Howo Series Transmission

SINOTRUK
Training Materials for HW Series

Transmission
SINOTRUK (Hong Kong) LIMITED
November 2009
Preface
This course book series are compiled on the basis of the demand for developing Corporation
Company, in order to enhance professional ability of service marketers, strengthen professional
training of HW series transmission over the users and advance training over various types of new
products promotion, simultaneously popularize products knowledge in the Corporation Company.
According to the actual requirements of training, we compiled training course book of primary
level, secondary level and high level.
The primary training course book includes basic knowledge of transmission, structural principle of
HW series transmission, operating requirements, its own features and advantages, and its
comparison with the normal transmission on the market. In addition, the trainer shall get some
ideas of assembly process and maintenance process, and master the form process of the
transmission.
The secondary training course book includes Spare Parts Manual and complete maintenance
process of HW series transmission. In principle, the people who are going to receive the secondary
training must understand and master the contents of the primary training course book. It is
required that the trainer shall have a better understanding of the contents of the primary training
course, master the structure of HW series transmission, know the basic principle of HW series
transmission. Learn the secondary course book; master the correct operation, operation methods
and daily maintenance control points for the transmission. When finishing the secondary training,
the trainer shall master the correct methods to dismantle, adjust, maintain and repair HW series
transmission; have the ability to instruct the service station in daily maintenance of HW
transmission, to diagnose the common faults and to make preliminary analysis on some special
faults; and also have basic ability to train the people at his service station an at other ones.
The high level training course book includes common fault mode, common fault analysis and
diagnosis and identification of components and accessories of HW series transmission. The people
who are going to receive the high level training must read the primary and secondary course books
carefully; know everything about the interrelationship among structure, principle and all parts of
HW series transmission, and master the maintenance control points of HW series transmission.
When finishing the high level training, the trainer shall be able to diagnose various maintenance
methods and influence of damaged parts on transmission assembly; shall be familiar with the
influence of other components and parts connecting to the transmission on the transmission; be
able to diagnose the true cause of the fault occurred in the transmission via analysis on the service
condition and the condition of damaged parts, and be able to take the proper maintenance
measures to solve the problems and instruct the relevant personnel in maintaining and repairing
according to the actual condition.
This course book is a bound volume consisting of contents of the primary, secondary and
high level course books. The first part is the contents of primary level; the second part is the
contents of secondary level including Chapter One and Chapter Two; and the contents of
high level including Chapter Three and Chapter Four.
This course book is compiled by Leading & Training Group of Products and Marketing Service of
CHINA NATIONAL HEAVY DUTY TRUCK GROUP GEAR CO.,LTD. (CNHTC).
Editor in chief：YU Tianming
Chief censor：OUYANG Ping
Compiled by：REN Fuchen

Suggestions for improvement will be gratefully received.
Editor
March 2009
HW Series Transmission
Part One
（Primary Contents）
Chapter I Basic Knowledge of HW Transmission
Requirements:
Comprehend the function and model of transmission, the features of structure of twin countershaft
transmission and Structure of Planetary Gear Transmission. Grasp the feature and advantage of
HW series transmission, as well as its position at home and abroad.
Section I Cognizing of Transmission
I. Transmission Position
Master Different
Clutch Transmission Universal joint reducer
Drive axle
Drive axle housing Half axle
II. Functions of Transmission

Drive from the engine passes to the transmission by clutch, and then is altered to suitable ration by
transmission to drive axle, master reducer, different, half axle to the vehicle drive wheel in the
automobile drive system. Transmission play an important role in the vehicle drive system, and its
function can directly affect the driver’s comfort and operation.
Main functions of automobile transmission:
a) Alter the transmission ratio, enlarge the changing ranges of drive wheel torque and speed to
fit the often changing driving conditions and at the same time, make the engine running
under the best conditions (higher power and lower oil consumption).
b) Make the automobile to reverse driving under the condition that the engine does not change
its turning direction.
c) Make the engine start, idle and be convent to shift gear by using neutral position to breakout
the power transferring.
III. Classification of Transmission

1. Manual Transmission(MT)
Manual Transmission (MT) is the most normal transmission, which is composed by gear
and axle and can meet the purpose of changing speed and torque by engaging different
gears.
2. Automatic Transmission (AT)
Automatic Transmission (AT) is composed by hydraulic torque-converter, planet gear,
hydraulic operation system, and changes the speed and torque by hydraulic transferring and
gear combination. It can automatically change the shift gear by the position of accelerator
pedal and driving speed change, and the driver only need to operate the accelerator pedal
and braking pedal to control the automobile speed. Although there is not operating clutch in
the automatic transmission vehicle, there are lots of clutches in the automatic transmission.
All these clutches can automatically separate or close with the speed changing to realize the
purpose of automatic speed changing.
3. Automated Mechanical Transmission (AMT)
Automated Mechanical Transmission (AMT) is also called Electronic Control Mechanical
Automatic Transmission. This transmission does not change the main structure of traditional
manual transmission; its key technology is digital shift gear structure controlled by a set of
Electronic Control Unit (EUC). Its basic principles is, recurring by the related executive
structures (oil supporting, chosen shift gear, clutch joint and split), integrated operation to
the engine, clutch, and transmission of vehicle power drive system to realize the starting,
gear shifting and automatic operation according to the driver intentions (accelerator pedal,
braking pedal) and the vehicle situations (engine speed, output shaft speed, vehicle speed,
and shift gear and others), and by a certain rules ( shift gear, clutch joint and split and
others).
4. Continuously Variable Transmission (CVT)
Continuously Variable Transmission (CVT) is only adopted two sets of belt pulley to carry
on variable transmission, which is the most difference from the ordinary automatic gear
transmission which used the complex and heavy gear assembly to variable transmission.
This transmission carries on the speed changing by alteration the contact radius of the
driving wheel and the driven wheel. The pulley is usually made of rubber belt, metal belt,
metal chain and others. Its advantages are lighter heavy, smaller volume, fewer parts and
higher efficiency and lower oil consumption compared with the Automatic Transmission.
However, its disadvantages are distinct, that is the drive belt easier damage or slip, and not
bearing the heavier load.
5. Dual Clutch Transmission (DCT)
Dual Clutch Transmission (DCT), based on the manual transmission but not the automatic
transmission, is different from the ordinary automatic transmission system, and can offer
continuous power output except the flexibility of the manual transmission and comfort of
the automatic transmission. While the traditional manual transmission, adopting one set of
clutch, can lead the power output to be broken by power gap during gear shifting period
when the driver stamp the clutch pedal and change another shift gear by hand.
DCT，equipped with two automatic control clutches, can control two clutches operation by
electronic controlling and hydraulic pressure pushing. When transmission operating, one set
gear engaged; however, when shift gear is closed, next set gear has been pre-elected and this
clutch is still in the split. When gear shifting, one clutch separates the engaged gear, another
clutch has been pre-elected and this ensure to keep at least one set of gear to output power
during the gear shifting period and no power output breaking occurring. In order to
cooperate with the above-mentioned operation, movement of DCT drive axle is divided to
two parts, one is solid drive axle, and another is hollow axle. The solid drive shift connects
to the one, three, and five-shift gear, and the hollow drive axle connects to the two, four,
six-shift gear. Each clutch takes charge of one engaged action of a drive axle, and power of
the engine can be continuous transmitted by one of the drive axle.
DCT, based on the manual transmission and special design, can resist 350 N.M torque; and
due to the exact computer operation, it posses more precise gear shift controlling compared
with ordinary manual transmission. So, DCT can also become less oil consumption
transmission system. Based on the feature and operation model, DCT system can bring the
driver a feeling of racing car driving. In addition, it eliminates the power broken of manual
transmission during gear shifting, and makes more comfortable driving.
Section II HW Series Transmission Features
I. Revelation of HW Series Transmission.

Sino-truck, in order to adapt to the developing trend and matching demand of greater power of
heavy truck, independently develop HW series new transmission assembly for different working
and road conditions technological innovation, depending on the strong research and developing
strength and several years’ technological accumulation, as well as collecting the great
achievements of transmission of the world. At present, there are six series: HW18709、HW20716、
HW18710、HW14710、HW18712、AMT, have been developed, as shown in Figure 1-1.
Figure 1-1: Shape of HW Series Transmission
II. Main Structure Features and Advantages of HW Series Transmission.

1. Main gear-box adopts a twin countershaft structure, and supplementary gear-box
adopts planetary gear drive structure. This greatly upgrades the reliability of
assembly.
Figure 1-2: Drive Structure of HW Series Transmission

Main gearbox is twin countershaft structure, which can distribute the power. Each
countershaft, two end bearings and gears of countershaft only bears 1/2 general power, and
the input shaft and gears of the spindle bears 1/2 general powers too. So, the spindle bears
the same power which is in opposite direction, and only bears the torque, not bending
moment. This design eliminates destroy to the engaged area caused by the spindle
deforming, reduces the noise of gear engagement of transmission and increases the
longevity of the gears. By these means, the transmission can prolong its use life and make it
more stability and reliability.
The twin countershaft, by reducing the center distance, diameter of each shift gear, width of
gear and diameter of each axle, can shorten the dimension of transmission axles, lighten the
weight. Short dimension is convent for arrangement of whole vehicle, and light
transmission weigh can reduce the oil consumption, then the economic benefits can be
increased.
Supplementary gearbox is planet gear drive structure, which effective overcomes the
problem of pre-malfunction of supplementary gearbox (especially used in the worse
conditions, such as mine industry and others, its effect is more distinctness), and greatly
prolongs the use life of transmission assembly based on the sufficient analysis of
malfunction model of supplementary gearbox by using twin countershaft and overcome this
defect.
2. Main gearbox adopts two-stage floats, and supplementary gearbox adopts center
wheel float. This can ensure each gear even load.
Both end of the spindle have float amount and gear float of spindle; this can ensure the load
to be distributed evenly. Sun wheel and gear float of supplementary gearbox ensures the
planet structure to be loaded evenly. The structure, connected the twin countershaft of main
gearbox with the supplementary gearbox, needs special positioning device of spindle as the
following figure shown.
1. spindle，2. bush，3. ball joint，4. output shaft，5. bearing，6. input shaft
Figure 1-3: Float of Spindle and Planet Structure
3. Input shaft adopts Span Support Structure to increase the support rigidity, and the
reliability of supplementary gearbox.
Rigidity support of big span bearing of output shaft ensures the support rigidity of output
shaft, and it increases the life of gear and synchronizer of supplementary gearbox, and
effectively resolves the disadvantage of short life of other products.
4. The Gear Shifting between main gearbox and supplementary one, has mutual
interlocking gear, this effectively protect the synchronizer of supplementary gearbox.
Figure 1-4: Interlocking Gear of main and supplementary gearboxes
The synchronizing ring of synchronizer of supplementary gearbox, which is made by

Molybdenum sprayed on steel base, has features of larger friction force and longer use life.
Additional main and supplementary gearboxes can ensure that before the supplementary
gearbox shifting gear, the main gearbox can do this. This can greatly prolong the use life of
synchronizer of supplementary gearbox.
When range gear fork axle of supplementary gearbox does not get position, the interlocking
plate is exactly inside of the groove of fork axle of main gearbox by the spring operation,
and then the fork axle of main gearbox is locked in the neutral position. When range gear
fork axle of supplementary gearbox gets position, it can push the interlocking turning to
unlock the control of fork axle of main gearbox, and then the driver can put into gear on
demanding.
5. The Housing of Transmission Adopts Vertically-split Structure which is Convenient to
assemble and maintain.
The main housing adopts vertically-split structure. The dimension of the middle part of the
housing can be adjusted in accordance with the volume and shift gears of the transmission,
and another two parts can be in common use. In addition, the vertically-split structure
makes the gear alignment easily and rapidly.
Figure 1-5: The Housing Structure of HW Series Transmission

6. Design of Small Functional Integrated Cover makes the Assembly Structure
Compaction.
Figure 1-6: Structure of Small housing Assembly of HW Transmission
Shift gear swing-arm, shift gear head, interlocking fork, sensor drive ring, sector lock block,
high and low shift gear locating ring, all are equipped in the gear axle. The gear shift choice
can be realized by gear axle horizontal movement through swing-arm operation, and putting
into gear and out of gear can be realized by gear axle front and back movement. Shift gear
interlocking function, which can avoid the random gear, can be realized by interlocking fork.
Shift gear locking, which can avoid gear escaping, can be realized by lock device. All
functions of the locking, interlocking and shift gear choice are centralized in the small
housing, it can make the function more reliability and maintenance more convenience.
7. Initiative Lubricating Adoption.
The key parts of HW series transmission adopt initiative lubricating. Adding lubrication oil
pump and relative oil pipe in the transmission assembly can greatly prolong the use life of
transmission.
Figure 1-7: Lubricating System of HW Series Transmission

8. Power Take-off (PTO) Output with Direction invariable and Convenient PTO for
Braking and Travelling.
Figure 1-8: PTO Installment of HW Series Transmission
PTO is driven by right auxiliary axle of main gearbox; its direction and speed are not
affected under this condition. This can be convenient to realize power take-off in neutral
position, and ensure normal direction turning under the reverse shift gear conditions.
9. Greatly Increasing the Reliability of Dual H Valve by its Cut-off Structure Design
Dual H valve assembly in the HW transmission adopts end seal, and greatly increases its
reliability.
Figure 1-9: Dual H Valve Assembly of HW Series Transmission

10. Range Shift Gear Fork Adopts Swing-fork Design, and Fork Axle Adopts Span
Support Structure, all these increase the use life of shift gear structure.
This kind of design can effectively reduce the bending moment of range shift gear fork and
fork axle, improve the interaction of the shift gear axle and hole of housing, and increase the
relevant use life and reliability.
Figure 1-10: Shift Structure of HW Series Transmission
Section III Comparing HW Series Transmission with Another
I. Comparing with All Structures of Transmission.

The structure of main gearbox of transmission has single countershaft and twin countershaft
structures, such as the ordinary structure of ZF Series Transmission is single countershaft structure,
the ordinary structure of Fuller transmission is twin countershaft structure. The structure of back
supplementary gearbox of transmission has twin countershaft structure and planet drive gear
structure, such as the ordinary structure of ZF series transmission is planet drive gear structure and
the ordinary structure of Fuller series is twin countershaft structure.
1. Comparing Single Countershaft Structure with Twin Countershaft Structure.
The ordinary parts of transmission is gear, which is extensively applied in all kinds of
mechanical products due to advantages of its smaller volume, lighter weight, invariable
drive ratio, stable working and larger drive power. Involute gear, easily manufactured and
inspected, suitable for scale production, is ordinary transferring parts of transmission.
20°pressure angle, which comprehensive performance is best, is often used in Involute gear.
During gear driving period, the gear bears tangent force and radial force at the same time,
its ratio is 2.75 (20°pressure angle). Suppose drive torque is 1000 Nm, center distance of
gear is 150mm, and the drive ratio is i, then it bears 2424 (i +1) radial force. The more
radial force, the more bending deformation of gear axle and that worsens the engagement
condition.
The principle of twin countershaft structure is that the inputting power, from input shaft, is
divided into the two countershafts by drive gear, then influxes to the output shaft.
Theoretically, because each countershaft only transfers 1/2 torque, the transmission, adopted
twin countershaft structure, can reduce the thickness and center distance of gear, shorten the
whole length of axle, and lighten the weight of whole transmission. Twin countershaft
structure, in order to meet the correct engagement and try to distribute the load evenly,
eliminates needle bearing in the hole of spindle gear of single countershaft structure by
spindle gear radial floating in the spindle. During working, the force, imposed to the spindle
gear by the two countershaft gears, is equal and direction opposite. So, the spindle only
bears torque and does not bear bending moment. This improves the force bearing condition
of spindle and bearing, and greatly increases the reliability of transmission.
Twin countershaft structure, in order to resolve the correct engagement of spindle gear and
countershaft gear, must be carried on gear alignment, which increases the manufacturing
difficulty, by correct locating of the countershaft gear in the countershaft. Therefore,
application twin countershaft structure in the transmission assemble with smaller input
torque is not suitable for its high manufacturing cost and not playing its advantage role.
2. Comparing Twin Countershaft Structure with Planet Drive Gear Structure in back
supplementary gearbox of Transmission.
From above-mentioned analysis, we can see that twin countershaft structure reduces the
transferring torque of each gear, and increases drive application performance. Back
supplementary gearbox, usually used as range shift gear supplementary gearbox, has large
gear difference due to drive ratio is less 3, and only two pairs of gear engagement. Input
torque of back supplementary gearbox of transmission is four times of input torque of
transmission. The more input torque of transmission, the more force bearing of
supplementary gearbox of twin countershaft, and the more possibility of malfunction. The
exhibition of twin countershaft supplementary of transmission in heavy car applied under
worse working condition also proof this point. The main malfunction is gear broken, crush,
and pit corrosion, housing crack of supplementary gearbox and short use life of
synchronizer.
The planet drive gear is composed by one sun wheel, five planet wheel, and one inner gear
ring. Theoretically, each planet wheel only transfers 1/5 torque, and force bearing condition
of gear is greatly improved and application reliability and life of back supplementary
gearbox of transmission is increased due to output shaft is supported in the large span axle.
When supplementary gearbox is in the high shift position, there is not gear engagement
drive among planet drive structure, so the drive ratio can arrive 100%. This is benefit for
saving oil.
From above-mentioned analysis we can see that with input torque increasing and under the
limited structure condition, main gearbox adopts the drive is from single countershaft to
twin countershaft; supplementary gearbox adopt the drive is from twin countershaft to
planet drive gear structure. HW series transmission, made by Sinotruck, is more suitable for
larger power, large torque, worse road condition, and for increasing the use life of assembly.
II. Developing Tendency of Heavy Truck Transmission

With energy crisis intensified, more and more strict requirement of environment protection all
over the world, the general developing tendency of world heavy truck is higher power, lower oil
consumption, and lower noise. In order to effectively increase the whole vehicle power and
sufficiently play the role of advantages of high efficiency and rapidness of the transportation of
heavy truck, the engine of this vehicle is required to equip with larger horsepower, lower rev and
greater torque to reduce the emission, environment pollution and to meet Europe three or even
more higher emission standard. At the same time, the transmission is required multi-shift gear,
larger torque (over 1500 Nm), larger rev ratio, higher efficiency and lower noise.
In recent years, ZF Company has manufactured ZF—New Ecosplit and ZF ASTronic series
transmission of heavy truck.
ZF New Ecosplit is manual transmission with 1600-2700 Nm torque; it is a successful production
of mechanical transmission of heavy truck of present ZF Company.
ZF ASTronic series transmission is full automatic mechanic transmission (AMT), developed by
ZF Company in recent years for equipment with heavy truck. Its largest torque is 2600 Nm. Its
whole structure is twin countershaft plus planet drive gear system, composed by insert shift
structure, basic main gearbox structure, range shift structure. It is first time that ZF Company
altered the design of the traditional single countershaft full synchronizer. Its insert shift and main
gearbox adopts twin countershaft drive, and the main gearbox has not equipped with synchronizer,
but adopts slip gear shift. ZF ASTronic series transmission is in the leader position of the world.
Eaton Corp, which main market in North America, manufactures twin countershaft series
transmission of heavy truck. Based on the Fuller RT-11509, and after a series technological
innovation, it designed a series transmission assembly of heavy truck. Eaton Corp is the more
important transmission manufacturing company in the world.
Chinese transmission technology of heavy truck mostly comes from America, Germany, Japan,
and others. The introduced technologies mostly belong to the products of 80s-90s of twenty
century. During the long introducing and digesting period, a series new product has been
developed by us through model changing. However, this developing is a common one; there is not
real key technological product.
Sinotruck
Twin countershaft + planet wheel
structure
Domestic factory
Twin countershaft structure
Domestic factory
Single countershaft + planet wheel
structure
Figure 1-11: Comparing Transmission of Heavy Truck
Green: common level of domestic factory.
Yellow: few domestic factories can meet the level; it must be paid high cost and the quality is difficulty to ensure.
Red: domestic factory hardly meet the level; it must be gained by long time technological innovation, paid high
cost, but the foreign advanced enterprise can arrive this level.
From above figure we can see that the largest torque of domestic transmission, made by domestic
factory which adopted single countershaft plus planet wheel structure, is very difficult to over
1000 Nm. But the largest torque of domestic transmission, made by domestic factory which
adopted twin countershaft structure, can arrive at 1500 Nm. Therefore, the factory which adopted
twin countershaft structure has relatively advantage in domestic transmission market of heavy
truck. But with China heavy truck walks up to internationalization, this advantage will be lost. The
largest input of HW series transmission, independently developed by Sinotruck, can arrive at 2000
Nm, and will be 2500 Nm after technological innovation. Therefore, it will posses absolutely
advantage in the domestic market of transmission of heavy truck.
Furthermore，the structure of HW series transmission has lots similarities with the ZF ASTronic
series, and adopted some special mechanism (have been applied patent). All theses explained that
the independent design capability of Sinotruck is arriving at the world advanced level. The special
structure of HW transmission can easily translate into automatic mechanical transmission (have
realized). This is perfect combination of world advanced technology and Chinese present
manufacturing level, and can support the top transmission of heavy truck for domestic consumer.
Important Points of This Chapter:
What the function of the automobile transmission and what the transmission classification is. The
structure features and advantages of HW series transmission. The structure features of twin
countershaft structure and planet drive gear structure. What the position of HW series transmission
is.
Exercises:
1. How many functions of automobile transmission?
2. How many main classifications of automobile transmission?
3. The structure features and advantages of HW series transmission.
4. What advantage of interlocking device between main gearbox and supplementary gearbox
of HW series transmission.
5. How many functions of small housing assembly of HW series transmission?
6. How to realize the PTO of neutral position of HW series transmission?
7. The principle of twin countershaft structure.
8. What advantage and disadvantage of comparing single countershaft structure with twin
countershaft structure.
9. What advantage of comparing planet drive gear structure and twin countershaft structure.
10. HW series transmission how to ensure that before the synchronizer of supplementary
gearbox finished transferring, the main gearbox can’t change shift.
11. Narrate developing tendency of heavy truck.
12. Narrate the position of HW series transmission.
Chapter II Principle of HW Series Transmission
Requirements：
Grasp structure principle of HW series transmission and shift figures of drive route.
Section I Structure of HW Series Transmission
I. Drive Structure of HW Series Transmission.
Main gearbox of HW series transmission adopts twin countershaft structure, the two countershafts
have 180° angle; the supplementary gearbox adopts planet drive gear structure. Inputting power
from input shaft is divided into the two countershafts, then influxes into the spindle, finally output
by planet drive gear of supplementary gearbox to realize the power transferring.
1. HW18709 Series Transmission
HW18709 series transmission is composed by main gearbox, two-section supplementary

gearbox. Main gearbox has five forward shifts, and the supplementary gearbox has two
shifts, so there are nine (4 x 2 + 1) forward shift and one reverse shift. The main drive
structure is as shown in figure 2-1:
Main gearbox is manual operation and supplementary gearbox is air operation. Operation
and controlling devices of HW 18709 series transmission have styles of single lever dual H
shift device and double lever dual H shift device.
Figure 2-1: Main Drive Structure of HW18709、HW18710 Series Transmission

