Amt XCMG PDF

FAST-XCMG
AMT Technical Service Training
Fast Auto Transmission Research Institute

Ma Bin
2017-9-18
http://www.chinafastgear.com E-mail:fastgear@chinafastgear.com Tel:029-88600072,88600074, 88600076 Fax:029-88600071,88600160

Contents
1 Transmission Description
1
1 Component & Installation

2
1 Function & Operation

3
1 Maintenance
4
1 Troubleshooting
5

1. Transmission Description

AMT
Remove the actuators of manual gearbox

Integrated shift actuator (which used for AMT ), clutch actuator ,harness ,distance
sensor and speed sensor.
Without clutch pedal
Transmission Model
Nameplate
16JZSD220A
A: Overdrive
Number of gears
Max input torque = factor X 10 (Nm)
Mechanical
Greater distance between two countershaft
Automatic
Two countershaft

Ratio Table
Number of Input Torque Input Power Input Speed Speed Ratio

AMT Type
Gears (Nm) (kW) (rpm) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 R1 R2
6 6DZS180 1800 331 2600 7.04 4.10 2.48 1.56 1.00 0.74 6.26
10 10JZSD160 1600 285 2600 14.91 11.04 8.10 6.04 4.48 3.33 2.47 1.81 1.35 1.00 14.29
10 10JZSD160A 1600 285 2600 11.06 8.18 6.00 4.48 3.33 2.47 1.83 1.34 1.00 0.74 10.59
10 10JZSD200 2000 355 2600 7.45 5.79 4.52 3.53 2.75 2.11 1.64 1.28 1.00 0.78 7.54
12 12JZSD160 1600 285 2600 15.53 12.08 9.39 7.33 5.73 4.46 3.47 2.71 2.10 1.64 1.28 1.00 14.86
12 12JZSD240A 2400 400 2600 12.60 9.80 7.62 5.95 4.46 3.77 2.83 2.20 1.71 1.33 1.00 0.85 12.05
16 16JZSD200 2000 355 2600 17.04 14.03 11.66 9.60 8.04 6.62 5.53 4.55 3.74 3.08 2.56 2.11 1.77 1.45 1.21 1.00 16.30 13.42
16 16JZSD200A 2000 355 2600 14.03 11.64 9.60 7.97 6.62 5.49 4.55 3.78 3.08 2.56 2.11 1.75 1.45 1.21 1.00 0.83 13.42 11.13
16 C16JZSDQXL220 2200 380 2600 17.09 14.13 11.82 9.77 8.09 6.69 5.47 4.52 3.78 3.13 2.61 2.16 1.79 1.48 1.21 1.00 15.7 13.00
16 C16JZSDQXL250A 2500 408 2600 14.13 11.70 9.77 8.09 6.69 5.54 4.52 3.74 3.13 2.59 2.16 1.79 1.48 1.22 1.00 0.83 13.00 10.77
16 C16 Standard 12 10 6

Application
Construction
OE Truck OE Coach & Bus OE
Machinery
E3/4/5 emission
Engine Weichai WP10/12/13
Cummins ISM/ISL/ISG/ISZ
Clutch SACHS VALEO Fast-Eaton

2.Component & Installation

Component
Pneumatic Clutch ActuatorPCA Shift Actuator Harness
Split Valve
Air Line
Split Distance Sensor TB Valve Air filter

Transmission BrakeTB
Component
Transmission
Output Speed
Sensor (orange)
Range Distance Sensor Range Valve Countershaft Speed

Sensorblack
Transmission
Main Section
Made up by Main Transmission(4 speed),Splitter Group(S /E ),Range Change

Group(H/L) 2X4X2
Main transmission has constant mesh engagement, Speed-matching is performed
by ECU & TB, Splitter Group and Range change group have synchronizer.
Equipped with two countershaft ,ensures a good distribution of torque , lower
gear loading levels , great efficiency .

