar onto main case 15 Install 4 bi head bolts ento shift bar fit locating spring and steel ball Note 5 6 speeds yoke shaft has a wide inner spring 4 3 Assemble and disassemble assembly of auxiliary case 4 3 1 Disassemble assembly of auxiliary case 1 the two synchronizers in main case mesh with gear respectively 2 Screw flan
44. ket of mainshaft gear rotate one tooth downward then a gasket rotate one tooth distance push the long key upward push the long key upward 9 Mount 3rd gear onto main shaft with meshing teeth upward then a gasket rotate one tooth distance push the long key upward 11 Mount one compounding of 3 4 synchronizer 12 Mount one hub of 3 4 synchronizer then mount a clamp then mount a clamp Note the aperture of clamp aims at the groove with a hole Note the aperture of clamp averting the groove with a hole E f Se 4 A k AAA 13 Mount another compounding of 3 4 speed synchronizer 41 5 3 2 Assemble and disassemble input shaft 1 Input shaft assembly of 16 speed transmission 2 Detach the clamp ring in inner hole of input gear 3 Take off the gear of input shaft and the spline gaskets beside it 6 Direction of sliding bush and taper rinz Mote Taper rings at both sides and constant meshing 5 Take off one compounding of synchronizer teeth are not interchangeable detach the clamp ring of one side gt Assemble input shaft 8 Mount a bearing Put input shaft vertically of input shaft mount a input gear mount the gasket for input gear with the flange side downward 42 9 Put input shaft horizontally mount a compounding 10 Mount a hub of synchronizer then a clamp ring of synchronizer mount a clamp ring f 2 Le
45. n shifting the synchronizer need to bear more torque there is a constant friction on the synchronizing cone face making it inactive 2 The gear ring s cone face of synchronizer does not have a good lubrication when there is not enough lubrication on the cone face threads on it will soon wear out and cause high temperature making it inactive 3 Lubrication oil within the transmission is not pure enough the oil is too dirty the impurity material will impair the gear ring s threads that will affect synchronizer s performance and life making it inactive 4 There is machining defects on the synchronizer s cone face such as cone face s roundness linearity and run out all of this will cause severe friction on the cone face making it inactive 2 The synchronizer s teeth get broken and fractured it is caused by design and machining problem such as too small filleting too thin thickness of shell cracks and so on 3 Inner cone face gets broken We should think if the space is suitable for installing synchronizer if the space 18 too big it will impair the performance and durability if the space is too small the cone face will have a bad lubrication or completely get broken 2 2 Controlling structure The basic mechanism of 12 speeds series 18 twin remote operation with impact structure clear speed position and good handle 2 3 4 5 6 are at the low speed section and R2 7 8 9 10 11 12 are at high speed position
46. nstall the side cover with the flat side outward E ia fL ur n ades 4 d 4 Ta er f Sm 4 118387 4 K 3 CR SE E 24 15 Mount the clamp ring onto parity shift cylinder 16 Mount a bolt on the yoke of parity shift cylinder fasten with steel wire 17 Mount 3 4 yoke shaft guide block and yoke fixing bolt install a interlock steel ball 45 19 Fasten 1 2 yoke and the bolt on guide block 20 Mount yoke shaft of reverse speed guide block fixing it with steel wire Mount a steel ball and reversing yoke Fasten bolts 22 Mount steel balls and springs for 3 holes of shift bar Note springs in 3 4 speed yoke shaft are wider 23 Fix the bolts on shift bar connect single H valve and air pipe 5 3 4 Assemble 16 speed transmissions 1 Remote control double H assembly can refer to double H assembly of twin countershafts transmission 2 Assembly of 16 speed transmissions including main and auxiliary case can refer to Part 2 Chapter 6 assemble and disassemble 12 speeds transmissions 3 Timing procedure of main case of 16 speeds transmissions can choose Ist gear differential gear of 15 gear any one 15 OK See the illustration Zz fo ei E s 6 Parts Catalogue 6 1 Clutch housing and transmission housing 2d Ts TARER TGS ese
