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The Repair Manual of SINOTRUK HOWO HW19710 Transmission 4

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The Repair Manual of SINOTRUK HOWO HW19710 Transmission 4

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III. Dismantle and Assemble the End Cover Assembly of Input shaft.

Only when oil seal of input shaft is leak, the end cover assembly of input shaft can be

allowed to dismantle. Specific techniques: firstly take off the oil guide ring of input shaft by

using M6 top thread, then take off oil seal by screwdriver or other tool, notice: not to scrap

the inner surface of end cover of input shaft. The assemblage of end cover of input shaft is

as follow:

1. Lay grease on inner surface of end cover of input shaft (see Figure 3-37), put the oil

seal as Figure 3-38 shown, then assemble the oil seal to its position (see Figure

3-39).

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2. Put oil guide ring align to the oil hole on end cover of input shaft (see Figure 3-40),

and assemble the oil guide ring to its position (see Figure 3-41).

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IV. Assemble the Middle Shell of Transmission

1. Put 1 idle wheel, 2 needle bearings, 2 washers as a group (see Figure 3-42) to make

up two groups to assemble the two idle wheel carriers position (see Figure 3-43).

Two groups of idle wheel, bearing and washer are same and can be changed use.

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2. Ensure that the oil hole of right idle wheel is paralleling the horizontal direction of

middle shell (see Figure 3-44 arrowed direction), and assemble to its position. The

oil hole of left idle wheel direct to the support pin of lock plate (See Figure 3-45

arrowed direction), and assemble to its position. Notice: right and left idle wheels

are different, can’t be changed to use. Inner hole of left idle wheel is larger and

a through hole, one end to the inner pipe 1 of hole connection box in middle

shell, another end to hole of the fork axle of range shift in back shell. Right

idle wheel is only used to the thread blind hole for dismantle (see Figure 3-46).

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V. Assemble the Transmission Assembly.

1. Measurement of the Main axle Adjustable Washer.

One point, measurement of main axle adjustable washer, must be noticed before

assemble the transmission assembly, otherwise the whole assembly performance

will be affected. There are 9 kinds of thickness of main axle adjustable washer, from

5.25mm to 6.45mm, can be chosen. If following parts are changed during

transmission repaired, the main axle adjustable washer must be re-measured: main

axle ball head assembly, middle shell of transmission, planet assembly of

supplementary gearbox assemble, rolling bearing 61820, rolling bearing 63/22,

spacer bush, high shift cone-hub assembly, oil guide ring assembly and back shell

of transmission.

The measurement is as following:

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Put the input flange of the supplementary gearbox assembly down to stead place

(the larger bolt of the back flange must be tightened, otherwise the measurement

shall be affected), then assemble the middle shell to the supplementary gearbox

(See Figure 3-47, firstly not assemble the paper washer of supplementary gearbox,

but put it on the special measuring plate G １ 5). Fit a pre-chosen main axle

adjustable washer on the screw of main axle assembly (to avoid the adjustable

washer and hex key dropping down, lay grease on the connection to keep then on

the main axle), and then put the spline key of main axle assembly to the spline hole

of sun wheel in the supplementary gearbox. Put the measure plate on the middle

shell in level way (see Figure 3-48, for convenient working, the arrowed place in the

Figure is putting the paper washer of supplementary gearbox under the depth ruler

after the paper washer was cut a section), and record the measure distance from

the paper washer of supplementary gearbox to the three-shift gear of main axle as A,

the thickness of measure plate as B (date chiseled on its surface), and the thickness

of pre-chosen main axle adjustable washer fitted on the main axle as C.

The chosen adjustable washer, , needs to ensure that the distance from the front

end of the middle shell to the gear end of three-shift gear of main axle is

69.22±0.2mm.

For example: HW 19710 series transmission assembly, the actual distance from

paper washer of supplementary gearbox to three-shift gear of main axle is 94.18,

the thickness of measure plate is 24.58, the thickness of pre-chosen main axle

adjustable washer is 5.85, therefore, the required thickness of main axle adjustable

washer is: 94.18-24.58+5.85-69.22=6.23, so the final chosen thickness is 6.30mm,

which is much closed to the thickness 6.23mm of main axle adjustable washer.

After measurement finished, assemble of the transmission assembly is as following:

2. Assemble HW19710 Series Transmission Assembly

① Support the front shell by soft material; take care of leaving position of input shaft in

the middle of the shell and stable. Use copper bar or hammer to gently strike the

input shaft assembly (see Figure 3-49), let one short section of bearing into the

bearing hole of forward shell. In addition, screw one M16 hollow bolt on the other

side of arrowed place on the figure.

② Mark a line on the root of the gear of input shaft, turn the input shaft and make the

marked line and center of the two supplementary axle holes on the same line (see

Figure 3-50). Alone the flat key of supplementary axle of its two assemblies to draw

a line (see Figure 3-51, gap arrowed and directed by the circle), and then hit the

bearing of supplementary axle to its position, take care of the stop groove of bearing

is in the outside to put the stop ring from the inner of front shell.