Shift actuator
Gear cylinder(Bigger)
Gear distance Sensor
Gear cylinder inlet
Select cylinder (small)

Gear solenoid valve
Select distance
Sensor
Select cylinder inlet Select solenoid valve
Operation Voltage: 20~32V

Operation air pressure:6.5~8Bar
Operation Temperature:-25~120

Shift actuator
Valve Connector Sensor Connector
PIN Description PIN Description

1 Not used 1 DSSE/DSG
2 VSE1/VG1 2 DSGND
3 VSE2/VG2
4 Ground
Resistance of Sensor:701 Gear Valve and Select Valve have the same
(PIN1&PIN2) connector , so does the sensor connector
Resistance of Valve:402
(PIN2&PIN4PIN3&PIN4)
Split /Range Valve & Split/Range Distance Sensor
Split Valve or Range Valve , interchange

the connectors are same with the Gear/Shift Valve
Operation Voltage: 20~32V PIN Description
Operation air pressure:6.5~8Bar 1 Not used
2 VR1/VSP1
3 VR2/VSP2
4 Ground
Armature PIN Description
Range Distance Sensor
Same with the Gear/Select 1 DSSP
distance Sensor , interchange 2 DSGND
Resistance of Sensor:701
(PIN1&PIN2)
Split distance sensor
Resistance of Valve:402
(PIN2&PIN4PIN3&PIN4)

Pneumatic Clutch Actuator (PCA)
Solenoid valve group

Inflation plug
Mounting Push rod
Distance sensor
Air inlet
Mounting flange Working cylinder
Resistance of Sensor:725%
Operation Voltage: 20~32V
(PIN1&PIN2)
Operation air pressure:6.5~8Bar
Resistance of Valve:15~16.5
(PIN2&PIN5PIN2&PIN6
PIN3&PIN7PIN4&PIN7)

Pneumatic Clutch Actuator (PCA)
Push Rod
Before installationmake sure

the length of push rod is 130mm.
The photo shows the right
direction of push rodthe bigger
Pay more attention on the Push end towards to the FORK.
Rod length and direction.
Transmission Brake (TB)
Transmission Brake
Constant engage with the
Gear of countershaft ,reduce
countershaft speed during upshift
Main section Bearing

Make sure install
the bearing in right
Air Route direction
Compressed air inlet
Sealing Ring Direction of Sealing Ring

Wrong Direction may lead
to leak , be careful

Bearing
Cylinder
Piston
Bearing
Plate Friction Disk Spring

Speed sensor
The speed sensors is used to measure the countershaft speed and output shaft
speed.
The input shaft speed sensor (black):used to measure the countershaft

speed , the gap between the sensor and gear is less than or equal 0.7mm
The output shaft speed sensor (Orange): measure the output shaft speed ,
and the gap is 1 0.8mm
the two sensor can not interchange
Counter shaft speed sensor Output shaft speed sensor

Shift Lever Unit(SLU)
SLU Connector
Handle transmission , integrated with TCU(transmission control unit)

F : Function button, Shift to launch gear from neutral , self learn
N : Neutral button
UP : Upshift
Down : Downshift
L : Low speed mode
E/P:Economic Mode/Power Mode
A/M : Automatic Mode/Manual Mode
Circuit Diagram of GB
Vehicle Circuit Diagram (GB to SLU)
Installation
Air inlet
Air inlet
Vehicle Connector
1.Remove the corrosion protection at the transmission input shafts spline ;

2.Grease input shaft spline ;
3. Mount clutch disk and pressure plate to the flywheel , the clutchs end marked with
flywheel side must point in the direction of engine connection;
4.Align transmission so than the input shaft is aligned with the bearing;
5.Guide input shaft into hub of clutch disk , fix transmission at the flywheel housing;
Installation
6.Secure release bearing in load-bearing ring , by using a lifting tool to pressure

the upper end of the release fork towards to the transmission output , this
push the lower end of the release fork towards to the engine until it snaps into
the load-bearing ring ;
7.Mount the PCA on the transmission housing , the bigger end of the push rod
must point in the direction of fork
7.Connect the air line to the filter and PCA;
8.Connect up vehicle connector and SLU connector for vehicle wiring.
9.Fill with oil , the oil volume is approx 16.5 liters , the oil grade we recommend
is 80W-90GL4/5.
3. Function & Operation