2. HW20716 Series Transmission
HW 20716 series transmission composed by front supplementary gearbox, main gearbox

and back supplementary gearbox. There are eight forward shifts, including four shifts of
main gearbox and two of supplementary gearbox. There are totally sixteen (2 x 4 x 2)
forward shifts and two reverse shifts after front located insert fork split. The structure of
main drive is as shown in Figure 2-2.
Main transmission is manual operation and front and back supplementary transmission is air
operation. Shift operation and controlling structures of HW 20716 series transmission has
two style of single lever double H shift device directly controlled by air valve and
double lever double H shift device directly controlled by air valve.
3. HW18710 and HW14710 Series Transmission
HW18710 and HW14710 Series Transmission are composed by main gearbox, two-section
supplementary gearbox. There are totally 10 forward shifts (5 x 2) and 1 reverse shift,
including 5 shifts of main gearbox and 2 of supplementary gearbox. The main drive
structure is as shown in Figure 2-1.
Shift operation and controlling of HW18710 and HW14710 Series Transmission has two
styles of single lever double H shift device directly controlled by air valve and double
lever double H shift device directly controlled by air valve.
Figure 2-2: Structure of HW20716 Series Transmission
II. Control Structure of HW Series Transmission

The control structure of HW18709 and HW20716 Series Transmission is as shown in
Figure 2-3. High and low shift locating ring and shift head is settled on the shift axle. High
and low shift locating spring, centering spring and others makes up the shift lock and
formed 5 clear shift positions. These five positions parallelize five positions of shift head;
each position can swing front and back to form two shifts. Shift head adopts double head
structure, which can be dialed one same axle in two different positions. At the same time,
axle movement of shift axle can drive along the interlocking fork to drive double H
assembly to realize the range shift to change. Main gearbox shift cooperates with range shift
to realize 9 shifts of HW 20716 and 10 shifts of HW 18709. Control structure of HW20716,
cooperated with air directly control insert fork, can realize 16 forward shifts and 2 reverse
shifts.
1—shift swing arm 2—dustproof cover 3—shift axle 4—sensor drive ring
5—pressure switcher of reverse shift 6—shift head 7—interlocking fork 8—centering spring
9—range shift lock pin 10—high and low shift locating ring 11—centering spring
12—end cover of small housing 14—drive pin 15—sector lock block
16—pressure switcher of neutral position 17—lock pin axle 18—double H valve assembly
19—lock spring 20—small cover housing
Figure 2-3: Control Structure of HW 18709 and HW 20716 Series Transmission
Interlocking fork, shift head, fork axle block unite and compose shift interlocking structure.
The shift head is opposite to the two grooves of interlocking fork. Only when the fork block
directly opposite to the groove of the interlocking fork, the fork block can be pulled out to
realize shift. If shift head is not opposite to the groove of the interlocking, the fork block
can’t be pulled out of the interlocking, and then can’t realize to shift. This ensures that shift
can only be changed in the five clear shift positions to realize reliable interlocking function.
Sector lock block, lock pin axle, lock spring and others unites and composes the lock
structure which ensures the reliability of locking.
The smaller housing, on which the shift choice, shift, locking, interlocking, and signal drive
are perfectly organized, makes all kinds of functions more reliability and much easily
maintenance.
Figure 2-4: Control Structure of HW18710 and HW14710 Series Transmission
The control structure of HW18710 and HW14710 Series Transmission is as shown in

Figure 2-4. Centering spring and centering seat ring are settled on the shift axle, which
unites and composes shift lock with small housing hull and spacer ring to form 3 clear shift
positions. These 3 positions parallelize 3 positions of shift head; each position can swing
front and back to form two shifts. Control structure of HW18710 and HW14710 cooperates
with air directly control insert fork, can realize 10 forward shifts and 2 reverse shifts.
Interlocking fork, shift head, fork axle block unite and compose shift interlocking structure.
The shift head is opposite to the two grooves of interlocking fork. Only when the fork block
directly opposite to the groove of the interlocking fork, the fork block can be pulled out to
realize shift. If shift head is not opposite to the groove of the interlocking, the fork block
can’t be pulled out of the interlocking, and then can’t realize to shift. This ensures that shift
can only be changed in the three clear shift positions to realize reliable interlocking
function.
Sector lock block, lock pin axle, lock spring unites and composes the lock structure which
ensures the reliability of locking.
Section II Drive Route and Shift Figure of HW Series Transmission
I. Drive Route of HW Series Transmission.

1. Drive Route of HW 18709 Series Transmission is as shown in Figure 2-5.
creep shaft gear
1-shift gear
2-shift gear
3-shift gear
4-shift gear
5-shift gear
6-shift gear
7-shift gear
8-shift gear
Reverse shift gear
Figure 2-5: Drive Route of HW18709 Series Transmission

2. Drive Route of HW18710 and HW14710 is as shown in Figure 2-6.
1-shift gear
2-shift gear
3-shift gear
4-shift gear
5-shift gear
6-shift gear
7-shift gear
8-shift gear
9- shift gear
10- shift gear
Reverse shift gear
Figure 2-6: Drive Route of HW18710 and HW14710 Series Transmission

3. Drive Route of HW20716 Series Transmission is as shown in Figure 2-7
1-shift gear
1-shift gear
2-shift gear
2-shift gear
3-shift gear
3-shift gear
4-shift gear
4-shift gear
5- shift gear
5- shift gear
6- shift gear
6- shift gear
7- shift gear
7- shift gear
8- shift gear
8- shift gear
Reverse shift gear
Reverse shift gear
Figure 2-7: Drive Route of HW20716 Series Transmission

II. Shift Figures of HW Series Transmission
Shift Figure of HW18709 Series Transmission Shift Figure of HW14710 Series Transmission
Shift Figure of HW20716 Series Transmission
Section III Main Technological Parameters of HW Series

Transmission
I. Nameplate of HW Series Transmission
Figure 1-8: Nameplate of HW Series Transmission

Model: numbered rules as follow:
HW 18 7 10 A X -S
Forward shift
Series number, heavy transmission series
1/10 1% torque, adopts 1/10 when less than three digitals.
Brand.
A-AMT；X- overdrive；S- Synchronizer……
Customer No.: such as HW18709 071011
Design series No.
Model of HW transmission assembly.
Series No.: mark specified by the enterprise to only identify the transmission assembly.
II. Major performance Parameters of HW Series Transmission

1. Main Technological Parameters of HW 18708 Series Transmission
Model HW18709 Installation length 843
Style 9 forward shifts,1 reverse shift (three-section shell)
The largest input torque 1800N•M Largest input rev. 2600rpm
Shift position Speed ratio Shift position Speed ratio
creep shift 12.68 5-shift gear 2.5
1-shidr gear 8.46 6-shift gear 1.85
Speed ratio of each shift
2-shift gear 6.26 7-shift gear 1.37
3-shift gear 4.64 8-shift gear 1
4-shift gear 3.38 Reverse shift 11.63
Main gearbox is splash lubrication and supplementary gearbox is
Lubrication method
forced lubrication
Lubrication brand 85W/90 GL-4 or 85W/90 GL-5
Fuel charge 12L(with PTO is 12.5L)

Style 16 forward shift,2 reverse shift (three-section shell)
The largest input 2600rpm
2000N•M Largest input rev.
torque
Shift Speed ratio Speed ratio Shift Speed ratio Speed
positions (L) (H) positions (L) ratio(H)
1-shidr gear 15.59 13.13 6-shift gear 2.49 2.10
Speed ratio of
2-shift gear 10.89 9.17 7-shift gear 1.71 1.44
each shift
3-shift gear 7.48 6.30 8-shift gear 1.19 1.00
4-shift gear 5.20 4.38 Reverse shift 14.29 12.03
5-shift gear 3.56 3.00
Lubrication Main gearbox is splash lubrication and supplementary gearbox is
method forced lubrication
The First Series
Speed ratio of each shift 3-shift gear 8.1 8-shift gear 1.85
4-shift gear 6 9-shift gear 1.37
Reverse shift speed ratio 15.04 3.44
Main gearbox is splash lubrication and supplementary
Lubrication method
gearbox is forced lubrication
The Second Series

Speed ratio of each shift 3-shift gear 7.87 8-shift gear 1.80
Reverse shift speed ratio 13.91 3.18
Lubrication method Main gearbox is splash lubrication and supplementary gearbox is forced lubrication

Speed ratio of each shift
Lubrication method Reverse shift speed ratio 13.91 3.18
Main gearbox is splash lubrication and supplementary gearbox is
Lubrication brand
forced lubrication
Fuel charge 85W/90 GL-4 or 85W/90 GL-5
12L(with PTO is 12.5L)
5. New Developing of HW Series Transmission

Sinotruck has researched a series new transmission, including HW 20716A automatic
mechanic transmission (AMT), HW 20716X series transmission with overdrive, and will
push out HW 18712 series transmission with 12 shifts.
Important Points of This Chapter.
Basic principle and shift figure of drive routine of HW series transmission; meaning of nameplate
and main technological parameters of the HW series transmission.
Exercises:
1. Which kinds of control structure of HW series transmission?
2. How to realize the locking, interlocking of the HW series transmission?
3. Shift figure of HW series transmission.
4. Drive routine of HW series transmission.
5. Which items of nameplate of HW series transmission?
6. Explain the numbered rule of HW series transmission.
Chapter III Maintenance of HW Series Transmission
Requirements:
Master maintenance of HW18709、HW18710、HW14710、HW20716 transmissions, comprehend
different structure and notice items of maintenance of HW transmission, and choose suitable
repairing method to repair the transmission assembly by the on-site conditions. Master the
repairing tools of HW series transmission and can be perfect use.
Section I Dismantle and Assemble of HW Series Transmission

Assembly
I. Basic Requirements of Dismantle of HW Series Transmission

Basic Requirements as Following:
① Be familiar with the assembly requirement, shape of settled parts, the location after parts
normal installation, and prevent to use any defect parts.
② Before installation, make good inspection of parts ensure the parts surface is clean and not
district manufactured defect, especially the combined surface is not burr, bump and others,
such as the matching surface of oil seal and transitional surface when equipment and the
gear surface shall not have distinct bump and other damages.
③ Handle parts with care, not damage the parts surface, especially the important combined
surface.
④ Before installed the oil seal, lay on suitable lithium grease on the connected mouth to
protect it.
⑤ After installation, clear the copper crumbs on the parts surface to keep the surface neatness
if the parts surface is knocked on by copper hammer and others.
⑥ After installation, examine the parts to ensure it is installed in the correct position. If
debugging, please debug by requirement till meet the installation requirement.
⑦ Bolt installation: firstly put the bolt through the light hole or threaded hole, then wring the
bolt to the fixed surface 2-3 threads. Tighten the bolt on the cross, and use torque wrench to
measure the bolt torque to keep the techniques required torque.
⑧ Use suitable work position and tools to put parts neatly, not random to avoid being knocked
and accidental damage.
⑨ Keep the assemble site clean.
II. Dismantle of the Transmission Assembly.

1. Fork Axle Dismantle of Push-type Clutch
3-1 3-2
Clean the transmission assembly, then put it on the ground with soft rubber mat (see figure
3-1). Dismantle the fork bolt of transmission, then the flat key, take off fork axle and fork to
separate bearing, low pressure hose and grease cup (see figure 3-2)
2. Fork Axle Dismantle of Pull-type Clutch.
Dismantle the two tightening screws for fastening fork and fork axle (see Figure 3-3). Take
off the elastic ring of fork axle by circlip pliers (see Figure 3-4).
3-3 3-4
Lift up fork axle, the flat key on the fork axle low end will naturally drop. Take off the flat
key (see figure 3-5), dismantle carrier bolt of fork axle and take off the fork axle carrier (see
figure 3-6).
Figure 3-5 Figure 3-6

3. Dismantle the fork axle carrier (see figure 3-7) and oil inlet of shell, oil inlet of input shaft
and oil outlet assembly (see Figure 3-8)
4. Dismantle end cover assembly of input shaft (see Figure 3-9) and end cover of
supplementary axle (see Figure 3-10. when dismantle the end cover of supplementary axle,
use plain end screwdriver to prize on the bulges of this figure).
5. Dismantle six M10 bolts connected oil pump and front housing, not dismantle two bolts
connected front and back housing of oil pump (Figure 3-11 shown by circle). Gently turn to
the input shaft to drive supplementary axle moving, make the top thread on the axle end of
left supplementary axle direct to the gap on the shell of oil pump (see Figure 3-12). Hold oil
pump and outside forcibly dismantle the oil pump assembly (if not easily dismantle, under
the condition that ensure the top thread on the end of left supplementary axle is direct to the
gap of the shell of oil pump) use M12X50 top thread to turn into the two screw holes
directed by Figure 3-11 arrow to push the oil pump out), take out of top thread from the end
of left supplementary axle (see Figure 3-13, arrow direction is the position of ball).
6. Pipe 2 in the box is clearance fit with front shell, it can be used screwdriver to hook inside
of the pipe 2 to pick it up (see Figure 3-14), and dismantle input shaft and stop ring of
supplementary axle (see Figure 3-15).
7. Dismantle all nuts connected middle shell and front shell in the front shell (see figure 3-16),
then dismantle the nut connected middle and front shells outside of the front shell, maintain
2-3 nuts to keep the middle and front shell not split when it left (see Figure 3-17).
8. Loose the four boles on the small housing and the two hollow bolt on air pipe of range shift
cylinder, dismantle small housing assembly (see Figure 3-18， Figure 3-19).
9. Make workbench ready for input shaft impending, put the transmission on the workbench
and let the output flange of the transmission vertically and steadily dropping on the
workbench, take care for protection the ring ridge of front shell and input shaft. Prize the
locking plate of output shaft (see Figure 3-20), and dismantle larger bolt (see figure 3-21)
by special tools of G01 or G14 (cooperate with pneumatic wrench).
10. Pull greasy blockage out by M10 bolt (see Figure 3-22), dismantle the tightening nut of
main axle in output shaft by extension bar bush (see Figure 3-23, before split main
gearbox from supplementary gearbox, it must firstly dismantle the tightening nut of
main axle, otherwise the main axle will be damaged), then fasten the larger bolt.
11. Screw off connected bolt of PTO, and then take off the back shell of PTO by M10 top
thread (see Figure 3-24). Screw off connected bolt of front shell of PTO and back shell of
transmission; take off the front shell of PTO (see Figure 3-25).
12. Screw off bolt connected back and middle shell of transmission (see Figure 3-26), prop up
the back shell of transmission by M12 top thread (see Figure 3-27), then lift up the
supplementary assembly by lifter or rope and take off the assembly.
13. Take off the input shaft of PTO by gently copper hammer striking (see figure 3-28), and put
the supplementary gearbox and PTO into the clean place.
14. Screw five bolts of tightening lock plate in main gearbox (Figure 3-29 circle shown), take off
the lock plate, bolt, padding block, interlocking plate of main and supplementary gearbox,
lock plate pad and spring, and then take off clamp spring outside of bearing on the two
supplementary axle by using spring pliers (see Figure 3-30).
15. Bring the two idle wheel forward by pin removal G06 (Figure 3-31), then in the far away
place of supplementary axle direction to dial idle wheel to leave the position of bearing on
supplementary axle to avoid scraping between bearing of supplementary axle and idle wheel
when split front and middle shells.
16. Unscrew bolt connected filter screen end cover of transmission, take off end cover and filter
screen (see Figure 3-33) to avoid filter and gear scraping when lift up the middle shell. Lift
up the middle shell of transmission by M12 bolt, lift down the middle shell and take off the
oil pipe 1 in the box (see Figure 3-34).
17. Use special tool G05 to dismantle the bearing on the two supplementary axles (see Figure
3-35), take off main axle and two supplementary axles (see Figure 3-36), and turn over the
front shell, dismantle input shaft assembly by copper bar or hammer. Notice: when
dismantle HW 20176 transmission assembly, input shaft assembly, supplementary axle
assembly, main axle assembly and fork axle assembly shall be dismantled at the same
time.
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).

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).
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.
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).
Right idle wheel only for Left idle wheel for fork axle of
dismantle and assembly uses range shift insert.
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:
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 G１5). 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, (for HW18709 、 HW18710 and HW14710 series
transmissions), 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, and (for HW 20716 series
transmission) the distance from the front end of the middle shell to the gear end of drive
gear (high) of main axle is 95.57±0.10 mm. The thickness of final-chosen main axle
adjustable washer shall be ensured the above-mentioned data.
For example: HW 18709 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 HW18709、HW18710 and HW14710 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.
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.
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).
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.

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、2-61、2-62、2-63). Notice: anything shall not drop into the middle shell.
Notice: interlocking plate, locking washer plate, locking pressure plate (large) of
HW18710、HW14710 series transmission are different from those of HW18709、
HW20716 series.
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.

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).
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.
○
11 Assemble 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.
○
12 Tighten 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).
Assemble of HW50 PTO
○
13 Put the needle bearing into the back end hole of input shaft of PTO, align with the inner
hole of spline on the right supplementary axle, and then assemble the input shaft of PTO to
the PTO hole of back shell (see Figure 3-74). Put the paper washer of end cover on output
shaft of PTO, O ring, and then put the front shell of PTO to its back shell, and its bolt
tightening torque is 73-89Nm (see Figure 3-75).
○
14 Lay grease on the combined face of front shell of PTO, and post PTO paper washer on the
front shell of PTO (see Figure 3-76), and then connect the back shell of PTO with the front
shell, the bolt tightening torque is 41-51Nm (see Figure 3-77).
Assemble method of HW70 is similar with the HW PTO; lay seal glue in the middle of front
and back shells of PTO, the most important is the glue shall be even to ensure the seal
interface not to be leak.
Other Parts Assemble.
○
15 Put the filter screen assembly, o ring, end cover of filter screen into the middle shell by bole,
the bolt tightening torque is 21-25Nm (see Figure 3-78), and then tighten the nut connected
middle and front shells in turn. Pay attention to install lifting plate (see Figure 3-79 arrowed
place).
○
16 Lay the transmission assembly on the plane ground by lifter, and pay attention to safety and
stability. Install the input shaft and stop ring of two supplementary axles (see Figure 3-80)
and its clamp spring (see Figure 3-81).
○
17 Measure the thickness of input shaft adjustable washer (there are 3 thickness of washers can
be chosen: 0.15、0.20、0.25). gently hit the end of input shaft by copper hammer, let the stop
ring of input shaft to be close to the end of front shell, and measure the distance from the
end of bearing of input shaft to front shell by depth rule, recorded as A (see Figure 3-82);
put the paper washer on the end cover of input shaft, and measure the distance from paper
washer to ring ridge of bearing, recorded as B (see Figure 3-83), and then choose the
adjustable washer which thickness is between B-A-0.1 and B-A.
○
18 Lay suitable grease on the middle of end cover of input shaft and paper washer, and put it
with chosen adjustable washer into the front shell by order; the thread of screw must be laid
Locitite 242 screw thread tightening glue on, its tightening torque is 41-51Nm (see Figure
3-84); put the end cover of supplementary axle, paper washer into the end of right
supplementary axle, and must lay Locitite 242 tightening glue on the bolt thread, its
tightening torque is 41-51Nm (see Figure 3-85).
○
19 Lay grease on the relevant combined interface of front shell, and after paper washer on end
cover of supplementary axle and paper washer of oil inlet align with the hole each other,
post them on the front shell. Install the drive top thread of oil pump into the hole of left
supplementary axle (see Figure 3-87 arrowed shown), top thread align with the gap of oil
pump (see Figure 3-87), and install the oil pump assembly (see Figure 3-88). Notice: there
are 3 kinds of oil pump tightening bolt with different length (including Figure 3-88, the bolt
5 is Q150B1040, bolt 6 is Q150B1090, and other bolt is Q150B1070), its thread must lay
Locitite 242 tightening glue and its torque is 41-51Nm, among them there are 2 bolts use
flat washer, and the screw shall be laid enough plane seal glue on the bolt (see Figure 3-88,
bolt 1 and bolt 4), others are spring washer.