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③ Put the slip bush on the front end of the main axle (notice: spline gap of main axle

slip bush direct to the hex key), then put them into the bush guide hole of input shaft

together (see Figure 3-52), push the two supplementary axle assemblies to the

holes of supplementary axle. Left and right supplementary assembly shall not put

wrong position (as Figure 3-53 arrow shown, the end of right supplementary axle

has a spline groove for combine with the spline axle of PTO), the marked line on the

supplementary axle shall be aligned to the first axle line (see Figure 3-53). Notice:

the tooth of gear shall not be wrong; otherwise all the gear can’t be correctly engaged.

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④ Put the fork of fork axle assembly insert the groove of main axle slip bush in turn,

fork axle insert the hole of front axle, and take care of the correspond position of fork

axle assembly shall not be wrong (Figure 3-54). And then, by copper bar assemble

the supplementary axle assembly, main axle assembly, fork axle assembly, input

shaft assembly to its position in turn. After that, put the pipe 1 in the box insert the oil

pipe of front shell (Figure 3-55).

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⑤ Lay Loctite 242 tightening glue on the inside of screw thread hole connected the

middle shell and front shell, put 25 double heads studs and tighten by wind trigger,

hit into the locating spins. Lift up the middle shell assembly equipped with front shell

paper washer; roughly align with the front shell (see Figure 3-56). Put a cross

screwdriver into the hole of left idle wheel axle, in order to guide the pipe 1 of main

gearbox into the hole of left idle wheel axle (see Figure 3-57). Dial the idle wheel

and reverse gear of main axle, put fork axle insert the hole of fork axle in the middle

shell in turn, meanwhile, put the locating pin and double heads stud of middle shell

into the correspond hole of front shell. After that, hit the place as shown in Figure

3-57 by copper bar to assemble the middle shell to its position.

⑥ Put the two supplementary axle bearing into its axle positions (see Figure 3-58),

take care of the larger rounding chamfer of bearing shift ring is adown. Then put the

two supplementary axle clamp spring by use circlip Pliers (see figure 3-59), equip

with the measured main axle adjustable washer into the main axle.

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⑦ Assemble lock washer plate, spring, interlocking plate of main and supplementary

gearbox, pressure plate block, locking pressure plate (large), locking pressure plate

(small) in turn (see Figures 3-60、3-61、3-62、2-63). Notice: anything shall not drop

into the middle shell.

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⑧ Lay Loctite 271 screw thread glue on the 5 heads of bolt of interlocking device of

main and supplementary gearbox, then tighten them, the torque is 41-51Nm (see

Figure 3-64). Dial the interlocking palate, its return agility. If its return is not agility,

the clearance between the interlocking plate and washer plate shall be adjusted

(see Figure 3-65). Lay grease on the end of middle shell; post the paper washer of

supplementary gearbox onto the middle shell, and pay attention to align the locating

pin, screw thread hole and paper washer hole.

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⑨ Pull the interlocking plate to the position away from the idle wheel hole by use iron

wire to stick in the middle of interlocking plate and locking pressure plate, so that the

fork axle of range shift can smoothly insert (see Figure 3-66). Air the cylinder of

range shift to make it in the high shift position (if not air the cylinder, firstly dismantle

the cylinder of range shift, and then push piston to close the back shell of the

transmission). Lift up the supplementary gearbox assembly; let the fork axle of

range shift insert the hole of left idle wheel; bearing of supplementary gearbox align

the ring ridge of bearing in middle shell; turn output flange to let the spline groove in

sun wheel of supplementary gearbox align with the spline of main axle. Meanwhile,

align the locating pin on the shell of transmission (see Figure 3-67).

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⑩ Assemble the supplementary gearbox to its position, and lay loctite 242 screw

thread glue on the thread heads in turn, and then tighten the thread into the

connection hole of main and supplementary gearboxes, the torque is 41-51Nm.

There are 3 kinds of connection bolt, pay attention to its position and lifting plate

position (see Figure 3-69). Unscrew the large back bolt; lay locitite 271 screw thread

glue on thread of main axle tightening nut (see Figure 3-69); tighten into the screw

thread of main axle ball head, its torque is 73-89Nm; push the groove on screw

thread bolt of main axle ball head to open after tightening to lock the screw thread.

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⑪Assemble the oil blockage assembly and elastic column pin on the end of output

shaft (see Figure 3-70); lay enough plane seal glue on the spline of connection of

flange and output shaft (see Figure 3-71), and then put into the pressure plate and

tighten the large bolt.

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⑫Tighten the large bolt by special tool G01 or G14 with wind trigger (or lengthening

splice bar), its torque is 1200-1300Nm (see Figure 3-72), put into the locking plate

and clinch (see Figure 3-73).

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