Repairing Tool for HW Series Transmission 1

Section V Repairing Tool for HW Series Transmission

The maintenance tools, repairing HW series transmission made by Sinotruck,there are shape and use method as followings:

1. Labor-saving Wrench (G01).

Connected bolt of HW series transmission output flange nut is tightened by 1260Nm.

When dismantle or tightening, even use extension lever is also difficult. Especially

dismantle on-sit; it is more difficult to remove it. Such as Figure 1a, flange nut

labor-saving wrench is made up of multi power, multi power support, flange nut

collet head, slide bar, slide head and wrench level. Multi power is one kind of planet

gear multi power that is input 1Nm torque, and output 4.5Nm torque. Such as Figure

1b, firstly, When the removal of the flange nut, place the collet head (G14) of

S=60mm on the flange nut, and then use two flange bolts to fix the support on the

flange of the transverse gear. Insert the square output end of the multi power into

the collet head, and insert the hexagonal of the multi power body into the inner

hexagonal of the support and then fix the multi power on the support. Apply the

ratchet wheel spanner or guide bar head and wrench lever to turn the input end of

multi power in the unscrewing direction, and then remove the flange nut smoothly

 

2. Hanging Scaffold of Supplementary Gearbox (G02)

Figure 2a is hanging scaffold of supplementary gearbox. When repairing and

dismantle the transmission and separation main gearbox and supplementary

gearbox, use this device is very convenient.

Before dismantle transmission, firstly use labor-saving wrench to dismantle flange

bolt, then pull out of the oil seal plug from the hole of output shaft, then dismantle the

fastening nut of main axle in the output shaft hole by extension bar, and then install it

by flange bolt . Such as Figure 2b, use two flange bolts to fasten the hanging scaffold and output

flange nut of transmission. Use hanging scaffold to erect the transmission

assembly.(notice: when erecting the transmission, use wood block to pad the

transmission housing, and let input one axle suspending to prevent it damage).

If supplementary gearbox needs to be dismantle, firstly, unscrew the bolt connected

main gearbox and supplementary gearbox, and confirm that the fastening nut of

main axle in the center hole of output shaft has been dismantled (this is very

important, if the fastening nut is not dismantled previously, separate main gearbox

and supplementary gearbox by force will damage the main axle). And then use two

M10 top threads to separate supplementary gearbox assembly from the housing of

main gearbox, such as Figure 2c, use hanging scaffold to separate supplementary

gearbox from the main gearbox.

 

3. Extractor (G03) of Planet Supporter Bearing (G020)

Extractor is made up of two semicircle clipping bushings, support board, top thread

of the ejection screw, clipping bushing and others (as shown in Figure 3a). Firstly

clip the two semicircle clipping bushings of the extractor on the bearing respectively,

tighten the two semicircle clipping bushings with fixing sleeve, secure the support

board on two tie rods, and block the round end cap at the end of the shaft tube.

Tighten the ejection screw to stand the top thread of the ejection screw to the middle

of the end cap. Use the spanner to tighten the ejection screw so as to disassemble

the bearing in intact way (As shown in Figure 3b).

 

4. Extractor of High Shift Cone-hub and Synchronizer Gear Seat (G04).

Due to high shift cone-hub of supplementary gearbox is hotly equipped in the output

shaft; it must be used special tool to extract it out in normal temperature. As shown

in Figure 4a, extractor is made up of two semicircle head, board, clipper, plate and

top thread and 20 ton hydraulic Rama. When dismantle, firstly put extracting plate,

bar and hydraulic Rama on the high shift cone-hub, then let the two semicircle

extracting head clipping on the high shift cone hub flange. Notice: there is a circle

groove on the front end of extracting head, let the upward flange of cone-hub round

plate clip the flange of high shift cone-hub, at last, put the top board on the center

hole of output shaft. Turning the hydraulic Rama, let its top head prop up the center

of board. There is a black switcher on the hydraulic Rama, tightening screw, and use

lever to press Rama column plug up and down, and the high shift cone-hub will be

smoothly pulled out. Then unscrew the Rama button, the piston can automatically

retract. Extracted high shift cone-hub is as shown in Figure 4c. When dismantle high

shift cone-hub, pay attention to not draw the cone-hub to slanting.