Topology
Air reservoir
CAN signal
Sensor signal
Engine ECU ABS Other ECU Valve signal
Air path
Information Display
The dashboard will display the operation mode ,

current gear , intended gear and shift in process .
Upshift in process
When suffering failures , the dashboard also
display failure information and failure code.
Display A/M Display E/P/L Current gear Intended gear

Launch vehicle
1. Parking brake is set ;
2. Start engine and make sure air pressure of vehicle is over 8 bar;
3. Shift to a proper launch gear:
Driver can do this by press button <F> on the left of the SLU and push forward ,the max launch
gear is 8 .
The default gear is 4th , sometimes it may not proper for the current condition , so driver
should change the launch gear depending the condition ,which can achieve by push forward
or pull backward the SLU .
Driver also can shift to a certain launch gear by follow:

Press the <F> button x times , then press the <F> button again and push forward the SLU , the
launch gear will be x . For example ,press <F> 3 times , then press the <F> and push forward ,
the gear will be 3rd .
4 .Press the accelerator pedal , when feel the vehicle is shaking , release the parking brake.
When driver want to launch vehicle in reverse gear , follow the steps above and instead of push
forward by pull backward . The default reverse gear is R1 and max reverse gear is R2 .
Launch Mode
Mode 1: Common Launch

Shift to a proper launch gear , press the accelerator according the condition but dont press the
accelerator to end. In this mode , clutch engages slowly , at the same time, engine speed keeps
in idle . when clutch reach to touchpoint , engine speed start to increase.
Mode 2: Full Acc Launch

Shift to a proper launch gear , press the accelerator to end . In this mode , clutch engages and
engine speed increase in the same time .
Mode 3: L Mode Launch

Push the <L> button in SLU , dashboard will display L , Shift to a proper launch gear , press
accelerator according the condition . In this mode , engine speed increase to about 1200rpm,
then start to engage clutch.
Mode 2 & Mode 3 are usually used in dirty road , heavy duty and challenging ramp etc . Use
the two modes too often will damage the clutch , so launch with the Mode 1 as possible.
Shift Gear to Gear
Driver can shift gear by following three methods when vehicle is running :
1. Press <F> and push forward or pull backward SLU ,AMT system will execute a one
gear shift.
2. Push forward or pull backward SLU , a shift will be execute and the intended gear is
decided by TCU .
3. Press <F> certain times and push forward or pull backward SLU , AMT will execute
a shift and the intended gear is corresponding with the times driver presses <F>.
example : current gear is F2 ,press <F> 3 times , AMT will shift to F5.
Driver can use these methods in both <A> and <M> mode .
AMT will reject the shift request or shift to a suitable gear if drivers request dont match
with the current condition.
Upshift process
16 speed selector and

shift location layout Clutch position
Gear position
Forward
direction
Countshaft speed
Outshaft speed
Select position
Current gear
Disengage clutch;
Shift to neutral; intended gear
Reduce countershaft speed
and synchronize; Engine speed
Shift to intended gear;
Engage clutch; From gear 4 to gear 6

Downshift process
Clutch position
16 speed selector and
shift location layout Gear position
Range position
Forward
direction Split position
Countshaft speed
Outshaft speed
Select position
Disengage the clutch; Current gear

Shift to neutral;
Increase the countershaft Intended gear
speed and synchronize;
Shift to intended gear; Engine speed
Engage clutch;
From gear 10 to gear 8

Shift to Neutral
Press the button <N> in the right of SLU , transmission

will shift to neutral .
NOTE : Dont shift to neutral if the vehicle speed is

over 30km/h .
Acceleration, deceleration and parking
1. Press accelerator pedal, vehicle will accelerate.

2. Release accelerator pedal or press brake pedal, vehicle will decelerate.
3. Keep brake pedal pressed , vehicle will stop .After vehicle stops , driver should select
neutral gear and set the parking brake .
4. After vehicle stops , if there is no action in 90 seconds , AMT will shift to neutral gear
automatically .
NOTE:
If driver switch off engine without shift to neutral gear , AMT will shift to neutral
automatically . Although this , driver should select neutral gear before switch off engine.
Automatic Mode <A> and Manual Mode <M>
The default operation mode is Automatic , Driver can switch the operation mode through the
A/M button in the SLU , press the button once , the mode will switch once between A and M .
The operation mode displays in the dashboard , through watching the dashboard , driver can get
the current operation mode . <A>/<M> mode can be switched in any time .
In A mode , a shift is usually triggered automatically by TCU, which depending on the engine
work condition , GVW , accelerator position , brake pedal state , road condition , etc.
If the current gear is not suitable for current condition in A Mode , driver can shift gear by
handle SLU and this action will not lead to exit of A Mode.
In M mode , a shift is triggered totally by driver , that is to say , gear will not change until driver
gives TCU a shift request through SLU .
TCU will not execute the shift if drivers shift request isnt proper both in A and M mode .
M mode is a better choice in

