HW19710 Manual de manutenção e serviço.doc

Maintenance Manual for HW19710T Transmission

CHINA NATIONAL HEAVY DUTY TRUCK GROUP DATONG GEAR CO.,LTD. (CNHTC)


ContentsMAINTENANCE DATA OF TRANSMISSION.................................................................................................3

1. TECHNICAL PARAMETERS............................................................................................................................32. MAINTENANCE STANDARD..........................................................................................................................33. TIGHTENING TORQUE...................................................................................................................................4

FAULT DIAGNOSIS AND CAUSE ANALYSIS................................................................................................5

1. BASIC PROCEDURE FOR FAULT DIAGNOSIS.................................................................................................51.1 Preliminary Check：...........................................................................................................................51.2 Break-down..........................................................................................................................................51.3 Replacement of the Lubricant：..........................................................................................................5

2. CAUSE ANALYSIS AND TROUBLESHOOTING METHOD.................................................................................5

DISMANTLING OF THE TRANSMISSION AND PRECAUTIONS.............................................................6

1. PRECAUTIONS OF DISMANTLING..................................................................................................................62. BREAK-DOWN OF THE TRANSMISSION ACCESSORIES..................................................................................73. BREAK-DOWN OF THE TRANSMISSION ASSEMBLY.......................................................................................74. BREAK-DOWN OF SUB-ASSEMBLY OF THE TRANSMISSION..........................................................................8

⑴ Break-down of the Input Shaft Assembly：.........................................................................................8⑵ Break-down of the Output Shaft Assembl:...........................................................................................8⑶ Break-down of the Intermediate Shaft Assembly：.............................................................................9⑷ Break-down of the Small Cover：.......................................................................................................9⑸ Break-down of the Planetary Mechanism Assembly：.....................................................................10⑹ Break-down of Operation Mechanism...............................................................................................10

REASSEMBLING OF THE TRANSMISSION AND PRECAUTIONS........................................................11

1. WASH THE PARTS OF THE TRANSMISSION.................................................................................................112. CHECK THE PARTS OF THE TRANSMISSION................................................................................................113. PRECAUTIONS OF ASSEMBLING THE TRANSMISSION..................................................................................134. ASSEMBLING OF SUB-ASSEMBLY...............................................................................................................14

⑴ Sub-assembling of the Input Shaft Assembly.....................................................................................14⑵ Sub-assembling of the Output Shaft Assembly..................................................................................14⑶ Sub-assembling of the Intermediate Shaft Assembly.........................................................................16⑷ Sub-assembling of the Operating......................................................................................................17⑸ Sub-assembling of the small cover....................................................................................................17⑹ Sub-assembling of the planet carrier assembly.................................................................................19⑺ Assembling of Transmission Assembly..............................................................................................20⑻ Install the transmission assembly on the finished vehicle:................................................................23

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Maintenance Data of Transmission

1. Technical Parameters

Table 1 Technical Parameters of the TransmissionModel HW19710T \ HW19710TCType 1 to 10-speed synchronizer gear-shifting; reverse—engaging sleeve gear-shifting

Gear ratio

of each gear

Gear 1 2 3 4 5 6 7 8 9 10 R1 R2HW19710T 14.36 10.66 7.88 5.82 4.38 3.28 2.74 1.8 1.33 1 14.01 3.20

HW19710TC 10.79 8.01 5.92 4.38 3.29 2.47 1.83 1.35 1 0.75 10.53 2.40

Max. input torque 1900 N.m \ 2100 N.mMax. input rotating

speed 2600r/min

Lubricant 85W/90 middle load vehicle, gear oil（GL-4 ）Capacity of lubricant

tank 15L(if add PTO assembly, it should be 15.5L)

Weight of assembly 430Kg（including clutch housing assembly, excluding lubricant）Overall dimensions

(mm) 1030mmX610mmX660mm（length×width×height）2. Maintenance Standard

Table 2 Maintenance Standard of the Transmission

Item Standard size Wearing limitClearance between constant engaged gear of the reverse gear 0.337- ~0.633 1.0

Radial clearance between the sliding gear sleeve and spline of the fixed gear seat 0.2 ~0.3 0.5

Clearance between the sliding gear sleeve and shifting fork 0.2~ 0.3 0.5

Radial clearance between the sliding gear sleeve and monoblock of the gear

0.4~ 0.5 1.00.2~ 0.3

Axial clearance between the ball bearing —— 0.5Clearance between the shifting lever and selector lever 0.1~0.4 0.8

Clearance between shifting lever and spline of the operating shaft 0.02-0.08 0.5

Clearance between shifting lever and gear shift fork 0.74-0.96 1.5Clearance between reverse shift fork and reverse gear sleeve 0.10~0.29 1.0

Clearance between jaw of shift fork and gear shift fork 0.02~0.05 ——

Clearance between jaw of shift fork and gear sleeve of gear shift 0.1~0.5 1.0

Clearance between cylinder and gear shift shaft 0.04 ~0.18

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Item Standard size Wearing limit

Clearance between Synchro-ring and conical ring of the synchronizer

1.7~2.3(1, 2 and low gear of rear auxiliary

gearbox)Service limit 0.5

1.4~2.0(3 and 4 gear)1.5 ~2.1(high gear of rear auxiliary gearbox)

Clearance in the oil pump gear 0.05 ~0.09 ——Clearance between oil pump gear and spline of the intermediate shaft 0 ~0.18 ——

3. Tightening Torque

Table 3 Tightening Torque of the Transmission

Serial No. Installation Location Diameter of

threadTightening torque N.m

1 Bearing cover, top cap, cylinder cap and oil filter of the input shaft M10 41-51

2 Connecting bolt of front/rear housing of PTO M12 73－893 Conical plug of gear shift fork shaft M12×1 73-894 Front locking nut of the output shaft M56×1.5 Left 420-4705 Oil-filling plug and oil-drain plug M24×1.5 120-140