○
20 Insert pipe 2 of gearbox (see Figure 3-89), connect all oil pipe assemblies, and the
tightening torque of hollow bolt is 50±10% N•M, the largest torque is not more than 60Nm
(see Figure 3-90).
○
21 Connect fork axle with bush assembly to the front shell (see Figure 3-91); put the fork axle
of clutch through the bush hole of front shell, and install flat key (see Figure 3-92), and then
pass split fork, fork axle carrier, and connect the split bearing at the same time and connect
left and right connection spring. After the fork axle of clutch turning agility, then fasten the
fork axle carrier; if turning not agility; gently strike the fork axle carrier. Notice: the screw
thread, connected the bolt of carrier of fork axle, must be laid Locitite 242 tightening glue
(see Figure 3-91), its tightening torque is 41-51Nm, and tightening bolt torque of split fork
axle of clutch is 21-25Nm, and the inner hole of complex bush must be laid on enough
grease.
○
22 Connect the low pressure oil pipe with the split bearing of clutch and front shell (see Figure
3-93), and install grease mouth (cup) on the front shell; fill enough grease into the split
bearing of clutch by the grease mouth (cup) (see Figure 3-94).
○
23 Install the paper washer and assembly of small housing onto the transmission assembly
which required shift choice agility. The connected bolt head shall lay Locitite 242 tightening
glue, and its torque is 41-51Nm (see Figure 3-95). Connect air pipe with the double H valve
and range shift cylinder, and pay attention to the air pipe connection not wrong (see Figure
3-96 arrowed place that is two closed end connections and two far end connections).
Hollow bolt torque is 42±10%N•M. Install the reverse switcher, neutral switch, pressure
switch of range shift on the small housing, and all the pressure switches torque is less than
35Nm (see Figure 3-96, the arrow directed places of 2, 3, 4, and 5 is reverse switcher,
neutral position switcher, range shift switcher and PTO switcher).
○
24 Install oil inlet pipe of supplementary gearbox and PTO oil Pipe, M16 hollow bolt torque is
50±10%N•M(see Figure 3-97). Examine the entire oil pipe to ensure there are not leak. Install
soft axle carrier (see Figure 3-98).
Air Piping Installation of Small Housing of HW18710 and HW14710
As Figures of 3-99、2-100 shown that installation of the air piping of small housing of
HW18710 is two close end connection and two far end connection.
After the transmission assembly installation, carefully examine the transmission and test the
signal condition of all the pressure switchers to ensure that there are not any wrongs, and
then equip it with the vehicle.
3 Assemble of HW20716 Transmission Assembly (Others as same as HW18709).
① Support the front shell by soft material and pay attention to leave the position of input shaft
and ensure the position is safety and reliability. Put station on the hole of input shaft of front
shell (see Figure 3-101); put the input shaft assembly (see Figure 3-102) into the hole of
front shell, and install the synchronizing slip bush and make the center of sector gap of
inner ring align with the small open groove of input shaft (see Figure 3-103); put the spring
of ejector pad into the outside spring, and then install the two pieces to the synchronizing
ejector pad and locating (totally three groups, see Figure 3-104), meanwhile, install the
three pieces into the small open groove of input shaft. In addition, on the other side of arrow
directed place, screw a M16 hollow bolt (see Figure 3-101).
② Put the synchronizing ring on the input shaft; let the large bulges station of synchronizing
ring align with the large open groove of input shaft(see Figure 3-105); install the main axle
assembly into the guide bush hole in back end of input shaft (see Figure 3-107).
③ Put the fork swing block into the hole of insert and split shift fork (see Figure 3-106), and
let the fork swing block inset the synchronizing slip bush, and install insert and split shift
fork axle into the correspond hole of front shell and locating. Assemble three- and four-shift
gear, one- and two-shift gear assembly in turn, and let the fork insert into the groove of
main axle slip bush (see Figure 3-108).

④ Put the reverse shift slip bush onto the top end of main axle, and pay attention to the hex
key position. The thicker side of reverse shift slip bush is adown; install the reverse shift
fork axle to its position, and let fork insert into the groove of slip bush, and fork axle insert
into the correspond hole of front shell (see Figure 3-109).
Figure 3-109
⑤ Draw a symmetry line on the top of the gear of drive gear (low) of input shaft (see Figure
3-110). Draw a line along the direction of long flat key of supplementary axle in the two
supplementary axle assemblies (see Figure 3-111, gap directed by left arrow and circle), and
then install the supplementary axle bearing, and pay attention to the stop groove on the
bearing is toward outside, for being convenient to install stop ring in the front shell.
Figure 3-110 Figure 3-111 Figure 3-112

⑥ Put the two supplementary axles onto the bearing holes of front axle, let the gear top which
marked by line on the (low) drive gear of supplementary axle engage to the gear groove
marked by line on two teeth of gear on input shaft, and then pull out the station (see Figure
3-112), and pay attention to the position of left and right supplementary axles shall not be
wrong (there is spline groove on the end of right supplementary axle assembly to cooperate
with the PTO spline axle, such as Figure 3-113, the arrow directed place is right
supplementary axle assembly). Install input assembly, main axle assembly and two
supplementary axles to its positions.
Figure 3-113 Figure 3-114 Figure 3-115
⑦ After the axle assembly installation, dial the main axle slip bush to the neutral position, and
dial the insert and split shift to low or high shift position, and then turn the two
supplementary axle assemblies to turning agility, and ensure tooth align correctness (see
Figure 3-114). Install pipe 1 of gearbox to its position (see Figure 3-115).
⑧ Lay Locitite 242 tightening glue on the thread hole on the middle shell connected with front
shell, install 25 double heads stubs and fasten them by wind trigger (notice: the double
heads shall not be installed in the thread hole connected with the oil pump), use copper
hammer hit the two locating spins into its positions. Lifting up the middle shell assembly
installed paper washer of front shell, align with the front shell (see Figure 3-116). Insert a
screwdriver from the hole of left idle wheel axle, so that the pipe 1 of main gearbox can be
guided into the hole of left idle wheel axle when the middle housing dropping down (see
Figure 3-117). Dial idle wheel and reverse gear of main axle, insert the fork axle to the hole
of fork axle on the middle shell, meanwhile, insert the locating pins and double heads stub
on the middle shell into the hole of correspond hole of front shell, and then assemble the
middle shell to its position.

Assemble Insert and Split Shift and Locking Device
① Install insert and split shift piston, and there are o rings inside and outside of piston (see
Figure 3-118). Before install the fastening nut, the thread shall be laid on Locitite 271
tightening glue (see Figure 3-119).
② Lay suitable grease on the inner wall of cylinder of insert and split shift and o rings (such as
Figure 3-120), put on paper washer and install cylinder of plug-in and split shift, and align
the air inlet hole of cylinder with the combined air hole of back shell (see Figure 3-120
arrow directed place), and then lay Locitite 242 tightening glue on the bolt thread, its
tightening torque is 41-51 Nm (see Figure 3-121).

③ Install locking top thread, locking spring and inner hex screw plug (see Figures 3-122,
3-123).

Others Assemble are as same as HW 18709 Series.
4. Assemble the Parts of Pull-type Clutch
① After lay suitable Locitite 242 tightening glue on the connected bolt, install the fork axle on
the front shell (such as Figure 3-124 shown).
② Let the fork axle pass the fork axle hole, split fork, fork axle carrier in turn and install flat
key on the top key groove and locating. Let the fork axle install to the bottom and another
end equipped with flat key.
③ Install the low end elastic ring of fork axle by use circlip pliers, and then fasten the two
bolts connected fork and fork axle (see Figure 3-127).
④ Install assist cylinder carrier, and finish the assembly of control device of pull-type clutch as
Figure 3-128 shown.
Figure 3-127
Section II Dismantle and Assemble of HW Series Transmission Axle

Assembly.
I. Dismantle of Axle Assembly (Supplementary Axle Needs not Dismantle,

Change the Supplementary Axle when it Repairing)
① Lift up the middle shell, and take off the main axle and fork axle. Punch the pins on fork
and fork block in turn by use punch nail (see Figure 3-129), and punch the pins out of its
position, and then finish the fork axle dismantle.
② Let the main axle in vertical condition, take off hex key, and turn the large barrier chip of
main axle. When the key groove aligns with the spline of main axle, the large barrier chip,
and reverse shift gear can be taken off. By this method, all the parts of the main axle can be
dismantled (see Figure 3-130).
③ Dismantle elastic barrier ring, input shaft bearing, spacer bush, gear elastic barrier ring, one
axle gear (reference the dismantle figure of input shaft in parts list). If only changing the
bearing of input shaft, the outside parts, such as separation bearing, oil pipe, end cover of
input shaft, stop ring, elastic barrier ring and others, only need to be dismantled. Use special
G08 to clamp the Snap ring groove of input shaft to dismantle the bearing of input shaft (see
Figure 3-131).
II. Axle Assembly Installation

1. Input shaft Assembly of HW18709、HW18710 and HW14710 Series Transmission
① Put elastic barrier ring for hole into one axle gear by circlip pliers (see Figure 3-132); install
input shaft bush into the inner hole of back end of input shaft and locating (see Figure
3-133).
② Put clamp spring of one axle gear belt, spacer bush, rolling bearing (notice: outside snap
ring groove of rolling bearing directs to the front of transmission), onto the input shaft, and
use special tool G10 to install rolling bearing to its position (see Figure 3-134); put elastic
barrier ring for axle use into the snap ring groove by circlip pliers, and pay attention that
there are more groups of barrier ring for axle use, and after elastic barrier ring for axle is
installed, it shall be ensured the distance between elastic barrier ring for axle and bearing is
less than 0.10mm (see Figure 3-135).
2. Input shaft Assembly of HW20716 Series Transmission.

① Install insert and split synchronizer cone hub onto the drive gear (low) assembly (see Figure
3-136); let the large bulges station of synchronizing ring is adown and insert to the large
open gar of the input shaft, and let the synchronizer cone hub is adown, then install the
drive gear (low) assembly and rolling bearing (notice: the outside snap ring groove of
rolling bearing shall direct the front of transmission), see Figure 3-137.
② Use special tool G10 to install rolling bearing to its position (see Figure 3-138); use circlip
pliers to put elastic barrier ring into the clamp spring groove of input shaft, and pay
attention that there are more groups of barrier ring for axle use, and after elastic barrier ring
for axle is installed, it shall be ensured the distance between elastic barrier ring for axle and
bearing is less than 0.10mm (see Figure 3-139).
3. Main Axle Assembly installation of HW18709 、 HW18710 and HW14710 Series

Transmission
① Put 2 elastic column pins to the bottom of pin hole of main axle (see Figure 3-140); put the
elastic barrier ring for hole use into the clamp spring grooves of three-shift gear, two-shift
gear, one-shift gear, creep-shift gear and reverse shift gear (see Figure 3-141) in turn by
using circlip pliers.
② Let the main axle vertically stand, firstly put the large barrier chip onto the main axle and
turning the half gear (use wood plug to insert to prevent it running more); the axle locating
between gears is as Figure 3-142 shown: spline adjustable chip can realize its locating by
turning half gear and passing hex key (can use punch to adjust the whole chip to drive the
half gear running); reference the locations of all parts in the parts explosive list Figure to
finish the main axle assembly installation. Adjust the axle clearance between gears, and the
axle clearance of three-shift gear and two-shift gear, one-shift gear and creep shift gear is
o.15-0.35mm, and reverse gear to large barrier chip of main axle is 0.30-0.50mm, its
measuring method is as Figure 3-143 shown, the measuring tool is clearance gauge, and pay
attention that hex key shall have installed 2 pieces.
4. Installation of Fork Axle

All kinds parts correspond positions of reverse shift fork axle assembly, one/two shift fork
axle assembly, three/four fork axle assembly, insert and split fork axle assembly can take
reference as explosive Figure of parts list shown. When installing pins of fork axle or fork
block, firstly put the pins in the symmetry position, then punch the two ends of pins off, and
pay attention to it shall be firm and stead to ensure that will not loose during using period
(see Figure 3-144).
5. Main Axle Assembly installation of HW20716 Series Transmission
① Put 2 elastic column pins to the bottom of pin hole of main axle (see Figure 3-145); put the
elastic barrier ring for hole use into the clamp spring grooves of drive gear (high) three-shift
gear, two-shift gear, one-shift gear, and reverse shift gear (see Figure 3-146) in turn by using
circlip pliers.
② Let the main axle vertically stand, firstly put the large barrier chip onto the main axle and
turning the half gear (use wood plug to insert to prevent it running more); then install the
drive gear (high) and spline barrier chip; choose suitable spline adjustable washer to ensure
the clearance from drive gear (high) to large barrier chip is 0.15-0.35mm. After that,
dismantle the drive gear (high), and put the insert and split cone-hub into the drive gear
(high) as Figure 3-147 shown, then put the chosen spline barrier chip and adjustable chip
together onto the main axle. spline adjustable chip can realize its locating by turning half
gear and passing hex key (can use punch to adjust the whole chip to drive the half gear
running); reference the locations of all parts in the parts explosive list Figure to finish the
main axle assembly installation. Choose suitable thickness of spline adjustable chip to
ensure the axle clearance of three-shift gear and two-shift gear is o.15-0.35mm, one-shift
gear and reverse gear is 0.30-0.50mm, its measuring method is as Figure 3-148 shown, the
measuring tool is clearance gauge, and pay attention that hex key (316 long) shall have
installed 2 pieces.
Section III Dismantle and Assemble the Supplementary Gearbox

Assembly of HW Series Transmission
I. Dismantle the Supplementary Gearbox Assembly

① Let the output flange upward, dismantle the large bolt, pressure plate (see Figure 3-149) and
use special tool G16 to dismantle the output flange (see Figure 3-150).
② Dismantle cylinder of range shift, piston (see Figure 3-151), end cover of output shaft (see
Figure 3-152, it has 8 fastening bolts).
③ Dismantle 2 support pins of fork axle (see Figure 3-153, the two arrows direct place), and
dismantle the bolt connected the torque drive chip with back shell (see Figure 3-154).
④ After dismantling the back shell of transmission, use special tool G03 to dismantle bearing
of planet carrier (see Figure 3-155). Turn over the planet device and use special tool G17 to
dismantle worm gear of odometer, rolling bearing (see Figure 3-156).
⑤ Keep suitable clearance between high shift cone-hub and synchronizing gear seat, and use
special tool G04 to dismantle high shift cone-hub (see Figure 3-157) and take off the
synchronizing ring; lift up synchronizing slip bush by two hands, and pay attention to not
lose and scattered ejector pad, inner and outside springs (see Figure 3-158).
⑥ Use circlip pliers to take off the elastic barrier ring clamped in the carrier of gear ring (see
Figure 3-159); use special tool G04 as Figure 3-157 shown to clamp the under part of
synchronizing ring (see Figure 3-160) and dismantle the synchronizing gear seat,
synchronizing ring and low shift cone-hub assembly.
⑦ Dismantle snap ring, bearing in the carrier of gear ring, and take off steel wire barrier ring,
inner gear ring (see Figure 3-161); the rest parts of planet carrier, input shaft and inner sun
wheel, planet wheel, washer and others need not to dismantle as a entire, called planet
device assembly (see Figure 3-162), and change it by a part when repairing.
II. Supplementary Assembly Installation of HW 18709 and HW20716 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 3-163, 3-164). For
supplementary gearbox assembly of HW20716 transmission, it also needs to put o ring
into the hole of fork axle of insert and split shift.
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 3-165) A, to back shell thickness B (see Figure 3-166), and
distance C from rolling bearing to oil guide ring (see Figure 3-167), 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 3-168).
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 3-169).
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 3-170); install the carrier of gear
ring into the inner gear ring, and clamp the steel wire barrier ring; (see Figure 3-171), use
punch to punch the steel wire barrier ring to its position (see Figure 3-172).
⑨ 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 3-174).
⑩ Use circlip pliers to install axle elastic barrier ring of synchronizing gear seat (see Figure
3-175); 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
3-176).
○
11 Firstly 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 3-177); 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 3-178).
○
12 Install 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 3-179); 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 3-179 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 3-180).
○
13 Use special tool G09 to install bearing of output shaft, worm ring of odometer to its
positions (see Figure 3-181); 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
3-182).
○
14 Lay 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 3-183); put the flange in its position, but before installing its position, the drive axle
shall connect with the bolt (see figure 3-184, 3-183).
○
15 Install pressure pate, large bolt in turn, and screw large bolt, its torque is less than 300Nm
(see Figure 3-186); 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 3-185).
○
16 Put 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 3-187).
○
17 Turn 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 3-188); lay
Locitite 271 glue on the connection bolt and screw it into the thread hole of torque drive
bush, its torque is 73-89Nm.
○
18 Put the front bearing of planet carrier to its bottom (see Figure 3-189); rivet 3 points on the
touching edge of planet carrier and bearing to prevent the bearing escaping outward (see
Figure 3-190).
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.
III. Supplementary Gearbox Assembly Installation of HW18710 Transmission

Compared with HW18709 transmission, the difference of supplementary gearbox of
HW18710 exists at:
① When installing torque drive bush, by longer torque drive bush joint the locking block of
range shift to back shell and torque drive plate together; lay Locitite 271 glue on the
connection bolt and screw it to the thread hole of torque drive bush, its torque is 73-89Nm
(see Figure 3-191); fork axle of range shift is with two grooves (see Figure 3-192).

② Put top thread, lock spring of range shift, hex screw plug fastening glue on its thread into the
hole of snap ring pad of range shift, and tighten it by inner hex wrench (such as Figures 3-193,
3-194 shown).
Section IV Dismantle the Small Housing Assembly of HW18709 and

HW20716 Series Transmission
I. Dismantle the Small Housing.
① Loose the locking nut on swing arm of shift, and dismantle shift swing arm and anti-dust
cover (see Figure 3-195); and dismantle all the pressure switchers, sensor end pins, double
H valves and air plugs (see Figure 3-196).
② Unscrew the connection bolt of end cover of small housing (swing arm side) and small
housing shell, take off the end cover of small housing (swing arm side), and no permit to
dismantle the oil seal of small housing end cover (swing arm side) and complex shim, and if
damaged, it needs destroyed dismantle and not damage the interface of the small housing
end cover (swing arm side) (see Figure 3-197); use punch to dismantle the connected elastic
column pin of sensor drive ring, take off sensor drive ring, sector locking block and drive
pin (see Figure 3-198).
③ Unscrew inner hex screw plug of two sides, take off seal ring, locking pin of range shift,
spring of range shift (see Figure 3-199), and dismantle bolt connected small housing end
cover (side of range shift) and small housing shell, take off small housing end cover (side of
range shift), centering spring (side of low shift), spacer ring, centering seat ring (see Figure
3-200).
④ Take off the needle of locking pin axle, and then the locking pin axle, locking spring (see
Figure 3-201); dismantle bowl-style shim, punch off the column pin connected shift head
and shift axle, and then take off shift axle assembly, shift head and interlocking fork (see
Figure 3-202).
⑤ Dismantle fastening bolt connected spacer bush and small housing shell, take off spacer
bush, centering seat ring, centering spring (high shift side) (see Figure 3-203); in generally,
the complex bush and bush on the small housing shell need not dismantle; if damaged, use
punch to punch it off, but not damage the small housing shell; after punch off the elastic
column pin connected locating spring of high and low shift and shift axle, the high and low
shift axle ring can be dismantled.
II. Installation of Small Housing Assembly
① Install the complex bush in the small housing end cover (swing arm side) (see Figure 3-204),
use special tool G11, G12 to install oil seal inside and outside of end cover (see Figure
3-205, 3-206, 3-207), and lay enough grease on the inner hole of complex bush, mouth of
oil seal.
② Put complex bush into the small housing shell and to its position (see Figure 3-208), 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 3-209).
③ Install centering spring (high shift side), centering seat ring (see Figure 3-210), spacer bush
(notice direction, see Figure 3-211) in the small housing shell; lay Locitite 242 fastening
glue on the thread of tightening bolt, screw the tightening bolt on the small housing shell
(see Figure 3-211 arrow directed place) to realize the spacer bush locating.
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 3-212, 3-213); 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 3-214).