complex road condition like
cross-country road , muddy
road ,country road , mountain
area .
Economic Mode <E> and Power Mode 
<E> mode and mode only work in A Mode ,In <A> mode , driver can switch
<E>/mode in any time.
The default Mode is <A><E> . By press the <E/P> mode in the SLU , driver can change the
operation mode , current mode usually display in the vehicle dashboard .
<E> mode has better fuel consumption , it means that engine usually works at
1000rpm~1500rpm;
 mode can provide more power , so engine will work at about 1300rpm~1800rpm and
vehicle have good performance of climbing and acceleration.
Driver should choose a suitable mode for current condition .

<E> mode is proper enough when driving in high-speed way , flat road ,or some other ;
If vehicle is overload or running in mountain area , you had
better switch to mode.
Switch between E and P

mode via <E/P> button.
Default mode is E
Low mode <L>
This function is usually used in the challenging condition , like soft muddy road and some
other extreme condition. In this mode , clutch is engaged at a higher engine speed.
In this mode , gears driver can used is limited in R1~F4 for 16 speed transmission.
Press <L> in SLU , L mode will be actived ,vehicle dashboard display L, press another
time , exit the L Mode.
Because the high engaging speed , the clutch will suffer serious wear-out , so dont use this
mode too frequent or in unnecessary condition.

Engine protection & Clutch protection
Engine protection
A upshift will be triggered if engine over speed , this usual occurrence in downhill
road .
Clutch protection
Launch frequently with full accelerator , <L> mode or launch in big slope , the
clutch will be overload easily . When clutch is overload , an error code displays in
dashboard will warn the driver. the code is 520448 . It would be best stop the
vehicle for a while .
4. Maintenance

Diagnostic tools
In order to update AMT SW and

diagnose AMT fault , you need
following tools:
PC , Diagnostic box ;
Wire used to connect PC and
diagnostic box ;
Wire used to connect diagnostic
box and OBDII connector.
Following table shows the description of OBD II and DB9

connector
CAN1_L CAN1_H VCC(+24) GND
PIN4 PIN5 PIN1 PIN2 DB9
PIN14 PIN6 PIN16 PIN4&PIN5 OBD II
SW Update
Usually , we issues new AMT SW every year .

By using diagnostic tools , you can update the SW.
Before update , the following must be ensured
Switch on the KL15 but dont ignite the engine

Parking brake is set
Dont switch off supply voltage while download in progress
Make sure that a power supply at least 23V is provided
Ensure an air supply pressure of at least 7 Bar
Dont interrupt the diagnostic connection while download is in
progress
SW Update
Following steps show how to update AMT SW:

1. Connect PC , diagnostic box and OBD II connector ;
2. Open diagnostic software;
3. Click system ECU update;
SW Update
4 . In the popups , click read from file , then find the SW which you want to
download;
SW Update
5 . Click write to ECU , then in the popups , enter your user ID and PIN code ,
click OK , start to download.
SW Update
6. Ignition off for 1 min after download completed.

Self-learn
Self-learning is necessary after update SW . There are 2

self-learning methods.one is self-learn with diagnostic
box , another is self-learn without diagnostic.
No matter which method you use , the following
condition must be fulfilled before self-learning:
Vehicle stops in flat road and parking brake is set

Engine stops
Air pressure of AMT is over 7 bar
Self-learn with diagnostic box
Establish diagnostic connection ;

Click start-up vehicle test
Select big learning procedure , click start learning , learning procedure

is active.
During the learning procedure , when dashboard shows that current gear is neutral ,
ignite the engine .
A popup window will show transmission information after learning procedure
finished .
If self-learn is fail , popup window will show the error code in the column of
tech-in error . You can get the information about the error in error code list.
After troubleshooting , do the self learning again .