6 Connecting bolt of front housing, middle housing, rear housing and rear cover M10 41－51

7 Bolt for connecting the oil pump housing and middle housing M10 46-51

8 Self-locking nut of sectional-type cylinder piston M12×1.5 199－243

9Large bolt for the spline at the location where the output flange connecting to the output shaft, and inner surface of the pressure plate

M42×1.5 600－1300

10 Cover board of PTO hole, cover board of reverse gear hole M10 19-26

11 Bolt for connecting the front housing of the PTO to the auxiliary gearbox housing M12 73－89

12 Neutral, reverse, PTO,RANGE high gear switch M14×1.5 ＜4513 Hollow bolt at each oil pipe M16 35－5514 Bolt for fixing the fork shaft support M12 73－8915 Bolt for fixing release fork of the clutch M10 21－2516 Bolt for fixing the small cover M8 21－2517 Hollow bolt of air pipe of RANGE gear M14 32－52

18 Bolt for connecting the housing of the small cover to the end cover M8 21－25

19 Fastening bolt of dual valve M8 21－2520 End cover bolt of output shaft M10 41－5121 Fastening of pressure plate M8 21－2522 Cover board of external cooler port M10 41－5123 Locking nut of rear auxiliary gearbox M18X1.5 57-76

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Fault Diagnosis and Cause Analysis

1. Basic Procedure for Fault Diagnosis

1.1 Preliminary Check：① Visual check： Find sign of damage, pay attention to the critical component, such as

installation point, joint or support.

② Ask the owner or the driver：Collect related materials, such as working conditions, fault history, etc.

③ Establish related files： Include maintenance and lubrication periods, occurred fault, service mileage and time.

1.2 Break-down

① Save the oil sample, use it to check the impurity content when necessary;

② During break-down, check the parts for correct installation, check for missing parts or parts used with poor quality;

③ Wash every parts carefully, please see “Washing of the parts” for details;

④ Check every parts carefully, please see “Check of the parts” for details;

⑤ Determine the type of fault, analyze the fault reason.

1.3 Replacement of the Lubricant：① After 2000 to 5000 km running of the new transmission, it is necessary to replace the

lubricant and filter assembly (or filter cartridge). For service every 10000 km, you shall check the lubricant level and oil leakage, and replenish it if necessary.

② For service every 30000 km, you shall replace the lubricant and filter assembly (or filter cartridge).

2. Cause Analysis and Troubleshooting Method

Manifestation of a fault Possible cause and analysis Troubleshooting methodAbnormal sound or noise

Low viscosity of lubricant Use the lubricant with proper gradeInsufficient amount of lubricant Fill the designated lubricantTooth surface of the gear is damaged or tooth clearance due to over-wear

Repair or replace the faulty parts

Bearing is damaged or with crack Repair the bearingImproper connection of the gear shift fork to gear

Check the gear shift fork, replace it if bending

The synchronizer is worn or damaged.

Replace the damaged parts.

Individual gear is damaged. Replace the damaged parts.(Transmission) Difficult to engage a gear

The bearing is worn or damaged. Replace the bearing.The synchronizer does not operate properly.

Replace the synchronizer.

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The shift fork is deformed or damaged.

Check, correct or replace.

Retaining ring screw of the shift fork is loose.

Fastening, locking firmly.

Others, improper release of the clutch

Adjust the clutch

High viscosity of the lubricant. Use the required lubricant.(Transmission)Automatic gear switching

The shift fork is deformed or worn.

Check the gear shift fork, correct or replace it if bending.

Locking ball or ball slot in the gear shift shaft is damaged.

Break down and replace the worn parts.

Locking spring is broken or fatigued.

Replace the spring.

Large clearance between the gears.

Adjust the gear clearance or replace the gear.

Monoblock gear or reversed taper tooth of the gear sleeve is invalid.

Check and replace.

Sliding parts of sliding bush or end face is worn out.

Replace the bush.

Axial float caused by worn bearing.

Replace the bearing.

Locking nut of the flange is loose. Tighten it as required.(Auxiliary gearbox) Difficult to engage a gear

Electromagnetic valve does not work.

Replace the electromagnetic valve.

Cylinder blow-by or sealing element is damaged or invalid.

Replace.

Switch lock pin of the auxiliary gearbox is stuck.

Check and repair.

Chaotic gear Interlock steel ball or interlock pin is missing or worn.

Overhaul and install the missed parts.

Oil leakage Too much of lubricant. Let off some of it.Sealing element is damaged or invalid.

Replace.

Fastener is loose. Fastening.Ventilation plug is blocked. Unplug.Sealing glue around the bolt is omitted to smear.

Smear the sealing glue again, and fit back.

Dismantling of the Transmission and Precautions

1. Precautions of Dismantling

① The position in this Manual is stipulated like this: the output terminal is as “rear”, according to the assembling position in the vehicle, the heading direction is as the “front” of the transmission; look from the output terminal of the transmission(rear) to the forwarding direction of the vehicle (front of the transmission);

② Before dismantling the transmission from the vehicle, you must place the vehicle at a flat and safe area, move the shift lever into the neutral position in low gears, switch off the engine and turn off the main power supply, wedge the front and rear wheels.

It is very important to keep safe；25/6

app:ds:electromagnetic%20valve


③ Wash the housing of the transmission clean before breaking down the transmission assembly;

④ You must break down the transmission at a clean place to avoid dust or other things entering into it, otherwise, the bearing will be worn and damaged quickly;

⑤ Use special tools to dismantle the bearing, wash it carefully;

⑥ When breaking down each sub-assembly, put all the parts at a clean workbench according to dismantling order. Avoid losing of the parts, and be easy to assembly;

⑦ Use circlip pliers to dismantle the clamp spring;

⑧ During dismantling the parts, pay attention to the force applied on the shaft or housing, etc. Do not handle roughly, avoid damaging the parts. It is forbidden to dismantle some of the parts. It is strictly forbidden to apply external force on the running driven gears.