⑤ Put locking spring into the locking spring hole of small housing shell, pass locking pin axle
(cone end outward) 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 3-215); install drive pin to its position, put on sector locking block
and let locking pin axle clamp to the groove of sector locking block; install sensor drive ring
(notice direction: HW18709 is as Figure 3-216 circle shown, HW20716 direction need
turning 180°around axle center of shift axle opposite to the Figure given direction), and
then locate it by use elastic column pin.
⑥ Lay 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 3-217); 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 3-218) is vertical to the surface of small housing.
⑦ Install locking pin, locking spring of range shift, inner hex screw plug on each side of small
housing shell, and screw inner hex screw plug (see Figure 3-219), install centering seat ring,
spacer ring, centering spring (low shift side) (see Figure 3-220), 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.
⑧ Install sensor top pin and pressure switch, its torque is not more than 35Nm (see Figure
3-221), each pressure switcher can take reference Figure 3-96; lay seal glue of bowl-style
shim, then install it to the hole on the small housing shell and ensure not oil leakage (see
Figure 3-222); if not installation shift-choice support axle, then install it.
⑨ Use connection bolt to install double H valve and paper washer onto the small housing shell,
its torque is 21-25Nm (see Figure 3-223).
Figure 3-223
After installation small housing assembly, test the shift gear and examine whether it is
reliable and returning normal or not.
Section V Dismantle the Small Housing Assembly of HW18710 and

HW14710 Transmission
I. Dismantle the Small Housing Assembly

① Loose locking nut on the shift swing arm, dismantle shift swing arm and anti-dust cover
(see Figure 3-224); dismantle pressure switcher, sensor top pin, air pipe, two five-way valve
assembly, cut-off valve, air plug (see Figure 3-225).
② Unscrew the bolt connected small housing end cover (swing arm side) and small housing
shell, take off small housing end cover (swing arm side), and oil seal and complex bush in
the small housing end cover (swing arm side) is not need to be dismantled; if it is damaged,
then need destroyed dismantle, but not permit to damage the interface of small housing end
cover (swing arm side) (see Figure 3-226); use punch to punch off elastic column pin
connected sensor drive ring, take off sensor drive ring, sector locking block and drive pin
(see Figure 3-227).
③ Dismantle the bolt connected small housing end cover (range shift side) and small housing
shell, take off small housing end cover (range shift side) (see Figure 3-228).
④ Take off rolling needle of the locking pin axle, then the locking pin axle and locking spring
(see Figure 3-229); dismantle bowl-style shim, and use punch to punch off the column pin
connected shift head and shift head (see Figure 3-230).
⑤ Dismantle spacer bush, shift axle assembly, fork, and interlocking fork in turn (see Figure
3-231); in generally, the complex bush and bush on the small housing shell need not
dismantle; if damaged, use punch to punch it off, but not damage the small housing shell;
dismantle clamp spring on the shift axle assembly by use circlip pliers, then the centering
ring and spring can be dismantled.
II. Installation of Small Housing Assembly

① Install complex bush in the small housing end cover (swing arm side) (see Figure 3-222),
use special tool G11, G12 to install oil seal on inside and outside end cover (see Figure
3-233, 3-234, 3-235).
② Install complex bush into the small housing shell and to its position (see Figure 3-236), 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 3-237).
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
3-238, 3-239).
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 3-240, 3-241); 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 3-242).
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; install drive pin to its position, put on
sector locking block and let locking pin axle clamp to the groove of sector locking block;
install sensor drive ring (notice direction: HW18709 is as Figure 3-244 shown), and then
locate it by use elastic column pin.

⑥ Lay 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 3-245); 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 3-246 inner circle part) is vertical to the surface of small
housing.
⑦ Put spacer bush on the side of small housing shell (see Figure 3-247), use bolt to connect
small housing end cover (range shift side) and small housing shell; put on single clamp
shim, and 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 3-248).
⑧ Install sensor top pin and pressure switch, its torque is not more than 35Nm (see Figure
3-249), each pressure switcher can take reference Figure 3-96; 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 3-250); if not installation shift-choice support axle, then install it.
⑨ Use connection bolt to install cut-off valve, two-position five-way valve assembly and paper
washer onto the small housing shell(see Figure 3-251,3-252), M4 bolt tightening torque is
2-3Nm, M6 bolt tightening torque is 9-11Nm, M8 bolt tightening torque is 21-25Nm .
⑩ Connect air pipe with cut-off valve and two-position five-way valve, the connection method
is as Figure 3-253,3-254 shown, and then screw the nut to ensure the joint not air leakage.
○
11 Use single clamp shim to fasten air pipe to its position as Figure 3-255 shown; and finished
small housing assembly is as Figure 3-256 shown.
Figure 3-256
After installation small housing assembly, test the shift gear and examine whether it is
reliable and returning normal or not.
Section VI Repairing Tool for HW Series Transmission
The maintenance tools, repairing HW series transmission made by Sinotruck, is supported by

Jinan Tanaka Commerce Co., Ltd., 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
Figure 1a: Flange Nut Labor-saving Wrench Figure 1b: Removal/Installation Operation of Flange
Nut Using the Labor-saving Wrench
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.
Figure 2a: Hanging Scaffold of Supplementary Gearbox Figure 2b: Lifting up the Transmission Assembly by
Hanging Scaffold.
Figure 2c: Lifting up and Dismantle Supplementary Gearbox by Hanging Scaffold
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).
Figure 3a: Extractor of Planet Supporter Bearing Figure 3b: Pull out of Planet Supporter Bearing by
Extractor.
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 4a: Extractor of High Shift Cone-hub Figure 4b: Use Extractor to Dismantle Synchronizer
High Shift Cone-hub or Synchronizer Gear Seat.
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.
Figure 5a: Extractor of Bearing on Auxiliary Shaft Figure 5b: Dismantle Front and Back Bearing
by Extractor.
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.
Figure 6a: Extractor of Idle Wheel Axle Figure 6b: Use Extractor to Dismantle
(Middle Axle of Reverse Shift) 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.
Figure 7a: Special Snap Ring Pliers Figure 7b: Dismantle and Install Snap Ring by Snap
Ring Pliers
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 (One Axle) Figure 8b: Dismantle Bearing of Input shaft (One Axle)
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).
Figure 9a: Install Tube Processor Figure 9b: Use Tube Processor to Install Planet
Supporter to its Position
Figure 9c: Use Tube Processor to Install Figure 9d: Use Tube Processor to
Bearing of Input shaft Install Odometer Worm

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)
Figure 11a: Press Plate of Output shaft Oil Seal Figure 11b: Install Output shaft Oil Seal by Using
Press Plate.
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.
Figure 12a: Punch Bar of Oil Seal in Small End Cover Figure 12b: Use Punch Bar to Install Interior Oil
Seal of Small End Cover
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.
Figure 13a: Punch Bar of Oil Seal in Small End Cover Figure 13b; Use Punch Bar to Install exterior
Oil Seal of Small End Cover
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.
Figure 14a: Tube Processor of Flange Nut Figure 14b: Use Tube Processor of Flange Nut to
Dismantle Extensive lever
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.
Figure 15a: Measuring Plate Figure 15b: Use Measuring Plate to Measure the
Adjustable pad Thickness of Main Axle.
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.
Figure 17a: Extractor of Output shaft Bearing Figure 17b: Dismantle Output shaft Bearing by
Extractor.
Important Points of this Chapter.

Master the repairing methods and notices of HW18709、HW18710、HW14710、HW20716 series
transmissions, comprehend all different structure and principles of HW series transmissions and its
repairing tools and application methods.
Exercises:
1． What’s requirements when assemble end cover of auxiliary axle, end cover of input shaft,
oil pump assembly, and if not according to these requirements, what’s the caused results?
2． What are the Mechanic lubrication parts in HW transmission? and description the oil route.
3． Before dismantle supplementary gearbox assembly, what shall be noticed?
4． Why need add locking device of range shift in supplementary gearbox of HW18710 series
transmission? And which parts included in the locking device?
5． What problems shall be noticed when assemble the supplementary gearbox?
6． Why need to carry on the measurement of adjustable pad of main axle? Which parts needs
to be re-measured when they are changed? What caused result when not measuring or
measuring not precise?
7． Description the measuring method of adjustable pad of main axle.
8． Why double supplementary axle structure needs align to teeth? How to align? What’s result
if wrong align to teeth?
9． Why firstly screw a M16 hollow bolt in the bottom of the front housing before installing HW
transmission assembly?
10． What’s difference from (left) supplementary axle and (right) supplementary axle? What’s
use for its structure?
11． What special structure adopted by Fuller transmission for PTO in neutral position? Is there
this special structure in the HW transmission for PTO in neutral position?
12． What difference of interlocking device of main gearbox and supplementary gearbox of
HW18710 from HW18709?
13． How to adjust the adjustable pad of input and output shaft? What’s advantage to adjust the
shim?
14． What’s the axial clearance between each gear of main axle assembly of HW transmission?
15． What are the kinds of adjustable pad of HW transmission? And description them.
16． What are the requirements when assemble cylinder of range shift and insert and split
cylinder?
17． Why lay grease on the open mouth of oil seal when it installing?
18． What are the requirements when installing the sensor drive ring? Why HW18710 is
different from HW 20716?
19． What are the repairing tools and methods of HW series transmission?
HW Series Transmission
Part Two
(Chapter One and Two Includes Secondary Contents;

Chapter Three and Four Includes Third Level Contents)
Chapter I Operation of HW Series Transmission
Requirements
Understand the operating requirements and precautions of HW series transmission
Section I Operation & Maintenance of HW Series Transmission
Correct operation and periodical proper maintenance of the transmission is of great importance to
drive safely and reliably, and can prolong service life of transmission. Please abide by the
following operating requirements:
1. Lubricating oil grade
Only automobile gear oil 85W/90GL-4 or 85W/90GL-5, made by China National Heavy
Duty Truck Group Co., Ltd (CNHTC) can be injected into the transmission.
2. Correct injection of lubricating oil
① Correct oil level
Make sure that the oil level is even with the oil port. Check the oil level from the oil
port at the side of housing. Oil rejection is finished when the oil is injected up to the
hole and overflowed
② Check oil level
Oil level should be checked periodically. The car should be parked on horizontal road
and the oil shouldn’t be checked within half an hour after the car parked.
3. Lubricating oil charging
Check lubricating oil level and for leakage frequently and charge it when necessary. Keep
the same lubricating oil grade as the original to prevent chemistry reaction of different
lubricating oils.
4. Periodical change of the lubricating oil
Drain all lubricating oil in the transmission completely and clean the filter assembly before
changing lubricating oil. Change lubricating oil after driving 2000 to 4000 km of a new
transmission.
Lubricating oil of road vehicle for good driving conditions is suggested to be changed after
driving 2000 km; and that of off-road vehicle for bad driving conditions is suggested to be
changed after driving 1000 km.
Section II Operation Precautions of HW Series Transmission
Operating requirements and precautions of HW series transmission are as follows:

1. When shifting gears, the clutch must be released completely and the shift lever must be set
in gear exactly.
2. The shift lever consists of two neutral gears: the high gear and the low gear. The shift lever
should be set at the neutral gear of the low gear when the vehicle is parked.
3. Park the car before setting the vehicle in gear when the gear needs to be set at the lower
position (creeper speed) or reverse gear to prevent parts damage in transmission. When
setting the reverse gear, exert comparatively heavier gear selecting force to overcome the
resistance of reverse gear lock.
4. Going down a steep slope, the driver mustn’t gear up and down of the vehicle.
5. Choose creeper speed, the first gear or the second gear when starting vehicle according to
the actual road conditions.
6. The vehicle can’t be set in gear and started until the pressure rises to the setting value and
release the brake.
7. Park the vehicle as soon as unmoral symptoms found such as, abnormal noise from
transmission, obvious inflexible operation in driving and others. Drive on when all faults
have been removed.
8. When shifting gears, if the gear can’t be set at the right position, check cylinder and its air
circuit parts to ensure the auxiliary gearbox is set at the right position.
9. When towing or gliding, pay attention to the followings:
① When the vehicle is gliding at the neutral gear, the clutch must not be engaged.
② When the vehicle is towing, the transmission shaft should be detached.

10 Operating temperature of transmission
The transmission’s continuous operating temperature should be not less than -40℃ and not
more than 120℃ If the operating temperature is higher than 120℃, the lubricating oil may
break up and the service life of transmission shortened. The following conditions may result
in over high temperature of transmission:
z Oil level is over high or over low, or the oil grade is incorrect
z Drive up a slope greater than 12° continuously
z Drive a long distance at a low speed
z Motor speed is too fast
z Air circulation around the transmission is poor
z Ambient temperature is over high
z Vehicle is overloaded or overspeeded
11. Transmissions that are within warranty period are not allowed to be detached or modified freely.
Section III Operation of HW Power Takeoff
1. Classification of HW power takeoff

Table 1-1 Parameters of Power Takeoff
Type HW50 HW70
Rated output torque Nm 500 700
Rated input rotational speed rpm 2600
Installation position At the back of and top right corner of the transmission
Output steer The same rotational direction as the engine
Structure Pneumatic control (Single-acting cylinder)
Operating air pressure 0.5～0.8MPa
Speed ratio 0.74 0.76
Torque extraction type Extracting torque at the right countershaft in main tank of
HW transmission
2. Operation of HW power takeoffs
Set the control lever of transmission in neutral gear, engage the clutch, connect the switch of
the power takeoff which should be kept in gear, loosen the clutch slowly and then the power
takeoff starts working.
Key points in the chapter:
Operating requirements and precautions of HW series transmission; operation of HW power
takeoffs
Exercises:
1. Why proper measures should be taken to HW series transmissions in the housing of trailer?
If not, what will happen?
2. In what housings may the temperature of transmission become too high?
3. Why trip jump is not allowed when change the transmission from the low gear to the high
(vice versa)?
4. Whether or not changing gears is allowed when the vehicle is going down a slope?
5. How to operate the HW power takeoff?
Chapter II Spare Parts Manual of HW Series
Transmission
Requirements
Understand types of HW series transmissions and common transmission serial numbers; know the
differences in structures of various transmissions; master the skill of looking up required parts in
spare parts manual.
Section I Contents of HW Series Transmission Assembly
By the end of October 2008, Contents of HW series transmission assembly are:

I. HW18709 Transmission Assembly
Figure 2-1 Content of HW18709 Transmission Assembly
No. S/N. Name
1 HW18709071001 9-shift transmission (pull-type, double lever, XS180)
2 HW18709071002 9-shift transmission (push-type, single lever, XS180)
3 HW18709071003 9-shift transmission (pull-type, single lever, XS180)
4 HW18709071004 9-shift transmission (push-type, single lever, power takeoff)
5 HW18709071005 9-shift transmission (pull-type, single lever, XS180, power takeoff)
6 HW18709071010 9-shift transmission (push-type, double lever, XS180)
7 HW18709071011 9-shift transmission (push-type, double lever, XS180, power takeoff)
8 HW18709071012 9-shift transmission (pull-type, double lever, XS180, power takeoff)
9 HW18709080101 9-shift transmission (push-type, single lever, XS180,for Frame 780)
9-shift transmission (push-type, single lever, XS180, power takeoff,
10 HW18709080102
for Frame 780)
9-shift transmission (push-type, single lever, XS180, HW70 power
11 HW18709080501
takeoff)
9-shift transmission (pull-type, single lever, XS180, HW70 power
12 HW18709080502
takeoff)
9-shift transmission (push-type, double lever, XS180, HW70 power
13 HW18709080505
takeoff)
14 HW18709080506
takeoff)
15 HW18709080509
takeoff ,for Frame 780)
9-shift transmission (pull-type, double lever, XS180, HW70 power
16 HW18709080519
takeoff, electromagnetic sensor)
17 HW18709080520
9-shift transmission (pull-type, double lever, XS18, electromagnetic
18 HW18709080702
sensor)
9-shift transmission (push-type, double lever, XS180, electromagnetic
19 HW18709080703
sensor)
II. HW18710 Transmission Assembly
Figure 2-2 Contents of HW18710 Transmission Assembly
No. Drawing No. Name
4 HW18710080314 10-shift transmission (pull-type, double lever, XS180, power takeoff)
7 HW18710080317 10-shift transmission (push-type, single lever, XS180, power takeoff)
9 HW18710080515
takeoff)
10 HW18710080516
takeoff)
11 HW18710080517
takeoff)
12 HW18710080518
takeoff)
10-shift transmission (pull-type, double lever, XS180,
13 HW18710080701
electromagnetic sensor)
10-shift transmission (push-type, double lever, XS180,
14 HW18710080704
15 HW18710080901 HW18710 transmission (14.28, push-type, double lever, XS180)
16 HW18710081010 HW18710 transmission (14.28, pull-type, double lever, XS180)
HW18710 transmission (14.28, push-type, double lever, XS180,
17 HW18710081011
HW50 power takeoff)
HW18710 transmission (14.28, pull-type, double lever, XS180,
18 HW18710081012
HW50 power takeoff)
19 HW18710081013
HW70 power takeoff)
20 HW18710081014
HW70 power takeoff)
21 HW18710081015
22 HW18710081016
23 HW18710081017
HW50 power takeoff, electromagnetic sensor)
24 HW18710081018
25 HW18710081019
26 HW18710081020
27 HW18710081021 HW18710 transmission (14.28, push-type, single lever, XS180)
28 HW18710081022 HW18710 transmission (14.28, pull-type, single lever, XS180)
HW18710 transmission (14.28, push-type, single lever, XS180,
29 HW18710081023
HW50 power takeoff)
HW18710 transmission (14.28, pull-type, single lever, XS180, HW50
30 HW18710081024
power takeoff)
31 HW18710081025
HW70 power takeoff)
32 HW18710081026
power takeoff)
33 HW18710081027
HW18710 transmission (14.28, pull-type, single lever, XS180,
34 HW18710081028
35 HW18710081029
36 HW18710081030
power takeoff, electromagnetic sensor)
37 HW18710081031
38 HW18710081032
HW18710 transmission (14.28, push-type, single lever, XS180, for
39 HW18710081107
Frame 780)
40 HW18710081108
HW50 power takeoff, for Frame 780)
41 HW18710081109
HW70 power takeoff, for Frame 780)
Note: the first 14 types in the above table are the first series of HW18710, and others are the
second series of HW18710 with a speed ratio of 14.28.
III. HW20716 Transmission Assembly
Figure 2-3 Contents of HW20716 Transmission Assembly
3 HW20716071033 16-shift transmission (push-type, single lever, XS180, power takeoff)
9 HW20716A080401 16-shift transmission (pull-type, XS180)
10 HW20716A080402 16-shift transmission (pull-type, XS180, power takeoff)
11 HW20716080510
takeoff)
12 HW20716080511
takeoff)
13 HW20716080512
takeoff)
14 HW20716080513
takeoff)
16-shift transmission (pull-type, single lever, XS180, electromagnetic
15 HW20716080601
sensor)
16 HW20716080602
takeoff)
17 HW20716080603
18 HW20716X080812 16-shift transmission (pull-type, double lever, XS180, overdrive gear)
IV HW14710 Transmission Assembly
Figure 2-4 ontent of HW14710 Transmission Assembly
1 HW14710080710 HW14710 transmission (push-type, double lever, XS180)
2 HW14710081001 HW14710 transmission (pull-type, double lever, XS180)
HW14710 transmission (push-type, double lever, XS180, HW50
3 HW14710081002
power takeoff)
4 HW14710081003 HW14710 transmission (pull-type, double lever, XS180, HW50
power takeoff)
5 HW14710081004
power takeoff)
HW14710 transmission (pull-type, double lever, XS180, HW70
6 HW14710081005
power takeoff)
7 HW14710081006
power takeoff)
8 HW14710081007
9 HW14710081008
10 HW14710081009
HW14710 transmission (push-type, double lever, XS180,
11 HW14710081010
HW14710 transmission (pull-type, double lever, XS180,
12 HW14710081011
13 HW14710081012 HW14710 transmission (push-type, single lever, XS180)
14 HW14710081013 HW14710 transmission (pull-type, single lever, XS180)
HW14710 transmission (push-type, single lever, XS180, HW50
15 HW14710081014
power takeoff)
HW14710 transmission (pull-type, single lever, XS180, HW50 power
16 HW14710081015
takeoff)
17 HW14710081016
power takeoff)
18 HW14710081017
takeoff)
19 HW14710081018
20 HW14710081019
21 HW14710081020
22 HW14710081021
HW14710 transmission (push-type, single lever, XS180,
23 HW14710081022
HW14710 transmission (pull-type, single lever, XS180,
24 HW14710081023
25 HW14710081101 HW14710 transmission (fine pull-type, double lever, XS180)
HW14710 transmission (fine pull-type, double lever, XS180, HW50
26 HW14710081102
power takeoff)
HW14710 transmission (fine pull-type, double lever, XS180, HW70
27 HW14710081103
power takeoff)
HW14710 transmission (push-type, single lever, XS180, for Frame
28 HW14710081104
780)
29 HW14710081105
power takeoff, for Frame 780)
30 HW14710081106
power takeoff, for Frame 780)
Section II Spare Parts Manual of HW Series Transmission
Assembly
I. Operating accessories of the clutch and other parts in front housing