Compare the values in the popup window with the value in the following table
after self-learning successful , if there is a obvious gap between them , do the
self-learning again.
Range max-range min Gear max-gear neutral Gear neutral-gear min Split max-split min
28mm 15mm 15mm 7mmm
Selection max-selection mid Selection mid-selection min Clutch max-clutch min
10mm 13mm 22mm
Note: this table is only fit the 16 speed gearbox . In 16 speed gearbox , selection
intermediate position 2 and selection intermediate position 1 are the same.
Self-learn through SLU
Before start a self-learning , you must check the self-learn precondition .

The following steps shows how to do a self-learning through SLU.
Switch off the key for 1 min then , press the <F > and <N>;
Switch on but dont ignite the engine;
When dashboard shows that current gear is neutral , ignite the engine ; after
this , you can hear that AMT shift gear automatically ;
When you see A E N N or M E N appears in the dashboard ,release
<F >and <N > , self learning is complete.
Dashboard will give you the error code when something wrong with the
self-learning , check the error code list and find the cause ,then do the self-
learning again .
Note: you must press the <F > and <N > before error code appear or finishing
the self-learning successful !
No matter which method you use , after a successful self-learning , switch off
the engine for 1 min ,then switch on and ignite , do the following several times:
Shift to launch gear then shift to neutral and waiting for 20 seconds.
Oil
Oil grade
The oil grade we recommend is 80W-90GL4/5
Oil volume
The oil level must reach up to the lower edge of the of overflow aperture.
Oil change interval
Change the oil in the first 5,000 kilometers ; after this , Check whether the oil is
enough every 10,000 kilometers and change oil every 50,000 kilometers .
To ensure a good performance of

transmission , the oil grade , oil
change interval and oil quantity must
be observed .
Only vehicle stops in flat road and

transmission is cold you can check
and change oil .
Oil overflow aperture

Advices
Hold on accelerator pedal position when you launch vehicle ;
You dont need to release accelerator pedal when system is executing a shift ;
Launch frequently on big slope will damage the clutch driver should avoid this as
possible ;
No matter which operation mode you are using , downshift manually before climbing big
slope ;
<M > mode or <A> mode is a better choice in the challenging condition such as soft
road , muddy road , cross-country road and mountainous area ;
Although < E > mode can satisfy most condition , but sometimes mode is
necessary , driver should change the operation mode according current condition ;
For better fuel consumption , you can press accelerator pedal or brake pedal gradually
when accelerating or decelerating ;
5. Troubleshooting

Troubleshooting
When AMT malfunction , you need to do troubleshooting , following steps show the
procedure .
1. Establish diagnostic connection , click Message diagnostic memory , the failure
is showed in popup windows .
Troubleshooting
2 .The red is active failure the blues are inactive failure .

Clickdeleteand remove the inactive failure .
Select a failure and click Info , you can get information about how to troubleshoot.
Also , you can read error code from dashboard and get help from error code list .
Troubleshooting
3. ABS or engines failure may lead to an AMT failure , remove these failure first ,
then check if the AMT recover from failure .
4. Troubleshoot AMTs failure
5. When finishing the troubleshooting , undertake a test run .
Note: Its necessary to do a self-learning after change or disassemble mechanical

part of AMT.
Troubleshooting
The following pictures show some function of diagnostic tool which are very useful for
troubleshooting.
Click measure value shift lever , you can test if SLU work well .
Troubleshooting
Click measure value transmission , the popup window will give you
some current value about AMT.
Troubleshooting
You can get current value through click measure value display measures value
too .
Troubleshooting
Click output control ,in the popup window, you can control the actuator
or valve . Secure than vehicle is secured against rolling ,power supply is ok and
compressed air is above 7bar.
Advices about Troubleshooting
The method used to measure the transmissions current value and control the
actuator show above is very useful , you can compare the current value with
following table to check if the transmission is ok.
Range max-range min Gear max-gear neutral Gear neutral-gear min Split max-split min
28mm 15mm 15mm 7mmm
Selection max-selection mid Selection mid-selection min Clutch max-clutch min
10mm 13mm 22mm
If the actuator in wrong position or shaft speed is not reliable , the current
gear will be invalid , in this condition , you need to check the wire , speed
sensor , distance sensor ,air pressure.
Harness wear out easily , so pay more attention on it .