2. Break-down of the Transmission Accessories

① Unscrew the drain plug under the transmission, drain out the lubricant in the transmission (drain the oil when the vehicle is warm-up);

② Remove the drive shaft assembly and intermediate support(If equipped with PTO, remove the connecting shaft of PTO simultaneously);

③ Take apart the flexible shaft of speedometer connecting to the transmission;

④ Take apart the operating mechanism of the transmission;

⑤ Remove the clutch booster (fix it on the vehicle frame temporarily);

⑥ Dismantle the wires and pipes connecting to the transmission;

⑦ Use a wire rope to hang the transmission or put a jack under the transmission;

⑧ Dismantle the bolt for connecting the clutch housing to the flywheel housing;

⑨ Remove the transmission assembly by using jack or wire rope.

⑩ Break-down of the transmission shall be under its vertical status.

3. Break-down of the Transmission Assembly

1. Dismantle the small cover of the transmission and release system of the clutch;

2. Dismantle the planetary mechanism assembly of the rear auxiliary gearbox: a. Unscrew lock pin of fork shaft of sectional auxiliary gearbox, take out the lock spring and damping spring seat of gear-shifting; b. Unscrew the hollow bolt connecting air pipe of high/low gear at the position where the cylinder is; unscrew the bolt connecting rear housing and middle housing, hang the rear auxiliary gearbox (including PTO and cylinder of auxiliary gearbox);

3. Dismantle the middle housing and related components: a. dismantle the cover for reverse gear hole, fixing jackscrew of the reverse gear shaft; b. pull out the reverse gear shaft by shaft-withdrawing device, take out constant engaged gear of reverse, needle bearing, thrust needle bearing and retaining ring; c. take out the bolt connecting middle housing to front housing; d. hang the middle housing and related components.

4. Take out oil connector of rear end of the output shaft and of front end of inner hole in order by using the tools which are used for dismantling the oil joint of front & rear end of the output shaft;

5. Hoist the tools by components composed of the input shaft assembly and the output shaft assembly to penetrate into the hole of the output shaft, twist it and screw hole round. Hoist

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the components composed of the input shaft assembly and the output shaft assembly, at the same time of hoisting, use the tommy bar to pry three fork shafts up, and take out the intermediate shaft assembly.

6. Take apart the components composed of the input shaft assembly, the output shaft assembly and fork shaft.

4. Break-down of Sub-assembly of the Transmission

⑴ Break-down of the Input Shaft Assembly：The conical ring of the synchronizer in the input shaft is stuck to the built-in lock ring of the input shaft. It cannot be broke down in principle, but in particular cases, the conical ring could be supported steadily, use the press machine to press the input shaft out; the bearing of the input shaft cannot be taken out due to inner ring, if the input shaft or bearing is damaged, you need to replace the whole set.

⑵ Break-down of the Output Shaft Assembly:

① Dismantle the check ring of the rear bearing of the output shaft, remove the adjustable bushing of the inner ting and oil joint; support the edge of the first shift gear, and press the rear end of the output shaft.

② Take out the first shift gear, fixed gear seat of the first & second shift gear, sliding gear sleeve, synchronizer assembly, reverse gear, thrust pad, rear bearing of the output shaft and sealing ring of the rear shaft together; turn the output shaft, and remove the front bearing of the output shaft；

③ Prize up the locking position of the lock blade of the locking nut, use the wrench to unscrew the locking nut; take out the fixing gear seat of fourth/fifth shift gear and synchronizer components. Please do not throw the synchronizer spring, lock unit of the synchronizer and lock unit seat away;

④ Take out the fourth shift gear and needle bearing, third shift gear and needle bearing, gear sleeve of second/third shift gear seat and synchronizer components, second shift gear and

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Front bearing of the second shaftLocking nut

Tool used for oil extracting/guiding joint


needle bearing in order.

⑶ Break-down of the Intermediate Shaft Assembly：

You cannot break down the intermediate shaft assembly. It is necessary to replace the assembly when repairing.

⑷ Break-down of the Small Cover：① Unscrew the nut for fixing the gear-shifting rocker, take out the bolt, dismantle the rocker,

and take out the dustproof cover and selector lever assembly, support bar assembly, remove the switch;

② Unscrew the bolt of the end cap of the small cover and right end cap of the small cover, remove both caps; pull out self-locking pin shaft, take out the needle, spring and spring baffle plate;

③ Remove the flexible cylindrical pin used for fixing the drive ring of the sensor, then remove the sensor drive;

④ Remove the shaft-used flexible check ring at the low gear side in the gear-shifting shaft;

⑤ Polish and remove the pin used for fixing the gear-shifting head, pull out the gear-shifting shaft.

⑥ Take out the centering spring, centering seating ring and spacer ring in the small cover housing;

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Selector lever assembly

Support shaft of gear-selectorSupport bar assembly

Self-locking pin shaft

Gear-shifting shaft

Gear-shifting head

Interlock fork

Centering springSpacer ring

Centering seating ring

Small cover housingComposite bush


⑸ Break-down of the Planetary Mechanism Assembly：① Prize the lock blade open, unscrew the bolt of flange cover board; take out the pressure

plate of flange, using a tool to remove the flange;

② Remove the cylinder and its piston; remover the housing simultaneously;

③ Unscrew the bolt used for fixing the conical disc assembly of the low gear in the low gears, remove the conical disc assembly of the low gear in the low gears;

④ Support the rear housing steadily, press the planet carrier assembly out;

⑤ Pull out the for shift and its shaft;

⑥ Remove the synchronizer assembly and shaft-used flatten spacer ring, which is made of steel wire; remove gear seat of rear auxiliary gearbox and gear sleeve assembly;

⑦ Remove the check ring made of steel wire, and inner gear ring;

⑧ Unscrew the hexagon socket screw of planet carrier, remove the front body of the planet carrier and all the planetary gears.