1. Operating accessories of push-type clutch
Figure 2-5 Operating Accessories of Push-type Clutch

No. Drawing No. Name Quantity Remarks
1 Q150B1030 Hexagon bolt 4
2 Q40310 Spring washer 4
3 WG2222000001 Auxiliary shaft end cap 1
4 WG2229000002 Auxiliary shaft end cap gasket 1
5 AZ9003990100 Retaining ring 100/106.5-GB305 1
6 199000210053 See 880 280030 for the low-pressure hose 1
7 190003962607 Hollow bolt 1
8 Q72310 Seal washer 2
Before modified:
9 AZ2209260005 Release bearing assembly of the clutch 1
WG9012210078
Note: modified release bearing assembly of the clutch should be applied together with the release
fork.
2. Other parts in front housing (push-type)
Figure 2-6 Other Parts in Front Housing (Push-type)
1 AZ9003338000 Steel ball 8.000G200b GB308 1
3 WG2229000002 Auxiliary shaft end cap gasket 1
4 Q5510825 General flat key 1
5 WG1610326003 Declutch shift shaft assembly 1
6 AZ2222240001 Oil pump body 1
7 AZ2210240001 Drive gear of oil pump 1
8 AZ2210240002 Internal gear ring of oil pump 1 Oil pipe assembly
9 AZ2222240002 End cap of oil pump 1 WG2203240005
Q150B0618 Hexagon bolt 2
17
Q40306 Spring washer 2
Oil inlet pipe assembly of tank Aluminium oil pipe
10 AZ2203240003 1
body AZ2203240013
Oil inlet pipe assembly of input Aluminium oil pipe
11 AZ2203240002 1
shaft AZ2203240012
Aluminium oil pipe
12 AZ2203240001 Oil outlet pipe assembly 1
AZ2203240011
13 AZ9003961670 Hollow bolt 1
Washer for aluminium
14 Q72316 Seal washer 10 oilpipe
WG9004130016
15 190003962627 Hollow bolt 3
Q40110 Flat washer 2
18 WG2229240003 Paper washer for oil inlet pipe 1
19 Q341B10 Hexagon bolt, type 1-fine pitch 25
Before modified:
AZ2214260005 Clutch release fork 1
199100230024
Left handed snap spring of release
23 AZ2214260010 1 Modified parts
bearing
Right-hand snap spring of release
AZ2214260015 1 Modified parts
bearing
24
Declutch shift shaft bracket
AZ2203260101 1 Assembly, detachable
assembly
26
AZ2229260101 Declutch shift shaft bracket 1
WG2229002520 Composite bush SF2 25×28×20 1
Input shaft end cap and oil-guiding
27 AZ2203020106 1 Assembly, detachable
ring assembly
Before modified:
Metric tape screw thread grease
28 190003963127 1 grease cup 12700
nozzle
060125
29 WG2229000003 Lifting plate 1
AZ2208020002 Adjust shim group of input bearing 1
WG2229020011 Adjust shim, thickness: 0.15
30 As
WG2229020012 Adjust shim, thickness: 0. 20
required
WG2229020013 Adjust shim, thickness: 0. 25
Paper washer for input shaft end
32 WG2229020008 1
cap
Note: 1) Modified clutch release fork should be applied together with modified clutch release
bearing.
2) Aluminium oil pipe should be applied together with washer WG9004130016.
3) When the grease cup is broken, replace it with metric tape screw thread grease
nozzle.
3. Operating accessories of pull-type clutch (omit the same parts as push-type)
Figure 2-7 Operating Accessories of Pull-type Clutch

WG2214260001 Clutch release fork 1 For general pull-type
1
WG2214260004 Clutch release fork 1 For fine pull-type
For HW18709,
HW18710 and
3 WG2203260006 Declutch shift shaft assembly 1
HW14710, replacing
AZ2203260002
For HW20716,
WG2203260007 Declutch shift shaft assembly 1 replacing
AZ2203260005
9 AZ2229260015 Bracket 1
10 AZ2229260001 Declutch shift shaft bracket 1
12 Q43130 Circlip for shaft 1
Composite bush (DX) 30×34×30
13 WG2229003030 1
Composite bush
Hexagon bolt Q150B1062
AZ9003801062 3
14 Hexagon bolt
Inner hexagon socket set screw
15 Q2881016F9 2
with cone point
Note: Declutch shift shaft assemblies AZ2203260002 and AZ2203260005 must be replaced to the
corresponding one during prophase to prevent pull-type declutch shift shaft assembly breaking at
the swing arm weld joint.
4. Input shaft end cap & oil-guiding ring assembly
AZ2203020106, used for push-type assembly of HW series transmission

Steel ball 5.500G200b Consisting of end cap
1 AZ9003335500 1
GB308 assembly of input shaft
2 WG2222020101 Input shaft end cap 1 AZ2203020102
3 AZ9003070055 Framework oil seal 1
4 WG2229020007 Oil-guiding ring 1
AZ2203020108, used for pull-type assembly of HW series transmission, details are as follows:
1 AZ9003335500 Steel ball 5.500G200b GB308 1 Consisting of end cap
assembly of input shaft
2 WG2222020001 Input shaft end cap 1
AZ2203020002
3 AZ9003070055 Framework oil seal PS 55 75 12 1
AZ2203020109, used for fine pull-type assembly of HW series transmission, details are as
follows:
Steel ball 5.500G200b Consisting of end cap
1 AZ9003335500 1
GB308 assembly of input shaft
2 WG2222020011 Input shaft end cap 1 AZ2203020002
Framework oil seal PS 55 75
3 AZ9003070055 1
12
II. Small cover assembly and auxiliary gearbox assembly are mounted on the
transmission assembly
1. Installation of small cover and auxiliary gearbox assembly for HW series transmission
Figure 2-8 Installation of Small Cover & Auxiliary gearbox Assembly

1
AZ2203210101 Small cover assembly (single lever) 1 Small cover
AZ2203210102 Small cover assembly (double lever) 1 assembly, detachable
AZ2203210015 Small cover assembly (double lever) 1 Small cover
2
AZ2203210016 Small cover assembly (single lever) 1 assembly, detachable
AZ2203210005 Small cover assembly (single lever) 1 Small cover
AZ2203210001 Small cover assembly (single lever) 1 assembly, detachable
3 WG2229210025 Paper washer for small cover 1
4 WG2229100062 Paper washer for auxiliary gearbox 1
Parts of HW18709,
WG2229240108 In-box pipe 2 1 HW18710 and
5
HW14710
WG2229240008 In-box pipe 2 1 Parts of HW 20716
Range gear of auxiliary gearbox
AZ2203100015 1
assembly
AZ2203100016 1
assembly (with extracting torque) HW18709 auxiliary
Range gear of auxiliary gearbox gearbox assembly,
AZ2203100017 assembly (with extracting torque 1 detachable
6
electromagnetism)
AZ2203100021 1
assembly (electromagnetism)
Range gear of auxiliary gearbox HW18710 auxiliary
AZ2203100040 1
assembly gearbox assembly,
AZ2203100041 Range gear of auxiliary gearbox 1 detachable
assembly (with extracting torque)
AZ2203100042 1
AZ2203100043 assembly (with extracting torque 1
electromagnetism)
AZ2203100044 1
assembly
AZ2203100045 1
assembly (with extracting torque)
Range gear of auxiliary gearbox 1
AZ2203100046
electromagnetism)
AZ2203100001 1
assembly
AZ2203100011 1
assembly (with extracting torque) HW20716 auxiliary
Range gear of auxiliary gearbox gearbox assembly,
AZ2203100018 1
assembly (electromagnetism) detachable
electromagnetism)
8 WG2229240010 Bush 1
Oil inlet pipe assembly of auxiliary
9 WG2203240004 1
gearbox
10 AZ9003961650 Hollow bolt 1
11 190003962627 Hollow bolt 1
12 Q5280514 Elastic cylindrical pin 1
13 WG2229100074 Locking plate 1
14 WG2229100073 Bolt 1
15 WG2229100072 Press plate 1
16 WG2229100071 Plugging 1
17 AZ9003073150 O ring 35503150 1
18 WG2229100011 Set screw nut 1
Mounted on the
19 179100710069 Pressure switch (KOSTAL Factory ) 1 cylinder of insert
gear and range gear
20 WG2229280001 Seal washer 1
21
AZ9003801058 Hexagon bolt 2
22 WG2229100061 Lifting plate 1
23 AZ2208040002 Adjust shims of main shaft 1
WG2229040031 Adjust shim of main shaft Thickness: 5.25
WG2229040034 Adjust shim of main shaft As Thickness: 5.70
WG2229040035 Adjust shim of main shaft required Thickness: 5.85
24 190003962621 Hollow bolt 4 Parts of HW18709
26 Q72314 Seal washer 8 and HW20716
24 190003962621 Hollow bolt 2 Parts of HW18710
26 Q72314 Seal washer 4 and HW14710
Range gear (low gear) air pipe
25 WG2203250007 1
assembly
Parts of HW 18709
Range gear (high gear) air pipe
WG2203250008 1
assembly
WG2203250005 1
assembly
Parts of HW20716
Range gear (high gear) air pipe
WG2203250006 1
assembly
WG2203250012 1
assembly Parts of HW18710
Range gear (high gear) air pipe and HW14710
WG2203250013 1
assembly
2. Insert gear cylinder and self-locking mechanism of HW20716 (omit the same parts as
HW18709)
Figure 2-9 Insert Gear Cylinder & Self-locking Mechanism of HW20716

Hexagonal socket head plug
10 AZ9003960004 1
DIN908-M16×1.5
12 WG2229210019 Range gear locking spring 1
13 AZ9003331349 Steel ball 13.4938 G200b GB308 1
19 AZ9003075450 O ring 53005450 GB3452.1 1
Replacing
20 WG2229230005 Insert gear plunger 1
WG2229230002
21 AZ9003071700 O ring 26500170 GB3452.1 1
22 AZ9003870016 Hexagon nut M16×1.5 1
Before modified
23 AZ2222230003 Insert gear cylinder 1
AZ2222230001
26 179100710069 Pressure switch (KOSTAL Factory ) 1
36 AZ2229230004 Paper washer for insert gear cylinder 1 Before modified
Note: 1) Insert gear plunger WG2229230005 and WG2229230002 can be used universally.
2) The rear housing of transmission AZ2220100005 (with inner flange) should be
applied with insert gear cylinder AZ2222230001 and paper washer AZ2229230003
for insert gear cylinder; the rear housing of transmission AZ2220100005 (with inner
flange) should be applied with insert gear cylinder AZ2222230003 (with outer flange)
and paper washer AZ2229230004 for insert gear cylinder.
III. Main & Auxiliary gearbox Interlocks
Figure 2-10 Main & Auxiliary gearbox Interlocks

3 WG2010310012 Spring locating pin assembly 1
4 WG2229100056 Lock plate fulcrum pin 1
Parts of HW18709 and
WG2229100055 Bearing plate for lock plate 1
HW20716
5
WG2229100175 Bearing plate for lock plate 1
HW14710
6 WG2212050102 Idler shaft (right) 1 Parts of HW18709,
HW18710 and
7 WG2212050101 Idler shaft (left) 1
HW14710
6 WG2212050001 Idler shaft (right) 1
Parts of HW20716
7 WG2212050002 Idler shaft (left) 1
Main and auxiliary gearbox interlock Parts of HW18709 and
WG2229100051 1
plate HW20716
8
Main and auxiliary gearbox interlock Parts of HW18710 and
WG2229100173
plate HW14710
WG2229100053 Press plate for lock plate (big) 1
HW20716
9
WG2229100174 Press plate for lock plate (big)
HW14710
10 WG2229100054 Spacer block for hold-down plat 5
11 WG2229100052 Press plate for lock plate (small) 1
Note: Main and auxiliary gearbox interlocks HW18710 and HW14710 are the same, as well as
main and auxiliary gearbox interlocks HW18709 and HW20716; main and auxiliary gearbox
interlocks of HW10 gear box should be able to lock declutch shift shaft of reverse–creeper gear.
V. Main Transmission
1 Main transmissions HW18709, HW18710 and HW14710
Figure 2-11 Main Transmissions HW18709, HW18710 and HW14710

HW18709, HW18710,
AZ2220000101 Front housing of transmission 1
HW14710 Push-type
1
Pull- type HW series
AZ2220000001 Front housing of transmission 1
transmission
Pad for front housing of
2 WG2229000001 1
transmission
Used for HW18709,
Declutch shift shaft assembly of
3 AZ2203220103 1 HW18710 and HW14710,
the third and forth gear
detachable
4 AZ2203220102 Declutch shift shaft assembly of 1 Used for HW18709,
the first and second gear detachable
Declutch shift shaft assembly of Used for HW18710 and
AZ2203220010 1
the first and second gear HW14710, detachable
Used for HW18709,
Declutch shift shaft assembly of
5 AZ2203220101 1 HW18710 and HW14710,
reverse and creeper gear
detachable
Used for HW18709,
AZ2203030102 Countershaft assembly (right) 1
detachable
Used for the first series of
HW18709, detachable
6
Used for the second series
of HW18709, detachable
Used for HW14710,
detachable
7 WG2229050001 Washer 4
Used for HW18709 and
WG2210050001 Idle wheel 2
8 HW18710
WG2210050301 Idle wheel 2 Used for HW14710
9 AZ9003320309 Cylindrical roller bearing 2
Intermediate housing assembly Used for HW18709,
AZ2203010101 1
of transmission detachable
10
Counter housing assembly of Used for HW18710 and
AZ2203010005 1
transmission HW14710, detachable
13 WG2222240005 Strainer end cap 1
14 AZ9003077100 O ring 26507100 1
15 AZ9003070085 O ring 26500850 2
16 WG2203240007 Strainer assembly 1
Used for HW18709,
AZ2203040101 Main shaft assembly 1
detachable
HW18710, detachable
18
Used for HW14710,
detachable
19 AZ9003395320 Needle bearing 4
Used for HW18709,
AZ2203030101 Countershaft assembly (left) 1
detachable
HW18710, detachable
20
Used for HW14710,
detachable
21 WG2229240107 In-box pipe 1 1
Used for push-type of the
Input shaft and first-shaft gear
AZ2203020105 1 first series of HW18709
assembly
and HW18710, detachable
22 Used for pull-type of the
AZ2203020107 1 first series of HW18709,
assembly
HW18710, detachable
AZ2203020205 Input shaft and first-shaft gear 1 Used for push-type of the
assembly second series of
HW18710, detachable
Used for pull-type of the
AZ2203020206 second series of
assembly
HW18710, detachable
Used for push-type and
AZ2203020305 1 fine pull-type of
assembly
HW14710, detachable
Input shaft and first-shaft gear Used for pull-type of
AZ2203020307
assembly HW14710, detachable
Push-type assembly of
WG2229002520 Composite bush 1
HW18709 and HW18710
23
WG2229003030 Composite bush 1 Pull-type assembly of HW
AZ9003073001 Framework oil seal PS 30 45 8 1 series transmission
Note: refer to specifications for the dividing of 2 series of HW18710 transmission; the second
series are those with a speed ratio of 14.28, and the remaining are the first series.
2. Main transmission of HW20716 (omit the same parts as HW18709)
Figure 2-12 Main Transmission of HW20716

4 AZ2203220003 Declutch shift shaft assembly of 1
the third and forth gear
the first and second gear
6 AZ2203220001 Reverse-gear declutch shift shaft 1
assembly
7 AZ2203030002 Countershaft assembly (right) 1
11 AZ2203010001 Intermediate housing assembly 1
of transmission
20 AZ2203040001 Main shaft assembly 1
21 AZ2203030001 Countershaft assembly (left) 1
22 WG2229240021 In-box pipe 1 1
23 AZ2210020004 Insert synchronizer and ring 1
24 AZ2229230001 Declutch shift centering block 2
insert gear
AZ2203020005 Input shaft and gear assembly 1 Push-type
26
AZ2203020007 Input shaft and gear assembly 1 Pull-type
AZ2220000001 Front housing of transmission 1 Pull-type
27
AZ2220000002 Front housing of transmission 1 Push-type
Note: parts generally used in HW 18710 are not listed.
3. Intermediate housing assembly of transmission
Figure 2-13 Intermediate housing Assembly of Transmission

Q1231035 Stud bolt 23
Push-type
1 Q1231040 Stud bolt 2
Q1231035 Stud bolt 25 Pull-type
2 WG2229010001 Locating pin 4
Intermediate housing of
AZ2220010102 1 Parts of HW18709
transmission
Intermediate housing of Parts of HW18710 and
3 AZ2220010005 1
transmission HW14710
Intermediate housing of
AZ2220010002 1 Parts of HW20716
transmission
Oil level peep hole,
4 WG2229010002 Screw plug 2
grease hole
5 WG2203010002 Drain screw plug assembly 1
V. Shaft Assembly
1. Countershaft assembly of transmissions HW18709, HW18710 and HW14710
Auxiliary shaft assembly (left) Auxiliary shaft assembly (right)
Figure 2-14 Countershaft Assembly of Transmissions HW18709, HW18710 and HW14710

Cylindrical roller bearing
2 AZ9003329309 1 With snap groove
NUP309E
The first series of
AZ2210030105 Countershaft drive gear 1
HW18709 and HW18710
4 The second series of
AZ2210030207 Countershaft drive gear
HW18710
AZ2210030305 Countershaft drive gear HW14710
The first series of
AZ2210030006 The third gear of countershaft 1
HW18709 and HW18710
AZ2210030206 The forth gear of countershaft
HW18710
AZ2210030306 The forth gear of countershaft HW14710
The first series of
AZ2210030104 The second gear of countershaft 1
HW18709 and HW18710
AZ2210030204 The third gear of countershaft
HW18710
AZ2210030304 The third gear of countershaft HW14710
The first series of
AZ2210030103 The first gear of countershaft 1
HW18709 and HW18710
AZ2210030203 The second gear of countershaft
HW18710
AZ2210030303 The second gear of countershaft HW14710
8 WG2229030101 Long flat key 1
AZ2210030101 Countershaft (left) 1
Parts of HW18709
AZ2210030102 Countershaft (right) 1
AZ2210030020 Countershaft (left) 1 Parts for the first series of
AZ2210030015 Countershaft (right) 1 HW18710
10
AZ2210030220 Countershaft (left) Parts for the second series
AZ2210030215 Countershaft (right) of HW18710
AZ2210030320 Countershaft (left)
Parts of HW14710
AZ2210030315 Countershaft (right)
2. Countershaft assembly of transmission HW20716
Auxiliary shaft assembly (left) Auxiliary shaft assembly (right)
Figure 2-15 Countershaft Assembly of Transmission HW20716

2 AZ9003329309 Cylindrical roller bearing NUP309E 1 With snap groove
4 AZ2210030005 Countershaft drive gear (low) 1
5 AZ2210030004 Counter drive gear (high) 1
6 AZ2210030003 The third gear of countershaft 1
7 WG2229030001 Long flat key 1
9 AZ2210030001 Countershaft (left) 1
AZ2210030002 Countershaft (right) 1
3. Input shaft assembly of transmission HW18709, HW18710 and HW14710
AZ22030220105 input shaft and first-shaft gear assembly
Figure 2-16 Input Shaft Assembly of Transmission HW18709, HW18710 and HW14710
1 WG2229020005 Bush 1
WG2210020101 Input shaft 1 Push-type
2
WG2210020105 Input shaft 1 Pull-type
The first series of HW18709 and
WG2210020102 First-shaft gear 1
HW18710
3
WG2210020202 First-shaft gear 1 The second series of HW18710
WG2210020302 First-shaft gear 1 HW14710
4 WG2229040003 Snap spring 1
5 WG2229040103 Spacer 1
Rolling bearing
6 AZ9003326213 1
6213N
Selected parts for
AZ2208020001 1
snap spring
AZ9003991065 Circlip for shaft Thickness: 2.50
7 AZ9003992065 Circlip for shaft Thickness: 2.58
As
required
4. Input shaft assembly of transmission HW20716
Figure 2-17 Input Shaft Assembly of Transmission HW20716

1 AZ2210020005 Insert gear synchronizer sliding bush 1
2 WG2229020005 Bush 1
3 WG2229020001 Synchronizer thrust block 3
4 WG2229020002 Spring outside thrust block 3
5 WG2229020003 Spring inside thrust block 3
7 WG2210020003 Insert synchronizer cone hub 1
WG2210020111 Input shaft 1 Pull-type
8
WG2210020108 Input shaft 1 Push-type
9 Main transmission gear (low)
WG2203020112 1 Modified
assembly
10 AZ9003326213 Rolling bearing 6213N 1
11 AZ2208020001 Selected parts for snap spring 1
Note: HW20716 transmission assembly with power takeoff must use the above input shaft and
main transmission gear (low) assembly, or gear off may happens when extracting torque, while
those without PTO don’t have to.
5. Declutch shift shaft assembly of transmission
Reverse-creeper speed declutch

Reverse-creeper speed shift assembly
declutch shift shaft
Figure 2-18 Reverse-gear Declutch Shift Shaft Assembly of Transmission