Use the same extractor and adopt the same method can dismantle synchronizer

gear seat. Before dismantle, firstly, dismantle the elastic barrier ring from the

synchronizer gear seat, then lift up the synchronizing ring under the gear seat, let

the two semicircle extracting head clip the gear seat and cone-ring, and clip sleeve

locate on the extracting head, press the column plug of hydraulic Rama, gear seat

and synchronizing ring can be smoothly extracted out.

Notice: hydraulic Rama piston only has 50mm long, therefore, each extracted

distance is not more than 40mm. if the extracting distance is not enough, then

turning the Rama knob let the piston of Rama retract, and then entirely turning

Rama, let the Rama piston re-prop up the top board. If the Rama moving distance is

still not enough, it can be changed and connected longer top board.

 

     Figure 4c: Dismantled High Shift Cone-hub      Figure 4d: Dismantled Synchronizer Gear Seat

 

5. Extractor(G05) of front and back Bearing of Auxiliary Shaft.

When dismantle auxiliary shaft of main gearbox, and need change front and back

bearing of auxiliary shaft, it can be dismantled by extractor. Due to front and back

bearing have the same size (only difference is the front bearing has snap ring

groove, but the back bearing has not), so it can only use one extractor to remove it.

Before dismantle, firstly remove the snap ring (front bearing), then let the two

semicircle extracting plate clip on the bearing flange bottle, put clip sleeve on the

extracting plate for locating, fasten extracting bar and top thread on the two rods,

tighten screw top thread (as shown in Figure 5b is dismantling back bearing without

snap ring), the bearing can be smoothly extracted out.

 

 

6. Extractor of Idle Wheel Axle (G06)

As shown in Figure 6a, idle wheel axle (middle axle of reverse shift) extractor is

made up of handle, extracting bar, and glide hammer. When dismantle reverse shift

middle axle, firstly screw the thread of M12 of front end on extracting bar to the

center thread hole of middle axle of reverse shift, then as shown is Figure 6b,

continuously lift up the glide hammer, let the glide hammer up-thrust the handle for

smoothly pulling out the middle axle of reverse shift.

 

7. Snap Ring Pliers (G07)

Due to there are lot of non-standard snap ring equipped in the transmission, it needs

special pliers to carry on dismantle and install. As shown in Figure 7b, it is used

snap ring pliers to dismantle exterior snap ring of input one axle bearing.

 

8. Extractor(G08) of Input shaft Bearing (6213N).

When change and dismantle bearing of input shaft (one axle) without disassembly

the transmission, the extractor of input shaft (one axle) can be used. As shown in

Figure 8a, extractor is made up of extracting plate, extracting bar, top thread and

two extension supporter bar. Before dismantle, firstly, dismantle the inside and

outside snap ring from the input shaft (one axle), use copper bar thrust the front

housing of transmission, let the bearing out of a little bit, put the two semicircle

extracting plate clip on the snap ring groove of bearing, put the clipper sleeve on the

extracting plate for locating, then install two extension supporter bar, extracting plate

and top thread, then screw the top thread, the bearing can be smoothly extracted

out.

              Figure 8a: Extractor of Input shaft         Figure 8b: Dismantle Bearing of Input shaft

 

9. Tube Processor (G09)

When re-assemble the planet supporter assembly, as shown in Figure 9b, use tube

processor and copper hammer to thrust planet supporter, let the planet to get to its

position. This tube processor can also be used to thrush and install bearing of input

shaft (Figure 9c) and odometer worm ring (Figure 9d).

 

 

 

10. Press Plate of output shaft Oil Seal (G11)

As shown in Figure 11a, this is press plate of output shaft oil seal. When install oil seal of

output shaft, firstly put oil seal into the plate, and then use press plate to push the oil seal

into the end cover of output shaft (as shown in Figure 11b)

 

11. Punch Bar of Interior Oil Seal of Small End Cover (G12)

There are installed interior and exterior oil seals on the small end cover of shift

housing of transmission level. As shown in Figure 12b, when installing, put the

interior oil seal on the end of punch bar, then press the interior oil seal into the small

end cover by punch bar.