⑹ Break-down of Operation Mechanism

1) Break-down of the first reverse gear shift fork shaft assembly: unscrew the fastening bolt of shift fork, remove the guide block of the first reverse gear and transmission fork in order;

2) Break-down of the shift fork shaft assembly of the second/third shift gear: unscrew the fastening bolt; remove the second and third transmission fork in order;

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Rear housing

Keep plate\bolt\lock bladeOutput flange

Inner gear ring

Gear sleeve components of gear seat of rear auxiliary gearbox

Synchro-ring assembly of the rear auxiliary gearbox

Planet carrier

Bearing assembly of output shaft

Shift fork of sectional auxiliary gearbox

Conical disc assembly of low gear

Reverse gear guide block

Shift fork shaft of the first reverse gear

Fastening bolt Shifting fork

Transmission fork of the second/third shift gear

Fastening bolt

Transmission fork shaft of the second/third shift gear

Guide block of fourth/fifth shift gear


3) Break-down of the shift fork shaft assembly of the fourth/fifth shift gear: unscrew the fastening bolt of the shift fork, remove guide block of the fourth & fifth shift gear and shift fork.

Reassembling of the Transmission and Precautions

1. Wash the Parts of the Transmission

It is compulsory to wash the parts, for they are covered by dirty oil and sludge. The applicable washing methods include: steam cleaning, pressure cleaning, light oil cleaning, acid or alkaline solution, neutral medium cleaning, trichloroethylene steam cleaning, Magnus solution cleaning, etc. During washing, the damaged parts will be exposed, thus, pay close attention to it.

● Metal parts:

Light oil; different from other solution, the light oil does not have osmosis or sludge dissolution capabilities. Thus, except polished surface, you shall use scratching brush or other tools to get rid of sludge, and scrub twice by using the methods mentioned above. Alkaline solution: if the components are made of alloy, please do not wash it with the alkaline solution. The alkaline solution is quite good for washing the steel and cast iron. Notice: if wash the parts with the alkaline solution, please prepare neutralization medium, such as boric acid solution. Once the skin or eyes contact(s) with the alkaline solution, wash the alkaline solution away with the neutralization medium.

● Rubber components. Do not wash them with mineral oil. Use alcohol or clean cloth to erase the oil sludge.

● Lubricate the oil duct. Make the wire go through the oil duct, make sure that the oil duct is clear, and then the cleaning solution is sprayed into the oil duct by the pressure nozzle to make a wash.

● Corrosion prevention. After removal of old grease on the components surface, you shall smear a layer of fresh grease to protect the components from rusting.

2. Check the Parts of the TransmissionBefore reassembling, you shall check the parts carefully one by one. Check the parts for damage or abnormal wear or over wear. Avoid installing non-serviceable parts into the transmission, lest cause needless loss. When determine whether the parts could be used continuously, sometimes you need to consider service time of the parts, mileage, and service conditions, etc. The following is the recommended inspection procedure:

● Bearing

① Check steel ball, roller and ball track for pockmark or peeling;

② Check axial and radial clearance of the bearing, replace the bearing with excessive clearance;

③ Check the assembling clearance between the bearing and housing hole. If the bearing could

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Fastening bolt

Shift fork of fourth/fifth shift gear


turn freely in the hole, replace the housing;

④ Measure the axial clearance of the ball bearing: wear limit: 0.5mm

⑤ Check the radial clearance between needle bearing and inner ring of the gear:

Maintenance standard: 0.049mm

Wear limit: 0.30mm

● Gear

① Check the tooth surface of the gear for pitting corrosion; replace the gear with pitting-corrosive tooth surface;

② Check all the meshing gear for abnormal wear, worn to be conical type; or it cannot be all tooth engagement due to improper gear-shifting; replace if necessary.

③ Check the axial clearance of the gear. For the position with excessive clearance, you shall check retaining ring, washer, adjustable pad and gear hub for over wear.

④ If the measured tooth clearance exceeds the value of the wear limit, check contact marking of the gears and working conditions of the bearing;

Maintenance standard: 0.1 to 0.3mm

Wear limit: 0.5mm

● Spline.

Check the splines on all the shafts for abnormal wear. If the splines on the shaft are influenced by the over worn output flange disc and synchronizer, replace the influenced shaft.

● Retaining ring.

Check the surface of all the retaining rings. Scratched or over worn ring must be replaced.

● Constantly engaged gear of the reverse.

Check the constantly engaged gear of the reverse and needle bearing for over wear.

● Grey cast iron parts.

Check all the grey cast iron parts for crack or damage. Replace or repair if necessary. Repair the crack of the large cast components with fusion welding or braze welding, but for the cast components whose cracks have extended to the position connecting the bearing hole to the conjunction plane of the bolt, it must be replaced.

● Release components of the clutch

① Check the release components of the clutch for wear. Replace over worn release fork and release bearing;

② Check the release fork shaft of the clutch for wear.

● Fork shaft assembly of the transmission

① Check shift fork, guide block, rotary shifting block and locating slot of the shift fork shaft for wear. Replace all the over worn parts;

② Check the entire shift fork for deformation. Replace deformed shift fork;

③ Check shift fork and guide block for fastening of the locking screw. Tighten the loose ones;

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④ After break-down of the fork shaft, check interlocking steel ball and shift fork hole corresponding to it for wear.

● Bearing cover

① Check bearing cover for wear, and replace the damaged one;

② Check bearing hole for wear. Replace the over worn parts;

● Sealing element and oil seal

① Check the oil seal in the bearing cover of the input shaft and in the odometer housing. If the oil seal is invalid, replace it;

② Check the spigot for wear. Replace it if necessary;

③ Check the oil seal for operating. If the sealing function of the lip is invalid, replace the oil seal.

④ Check all the O-ring for crack and deformation. Replace it if necessary.

● Synchronizer

① Check the synchronizer for burr, deformation and over wear;

② Check the locking pin for over wear;

③ Check the touching face of the gear to the synchronizer for over wear. The gear with burnt touching face or the burnt synchronizer must be replaced.

④ Check positional dimension between the conical ring of the synchronizer and synchro-ring;

3. Precautions of Assembling the TransmissionWash the parts to be assembled thoroughly before assembling. Do not let the dust and debris into the transmission, lest cause needless damage. During assembling, please observe the following precautions:

⑴ When assembling the transmission, primarily, it shall be assembled as it is vertical; after basic assembling, turn it into the horizontal type, then assemble the top cap, release system of the clutch and electrical wire harness, etc.