47. of input shaft gear Ld ia L qe D 9 Use the pressing plate and bolt 01011 to press input shaft to avoid impairing the 5 6 synchronizer when assemble and disassemble The pressing plate can be customized according to actual situation EE 4 4 2 Disassemble the driving gear assembly Cut off the steel wires of drive gear assembly 2 Take out the clamp circle on the inner hole of drive gear demount the B bolts take off the drive gear and locating plate 4 4 3 Disassemble reverse idler gear assembly Disassemble the clamp in the reverse gear of main shaft 2 Disassemble the gear gasket of main shaft in the reverse gear 3 Demount the bearing at the end of idler gear shaft with special tools 1 Screw out the bolt in reverse idler gear shaft f im x e 9 Loosen interlocking nut on the shaft of reverse idler gear 6 Use a pulling tool to extract the shaft of reverse idler gear 7 All the components of idler gear assembly 4 4 4 Disassemble main case assembly 1 Demount the clamp at the rear part of countershaft in main case 2 Mount drive gear bearing set fix the rear part of main shaft 4 Knock the countershaft with bronze stick to make it move backward for about 10 mm demount 2 front bearings with special tools ET _ _ L E Ze 5 Again demount the drive gear bearing 6 Take main shaft assembly out from the main case
48. or hill way the engine may not at best working condition at some speed at this time turn the switch can realize whole speed and half speed shift In this way the working strength can be reduced and working life of synchronizer In the front auxiliary case will be prolonged The front and rear auxiliary cases of 16JS200T transmission are all pneumatic control and their air path see figure 12 The compressed air from the vehicle air tank about 7 8 MPa is divided into two ways by the transmission air filtrating regulator one is provided to the front auxiliary case about 2 8 3 2 Mpa the other is provided to the rear auxiliary case about 6 7 7 1 Mpa Air path of that providing to front auxiliary case the compressed air from the air filtrating regulator enters into single H valve 6 through air valve 4 the getting through or breaking of valve is controlled by clutch pedal When the clutch is released completely air path gets through when the clutch 1s connecting air path breaks The getting through or breaking of single H valve is controlled by the even and odd shift switch and result is connecting the whole speed or half speed Air path of that providing to rear auxiliary case the compressed air from the air filtrating regulator gets through double H valve the getting through or breaking of the valve is controlled by the double H control device and on the double H valve hole 1 18 air inlet hole 2 and hole 4 are air outlet hole 3 and hol
49. outine control valve location sleeve compressed spring cylinder pin 3 way connecter spring cylinder pin 13 horizontal sleeve of shift lever 14 15 16 LRC 17 18 19 wig 3 20 JE AE valve gasket of double H oil seal LRC shifting arm side plate bush end gasket spring pedestal 21 switch control of low reverse speed 22 FRIA hex bolt and spring gasket 23 bolt fine teeth 24 bes cylinder bolt 25 26 8 27 28 29 Wty BE 30 31 2 33 34 35 5 36 ORTA hex nut of 1 spring gasket spring gasket spring baftle ring for shaft bowl shim pressing switch launch pin of switch sealing gasket press switch sealing gasket launch pin of switch gasket for control window Section 7 assembly of shift bar 262 63 ia EUN PEEL GT Lael LTE JOBLEFEL DE steel ball 2 steel ball interlock pin of yoke shatt 1H Bj 3 64 A lock bolt of shift lock 5 6 7 fp SEE S 8 HIGH 9 BEES
50. r can not return to low speed position only staying in mid position 4 Shift the vehicle stops then power take off 11 3 Maintenance the twin countershaft transmission all synchronized 3 1 Use and maintenance transmissions It is very important to correctly use and periodically maintenance the transmission so that the vehicle can safely move and the life of transmission can be prolonged 3 1 1 Brand of the gear oil Transmission should be filled with GL 5 85W 90 vehicle gear oil 3 1 2 Correct oil level Ensure the oil level is even with the oil filling orifice The oil level should be inspected by conic filling hole on the side of case Fill the oil till it overflows at the orifice refer to content 1 1 3 1 3 Working Temperature The lubrication oil temperature can not be above 120 C or bellow 40 C in a continuous work period If the temperature is above 120 C the lubrication will decompound and life of the transmission will be shortened if the temperature 18 below 40 the oil seals will be damaged 3 1 4 Oil changing cycle New Transmission should change lubricating oil after running 2000 5000 Km Check lubricating oil level and leaking after 10000 Km make up at any time Change lubricating oil each 50 000K m When working in heavy burden in severe condition or steep slope the changing cycle should be shortened 3 1 5 Towing and sliding When the transmission is the working continuous rotation of ge
