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II. Supplementary Assembly Installation of HW 19710 Series
Transmission
① Put o ring into the middle of oil inlet hole in the back shell of transmission and ring
groove of fork axle hole of range shift, and lay grease on the o ring (see Figure
3-128, 3-129).
② Choose the adjustable washer in the end cover of output shaft: put paper washer on
the end cover of output shaft, and measure the depth from paper washer to ring
ridge of end cover of output shaft (see Figure 3-131) A, to back shell thickness B
(see Figure 3-132), and distance C from rolling bearing to oil guide ring (see Figure
3-133), then the thickness of adjustable washer is between A+B-C-0.1 and A+B-C.
And install joint of odometer to its position (see Figure 3-134).
③ Use connected bolt to join the transmission back shell, assembly of oil guide ring,
bearing, chosen adjustable washer, back end cover of output shaft together, and
their torque is 41-51Nm; pay attention to lay enough plane seal glue on the longest
connected bolt to prevent oil leakage on the bolt point (see Figure 3-135).
④ Put bearing in the carrier of gear ring, and clamp elastic barrier ring for hole use; use
punch to punch the elastic barrier ring to its position (see Figure 3-136); install the
carrier of gear ring into the inner gear ring, and clamp the steel wire barrier ring; (see
Figure 3-137), use punch to punch the steel wire barrier ring to its position (see
Figure 3-138).
⑤ Put gear ring module in the planet carrier assembly and align the teeth, then put on
the spacer bush (its gap upward); use tube processor G09 to install the gear ring
module to its position, turn the inner gear ring to ensure it engages with planet wheel
and turning agility (see Figure 3-173); install low shift cone-hub assembly,
synchronizing ring, synchronizing gear seat (notice the settle direction of gear seat)
it turn, and use G09 to install them to their positions (see Figure 3-139).
⑥ Use circlip pliers to install axle elastic barrier ring of synchronizing gear seat (see
Figure 3-141); when installing synchronizing slip bush, pay attention to the groove of
synchronizing slip bush is opposite to the groove of synchronizing gear seat (see
Figure 3-142).
⑦Firstly install the outside and inner springs and ejector pad of 9 ejector pads to its
positions, and pay attention to the synchronizing ejector pad direction, then install
the synchronizing ring (see Figure 3-144); draw a line on the gear groove of oil hole
in output shaft by remark pen, let short of tooth place of the inner gear of high shift
cone hub directs to the remark line, and install the high shift cone-hub to its position
(see Figure 3-143).
⑧Install fork of range shift (notice gap direction), fork swing block, range shift fork axle
to the synchronizing slip bush, and pay attention to the range shift fork axle position
(see Figure 3-145); if the torque drive bush is left the top of the low shift cone-hub
assembly, use punch to push it the same level as torque drive plate (see Figure
3-145 arrow directed place); put the back shell assembly into the planet carrier
assembly, and pay attention to the fork axle of range shift aligns to the fork axle of
range shift in back shell, and then install the back shell to its position (see Figure
3-146).
⑨Use special tool G09 to install bearing of output shaft, worm ring of odometer to its
positions (see Figure 3-147); use special tool G11 to install oil seal of output shaft to
its position, and notice the oil seal direction and lay grease on the mouth of oil seal
(see Figure 3-148).
⑩Lay Locitite 242 glue on the screw thread of support pin of fork axle, then screw it to
the back shell and pass through the pin hole of fork of range shift, its torque is
195-215Nm (see Figure 3-149); put the flange in its position, but before installing its
position, the drive axle shall connect with the bolt (see figure 3-150, 3-151).
⑪Install pressure pate, large bolt in turn, and screw large bolt, its torque is less than
300Nm (see Figure 3-151); put the piston assembly of range shift (including piston
of range shift, interior and exterior o rings) on the fork axle of range shift; lay Locitite
271 glue on the inner thread of locking nut and its torque is 119 -145Nm (see Figure
3-152).
⑫Put the paper washer of range shift cylinder, range shift cylinder (with seal ring and
pressure switch) on the piston of range shift in turn, notice the groove of back shell
aligns to the air inlet of range shift cylinder; before installation, lay suitable grease on
the inner wall of cylinder and o ring of piston and ensure there are not any dirty on
each parts; use connection bolt which thread laid Locitite 242 glue to fasten cylinder
of range shift to the back shell, its torque is 41-51Nm (see Figure 3-153).