⑵ Taper roller bearings are massively used in the transmission, they are used in pairs. During assembling, you must measure the clearance; select the proper gasket to adjust the axial clearance of the taper roller bearing (See Assembling of the Transmission for measurement method).

⑶ The transmission adopts compulsory lubrication. When assembling, you need to install oil pump, filter cartridge, at the same time, and make sure the oil duct is clear and smooth.

⑷ When assembling the parts, make sure that the thrust washer of the gear, needle bearing and spacer are in a correction direction.

⑸ Smear clean gear lubricant on all the running surface.

⑹ According to the repair rules, replace all the self-locking nut, oil seal and O-ring.

⑺ When reassembling the synchro-ring and conical ring of the synchronizer, please pay attention to their location and direction, and make sure that the installing location and direction shall not be changed.

⑻ When reassembling, make sure that the lubricant filling port is non-blocking; no rust, sand hole or crack on the operating surface of each gear; clean the conical ring of the synchronizer; and smear fresh lubricant on the conical ring of the synchronizer, synchro-ring, oil seal and operating surface

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of the bearing.

Gasket: When reassembling the transmission, all the gaskets used shall be new, and be smeared with sealing glue. You cannot omit from installing any one of the gasket, otherwise, it will cause oil leakage or inaccurate positioning of the bearing cover. In order to prevent from oil leakage, please tighten the bolt. All the fastening bolts shall be smeared with thread sealants. See Tightening Torque on Page 5 in detail.

⑼ O-ring: All the O-ring shall be lubricated with silicon grease before assembling.

⑽ Initial lubrication: During assembling, all the thrust washer and splines in the shafts must be smeared with grease as initial lubrication to avoid scratching and dry friction.

⑾ Axial clearance: When reassembling, make sure that the axial clearance of the output shaft complies with the requirements.

⑿ Bearing: It is recommended that using bearing installer/remover with flange when assembling the bearing. You can apply the force to the inner/outer ring of the bearing by using this kind of installer/remover. It not only prevents steel ball and inner/outer ring of the bearing from damaging, but also assures a good concentricity between the shaft and the hole of the bearing. It is better not to use telescopic installer/remover, for it can only apply the force to one part of the inner/outer ring of the bearing, may cause damage of the bearing.

4. Assembling of Sub-assembly

⑴ Sub-assembling of the Input Shaft Assembly

① Place the spline of the input shaft downward, and make it stand up on the workbench;

② Fit the locking ring of the input gear over the gear of the input shaft, use the tool to jam the locking ring, press the conical ring into the gear of the input shaft.

③ Place the input shaft on the workbench, with the spline upward.

④ Install the conical bearing of the input shaft into the input shaft after heating, pay attention to the bearing direction, with the small end upward.

⑤ Install the shaft-used circlip into the input shaft.

⑵ Sub-assembling of the Output Shaft Assembly

1) Insert the output shaft into the jig of the output shaft (with the spline upward); make the oil hole on the top circle of output shaft directly toward the operator.

2) Smear the oil on the top circle of output shaft and end face of gear seat.

3) Fit two needle bearings used for the first shift

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The first shaft

Circlip for shaft use

Conical bearing

Locking ring of the gear

Conical ring

Front bearing of the output shaftSynchro-ring assembly of the fourth/fifth shift gearFourth shift gear

Third shift gearSynchro-ring assembly of the second/third shift gearSecond shift gear

First shift gear

Gear sleeve of the first reverse gear

Reverse gear

Output shaft


gear over the output shaft.

4) Fit the soldered tooth of the spline of the first shift gear upward over the needle bearing.

5) Fit the first/second conical disc over the soldered tooth of the first shift gear.

6) Install the whole set of the first/second synchro-ring assembly into the first shift gear. Smear much oil on the end face of the synchronizer, and make the oil immersed in the oil groove of the two synchro-rings.

7) Press the needle bearing race used for reverse gear into the output shaft, (the oil hole on the needle bearing race and oil hole in the output shaft are staggered with an angle of 90°), and fit the two needle bearings used for the reverse gear over the seat ring;

8) Fit the soldered tooth of the reverse gear downward over the needle bearing, and smear oil on the end face of the inner hole of the reverse gear;

9) Press the thrust pad of the reverse gear into the output shaft, with the oil sump side down;

10) Press the rear bearing of the output shaft and sealing ring of the bearing into the output shaft, measure the thickness of the adjust pad of the inner ring of the rear bearing of the output shaft. Install the proper adjust pad into the output shaft (make sure the clearance is between 0.05 and 0.15), install the rear bearing retaining ring of the output shaft (Figure. 1);

11) Rotate the output shaft 180°。12) Smear the oil on the end face of the gear seat of the output shaft and on the top circle; fit

the two second shift gears over the output shaft by using needle bearing;

13) Install the second shift gear and conical disc;

14) Install synchro-ring assembly of the first/second shift gear and components composed of gear sleeve and gear seat (Figure.2)

15) Put he third-speed-gear-used conical disc convex plate up to the syncho-ring assembly; turn the conical disc to make the bulging part on the synchro-ring go into the round hole of the conical disc;

16) Press the bearing race of the third shift gear into the output shaft, the oil hole on the needle bearing race and oil hole in the output shaft are staggered with an angle of 90°, and smear the oil on the end face of the inner hole of the second/third gear seat and on the top circle of the seat ring. Fit the two needle bearings over the seat ring.

17) Fit the third shift gear of the output shaft over the needle bearing, make its soldered tooth enter into the spline of the conical disc, and smear the oil on the end face of the inner hole of the gear;

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Fig. 1

Bearing retaining ring

Adjust pad

Sealing ring of the bearing

Rear bearing of the output shaft

Figure. 2

Synchro-ring assembly

Components composed of gear sleeve and gear seat

Synchro-ring assembly


18) Press the thrust pad convex pad of the third shift gear up into the output shaft;

19) Press needle bearing race of the fourth shift gear into the output shaft, the oil hole on the needle bearing race and oil hole in the output shaft are staggered with an angle of 90°and smear the oil, Fit the two needle bearings of the fourth shift gear over the seat ring.