1 AZ2229220002 Pin 1
2 WG2214220001 Declutch shaft 1
Reverse-creeper speed declutch shift Used for
WG2212220201 1
shaft AZ2203220101
3
Used for
WG2212220001 Reverse-gear declutch shift shaft 1
AZ2203220001
4 WG2214220002 Reverse-gear shifting block 1
5 AZ2229220001 Pin 1
Note: Reverse-creeper speed declutch shift shaft for HW18709 can use shaft without groove in the
end left from the prophase while shaft for HW18710 and HW14710 is only allowed to use
WG2212220201.
The first and second gear

declutch shift shaft assembly
declutch shift shaft assembly
Figure 2-19 First and Second Gear Declutch Shift Shaft Assembly of Transmission
1 AZ2229220002 Pin 1
2 WG2214220001 Declutch shift 1
The first and second gear Used for AZ2203220102
WG2212220102 1
declutch shift shaft and AZ2203220010
3
WG2212220002 1 Used for AZ2203220002
Used for AZ2203220102
4 WG2214220003 Forward gear shifting block 1
and AZ2203220002
WG2214220004 Forward gear shifting block 1 Used for AZ2203220010
5 AZ2229220001 Pin 1
The third and forth gear

declutch shift shaft assembly The third and forth gear declutch
shift shaft assembly
Figure 2-20 Third and Forth Gear Declutch Shift Shaft Assembly of Transmission
1 AZ2229220002 Pin 1
2 WG2214220001 Declutch shift 1
3 AZ2229220001 Pin 1
4 WG2214220003 Forward gear shifting block 1
5 WG2212220103 1 Used for AZ2203220103
WG2212220003 1 Used for AZ2203220003
Insert shift fork shaft assembly
Figure 2-21 Declutch Shift Shaft Assembly of Insert Gear of Transmission

1 Q5220840 Cylinderical pin 1
Gear-shifting Declutch shift of
2 AZ2214230001 1
insert gear
Gear-shifting declutch shift
3 AZ2212230001 1
shaft of insert gear
6. Main shaft assemblies of transmissions HW18709, HW18710 and HW14710
Figure 2-22 Main Shaft Assemblies of Transmissions HW18709, HW18710 and HW14710
1 WG2210040002 Big catch of main shaft 1
WG2210040007 Reverse gear of main shaft 1
HW18709 and HW18710
2 Used for the second series
AZ2210040207 Reverse gear of main shaft 1
of HW18710
AZ2210040307 Reverse gear of main shaft 1 Used for HW14710
4 WG2210040012 Spline strip 1
AZ2208040001 Spline adjusting shims 1
WG2210040021 Spline adjusting shim Thickness: 6.80
5 WG2210040022 Spline adjusting shim As Thickness: 6.65
WG2210040023 Spline adjusting shim required Thickness: 6.50
WG2210040024 Spline adjusting shim Thickness: 6.35
Before modified:
6 WG2210040210 Sliding bush of main shaft 1
WG2210040010
Creeper speed of main
WG2210040103 1 Used for HW18709
shaft
Creeper speed of main Used for the first series of
WG2210040030 1
7 shaft HW18710
AZ2210040230 The first gear of main shaft 1
of HW18710
AZ2210040330 The first gear of main shaft 1 Used for HW14710
8 WG2210040021～24 Spline adjusting shim 1
WG2210040106 The first gear of main shaft 1
HW18709 and HW18710
The second gear of main Used for the second series
11 AZ2210040206 1
shaft of HW18710
The second gear of main
AZ2210040306 1 Used for HW18710
shaft
14 WG2210040023 Spline adjusting shim 1
Used for HW18709,
Ball assembly of main
WG2203040221 1 before modified:
shaft
AZ2203040102
15
Ball assembly of main
AZ2203040009 1 HW14710, before
shaft
modified: AZ2203040008
16 WG2210040010 Sliding bush of main shaft 1 Modified: AZ2210040210
The second gear of main Used for the first series of
WG2210040105 1
shaft HW18709 and HW18710
The third gear of main Used for the second series
20 AZ2210040205 1
shaft of HW18710
The third gear of main
AZ2210040305 1 Used for HW14710
shaft
The third gear of main Used for the first series of
WG2210040104 1
shaft HW18709 and HW18710
The forth gear of main Used for the second series
24 AZ2210040204 1
shaft of HW18710
The forth gear of main
AZ2210040304 1 Used for HW14710
shaft
AZ2229040201 Hexagon key 2 Used for HW18709
27
28 AZ2229040211 Hexagon key 1
HW14710
Note: considering that during the prophase hexagon key broken, two measures are taken step by
step to prevent the breaking: 1) HW18709 transmission uses hexagon keys CB1612904101,
CB1612904102, CB1612904103 and rivets CB1612904002, other parts keeping as the original;
refer to related operating instructions for practical operation; 2) replace ball assembly and sliding
bush of main shaft with two long hexagon keys AZ2229040201 and AZ2229040211. Sliding bush
of main shaft can replace WG2210040010 but WG2210040010 can’t replace AZ2210040210. 3)
Modified or unmodified ball assembly of main shaft and hexagon key should be used separately
and mixed use is not allowed.
7 Main shaft assemblies of transmission HW20716
Figure 2-23 Main Shaft Assemblies of Transmission HW20716
Before modified:
1 AZ2210040211 Reverse-gear sliding bush 1
AZ2210040011
Select according to
requirement
5 WG2210040007 Reverse gear of main shaft 1
6 WG2210040006 The first gear of main shaft 1
10～ Before modified:
AZ2203040201 Ball assembly of main shaft 1
14 AZ2203040002
Before modified:
15 AZ2210040210 Sliding bush of main shaft 1
WG2210040010
Select according to
requirement
19 WG2210040006 The second gear of main shaft 1
20 WG2210040005 The third gear of main shaft 1
Select according to
requirement
28 WG2210040003 Main transmission gear 1
29 WG2210020003 Insert synchronizer cone hub 1
31 WG2210040002 Big catch of main shaft 1
Before modified:
33～
AZ2229040201 Hexagon key 2 CB2012904101 and
34
CB2012904102
Note: 1) Ball assembly of main shaft must be applied together with hexagon key that is
AZ2203040201 with AZ2229040201, AZ2203040002 with CB2012904101 and
CB2012904102.
2) Sliding bush of main shaft AZ2210040210 can replace WG2210040010 and
WG2210040010, but can’t replace AZ2210040210.
IV. Auxiliary gearbox Assembly of Transmission HW1870
Figure 2-24 Auxiliary Gearbox Assembly of Transmission HW1870
1 AZ9003326020 Rolling bearing 6020 GB/T276 1
2 AZ9003821250 Hexagon socket cap screw 5
3 AZ2225100102 Planetary frame(front) 1
4 WG2229100108 Planet pinion washer 10
5 WG2210100104 Planet pinion 5
6 WG2229100107 Roller spacer 15
Cylindrical roller 8×16Ⅲb
7 AZ9003320816 150
GB4661
8 AZ9003326322 Rolling bearing 63/22 GB/T276 1 Planetary mechanism
9 AZ2203100004 Output shaft assembly 1 assembly
33 Q5280430 Elastic cylindrical pin 5 AZ2201000002+003
35 WG2229100001 Torque transmission sheath 5
36 WG2229100105 Sun gear gasket (front) 1
37 WG2212100101 Planet wheel axle 5
38 WG2210100101 Sun gear 1
39 WG2229100106 Sun gear gasket (rear) 1
40 AZ9003991056 Circlip for hole 1
11 WG2210100105 Internal gear ring 1
12 WG2210100006 Gear bracket 1
13 WG2229100012 Round wire retaining rings 1
15 Q40112 Flat washer 9
20 WG2214100002 Range gear declutch shift shaft 1
21 AZ9003072503 O ring 35502500 GB3452.1 1
22 AZ9003071700 O ring 26500170 GB3452.1 1
Before modified:
23 WG2229100050 Range gear plunger 1
WG2229100045
24 AZ9003076900 O ring 53006900 GB3452.1 1
25 AZ9003870016 Hexagon nut M16×1.5 1
Paper washer for range gear Before modified:
26 WG2229100049 1
cylinder WG2229100046
27 AZ9003071001 Odometer joint oil seal 1
28 AZ2212100002 Odometer gear shaft 1
Odometer joint assembly
29 AZ9003072500 O ring 26502500 GB3452.1 1
AZ2203100009, used for
30 WG2222100002 Odometer joint body 1
general odometer Sensor
31 Q5220526 Parallel pin 1
32 AZ2210100016 Odometer gear 1
Used for electromagnetic
WG2209280010 Odometer Sensor 1
sensor
Flattened wire retaining rings for
41 AZ9003991125 1
hole
42 AZ2203100005 Cone hub assembly at low gear 1
43 WG2210100007 Range gear synchronizer detend 1
44 AZ9003991130 Circlip for shaft 1
45 WG2229100032 Spacer 1
Range gear synchronizer sliding
46 WG2210100008 1
bush
47 WG2214100001 Range gear declutch shift 1
48 WG2229100042 Declutch shift centering block 2
49 WG2210100009 Range gear synchronizer ring 2
50 AZ2203100006 Cone hub assembly at high gear 1
51 AZ2203100007 Oil-guiding ring assembly 1
52 WG2229100043 Support pin for declutch shift 2
53 AZ9003990024 Waver elastic washer 2
Transmission’s rear housing (with Before modified:
54 AZ2220100105 1
power takeoff) AZ2220100102
55 AZ9003070800 O ring 18000800 GB3452.1 1
Paper washer for rear end cap of
56 WG2229100041 1
output shaft
Cover plate for power takeoff axle
57 AZ2229100047 1
hole
Used when there is
power takeoff, otherwise
62 not used
AZ2229100075 Cover plate for oil return hole 1
59 AZ2229100048 Pad for cover plate 1
Used for general
WG2210100015 Odometer worm 1
odometer sensor
60
AZ2210100020 Sensor gear ring
sensor
AZ2208100003 Adjust shims 1
WG2229100035 Adjust shim Thickness: 0.15
61 As
required
Used for general
WG2222100001 Rear end cap of output shaft 1
odometer sensor
63
WG2222100005 Rear end cap of output shaft 1
sensor
Used for general
odometer sensor
65 AZ9003801087 Hexagon bolt Q150B1087 1
sensor
66 AZ9003070105 Framework oil seal 1
68 WG2210100018 Output flangeΦ180 face tooth 1
Before modified:
69 WG2222100009 Cylinder of range gear 1
WG2222100003
Note: 1) Range gear plungers WG2229100050 and WG2229100045 can be used universally
when repaired.
2) The transmission’s rear housing AZ2220100102 should be applied with range gear
cylinder WG2222100003 and paper washer WG2229100049 of range gear cylinder;
the transmission’s rear housing AZ2220100005 (with inner flange) should be applied
with range gear cylinder WG2222100009 (with outer flange) and paper washer
AZ2229230004 of range gear cylinder.
3) Replace corresponding parts when the range and auxiliary gearbox assembly is
attached with electromagnetic sensor
IV. Auxiliary gearbox Assembly of Transmissions HW18710, HW14710 and HW20716
Figure 2-25 Auxiliary gearbox Assembly of Transmissions HW18710, HW14710 and
HW20716
2 AZ9003821255 Hexagon socket cap screw M12X1.25 5
3 AZ2225100002 Planetary frame(front) 1
5 AZ2229100005 Sun gear gasket (front) 1
6 AZ2210100002 Spline housing 1
7 Q43875 Round wire retaining rings for hole 1
8 AZ2210100003 Interim cover 1
9 WG2210100001 Sun gear 1 Planetary
10 AZ2229100006 Sun gear gasket (rear) 1 mechanism
assembly
11 AZ9003326322 Rolling bearing 63/22 GB/T276 1
AZ2201000031+003
12 AZ2225100001 Output shaft 1
Used for HW20716
64 AZ9003991056 Circlip for hole 1
and HW18710
65 WG2229100008 Planet pinion washer 10
66 WG2210100004 Planet pinion 5
67 AZ9003321118 Cylindrical roller 11X18Ⅲb GB4661 120
68 WG2229100007 Roller spacer 15
69 WG2212100001 Planet wheel axle 5
13 AZ9003991125 Flattened wire retaining rings for hole 1
15 WG2210100005 Internal gear ring 1
16 WG2210100006 Gear bracket 1
17 WG2229100012 Round wire retaining rings 1
19 Q40112 Flat washer 9
WG2229100002 Torque transmission sheath 9 Used for HW20716
20 WG2229100002 Torque transmission sheath 7 Used for HW18710
WG2229100003 Torque transmission sheath 2 and HW14710
21 AZ2203100005 Cone hub assembly at low gear 1
22 WG2229100032 Spacer 1
23 WG2210100009 Range gear synchronizer sliding bush 2
WG2214100002 Range gear declutch shift shaft 1 Used for HW20716
WG2214100003 Range gear declutch shift shaft 1
AZ2229100029 Range gear locking block 1
24 AZ9003960007 Hexagonal socket head plug 1 Used for HW18710
WG2229210019 Range gear locking spring 1 and HW14710
AZ9003331349 Steel ball 1
25 WG2214100001 Range gear declutch shift 1
26 WG2229100042 Declutch shift centering block 2
27 AZ9003072503 O ring 35502500 GB3452.1 1
28 AZ9003071700 O ring 26500170 GB3452.1 1
Before modified:
29 WG2229100050 Range gear plunger 1
WG2229100045
30 AZ9003076900 O ring 53006900 GB3452.1 1
31 AZ9003870016 Hexagon nut M16×1.5 1
Before modified:
32 WG2229100049 Paper washer for range gear cylinder 1
WG2229100046
33 WG2222100009 Cylinder of range gear 1 Before modified:
WG2222100003
34
35 AZ9003071001 Odometer joint oil seal 1
36 AZ2212100002 Odometer gear shaft 1
Odometer joint
37 AZ9003072500 O ring 26502500 GB3452.1 1
assembly
38 Q5220526 Parallel pin 1
AZ2203100009
39 WG2222100002 Odometer joint body 1
40 AZ2210100016 Odometer gear 1
42 WG2210100018 Output flange Φ180 1face tooth 1
43 AZ9003070105 Framework oil seal PS 105 130 14 1
Q170B1055 Hexagon bolt with wire holes on head 1
44
AZ9003801087 Hexagon bolt Q150B1087 1
45 WG2222100001 Rear end cap of output shaft 1
46 WG2210100015 Odometer worm 1
47 AZ2208100003 Adjust shims 1 As required
49
Cover plate for power takeoff axle hole Used when there is
50 AZ2229100047 1
no power takeoff
Paper washer for rear end cap of output
51 WG2229100041 1
shaft
52 AZ2229100048 Pad for cover plate 1
Transmission’s rear housing Before modified:
1
（HW20716） WG2220100002
53
Transmission’s rear housing Before modified:
WG2220100105 1 WG2220100102
（HW18710）
54 AZ9003990024 Waver elastic washer 2
55 AZ2229100043 Support pin for declutch shift 2
56 AZ2203100007 Oil-guiding ring assembly 1
57 AZ2203100006 Cone hub assembly at high gear 1
58 WG2210100008 Range gear synchronizer sliding bush 1
59 AZ9003991130 Circlip for shaft 1
63 WG2210100007 Range gear synchronizer detend 1
Note: 1) Range gear plungers WG2229100050 and WG2229100045 can be used universally.
2) The transmission’s rear housing AZ2220100102 and WG2220100002 should be
applied with range gear cylinder WG2222100003 and paper washer WG2229100049
for range gear cylinder; the transmission’s rear housing AZ2220100105 and
WG2220100005 (with inner flange) should be applied with range gear cylinder
WG2222100009 (with outer flange) and paper washer WG2229100046 for range gear
cylinder.
3) Replace corresponding parts when the range and auxiliary gearbox assembly has
electromagnetic sensor
VIII. Small Cover Assembly of Transmissions HW18709 and HW20716
Figure 2-26 Small Cover Assembly of Transmissions HW18709 and HW20716

1 Q150B1040TF2 Hexagon bolt 1
2 Q41810 Waver elastic washer 1
3 Q340B10T13F2 I type hexagon nut 1
WG2214210004 Swing arm 1 Single lever
4
WG2214210004 Gear-shifting swing arm 1 Double lever
5 WG2229210026 Anti-dust cover 1
6 AZ9003072502 Oil seal outside the cap 1
7 AZ9003072501 Oil seal inside the cap 1
8 WG2229002520 Composite bush SF2 25×28×20 1
Cap for small cover (side of
AZ2222210002 1
swing arm) Single lever
9
AZ2222210003 1
swing arm) Double lever
15 WG2229210017 End cap gasket 1
Pay attention to direction
17 WG2229210014 Driving ring of sensor 1
when mounting
18 WG2229210013 Sector self-locking block 1
AZ2212210001 Gear-shifting shaft 1 Single lever
19
AZ2212210003 Gear-shifting shaft 1 Double lever
20 WG2229210012 Driving pin 1
21 WG2214210001 Interlock fork 1
22 WG2214210002 Gear-shifting knob 1
23 WG2229210009 Pin 1
Locating ring of high and low
25 WG2229210002 1
gear
28 WG2229210023 1
range gear lock)
30 WG2229210022 Spacer ring 1
Centering spring (side of the
31 WG2229210021 1
low gear)
32 WG2229210004 Centering socket ring 1
33 WG2229210005 Spacer bush 1
34 WG2229210004 Centering socket ring 1
Centering spring (side of the
35 WG2229210003 1
high gear)
37 WG2229210006 Set screw 1
38 190003960005 Hexagon socket cap head plug 1
Q72320 Seal washer 1
39
WG2229210019 Range gear locking spring 1 Single lever
40 WG2229210020 Range gear locking spring 1 Double lever
41 WG2229210018 Range gear locking pin 1
42 WG2203250001 Double H valve assembly 1
43 Q218B0820 Hexagon socket cap screw 4
45 199012710041 Pressure switch (keeping close) 1 Neutral gear switch
Lifting pin of neutral gear
47 WG2229210027 1
sensor
WG2229210010 Self-locking spring 1 Single lever
48
WG2229210015 Self-locking spring 1 Double lever
49 WG2229210011 Spring catch 1
50 AZ9003343178 Needle roller P3×17.8 GB309 1
51 WG2212210002 Self-locking pin 1
52 WG2229210001 Bush 1
53 179100710068 Pressure switch (keeping open) 1 Gear-reverse switch
Round wire retaining rings for
54 Q43708 1
shaft
Lifting pin of neutral gear
55 WG2229210028 1
sensor
Constant open-type breather
56 Q901 1
plug
57 AZ2229250005 Double H valve assembly 1
AZ2222210101 Small cover shell 1 Single lever
58
AZ2222210001 Small cover shell 1 Double lever
59 Q72220 Bowl-shaped tabular plug 1
60 190003960005 Hexagon socket cap head plug 1
WG2229210018 Range gear locking pin 1
WG2229210041 Support bar assembly 1 Double lever
63
WG2229270003 Gear-shifting supporting shaft 1 Double lever
WG2229210040 Gear stick assembly 1 Double lever
IX. Small Cover Assembly of HW18710 Transmission Assembly
Figure 2-27 Small Cover Assembly of Transmissions HW18710 and HW14710

1 Q340B10T13F2 Hexagon nut, type 1 1
2 Q41810 Waver elastic washer 1
3 WG2214210003 Gear-shifting swing arm 1 Single lever
WG2214210004 Swing arm 1 Double lever
4 Q150B1040TF2 Hexagon bolt 1
5 WG2229210026 Anti-dust cover 1
6 AZ9003072502 Oil seal outside the cap 1
7 AZ9003072501 Oil seal inside the cap 1
WG2222210002 Cap for small cover 1 Single lever
9 Cap for small cover(at the side of
WG2222210003 1 Double lever
double lever swing arm)
Constant open-type breather
12 Q901 1
plug
13 WG2229210028 Lifting pin of sensor 1
Round wire retaining rings for
14 Q43708 1
shaft
15 179100710068 Pressure switch (keeping open) 1
17 WG2229210014 Driving ring of sensor 1
19 AZ2229210016 sector self-locking block 1
20 WG2229210001 Bush 1
21 AZ2212210005 Self-locking pin 1
22 WG2229210011 Spring catch 1
23 AZ2229210033 Self-locking spring 1
24 AZ2214210010 Interlock fork 1
25 WG2229210027 Lifting pin of neutral gear sensor 1
27 199012710041 Pressure switch (keeping close) 1
AZ2222210015 Small cover housing 1 Single lever
28
AZ2222210010 Small cover housing 1 Double lever
30 AZ2229210007 Centering socket ring 1
Centering spring (side of the low
31 WG2229210021 1
gear)
32 AZ2229210007 Centering socket ring 1
33 AZ2229210029 Spacer ring 1
37 AZ2229210030 Cap for small cover 1
38 AZ2229210032 Paper washer for small cover cap 1
39 WG2229270003 Gear-shifting supporting shaft 1 Double lever’ parts
40 Q43112 Circlip for shaft 1 Double lever’ parts
41 WG2229210040 Gear stick assembly 1 Double lever’ parts
42 WG2229210009 Pin 1
43 AZ2214210103 Gear-shifting knob 1
AZ2212210006 Gear-shifting shaft 1
44
AZ2212210007 Gear-shifting shaft (double 1
lever)
45 AZ9003343178 Needle roller P3×17.8 GB309 1
46 WG2229210012 Driving pin 1
47 WG2229210041 Support bar assembly 1 Double lever’ parts
WG2209250001 Cut-off valve 1
AZ2229210035 Paper washer 1 Mounting of cut-off
Q150B0620 Hexagon bolt 2 valve
2 on cut-off valve, 3
on two-position &
WG2229250009 Feed-through (NPT 1/8-8X6) 5
five-way valve
assembly
Molding flexible tube (cut-off
WG2229250014 valve-two-position & five-way 1
valve)
Single pipe clip with one fixed Fixed molding
Q68208 1
end flexible tube
AZ2229210031 Bracket 1 Fixed two-position
Q150B0820 Hexagon bolt 2 & five-way valve
Q40308 Spring washer 2 assembly
Two-position & five-way valve
WG2209250005 1
assembly
Q150B0435 Hexagon bolt 2 Fixed two-position
Q40304 Spring washer 2 & five-way valve
Q340B04 Hexagon nut, type 1 2 assembly
WG2229250011 Muffle 2
WG2229250006 Feed-through (NPT 1/8-4X2) 1
Section III Content of Transmission Operating Mechanism
1. Single lever operating mechanism