When need to do self-learning , use the small self-learning procedure unless
you update the SW.
Case 1
The feedback shows that any shift request is rejected

Establish diagnostic connection .
In the measurement window we can find that the out-shaft speed is 729rpm , but vehicle
is stop and current gear is neutral , there must be something wrong with the sensor or wire .
Case 1
Check wire wire multimeter according with circuit diagram .We found than the
wire of speed sensor is short to power.
At last , we found the wire wore out and replace with a new one. Then transmission works
well
Case 2
The driver told me that transmission didnt work well , current gear in dashboard displayed
an impossible value .
We know that if actuator in a wrong position or shaft speed is reliable , current gear will be
invalid .
So inspect if there is some wear-out with the wire, then check the distance sensor and speed
sensor , at last ,check the mechanical part .
According the step above ,we found that the counter shaft sensor wore-out , replace with a
new one and put a thin gasket between sensor and the interface for spend senor installing .
Test run shows that the failure disappear .
Case 3
The driver told me than he cant shift between singular gear and even gear.
Form this we know there may be something wrong with the splitter group
Establish diagnostic connection , obverse the current value , it seems that everything is ok.
Then drive the splitter actuator to another position , and compare the value with the table
mentioned before , and the result shows than split travel is not correct .
When driving the actuator, we can hear the sound of valve. that is to say , wire and actuator
are ok. So we need to check the air line and the air pressure . If need ,disassemble
transmission.
Case 3
Air line and air pressure is ok.

At last , we found the cylinder which used to shift between singular gear and even
gear is broken . Change top cover and undertake a test run , everything is ok.
THANKS!
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FAST-XCMG

AMT Technical Service Training

Fast Auto Transmission Research Institute

http://www.chinafastgear.com E-mail:fastgear@chinafastgear.com Tel:029-88600072,88600074, 88600076 Fax:029-88600071,88600160

1 Component & Installation

1 Function & Operation

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http://www.chinafastgear.com E-mail:fastgear@chinafastgear.com Tel:029-88600072,88600074, 88600076 Fax:029-88600071,88600160

Remove the actuators of manual gearbox

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Number of Input Torque Input Power Input Speed Speed Ratio

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Clutch SACHS VALEO Fast-Eaton

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Pneumatic Clutch ActuatorPCA Shift Actuator Harness

Split Distance Sensor TB Valve Air filter

Range Distance Sensor Range Valve Countershaft Speed

Made up by Main Transmission(4 speed),Splitter Group(S /E ),Range Change

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Gear distance Sensor

Gear cylinder inlet

Select cylinder (small)

Operation Voltage: 20~32V

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Valve Connector Sensor Connector

PIN Description PIN Description

Split Valve or Range Valve , interchange

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Solenoid valve group

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Before installationmake sure

Main section Bearing

Compressed air inlet

Sealing Ring Direction of Sealing Ring

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Plate Friction Disk Spring

The input shaft speed sensor (black):used to measure the countershaft

the two sensor can not interchange

Counter shaft speed sensor Output shaft speed sensor

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Handle transmission , integrated with TCU(transmission control unit)

1.Remove the corrosion protection at the transmission input shafts spline ;

6.Secure release bearing in load-bearing ring , by using a lifting tool to pressure

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The dashboard will display the operation mode ,

Display A/M Display E/P/L Current gear Intended gear

1. Parking brake is set ;

3. Shift to a proper launch gear:

Driver also can shift to a certain launch gear by follow:

Mode 1: Common Launch

Mode 2: Full Acc Launch

Mode 3: L Mode Launch

16 speed selector and

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Disengage the clutch; Current gear

Press the button <N> in the right of SLU , transmission

NOTE : Dont shift to neutral if the vehicle speed is

1. Press accelerator pedal, vehicle will accelerate.

M mode is a better choice in

Driver should choose a suitable mode for current condition .

Switch between E and P

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