20) Fit the fourth shift gear assembly over the needle bearing, and smear the oil on the end face of the inner hole of the gear.

21) Install the synchro-ring of the fourth shift gear and conical ring;

22) Install the components composed of gear sleeve and gear seat of the fourth/fifth shift gear and sychro-ring at the other side (fifth shift gear);

23) Install the locking nut gasket, and fit the lock blade over the output shaft; use locking nut of the output shaft to lock, and bend the lock blade of the locking nut of the output shaft, and make sure that the locking nut is in a good locking condition;

24) Heat up the front bearing of the output shaft to 100°C , after that, install it into the output shaft.

Pay attention to the direction of the bearing; make the small end of the conical bearing upward. Fill oil in the bearing.

⑶ Sub-assembling of the Intermediate Shaft Assembly

1. Place the intermediate shaft vertically into the locating hole of the jig, with the tooth end down.

2. Thermally install the third shift gear of the intermediate shaft

3. Thermally install the fourth shift gear of the intermediate shaft

4. Thermally install the constant engaged gear of the intermediate shaft

5. Heat up the front bearing of the intermediate shaft several seconds; install it into the shaft with the small end of the inner ring upward.

Notice: Before pressing into the intermediate shaft, it is necessary to smear Loctite 684 on the top circle of the intermediate shaft.

25/16

Front bearing of the output shaft

Locking nut of the output shaft

Components composed of gear sleeve and gear seat of the fourth/fifth shift gear

Intermediate shaft

Third gear

Fourth gear of the intermediate shaft

Constant engaged gear of the intermediate shaft

Front bearing of the intermediate shaft


⑷ Sub-assembling of the Operating

1) Sub-assembling of the shift fork shaft assembly of the first reverse gear:

① Install the guide block of the reverse gear in the shift fork shaft of the first reverse gear, screw the two fastening bolts of the fork aiming at the pin hole of the fork shaft, primarily tighten the screw far away from the installing fork, then tighten the other one;

② Install the shift fork in the shift fork shaft of the first reverse gear; screw the two fastening bolts of the fork aiming at the pin hole of the fork shaft, primarily tighten the screw near to guide block, then tighten the other one.

2) Sub-assembling of the shift fork shaft assembly of the second/third shift gear:Install the transmission fork of the second/third shift gear in the transmission fork shaft of the second/third shift gear, screw the two fastening bolts of the fork aiming at the pin hole of the fork shaft, tighten the screw far away from the interlock slot, then tighten the other one.

3） Sub-assembling of the shift fork shaft assembly of the fourth/fifth shift gear:

① Install the guide block of the fourth/fifth shift gear in the fork shaft of the fourth/fifth shift gear, screw the two fastening bolts of the fork aiming at the pin hole of the fork shaft, tighten the screw near to the shift fork, then tighten the other one.

② Install the shift fork of the fourth/fifth shift gear in the shift fork shaft of the fourth/fifth shift gear, screw the two fastening bolts of the fork aiming at the pin hole of the fork shaft, tighten the screw far away from the guide block, then tighten the other one.

⑸ Sub-assembling of the small cover1) Sub-assembling of the housing of the small cover:

① Install the composite lining into the housing of the small cover;

② Install the centering seating ring, centering spring and centering seating ring into the housing of the small cover in order. Pay attention to the direction of the seating ring;

③ Install the spacer ring into the housing of the small cover in place;

④ Smear the Loctite 680 adhesive, make sure that it covers the whole outer cylindrical surface, spray Loctite 7649 accelerant, then install it into the small cover in place;

25/17

Guide block of the reverse gear

Shift fork of the first reverse gear

Fastening bolt

Transmission fork

Transmission fork of the second/third shift gear

Fastening bolt

Transmission fork shaft of the second/third shift gear

Fouth\Fifth gear fork

Fouth\Fifth guide block

Fastening screw

Centering springSpacer ring

Centering seating ring

Housing of the small cap Composite lining


2) Sub-assembling of the end cap of the small cover (at the rocker side):

① Install the composite lining into the end cap of the small cover (at the rocker side);

② Install the inner/outer oil seal into the end cap of the small cover (at the rocker side), and smear lithium base lubricant;

3) Install the sensor drive ring in the gear-shifting shaft; fix it by flexible cylindrical pin;

4) Install the drive pin into the pin hole of the gear-shifting shaft, and fit the self-locking block with the sector shape over the gear-shifting shaft and drive pin; make sure that the direction of the sensor drive ring is correct (when the gear-shifting head moves backward to shift a reverse gear, the bulge of the sensor drive ring is able to drive the reverse switch).

5) Put the self-locking spring into the hole of the self-locking spring on the housing of the small cover, and put the interlocking fork and gear-shifting head into the housing of the small cover (pay attention to the direction);

6) Install the gear-shifting components into the small cover, pass through the interlocking fork, gear-shifting head, composite lining of the small cover, centering seating ring and inner hole of the centering spring in order. Make sure the direction of the sensor drive ring is correct. Fix the gear-shifting head and gear-shifting shaft by pins, and use the flaring tool of the cylindrical pin to make both ends of the pin open to ensure the pin is secure;

7) Penetrate the self-locking pin shaft into the housing of the small cover. Pass through the self-locking spring, baffle plate of the spring, interlocking fork in order. And penetrate the needle into the pin hole of the self-locking pin shaft, and the needle is stuck by the baffle plate of the spring;

8) Push the gear-shifting shaft to press the groove of the sector-shaped self-locking block tightly to the top end of the self-locking pin shaft, confirm the needle does not drop out;

9) Smear the lubricant full on the blade of the oil seal on the end cap of the small cover (at the rocker side); install the components composed of end cap of the small cover and end cap lining on the housing of the small cover; fasten it with the spring gasket by using the hexagon bolt smeared with thread sealant;