Figure 2-28 Single lever Operating Mechanism
1 199112240085 Ball joint 1
2 Q341B14T13F2 Hexagon nut 1
Prevailing torque type full-metal
3 Q33210 1
hexagon nuts, style 2
4 1-99-951-038 Screw 1
5 WG9100240090 Ball joint 1
6 Q340B12 Hexagon nut, type 1 1
7 199112240122 Ball joint 1
8 190003871313 Hexagon nut (left) 1
2. Double lever operating mechanism
Figure 2-29 Double lever Operating Mechanism
1 WG2229270004 Flexible shaft bracket (pull-type) 1
2 WG2229270005 Flexible shaft bracket (push-type) 1
3 WG9725240118 Gear flexible shaft assembly 1
4 WG9719240112 Gear-shifting flexible shaft assembly 1
5 190003559486 Straight thread long connector-- body Used for air inlet
1 for power takeoff
6 Q80508 Straight thread cone connector—body Used for air inlet
1 for double H valve
Key points in this chapter

Types of HW series transmissions and common transmission serial numbers; differences in
structures of various transmissions assembly
Exercises
1. Please describe briefly the types of HW series transmissions.
2. Please describe briefly the differences between pull-type clutch and push-type one.
3. Please describe briefly operating principles of oil pipe assembly used for HW series
transmissions.
4. What are types of oil pipe assemblies? Please describe briefly usage.
5. How to connect release fork with release bearing of push-type clutch?
6. Please list operating mechanism types of HW series transmissions.
7. Please describe the differences of main and auxiliary gearbox interlocks between HW18710
and HW18709.
8. What are the differences of countershaft assembly between transmission HW18710 and
HW18709?
9. Please try to describe how to maintain main shaft assembly of HW18709.
10. Please try to describe how to maintain main shaft assembly of HW18710.
11. Please try to describe the differences of small cover assembly parts between transmission
HW18709 and HW20716.
12. Please try to describe the differences of countershaft assembly between transmission
HW18709, HW18710 and HW20716?
Chapter III Trouble of HW Series Transmission
Requirements:
Master common trouble types and maintenance methods of HW transmission as well as trouble
analysis methods for HW transmission; learn how to analyze the transmission troubles.
Section I Trouble Analysis Basis for HW Transmission
I. Basic Trouble Analysis Process for HW Transmission

This course requires the trainees not only to understand the common trouble types but also to
master the trouble analysis method for the HW transmission, analyzing the troubles in practice
independently, finding out the reasons for the troubles and determining the appropriate
maintenance method.
Transmission is an important component of automobile of which the normal and stable operation
depends on the performance, quality, connection of transmission, using conditions and habits of
the user
Trouble analysis process for transmission:
Understand
transmission
Listen reflection from
user Understand
complete vehicle
Check actual situation
Decide maintenance
Analyze reasons scheme
① Listen carefully to the (especially the drivers) detailed description about troubles of
the automobile and transmission from user, including initial troubles, treatment to the
troubles and detailed trouble symptoms.
② Understand detailed and basic situations of transmission, including the Order Number,
Manufacturing Number, troubles and maintenance at early stage.
③ Understand the basic situation of the complete vehicle, including model, purchasing
date, road conditions, actual load, mileage under trouble conditions, main troubles at
early stage, or inquiry by Integrated service digital network (ISDN).
④ Initially judge the troubles probably exist during communication with users and make
comparation with the current trouble types. The trouble similar to any existing trouble
type should be determined whether it belongs to the existing type after further
communication with user. Communication and confirmation are needed because
incorrect part’s name may be used or inaccurate description may be made by users
when they prescribe the problems.
⑤ Field check should be carried out if the trouble found is excluded by the existing
types. Careful observation, inquiring actual using conditions of the automobile and
transmission and field operation and testing should be carried out. Find out real
reasons resulting in troubles through analysis.
⑥ Disassemble the assembly to find out exact reasons if actual reasons still can not be
confirmed.
⑦ Make appropriate method to remove the troubles according to the reasons resulting in
those troubles.
It is a process to accumulate experiences and confirm new trouble types, which needs
mastering with efforts. Systematic method must be adopted in trouble analysis to detail
problems occurred, only by which can objective and accurate conclusion be made.
II. Classification of HW Transmission Spare Parts

Failure of any parts is greatly affected by the operating status, e.g. the mechanic and chemical
performances, specific part structure and external force it bears.
The transmission parts are generally classified into four categories to the functions: moving parts,
operating parts, basic parts and sealing parts.
The moving parts, such as gear, shaft, bearing, etc. are the main parts of transmission, which
directly affects the working status of transmission.
The operating parts include gear shift lever, shift shaft, shift head, high/low gear locating ring,
interlock fork, sector self-locking block, self-lock pin, angular cam, declutch shift shaft, clutch
shifter, main shaft slide bush, range gear cylinder, piston, shift shaft of range gear, clutch shifter of
range gear and synchronizer. The function of these parts is to realize transmission shift and to
ensure clear gear, reliable self-lock and interlock.
The basic parts, such as front housing, intermediate housing, rear housing, input shaft end cap,
output shaft end cap, small cover case, countershaft end cap, oil pump body, oil pump end cap etc
are the protection cases for the transmission, which can locate the moving and operating parts as
well as bear the forces from these parts and external force effected on these parts.
Basic parts of transmission assembly are assorted to several parts according to the processing,
assembly and maintenance requirements, which may be all connected during assembly. According
to the property, connection is classified as static sealing and dynamic sealing. Parts used for static
sealing are paper washer and plane sealing gum, which are assured by assembling method, so the
way and method must be pay attention to while assembling. Parts for dynamic sealing are oil seal
and O ring. Pay attention to the status of the parts while assembling and adopt appropriate method.
An example for trouble analysis for HW transmission is provided below to explain the knowledge
and technology as well as the attainment that have to be mastered during Level-III training.
III. Example for Troubles Analysis - Abnormal Transmission Assembly Noise

Certain noise is available when the transmission works normally. Especially for the double
countershafts, the gear on the main shaft is located by gear on countershaft, therefore the vibration
is more seriously than ordinary fixed shaft gear trains and the noise is louder accordingly. But if
the noise too loud or abnormal, e.g. booming or squealing occurs, all which prove that there are
some problems for transmission. If the noise is caused by the transmission itself, it may probably
because of the incorrect locating of moving parts itself or by basic parts. The background
knowledge about failure of moving parts is provided below.
1. Background knowledge
① Gear - Spur gear mainly bears normal force that is vertical to teeth surface and tangential
force that is tangent with teeth flank.
Figure.3-1 Force to Gear
Figure 3-2 Gear Engagement

Under normal conditions, the main gear failures are pit corrosion, teeth wear, teeth fracture. The
normal force that gear bears can cause pit corrosion, tangential force for teeth fracture. With pit
corrosion and wear becoming more and more serious, the teeth become thinner and thinner till
fracture occurs finally. This process goes through the whole service period of transmission and
lasts a very long time. Big pit results in slight knocking under low speed operation, squealing
under high speed and booming when the teeth fractured. Chomping can be heard when the torque
changes directions.
Whole process is as follows:
Normal force Friction force Normal force
Pit
corrosion Teeth fracture
Teeth surface
wear
Squealing Chomping Booming
Figure 3-3 Normal Failure Process of Gear

Lubrication film breaks under low speed over loading, cold welding and adhesion occur because
the teeth surface is partially heated resulted by friction force. After the welded part is separated, a
trace may be left on the teeth surface in the gliding direction, which is called “gluing”; if there are
a great deal of hard granules (such as iron scrap) in the lubrication, “abrasive wear” happens
during gear engagement; over loading strike also can cause “teeth fracture” in a short time.
Gluing
Friction force Normal force Teeth
Low speed over fracture
Impact force
loading Abrasive wear
Figure.3-4 Abnormal Failure Process of Gear

In addition, a new or newly maintained transmission assembly may generate abnormal noise when
the teeth surfaces touch each other, the noise would be knocking under low speed, squealing even
booming at high speed.
② Shaft - It mainly functions to transfer torque and bear radial force from gear. Failures
mainly include distorting and bending deformation.
Figure 3-5 Force to Shaft

Under low speed over loading, serious distortion and bending of countershaft may affect the exact
engagement of the gears on double countershafts, producing squealing and booming.
③ Bearing - It mainly functions to locate gear shaft in radial and axial directions and bear
radial force and axial force from gear shaft.
Under normal conditions, bearing failures mainly includes pit corrosion, roller and rolling way
wear, bearing cage falling into pieces, roller breaking etc. Forces functioning on roller include
normal force and friction force. Normal force results in pit corrosion of roller and rolling way and
tangent friction wear of roller and rolling way. With pit corrosion becoming more and more
serious, the transmission assembly may generate squealing while rotating at high speed; while
with more and more serious wear, central distance of the engaged gears becomes larger and larger,
which results in that load functions on top of the teeth and chomping occurs. Such situation may
also result in teeth fracture. This process goes through whole service period of transmission and
lasts a very long time. Big pit corrosion results in slight knocking while the gear running at low
speed, squealing high speed.
Under low speed over loading, roller or rolling way may be distorted and the bearing cage
ruptured, which results in early stage damage of bearing and booming occurs accordingly. The
whole process is as follows:
Pit Serious pit Roller

corrosion corrosion breaking
Enlarge center distance
Squealing Chomping Booming
Figure.3-6 Failure process of bearing

Another point to be paid with attention is that for double countershaft mechanism, if the teeth
engage incorrectly or countershaft/countershaft gear distorts, there will be loud booming and
irreparable damage to the driving parts and basic parts of transmission. So after assembled, test
must be carried out to check whether the gear can rotate flexibly and make sure the teeth do not
engage incorrectly.
2． Trouble analysis of abnormal transmission assembly noise
The noise may be generated by transmission itself or may be transferred to transmission
from other parts of the automobile and be amplified by it. The external reasons may be that
additional vibration of engine, clutch and transmission shaft functions on input and output
shaft of transmission, which affect the gear engagement inside the transmission, amplifying
noise further.
Common abnormal noise of transmission includes knocking, squealing, booming and
chomping. Pay attention to the producing rules of abnormal noise and make clear that under
what status it generates, under what status it becomes more obvious and under what status
less obvious. Such abnormal noise can be measured by sound level and frequency. Sound
level of noise is loud but the frequency low, while that of squealing loud and frequency high,
booming loud frequency high, chomping loud frequency low. The frequency of abnormal
noise must be compared with input transmission speed. There is chomping while the
frequency is lower than speed, knocking and booming while equals to, squealing while
high.
Chomping commonly occurs on new or newly maintained transmission assembly. That is
caused by touch of teeth surfaces, which can be distinguished from spots on teeth surface
after strong press and grind. Generally, when gear bears load, such noise would be more
obvious, so if there is noise after engaging gear, it proves that the gear for this engagement
has some problem. Such touch can be grinded by hone or emery wheel.
Squealing is caused by incorrect engagement of gears. Main reasons are pit corrosion of
teeth surface or teeth distortion and pit corrosion of bearing, etc.
Main reasons for booming are incorrect engagement of teeth, countershaft gear rotating on
countershaft, serious distortion of gear or serious damage of other parts.
Chomping is mainly caused by larger clearance between bearings or engaged gears. If the
engaging clearance between gears is too large, chomping occurs when torque changes
direction. Large radial clearance between bearings of countershaft may cause that central
distance of the shafts becomes larger and larger, resulting in teeth overloaded and fractured.
Above all, principles and status that the abnormal noise occurs should be understood in the
analysis before judging the reasons cause such problems. Define the reasons for the trouble
according to existing trouble types and experiences and find out the solution to remove
these troubles.
IV. Requirements for Trainees in Trouble Analysis Study

It is concluded from the above troubles analysis that if the trainees want to learn the course well,
they must meet the following requirements:
1. Passing Level-I, II trainings for HW transmission
Master the basic principle of HW series transmission, function of each part, detailed using
methods.
2. Learning of scientific and systematic analysis method.
Only after mastered the troubles analysis method and obtained the ability to analyze HW
series transmission can diagnosis the possible troubles and find out the essential reasons
caused the troubles. Learning the method is more important than memorizing troubles
types.
3. Interests to probe into the problems
Having the interests to probe into problems, the trainee would take initiatives to solve all
the problems.
4. Accumulation of basic knowledge
HW transmission assembly is a complex mechanical product, which needs knowledge in all
aspects. So the trainee must: a. understand basic structure and principle of the automobile
and be familiar with the force the transmission bearing in the whole body; b. know very
clearly the structure principle of the transmission and interaction of each part; c. obtain
certain knowledge in respect of mechanics and mechanics of materials.
Section II Trouble Analysis & Diagnosis of operating parts for HW

Transmission
Main failure types of transmission are mainly discussed in last section. Failure types of operating
parts for HW series transmission are to be discussed in this section.
I. Background knowledge
The operating parts are mainly: small cover assembly, declutch shift shaft, synchronizer shift of
range gear, synchronizer shift of insert gear, etc.
The small cover assembly mainly realizes gear selection, shifting, interlock, self-lock and neutral
gear as well as reverse gear signals. Small cover assembly helps to realize gear selection and
shifting of main transmission box and assures clear gear, reliable self-lock and interlock. Its failure
types include off-gear, shifting and neutral gear difficulties.
1. Small cover assembly of HW18709 and HW 20716 transmissions
Mechanism of HW18709 and HW20716 cover assemblies is as Figure. 3-7:
1-- Shift swing arm 2—Anti-dust cover 3—Shift shaft 4— Sensor roller 5—Pressure
switch of reverse gear 6—Shift head 7— Interlock fork 8—Centering spring 9—Range
gear lock pin 10—Locating ring of high/low gear 11—Centering spring 12— small cover
end cap 14— Drive pin 15— Sector self-lock 16—Pressure switch of neutral gear 17—
Self-lock pin 18—Double-H-valve assembly 19—Compression spring 20—Small cover
shell
Figure.3-7 Structure of HW18709 and HW20716 Small Cover Assemblies
Locating ring of high/low gear 10 is connected to the shift shaft by slotted spring pin,
together with the centering spring, centering seat ring, spacer bush, range gear lock pin,
caulking ring, etc. constitute the gear lock, which is the guarantee of clear gear of
transmission. As showing in Figure., push the shift shaft to the right is 1/2-shift when it is at
3/4-shift, reverse gear when pushed to the bottom of right; pull to the left is 5/6-shift, at the
same time, switch the air inlet direction of double H valves, it is 7/8-shift when pulled to the
bottom of left. The shift head 6 and interlock folk 7 move with shift shaft in axial direction
while shifting.
Shift lever controls the shift shaft to swing while shifting, shift head draws the pad out of
the slot of interlock fork so as to realize shifting of main box, at the same time, realize the
interlock and self-lock function. Interlock is realized by the interlock fork, there is at most
one pad right direct to the slot on interlock fork at any position, only one pad can be drew
out so as to realize shifting, which realizes the interlock of shifting structure.
R(C) gear First/Second gear Third / Fouth gear Fivth / Sixth gear Seventh / Eighth gear
Figure.3-8 Interlock Structure of HW 18709 and HW20716 Cover Assemblies

Self-lock pin is fixed to slot at side of self-lock quarter functioned by spring force, self-lock
block move around gear shift shaft. As showing in the Figure. transmission assembly
locates at the gear, so only by overcoming the function of spring force can self-lock block
move, so as to realize reliable self-lock.
Figure.3-9 Self-lock Structure of HW Small Cover Assembly

Sensor on small cover assembly is driven by the drive sensor on the driving ring (or quarter
self-lock block).
2. Small cover assembly of HW 18710 and HW14710 transmissions
Mechanism Figure.of small cover assembly of 10-shift transmission is as follows:
Figure.3-10 Self-lock Structure of HW Series Small Cover Assembly

Centering seat ring and centering spring located on the shift shaft by retaining ring constitute a
gear lock together with the small cover shell and caulking ring, which is the guarantee of clear
gear. As showing in Figure, shift shaft locates at 2/3-shift position it is reverse 1-shfit when pushed
to the left bottom, and 4/5-shift when pulled to the right bottom. The shift head and interlock folk
move with shift shaft in axial direction while shifting.
Shift swing arm controls the shift shaft to swing while shifting, shift head draws the pad out of the
slot of interlock fork so as to realize shifting of main box, at the same time, realize the interlock
and self-lock functions. Interlock is realized by interlock fork, there is at most one pad right direct
to the slot on interlock fork at any position, only one pad can be drew out so as to realize shifting,
which realizes the interlock of shifting structure.
Self-lock and sensor drive of small cover assembly of 10-shift transmission assembly is similar to
that of HW18790 series.
3. Control on range gear of auxiliary gearbox of HW18709 and HW20716 transmission
Range gear’s auxiliary gearbox of HW18709 and HW20716 transmissions is functioned by
controlling double-H-valve assembly and switching air inlet direction of range gear
cylinder.
The double-H-valve assembly is an end face sealed structure with double thrust pillars. The
compressed air enters adjacent outlet from inlet when pillar is under free status; the air vent
is connected with adjacent outlet when pillar is compressed. When the double-H-valve
assembly is installed on cover assembly, the pillar is controlled by the interlock fork and is
ensured that only one pillar being compressed. There are only high and low gears for range
gear at this time.
The range gear is sealed by the O ring which slides in cylinder. There are two O rings
between range gear declutch shift shaft and rear housing shell. Range gear declutch shift
shaft must go through from internal instead of external during installation, or damage will
be caused to o-ring and resulting in air inlet failure. This is mainly because that when main
box locates on the gear, there is air in range gear cylinder constantly to avoid off-gear
without self-lock needed.
Shift gear knob

Cut-off valve
Finished vehicle air valve
Finished vehicle air valve
Two-position five-way valve
Lower port of range gear cylinder Higher port of range

gear cylinder
Figure.3-11 Mechanism of Double-H_valve Figure.3-12 Control of HW 10-shift Range

Gear Auxiliary gearbox
4. Control on range gear of auxiliary gearbox of HW18710 and HW14710 transmissions
Control of range gear of auxiliary gearbox of HW18710 and HW14710 transmissions is
showing as Figure.3-12. The air source passing through switch valve on shifting handle
controls the port 14 of two-way valve. Inlet port 1 is connected to port 21 when port 14 is
not pressured, air pass through port 22; Inlet port 1 is connected to port 22 when port 14 is
pressured, air pass through port 21. Port 1 is connected to port 2 when globe valve locates at
neutral position; port 1 is closed to port 2 when globe valve locates at gear position. Switch
the switch valve on handle while range gear needs shifting, when gear of main box
backwards to neutral gear, air passes through globe valve and range gear shifting realized
under control of two-way valve. Self-lock is needed when the main box is at gear and there
isn’t air in range gear cylinder which can not ensure to avoid off-gear. Air control of such
range gear of auxiliary gearbox can keep main box at neutral gear when range gear shifting,
control of interlock of main box and auxiliary gearbox during shifting protects auxiliary
gearbox synchronizer.
5. Control of insert gear cylinder of HW20716 transmission
Control of insert gear of HW20716 transmission is similar with that of range gear of
auxiliary gearbox of HW 10-shift transmission, the former does not have globe valve and
the inlet port 1 of two-way valve is connected with outlet of clutch pressure cylinder, which
is different with the latter. Such control aims to ensure that shifting of insert gear can be
realized only when clutch separated completely so as to protect insert gear synchronizer.
When HW20716 works, insert gear must locate at low gear. Failure of insert gear also can
be caused if the air ports are incorrectly connected in insert gear cylinder.
II. Common Troubles of Operating Parts for HW Series Transmission

