Dongfeng FAST Gearbox Assy parts integrated valve 12JS160T-1703022-3

As the "hydraulic control core" of the 12JS160T gearbox, this integrated valve’s core function is to centralize control of the gearbox’s oil pressure, oil flow direction, and shifting actuation by integrating multiple single-function valves into one assembly. Its working principle is closely linked to the gearbox’s shifting operation:

When the driver operates the gear lever, the gearbox’s mechanical linkage or electronic signal triggers the integrated valve’s spool movement.

The valve adjusts the oil pressure (via a built-in pressure relief valve) and redirects oil flow to the target synchronizer cylinder or clutch booster—controlling the speed and force of synchronizer engagement and clutch disengagement.

Key integrated functions include: pressure regulation (stabilizing system oil pressure at 0.8-1.2 MPa), flow control (adjusting oil supply to different shifting cylinders), and check valve (preventing oil backflow to avoid shifting slippage).

This centralized control ensures smooth, precise gear shifting and protects the gearbox from damage caused by abnormal oil pressure

The integrated valve features a compact, modular structural design that optimizes hydraulic control efficiency and reduces system complexity:

Integrated Valve Block: The valve body is made of a single piece of high-strength aluminum alloy (6061-T6) with precision-drilled internal oil channels—replacing the traditional multi-valve pipeline connection. This design reduces oil pressure loss by 15-20% (compared to scattered valve setups) and eliminates oil leakage risks from pipeline joints.

Spool & Seal Design: Internal spools are made of hardened steel (HRC 58-62) with a polished surface (Ra ≤ 0.4 μm) to ensure smooth movement and minimal wear. Each spool is equipped with a nitrile rubber (NBR) sealing ring (Shore hardness 70±5) that resists gearbox oil corrosion and maintains a tight seal even under high oil pressure.

Compact Layout: The valve’s overall size (180mm×120mm×80mm) is 30% smaller than a combination of separate pressure valves, flow valves, and check valves—saving installation space in the gearbox and simplifying maintenance access

Designed to withstand heavy-duty shifting cycles, the integrated valve boasts excellent performance and long-term stability:

Pressure Control Range: The built-in pressure relief valve stabilizes system oil pressure within 0.8-1.2 MPa—matching the 12JS160T gearbox’s optimal shifting pressure range and preventing component damage from overpressure (≥1.5 MPa) or underpressure (≤0.6 MPa).

Response Time: The valve’s spool responds to shifting signals in ≤50 ms, ensuring rapid oil flow adjustment and reducing shifting time to 0.8-1.2 seconds (critical for heavy-duty vehicles requiring frequent gear changes).

Temperature Adaptability: Maintains stable performance across a wide temperature range of -40℃ to 120℃—covering extreme cold (e.g., winter in northern China) and high-temperature conditions (e.g., prolonged high-load driving, gearbox oil heating).

Durability: Under standard operating conditions (100,000+ shifting cycles), the valve’s spool wear is ≤0.02 mm, and sealing performance remains unchanged—ensuring consistent shifting quality over the gearbox’s service life

The integrated valve is primarily applied in Dongfeng FAST 12JS160T-equipped heavy-duty vehicles, including:

Dongfeng long-haul tractor-trailers (requiring smooth, reliable shifting for fuel efficiency during cross-country transportation);

Heavy-duty cargo trucks used for bulk goods transport (operating under continuous high-load conditions with frequent uphill/downhill shifting);

Specialized vehicles like concrete mixers (needing precise shifting control to maintain stable engine speed during mixing operations).

In terms of installation, it offers distinct advantages:

Direct OEM Replacement: Matches the original integrated valve’s mounting holes, oil ports, and linkage interfaces—no modifications to the gearbox’s oil circuit or shifting mechanism are needed. Installation only requires disconnecting the oil pipes, removing 4 mounting bolts, and replacing the valve, which can be completed with standard tools in 30-45 minutes.

Pre-Calibrated Configuration: The valve is factory-calibrated to the 12JS160T gearbox’s pressure and flow parameters, eliminating the need for on-site adjustment and reducing the risk of incorrect setup.

Maintenance Convenience: The integrated design allows technicians to inspect or replace the entire hydraulic control unit in one step (instead of troubleshooting multiple separate valves), reducing maintenance time by 40% compared to traditional systems