10) Push and press the gear-shifting shaft, press the centering spring and self-locking spring, let the circlip at the other side of the gear-shifting shaft expose outside the centering seating ring, and install the shaft-used elastic damping ring;

25/18

End cap of the small cover

Composite lining

Oil seal inside the end cap

Oil seal outside the end cap

Fig. 3

Self-locking pin shaft Self-locking spring

Right end cap of the small cap

End cap of the small cap

Dustproof cover

Gear-shifting head

Interlocking fork

Gear-shifting rocker

Cut-off valve Molding hose

Ventilation plug

Constant open pressure switch

Bracket components

Two-position five-way valve assembly

Constant closed pressure switch

Fig. 4


11) Install the right end cap of the small cover and paper washer, fasten it with the spring gasket by using the hexagon bolt smeared with thread sealant; install the normally open ventilation plug, top pin components of the sensor and normally open pressure switch on the right end cap of the small cover (Figure. 4);

12) Install dustproof cover and gear-shifting rocker, penetrate hexagon bolt, stack up the wave spring washers, fasten them with I type hexagon nut;

13) Install the shaft-used wire baffle ring into the circlip groove of the top pin of sensor, install the top pin of neutral sensor on the housing of the small cover, stack up the sealing washers and install the normally closed pressure switch;

14) Install the support bearing of gear selection above the small cover, smear the plane sealing glue on the bowl-shaped pad, and install the bowl-shaped pad on the housing of the small cover;

15) Use the support bar assembly to connect the gear-selector assembly to the gear-shifting rocker (after assembling of the small cover assembly, install the gear-selector in the support shaft of the gear selection, and fixed by shaft-used elastic damping ring);

16) After assembling of the small cover assembly, test the gear-shifting, check gear-shifting for reliability and return for normality.

17) Install the two-position five-way valve assembly on the support by hexagon bolt stacking up spring washer, fasten it with I type hexagon nut;

18) Install the muffler on the two-position five-way valve assembly;

19) Install the pass-through NPT1/8-8X6 and NPT1/8-4X2 on the two-position five-way valve assembly;

20) After fastening it by using the hexagon bolt smeared with thread sealant, stacking up with the spring washer, install the support components on the housing of the small cover;

21) Stack up the cut-off valve with paper to install it on the other side of the housing of the small cover, fasten it by bolt with spring washer;

22) Install the molding hose between the cut-off valve and two-position five-way valve.

⑹ Sub-assembling of the planet carrier assembly

1. Put the front body of the planet carrier onto the workbench, install oil diverting joint of the planet carrier, use the hole-used elastic damping ring to jam it;

2. Assemble five planetary gears（see the right figure） and fit them over the planetary gear shaft;

3. Take out the planetary wheel from the side groove of its assembly and install five planetary gear shafts, aiming at the pin hole of the planet carrier, then knock the elastic cylindrical pin into the pin hole;

4. Install the front thrust bearing of the plane carrier and axial baffle ring on the planet carrier assembly;

25/19

Support shaft of gear selector

Gear-selector assembly

Support bar assembly


5. Install the support saddle of gear ring into the inner gear ring, and install wire baffle ring to fix it;

6. Penetrate the planetary mechanism through the gear ring components, and install it in place, make sure the engagement of the inner gear ring and planetary mechanism, and it turns flexibly;

7. Install cone naves assembly of the low gear, synchro-ring assembly of rear auxiliary gearbox and components composed of gear seat and gear sleeve of rear auxiliary gearbox;

8. Install spacer of planet carrier, axial baffle ring and thrust bearing of the planet carrier, and in place;

9. Install conical disc of rear auxiliary gearbox on the planet carrier;

10. Install fork shaft of sectional auxiliary gearbox and shift fork of sectional auxiliary gearbox;

11. Install the rear housing;

12. Install the ball bearing of output shaft, with the slot up, on the housing of rear auxiliary gearbox;

13. Fasten the bearing cover assembly of the output shaft on the housing of the rear auxiliary gearbox (built-in oil seal); be careful not damage the oil seal;

14. Install worm screw of odometer and output flange;

15. Lock the elastic cylindrical pin, pressure plate, bolt and lock blade onto the output shaft;

16. Turn the rear auxiliary gearbox assembly, install nine torque transmitting sleeves into it, then fasten it with hexagon bolt covered by flat washer.

⑺ Assembling of Transmission Assembly

⑴ Use bolt combination parts (8 pieces) and bolt combination parts smeared with glue (2 pieces) to fasten the bearing cover of the input shaft on the front housing;

25/20

Inner gear ring

Components composed of gear seat and gear sleeve of rear auxiliary gearbox Synchro-ring assembly of

rear auxiliary gearbox

Planet carrier

Bearing cover assembly of output shaft

Shift fork of sectional auxiliary gearbox

Conical disc assembly of low gear

Rear housing

Keep plate \ bolt \ lock bladeOutput flange

Front housing

Bearing cover of the input shaft


⑵ Press the outer ring of the input shaft bearing and outer ring of the front bearing of the intermediate shaft into the front housing respectively, and knock two locating pins into the rear pin holes of the middle housing; install two locating pins of fork shaft into the locating pin hole of the fork shaft support saddle of the housing;

⑶ Put the spline, with long end downward, of the input shaft assembly on the sub-assembling support of axle series parts, install the output shaft assembly on the input assembly. Assemble the intermediate shaft assembly and output shaft assembly together. Install the sliding block of the transmission into the fork shaft assembly;

(4) Use general tools for fixing the fork shaft to hoist the assembled shaft and operating mechanism into the front housing of the transmission, and put them in place; Knock two cylindrical pins into the corresponding locating holes of the front housing; smear silica gel on the end face of the front housing, fasten the middle housing on the front housing; press the outer ring of the rear bearing of the output shaft and intermediate shaft into the middle housing respectively. Select the proper thickness of the adjust pad（ δ） , the methods are as follows:

Measure the exposed height of the outer ring of the rear bearing and spigot depth of the bearing on the oil pump housing, make a comparison between them, select the proper adjust pad for the rear bearing of the output shaft and of the intermediate shaft, and make sure that eh clearance between the rear bearing of the output shaft and of the intermediate shaft is 0.09 to 0.19mm.