⑬Turn supplementary gearbox assembly over, and align the holes of torque drive
plate and back shell, hit the torque bush to the level as torque drive plate (see
Figure 3-154); lay Locitite 271 glue on the connection bolt and screw it into the
thread hole of torque drive bush, its torque is 73-89Nm.
⑭Put the front bearing of planet carrier to its bottom (see Figure 3-155); rivet 3 points
on the touching edge of planet carrier and bearing to prevent the bearing escaping
outward (see Figure 3-156).
After supplementary assembly installation, test the two air holes of range shift
cylinder to ensure shift change of range shift in supplementary gearbox is agility.
Section IV The installation of HW19710 series small housing
I. Installation of Small Housing Assembly
① Install complex bush in the small housing end cover (swing arm side) (see Figure
3-157), use special tool G11, G12 to install oil seal on inside and outside end cover
(see Figure 3-158, 3-159, 3-160).
② Install complex bush into the small housing shell and to its position (see Figure
3-161), and lay suitable grease on the inner hole of complex bush; lay Locitite 680
bond on the bush and ensure to cover all the column face, and spray Locitite 7649
bond, and then install it into the small housing shell to its position (see Figure
3-162).
③ Assemble shift axle assembly: install centering spring, centering seat ring, and
another centering seat bush on the shift axle, compress spring on the elastic barrier
ring (see Figure 3-163, 3-164).
④ Put interlocking fork and shift head into the small housing cover, pass shift axle
assembly to inner holes of interlocking fork and shift head and install shift column
pin to its position (see Figure 3-165, 3-166); use punch to punch off the two end of
column pin of shift head to ensure the pin connection is firm and reliable (see Figure
3-166).
⑤ Put locking spring into the locking spring hole of small housing shell, pass locking
pin axle (cone end of locking axle outward side of swing arm) through pin hole and
spring barrier chip and locking spring, then put on needle (notice barrier chip
direction) and keep the rolling needle clamp on the groove of barrier chip( see figure
3-168); install drive pin to its position, put on sector locking block and let locking pin
axle clamp to the groove of sector locking block( see figure3- 169); install sensor
drive ring and then locate it by use elastic column pin ( see figure 3-170).
⑥Install sensor top pin and pressure switch, its torque is not more than 35Nm (see
Figure 3-171), lay seal glue on bowl-style shim, then install it to the hole on the small
housing shell and ensure not oil leakage (see Figure 3-172); if not installation
shift-choice support axle, then install it.
⑦Lay full of grease on the open of oil seal on small housing end cover (swing arm side),
fasten small housing end cover (swing arm side) on the small housing shell by
connection bolt; there is paper washer between small housing end cover (swing arm
side) and small housing shell, the connection bolt torque is 21-25Nm (see Figure
3-173,3-174); install anti-dust cover, shift swing arm to its positions, and screw
locking nut. The central line of short arm of shift swing arm (see Figure 3-175 inner
circle part) is vertical to the surface of small housing.
⑧ gears small housing assembly: install the spacer the range gear side of the small
housing shell. See figure 3-176.
Use bolt to connect small housing end cover (range shift side) and small housing shell;
there is end cover bush between small housing end cover (range shift side) and small
housing shell , the bolt tightening torque is 21-25Nm ( see figure 3-177).
⑨install sensor top pin and pressure switch, its torque is not more than 35Nm (see figure
3-182), each pressure switch can take reference figure.
⑩install the bush on the small housing shell, daub suitable lithium lubricating grease on
the end of the locking pin which part will stretch into the small housing shell, install it in the
small housing shell, ensure the locking pin move flexible on axial direction and no seizure
symptom (see figure 3-179,3-180). Put the spring on the locking pin and put the O-shape
ring on the small housing shell. See figure. (Shown as figure 3-181,3-182)
⑪install the paper gasket of the cut-off valve, assemble the cut-off valve on the small
housing shell and make them contact. Mount the dual H valve gasket and install the dual
H valve, fix it with hexagon socket head cap head screw, the torque is: 21-25Nm, shown
as figure3-183 .daub some Loctite572 on the thread of the direct connection, tighten it on
the cut-off valve3-184.
After installation small housing assembly, test the shift gear and examine whether it
is reliable and returning normal or not.
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