1. Shifting difficulty of main box
Different strengths are needed to shift different gears. Abnormal situation occurs if over
strength is used. Shifting difficulty usually occurs on remote control position by COE (Cab
over engine), therefore the connectors of remote control lever should be firstly inspected
when finding the reasons for shifting difficulty. The problem in connectors usually caused
by wear, occlude, inappropriate adjustment of connecting fork or bush and bad lubrications
or mechanical failure restricting free movement of lever.
In order to confirm whether the shifting difficulty is caused by transmission itself, the gear
shift lever or connector should be removed from transmission. Testing as follows: 1) Put a
round tube with adequate inner radius on gear shift lever, try to shift, it is proved that the
trouble exists in outside of the transmission if shifted flexibly, or inside of the transmission.
2) Remove the small cover assembly, use lever or screw driver to move the sliding pad so
that it can engage with each gear. If the gear shift shaft can slide smoothly and small cover
assembly can shift flexibly, it is proved that trouble exists in locating of small cover
assembly and transmission assembly. Screw off the bolts, and adjust the location of small
cover assembly till it can shift flexibly. If the gear shift shaft can not slide smoothly, trouble
may exist inside the transmission. If so, it may be caused by the following reasons:
1) Spline of main shaft bush engaged with main shaft. This is caused by shaft distortion,
bending of fork or of spline of main shaft bush.
2) Declutch shift shaft is engaged in housing, other parts interferes on fork shaft.
2. Off-gear of main box
When move synchronizer bushs to engage with gear of main box, the engaged teeth must be
parallel. If there is tape or wear on the soldered teeth, separation would happen while
rotating, off-gear may occur in some condition.
1) Input shift has different center with spigot bearing in flywheel of engine;
2) Violent strike between gears while shifting cause surface wear of soldered teeth;
3) Soldered teeth are grinded to cone shape;
4) Because the compression spring released or over wear of self-lock bolt shaft and
quarter self-lock block causes deficiency self-lock.
5) Inadequate adjustment of remote shifting operating parts causes that soldered teeth
can not engage completely with bush.
6) Off-gear usually happens when the automobile is slowed down while drove in full
power or be drove under loading.
7) When automobile is running on unsmooth road, the shift lever may swing like
pendulum if it is too long or overweight, possibly resulting in off-gear to the swing of
the shift lever and overcome pressure from lock spring.
3. Off-gear of auxiliary gearbox synchronizer
Off-gear of synchronizer in auxiliary gearbox may be caused by wear of low speed clutch
body assembly in auxiliary gearbox, high speed clutch body assembly, synchronizing ring
and synchronizer bush soldered teeth and there is taper or uncompleted engagement.
Reasons caused these defects include strike while shifting and regular wear after long use.
Vibration caused by improper installation of transmission shaft and low pressure in air path
system also can result in off-gear.
4. Off-gear of HW 20716 transmission insert gear
Off-gear of insert gear synchronizer may be caused by wear of insert gear synchronizer
clutch body, synchronizing ring and insert gear synchronizer bush soldered teeth and there
is taper or uncompleted engagement.
Reasons caused these defects include strike while shifting and regular wear after long use or
misuse of insert gear and power take-off.
5. Leakage of double-H-valve assembly and two-position five-way valve assembly
Leakage of double-H-valve assembly mainly behaves as leaking from air plug on
double-H-valve assembly. It is normal if only leaks when range gear shifts, which is caused
by the structure of double-H-valve assembly itself; while trouble exists if leakage is found
all the time, reasons are:
1) O ring in range gear cylinder is not Seal tightly, at this time, screw the range gear
cylinder and test the suction pipe. Note: suction pipe is different when shift shaft is at
high and low gear.
2) Damage of sealing parts in double-H-valve assembly or foreign matters existing
between sealing parts would cause leakage.
6. Pressure switch trouble
Pressure switch troubles are mainly founded as: light-on or light-off of backup light, engine
can not starting at neutral gear or start when gear engaged. Check should be performed as:
firstly check for the power of the automobile, then check the pressure switch for availability
and the sensor pin flexible; and check the wire harness quality and its contact if applicable.
Section III Other Troubles Analysis & Diagnosis for HW

Transmission
We discussed the main failure types of transmission parts and operating parts in the last section. In
this section, we will mainly discuss about the basic parts, sealing parts and other relevant
problems.
I. Troubles analysis of basic parts
The basic parts mainly include: front housing, intermediate housing, rear housing, input shaft
housing, output shaft housing, small cover shell, small cover housing, countershaft housing, oil
pump body, oil pump housing, etc. which provide protections to the transmission locating the
moving parts and operating parts as well as bearing forces from inside and outside. Its failure
types mainly include fracture and wear. Analyze and diagnose what nature of force caused the
failure according to failed position and type.
Common trouble analysis of operating parts for HW series transmission:
1. Oil leakage of transmission housing
Oil leakage of transmission housing is caused by defects on housing, e.g. crack, sand
inclusion, shrinkage, porosity, etc. However the potential of these kinds of problems is little,
as all transmissions are tight tested before delivery.
2. Crack of transmission housing
If the transmission bears abnormal strength during operation, the front, middle and rear
housings may crack. Analyze external reasons carefully if the trouble is found, including
hanging of transmission assembly.
II. Troubles analysis of sealing parts
Basic parts of transmission assembly are classified into several parts according to
processing, assembling and maintenance requirements. All parts are to be connected during
assembly. According to the property, connection is classified as static sealing and dynamic
sealing. Parts used by static sealing are paper washer and sealing gum, which is assured by
assemble method, so the way and method must be pay attention to while assembling.
Sealing parts for dynamic sealing are oil seal and seal ring. Pay attention to the status of the
parts while assembling and adopt appropriate method. Its main failure type is oil seal lip
damage which causes oil leakage.
1. Oil leakage of joint surface
Key to solve such problem is to find out the oil leakage position, eliminate the doubtful
position and analyze the detail reasons that caused the leakage, and then repair it according
to these reasons.
2. Oil leakage of oil seal
Oil seal lip is pressed on the shaft preventing the lip and oil return line from leakage at oil
seal lip when rotates. Check the lip, the joint surface of oil seal and shaft and guiding
surface are according to seal principle when assembled, and special tools should be used to
ensure assembling quality.
III. Analysis on Other Troubles

1 Transmission overheat
Transmission’s temperature should no be no more than excess 120℃ after a long time
operation, or lubrication oil may deteriorated and the performances of non-metallic parts
declined, affecting the reliability and service life of transmission.
Transmission may generate some heat under friction of moving parts. Normal working
temperature is usually 40℃ higher than ambient temperature. The heat is discharged from
transmission housing. If the heat can not be discharged normally or there is other heat
source, overheat may be caused. Check oil temperature gauge and oil temperature sensor
firstly before finding the overheat reasons so as to ensure correct reading of oil temperature
gauge.
Generally, reasons for overheat are as follows:
1) Bad lubrication. Lubrication oil lever is over high/low, oil with wrong grade is
adopted or working angle of transmission excess 12°.
2) Continuous driving speed is usually under 32 Km/h.
3) Engine speed is too fast.
4) The transmission surrounded by auto frame, floor and fuel box, or installed among
the large bumper assembly, may be blocked with air flow getting through.
5) Engine air exhausting system is too close to transmission.
6) Ambient temperature is too high.
7) Overloaded and overspeed driving.
The early stage troubles resulting in troubles must be found out during trouble
analysis, and understand the orders these troubles happening as a whole.
IV. Common Trouble Analysis & Troubleshooting of New Automobiles
1. Light-on or light-off of backup light.
Analysis: Check the power supply of the automobile firstly, and check the top pin of reverse
gear switch whether it is tightly fixed or the switch is always on or off. If the trouble is
caused by pressure switch or sensor top pin, repair or replace the correspondent part.
2. Automobile engine is not startup.
Analysis: Check the power supply of the automobile firstly, and check the neutral gear for
failure and whether the sensor top pin is tightly fixed or not, check the quality of wire
harness and the contact thereof if applicable.
3. Reverse gear or high gear can not be engaged.
Analysis: Check whether the gear selector is adjusted to the proper position and whether the
reverse gear or high gear can be selected firstly. If it is the problem of transmission, check
whether there is interference of small cover shell and inside of intermediate housing,
whether the position of small cover assembly is correct compared with intermediate housing
and whether the pad has too large roughcast and interfered each other.
4. Unclear gear, engaged steering, position of neutral gear is not exact.
Analysis: Check the bar system for interrupts. Check the location of gear lock in small
cover assembly if it is the problem of transmission, replace the correspondent parts.
V. Common Trouble Types of HW Transmission
Trouble
No. Troubles Detail Description
Classification
Knocking, teeth collision and peel of teeth
1 Main shaft gear
surface of main shaft gear
Knocking, teeth collision, peel of teeth
2 Countershaft gear
surface and crack of countershaft gear
Knocking, teeth collision and peel of teeth
3 I shaft gear
surface of I shaft gear
Teeth collision, peel of teeth surface and
4 Internal gear ring
crack of internal gear ring
Teeth collision and peel of teeth surface of
5
planet wheel
Planet wheel Burnt and abnormal wear of roller in planet
6
wheel
7 Over wear of shimming of planet wheel
Moving parts Collision and peel of teeth surface of sun
8
wheel
9 Sun wheel Over wear of shimming (front) of sun wheel
10 Over wear of shimming (rear) of sun wheel
11 Crack of transition bush on sun wheel
12 Damage of countershaft bearing
13 Damage of I shaft bearing
14 Damage of front bearing of output shaft
15 Bearing Damage of bearing in gear ring frame
16 Damage of small bearing in output shaft
17 Damage of rear bearing of input shaft
18 Burnt of needle bearing in idle wheel
19 Crack of input shaft
Input shaft
20 Wear of input shaft spline
Trouble
Classification
21 Wear of internal guide bush of input shaft
22 Countershaft Countershaft crack
23 Main shaft crack
24 Main shaft head crack
25 Great axial moving of main shaft head
Main shaft
26 Crack of main shaft hex key
27 Wear of main shaft spline adjusting flake
28 Wear of main shaft spline flake
Abnormal noise of
29
transmission
30 Off-gear of transmission
31 Difficult neutral gear of transmission
32 Main box shifting of Difficult shifting of transmission
33 transmission Confusion gear of transmission
34 Crack of shift fork
35 Abnormal wear of shift fork
Failure and leakage of double H valves
36
assembly
37 Leakage of air connection line
38 Reverse connection of air connection line
39 Auxiliary gearbox shifting of Blow-by of range gear piston
40 transmission Incorrect range gear shifting
41 Rust of range gear cylinder
42 Crack and failure of range shift synchronizer
43 Control parts Range shift synchronizer hindered
44 Abnormal wear of range shift synchronizer
Failure of main box and auxiliary gearbox
45
Interlock plate of main box interlock plate
and auxiliary gearbox Trouble reset of main box and auxiliary
46
gearbox interlock plate
47 Leakage of air connection line
48 Reverse connection of air connection line
49 Blow-by of insert gear piston
50 Incorrect insert gear shifting
Insert gear shifting of
51 Rust of insert gear cylinder
transmission
52 Failure of insert gear synchronizer
53 Crack of insert gear synchronizer
54 Insert gear synchronizer hindered
55 Abnormal wear of Insert gear synchronizer
56 Front housing of Crack of front housing of transmission
57 transmission Oil leakage of front housing of transmission
Crack of intermediate housing of
58
Intermediate housing of transmission
transmission Oil leakage of intermediate housing of
59 Basic parts
transmission
60 Crack of rear housing of transmission
Rear housing of transmission
61 Oil leakage of rear housing of transmission
62 Crack of input shaft housing
Input shaft housing
63 Loose (tight) match of input shaft housing
Oil leakage of oil sealing of front of
64
transmission
Sealing parts Dynamic sealing
Oil leakage of oil sealing of rear of
65
transmission
Trouble
Classification
66 Oil leakage of oil sealing of small cover
Oil leakage of joint of oil pipe at front of
67
transmission
Oil leakage of joint of oil pipe at rear of
68
transmission
69 Oil leakage of Oil pump
Oil leakage of touch parts of front housing
70
and intermediate housing
Oil leakage of touch parts of rear shell and
71 Static sealing
intermediate housing
Oil leakage of touch parts of small cover
72
assembly and intermediate housing
73 Oil leakage of filter net housing
Oil leakage of small cover housing (near
74
range gear) and small cover shell
Oil leakage of small cover housing (near
75
lever ) and small cover shell
76 Failure of reverse gear switch
Reverse gear switch
77 Bad touch of reverse gear switch
78 Failure of neutral switch
Neutral gear switch
79 Bad touch of neutral switch
80 Failure of high and low gear switch
High and low gear switch
81 Others Bad touch of high and low gear switch
82 Failure of power take-off
83 Power take-off Power take-off hindered
84 Oil-leakage of power take-off
85 Overheat of transmission
86 Oil-route blocked
Section IV Damaged Parts Display
Failure of spare parts of transmission assembly is mainly caused by normal wear, quality problem
(to avoid such situation, please select spare parts made by China National Heavy Duty Truck
Group Corp., Ltd. referred as China Heavy Truck) misuse of transmission. Situation of damaged
parts is as follows:
1. Main shaft bush and gear
While shifting of main box, there is wear to main shaft bush and gear during the
synchronization, violent strike while shifting may quicken the wear. If there is taper or
serious wear on the soldered teeth of main shaft bush or gear, off-gear may be caused.
Failure spare parts are showing as Figure. 3-13.
Figure.3-13 Main shaft bush Figure.3-14 Gear

2 Transmission gear
Transmission gear transfers the driving force to shaft, under normal operation there may
appear spots at the middle of teeth height at the end of service life, such type of failure is
called “pit corrosion”; Plastic flow may occur under the condition of overloading caused by
friction force, which can damage the correct engagement accordingly; High speed and
overloading drive generates instant overheating because of high sliding speed, which breaks
oil film and results in welding and adhesion between teeth flank, after the welded part is
separated, a trace is left on the teeth surface in the gliding direction; Cold welding and
adhesion occurs in condition of low speed and overloading, which is called “gluing”; If
there are a great deal of hard granules(such as iron scrap) in the lubrication, “abrasive wear”
happens during gear engagement; over loading impact also can cause “teeth deformation” in
a short time. See Figure. 3-14.
3 Synchronizer
In order to improve the comfortableness of shifting, a synchronizer is added in the shifting
mechanism. Synchronization of synchronizer bush and gear waiting to be engaged is
realized by friction of internal parts so as to be propitious to shift. Both normal and
abnormal operation of synchronizer cause wears of the synchronizing parts. The spare parts
easy to wear include synchronizer ring and synchronizer clutch body, when serious wear of
which occurs, wear of soldered gear of synchronizer ring and clutch body or even collision
of teeth is caused. If the synchronizer’s working life is too short, using conditions of
transmission and synchronizer should be analyzed carefully. See Figure. 3-15 for the worn
parts.
Figure 3-15 High Gear Clutch Body & Synchronizer Ring

4 Oil seal
Oil seal is a common spare part used to isolate internal and external circumstance if there is
relative motion in machine. Its performance is not only related to the quality but also greatly
related to assembling method and using condition. If the oil seal fails in very short time,
probable reasons may be as follows: unqualified oil seal, improper assembling tools and
method, status of assorted shaft or hole, unqualified lubricant as well as content of
impurities.
Key points:
Trouble classification and common trouble types of HW transmission; trouble analysis methods of
HW transmission; common troubles and troubleshooting of new automobile; reasons for common
troubles and troubleshooting of HW transmission; main failed spare parts and mechanism analysis
of HW transmission.
Exercises:
1. How many trouble types for oil leakage of transmission assembly, list to explain. In order to
avoid such troubles, what should be noticed during maintenance?
2. Describe the trouble analysis methods.
3. What are the common troubles for new automobiles; explain and presents the resolutions.
4. What are the probable reasons for chomping of transmission assembly and how to remove?
5. Why the reverse gear can not engage and how to remove?
6. What are the probable reasons for off-gear of main box and how to remove?
7. What are the probable reasons for off-gear of auxiliary gearbox and how to remove?
8. What are the probable reasons for off-gear of insert gear and how to remove?
9. What are the probable reasons for difficult shifting of HW transmission and how to remove?
10. If the double-H-valve assembly leaks, is it failed ? How to diagnose?
11. What’s influence to transmission if it is overheated? What are the reasons and how to
diagnose?
12. Is it normal for wear of main shaft bush? How to diagnose?
13. What should be noticed while assembling oil sealing?
Chapter IV Recognition of After-Sale Parts
Requirements:
Master the method to recognize real spare parts and auxiliaries from the false, be able to
distinguish the real and false products according to relevant mark and other information.
Section I Recognition of Spare Parts
Using the spare parts made by China Heavy Truck not only can protect profit of the manufacturer,
building good service circumstances but also be good for extending the service life of transmission,
reducing the frequency of troubles and maintenance time and bringing the users with great benefit.
The transmission department of China Heavy Truck will publish Product Mark Map for HW
Transmission Spare Parts, at that time users can recognize the products from the false according to
the Map.
Examples for the Mark Map:
Mark No. Name Mark Manufacturer Remarks
AZ2210020105 Input Shaft 00332 37.14.00332

AZ2210020105 Input Shaft 0AA03 37.01.0AA03
AZ2210020105 Input Shaft 0AB06 37.01.0AB06
Besides the above marks listed, supplier, packing and external status, etc. can also be referred to
for determination. Only by integrating as much information as possible can identify the false spare
parts.
Section II Recognition & Use of Auxiliaries
There are many auxiliaries for transmission, see following table for details:
No. Name No. or Oil Grade. Remarks
1 Overloading gear oil 85W/90GL-4 or 85W/90GL-5 Special oil by CHT
2 Lubricating grease 2# Used for Clutch Release
Bearing
3 Screw sealant LOCTITE 242
4 Screw sealant LOCTITE 271
5 Silicone sealant LOCTITE 5699
6 Anaerobic adhesive LOCTITE 680
7 Clean agents
Overloading gear oil is used for lubrication of moving parts e.g. gear, bearing, etc. during the
transmission operation. Its performance greatly affects the normal operation of transmission and
seriously affects the service life of transmission. If false oil or oil with wrong grade is used,
probably serious wear to gear and synchronizer may be caused at the early grinding stage resulting
in irremediable loss. So please purchase gear oil with right grade from regular supplier and fill or
replace lubrication oil as per operation and maintenance requirements.
For other auxiliaries, using the above mentioned auxiliaries or choosing auxiliaries of equal
quality and performance with other sign are permitted.
Key points:
Method of verifying real and false spare parts of transmission; significance for using spare parts
made by China Heavy Truck; affects of overloading gear oil to transmission assembly.
Exercises:
1. How to recognize a factory spare part?
2. What are influences caused to normal use of transmission by using false spare parts and
give 2 to 3 examples according to your experiences.
3. What are influences caused to transmission by using false gear oil and give some examples.

Howo Series Transmission

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SINOTRUK

Training Materials for HW Series

SINOTRUK (Hong Kong) LIMITED

Editor in chief：YU Tianming

Chief censor：OUYANG Ping

Compiled by：REN Fuchen

Section I Cognizing of Transmission

II. Functions of Transmission

III. Classification of Transmission

Section II HW Series Transmission Features

I. Revelation of HW Series Transmission.

Figure 1-1: Shape of HW Series Transmission

II. Main Structure Features and Advantages of HW Series Transmission.

Figure 1-2: Drive Structure of HW Series Transmission

1. spindle，2. bush，3. ball joint，4. output shaft，5. bearing，6. input shaft

Figure 1-3: Float of Spindle and Planet Structure

The synchronizing ring of synchronizer of supplementary gearbox, which is made by

Figure 1-5: The Housing Structure of HW Series Transmission

Figure 1-6: Structure of Small housing Assembly of HW Transmission

Figure 1-7: Lubricating System of HW Series Transmission

Figure 1-8: PTO Installment of HW Series Transmission

Figure 1-9: Dual H Valve Assembly of HW Series Transmission

Figure 1-10: Shift Structure of HW Series Transmission

Section III Comparing HW Series Transmission with Another

I. Comparing with All Structures of Transmission.

II. Developing Tendency of Heavy Truck Transmission

Twin countershaft structure

Figure 1-11: Comparing Transmission of Heavy Truck

Green: common level of domestic factory.

Section I Structure of HW Series Transmission

I. Drive Structure of HW Series Transmission.

1. HW18709 Series Transmission

HW18709 series transmission is composed by main gearbox, two-section supplementary

Figure 2-1: Main Drive Structure of HW18709、HW18710 Series Transmission

HW 20716 series transmission composed by front supplementary gearbox, main gearbox

3. HW18710 and HW14710 Series Transmission

Figure 2-2: Structure of HW20716 Series Transmission

II. Control Structure of HW Series Transmission

1. HW18709 and HW20716 Series Transmission

Figure 2-3: Control Structure of HW 18709 and HW 20716 Series Transmission

2. HW18710 and HW14710 Series Transmission

Figure 2-4: Control Structure of HW18710 and HW14710 Series Transmission

The control structure of HW18710 and HW14710 Series Transmission is as shown in

Section II Drive Route and Shift Figure of HW Series Transmission

I. Drive Route of HW Series Transmission.

Reverse shift gear

Figure 2-5: Drive Route of HW18709 Series Transmission

10- shift gear

Reverse shift gear

Figure 2-6: Drive Route of HW18710 and HW14710 Series Transmission

Reverse shift gear

Figure 2-7: Drive Route of HW20716 Series Transmission

Shift Figure of HW20716 Series Transmission

Section III Main Technological Parameters of HW Series

I. Nameplate of HW Series Transmission

Figure 1-8: Nameplate of HW Series Transmission

Series number, heavy transmission series

1/10 1% torque, adopts 1/10 when less than three digitals.

A-AMT；X- overdrive；S- Synchronizer……

Customer No.: such as HW18709 071011

Design series No.

Model of HW transmission assembly.