51. sition cylinder 11 13 will move left till the position ring here the range speed piston 15 will be in neutral position When you shift to a proper speeds connect with air path of PTO engage the clutch the static power taking off can be realized S Gate SY CH T y MARA LN d NN IK 22202224 NN Y 99 n n Z ees ACUC 15 14 11 10 ai 1 range speed voke shaft 2 range speed cylinder 3 rear cover housing 4 ring 5 hex nylon nut vent plug 7 mid position cylinder 8 baffe ring of shaft 9 cylinder cover 10 cylinder piston of mid position 11 ring 12 hollow shaft 13 cvlinder piston of mid position 14 bolt 15 cylinder piston of range speed Figure 8 structure of cylinder at neutral position If mid position cylinder was adopted instead of pressure adding cylinder the transmission and vehicle s air pressure difference is very small the static power taking off would be hard to realize in that case we can change controlling method to achieve that goal 1 Switch the transmission handle to high position the transmission is shifting to high speeds 2 Connect the pneumatic path of the PTO let air come into the inlet plug of mid position cylinder Push mid position cylinder s piston until it reaches the locating ring 3 Switch the pre selector handle to low speed position due to the air pressure the piston of shifting cylinde
52. t shaft of transmission through clutch The synchronizer on the input shaft connecting with the input shaft differential gear or input shaft gear which realizes the engagement of input shaft gear and countershaft drive gear then drives the countershaft and its gears to rotate mean while another gear on the input shaft 15 rotating with no engagement Gears on the countershaft constantly mesh with the main shaft gears consequently gears on the main shaft rotate at the same time Gears of mains shaft are freely set on the main shaft so the main shaft doesn t rotate when transmission 15 at neutral speed meaning the synchronizer at the middle position When the synchronizer of main shaft moves to a speed and connects the gear with main shaft the main shaft will rotate When the rear auxiliary case at high speed region that 18 the synchronizer sleeve moves to the front of the transmission the main shaft output power will be transferred to the auxiliary main shaft through auxiliary drive gear and synchronizer sleeve then output directly When the auxiliary case at low speed region that is the synchronizer sleeve moves to the back of the transmission the main shaft output power will be transferred to the auxiliary countershaft through auxiliary drive gear then via main shaft reduction gear of auxiliary case and synchronizer sleeve transferred to the auxiliary main shaft and output 5 1 3 Structure of synchronizers You can choose from 3 types o
53. tNo Description o 49 07831813 IT Swehsm ngpn 745 7900710008 Pressure switch _ 46 9072 lT 2 748 rem Compression spring 84 Ez AK Shift bar assembly 23 85 No Panno Description 1876 00868 1308 l4 7 i 16 34 4 yoke shaft 1 20 1 22 23 24 25 26 27 28 25 30 86 Drive gear assembly Aux case asarna 2 sons re om Sw 3 4 emm Bearing ocaon plat A case TIT 163820071707030 Driving gear Aucas 8 SOTTO seng ooe _ Hexbotwihhcleofhead According to 1819 Iron wire ciente main shaft assembly auxiliary case WUSmorvor s Mai hal Aux case A 2 remm Hghiowipeedsyehoneasemby 1 5 geren Spacer main shat Aux case J 1 4 Less Reducing gear main shat Aux case 75 ees Pressure piate main shaft gear Aux case 1 s Rexe ee 88 amp right countershaft Aux case io on 3 16JS200T 4707050 Welding countershaft assembly Aux case 1 4 192311 Shortoyindricalroller bearing LZ emmmer rem 89 Bl 8 Cylinder assembly Aux case o 90 PartNo Description ay 01
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