(5) Fasten the oil pump housing on the middle housing, and install the outer/inner rotor of the oil pump into the oil pump, install the oil pump cover; then, install idle gear assembly and idle gear shaft, fasten it by retaining ring bolt; (6) Install the interlocking shaft of the main/auxiliary gearbox on the middle housing in place, and use one shift fork of the main gearbox to insert into the shift fork shaft of the main gearbox for locating;

25/21

Output shaft assembly

Shift fork shaft assembly

Input shaft assembly

Intermediate shaft assembly

Adjust pad for clearance among the bearingsOil pump housing

Middle housing

Outer ring of the bearing Output shaft

Spigot depth of the oil pump housing; Exposed height of the outer ring of the bearing; Thickness of the adjust pad ;

Clearance between the bearings δ=H-h-a Guarantee 0.09≤δ≤0.19

Stop screw

Idle gear assembly


⑺ Install locking spring and interlocking spring seat of the sectional auxiliary gearbox;

⑻ Fasten the cover board of the interlocking shaft with three hexagon bolts;

⑼ Press two assembled sealing rings of the rear bearing of the output shaft into the output shaft, until they are against the inner ring of the rear bearing of the output shaft; then measure their clearance, select the proper adjust pad, and finally install the rear bearing baffle ring of the output shaft;

⑽ Fit the sealing sleeve of the oil pump housing over the sealing ring of the rear bearing of the output shaft, then install the wire baffle ring of the oil pump housing, press the front oil diverting joint of the output shaft into the front end of the center hole of the output shaft, and install rear oil diverting joint and oil-splashing assembly;

⑾ Knock two cylindrical pins into the housing, smear the silica gel on the end face of the middle housing, and fasten the planetary mechanism assembly on the middle housing; install O-ring and two O-rings for piston hole of the sectional fork shaft into the piston holes of the cylinder of the auxiliary gearbox; install cylinder paper pad and cylinder of the auxiliary gearbox, and fasten them with 4 pieces of bolt combination parts;

⑿ Install the lower housing of PTO, insert the output shaft into the power takeoff hole, and fasten the PTO;

⒀ Fasten the cover board of constant engaged gear of the reverse gear with eight pieces of bolt combination parts on the housing;

⒁ Fasten the oil filter gasket and oil filter assembly with bolt combination parts on the housing; fasten the port cover board of the oil cooler with four bolt combination parts; install locking pin of the fork shaft of the auxiliary gearbox, locking spring of the sectional auxiliary gearbox and damping spring seat of gear-shifting and fasten them;

25/22

Oil pump Rear oil diverting joint of the output shaft

Filter screen assembly

Rear bearing baffle ring of the output shaft

Oil-splashing assembly

Interlocking shaft of the auxiliary gearboxLocking spring of the fork shaft of the auxiliary gearboxInterlocking spring seatCover board of interlocking shaft

Planetary mechanism assembly

Cylinder of Range Gear

Oil filter assemblyLocking pin of fork shaft of the auxiliary gearboxLocking spring of the fork shaft of the auxiliary gearboxDamping spring seat of gear-shifting

Port cover board of the oil cooler Small cover assembly

PTO assembly Constant engaged gear cover board of the reverse gear


⒂ Turn the transmission over; fasten the small cover assembly on the housing;

⒃ Use two hollow bolts and four sealing washers to connect the air pipe assembly (high gear) to the upper port of the cylinder of the auxiliary gearbox, and to connect the air pipe assembly (low gear) to the lower port of the cylinder of the auxiliary gearbox (see the right figure)；

⒄ Knock the lining into the left hole of the clutch housing and into the support hole of the shift fork shaft, fasten the support assembly of the shift fork shaft, and trial assembling of sample of the release bearing, check release action for flexibility, if nonqualified, reassemble the support of shift fork shaft; at the same time, fasten the support of servo-cylinder and support of flexible shaft.

⑻ Install the transmission assembly on the finished vehicle:

Make sure that all the related parts are assembled well and fastened securely before the transmission is installed on the vehicle.

⑴ Use a jack used for the transmission and wire rope to install the transmission and support (as an assembly) in the vehicle, make sure that the spline of the input shaft aims at the spline of the driven plate hub of the clutch;

⑵ Install clutch booster, return spring and rod jaw pin; adjust idle stroke of outer push rod of the clutch; idle stroke of outer push rod of the clutch: 2 to 3mm

⑶ Install operating draw bar of the transmission;

⑷ Install the drive shaft and middle support;

⑸ Connect all the circuits and pipelines;

⑹ Tighten the oil-drain plug of the transmission, fill up with gear oil, then tighten the oil-filling plug.

Tightening torque： 120 to 140N·m.

25/23

Connect the air pipe assembly (high gear) to the upper port of the cylinder of the auxiliary gearbox

Oil pipe of power takeoff box

CylinderConnect the air pipe assembly (low gear) to the lower port of the cylinder of the auxiliary gearbox

Support of servo-cylinder

Support of flexible shaft

Support assembly of shift fork shaft


This Manual is compiled by Technical Center, CHINA NATIONAL HEAVY-DUTY TRUCK GROUP DATONG GEAR CO., LTD. (CNHTC)

Add.: No. 81 Xinkaibei Road Datong, Shanxi Province

Tel.:0352-2416352、2416353

Fax: 0352-2416444

Post code：037006 Free Service Hotline：8008062208

Website: http://www.dcgroup.com.cn

Email:[email protected]

Note: The words, pictures and parameters are only for reference.

25/24

http://www.dcgroup.com.cn/

HW19710 Manual de manutenção e serviço.doc

Documents

assembling of subassembly

gear sleeve of gear

gear oilgl

gear ratio

gear shift fork0

sliding gear sleeve

gear shift shaft0

input shaft assembly