 

 

12. Punch Bar of Exterior Oil Seal of Small End Cover(G13)

As shown in Figure 13b, put the exterior oil seal at the end of punch bar, and then

press the exterior oil seal into the small end cover by using punch bar.

 

14. Flange Bolt (S=60mm) Tube Processor (G14)

Output flange nut is fastened by exterior hex flange bolt which opposite side is

S=60mm, output flange tube processor, as shown in Figure 14a, is a special interior

hex tube processor which can be used by pneumatic pick (pneumatic wrench), also

can be used extensive lever, and cooperated with labor-saving wrench at the same

time.

 

15. Measuring Plate (G15)

In order to guarantee the axial stability of main axle, during repairing when change

the following parts, such as the main axle assembly with ball head, middle housing

of transmission, planet supporter assembly in supplementary gearbox assembly,

61820 bearing, 63/22 bearing, spacer bush, high shift cone-hub assembly, oil guide

ring assembly, back housing of transmission and others, the precise size from

three-shift gear end to front end of main gearbox housing must be measured to

ensure the thickness of the axial adjustable pad of main axle. As shown in Figure

15a, this is special measuring plate.

Notice: on the upward surface of the measuring plate, there are precise sizes of

measuring plate thickness. When measuring, firstly, put the middle housing

pre-install on the supplementary gearbox assembly and to its position.

As shown in Fig 15b, install a pre-chosen adjustable pad on main axle (in order to

prevent adjustable pad and hex key dropping down, lay grease on the interface and

let them stick on the main axle), then put the spline of main axle assembly on the

sun wheel spline of supplementary gearbox assembly and to its position. Let one

face with thickness marks upward, and pin hole of two side of measuring plate on

the locating pin of end surface housing, insert the tightening bolt of main axle into

the center hole of measuring plate, then put a paper washer sealed middle and front

housing on the plane of measuring hole, and then measure the distance from the

sealed paper washer to pointed gear upward end by using depth rule through

measuring hole.

 

16. Flange Nut Extractor (G16)

Before disassembly the transmission, it always needs to remove the flange nut of

output shaft. As shown in Figure 16a, flange nut extractor actually is made up of a

10 ton hydraulic Rama, extracting top board and two extracting bars, among them

one end of the two extracting bar is fastened on the extracting board by M18 nut,

another end is inner thread hole of M14. as shown in Figure 16b, firstly, remove the

flange nut and washer board, then put the top board on the center hole of output

shaft (notice: top board shall not damage the pin located output shaft and washer

board), then use symmetry M14 bolt on the flange to link the two extracting bars,

turn hydraulic Rama and let its top head prop up the center of board, and then screw

the Rama knob tighten, and use lever to press Rama column plug up and down, the

flange shall be smoothly pulled out. Notice: when connected the flange bolt and two

extracting bars, the two bars shall have the same length, otherwise, the flange will

be pulled slanting.

 

         Figure 16a: Flange Extractor                     Figure 16b: Use Extractor to Dismantle Flange

This extractor can share a 10 ton hydraulic Rama and extracting board with high

shift cone-hub extractor.

 

17. Extractor(G17) of Output shaft Bearing (6218)

When dismantle the planet gear wheel device of supplementary gearbox, it firstly

needs to remove sensor worm ring and bearing (6218) of output shaft of odometer.

If bearing and worm ring joint too close, it must be used special extractor to

dismantle. As shown in Figure 17a, this is a extractor of this bearing. As shown in

Figure 17b, before dismantle, firstly, put the semicircle extracting head clip to the

bearing, the ring ridge of extracting head shall be clipped the clearance of bearing

and end cover. Then put the clipper sleeve on the extracting head, use 10 tons

hydraulic Rama and extracting board to fasten it by two extracting bars, then turn

hydraulic Rama, let the top head of Rama prop up the extracting board of center

hole of output shaft, screw the knob firmly and press column plug by lever, the

bearing of output shaft can be smoothly pulled out.

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