NEWAGE 410 SERIES AXLE SERVICE MANUAL WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS U.K. Tel:++44(0)1204 854650 Fax:++44(0)1204 854663 E-mail service@winget.co.uk www.winget.co.
CONTENTS INTRODUCTION GENERAL DESCRIPTION IDENTIFICATION GENERAL SERVICE INFORMATION EXPLODED VEIW/PARTS LIST SECTION A PINION CARTRIDGE SECTION B DIFFERENTIAL ASSEMBLY SECTION C PLANET CARRIER ASSEMBLY SECTION D HUB, AXLE STUB AND AXLE ARM ASSEMBLY SECTION E BRAKES SECTION F SETTING UP CROWNWHEEL AND PINION SECTION G SPIRAL BEVEL GEAR TOOTH CONTACTS
Section 1 INTRODUCTION
Introduction Winget Limited gratefully acknowledge the assistance given by Newage Transmissions Limited in the preparation of this manual, however neither Winget Limited or Newage Transmissions can be held responsible for any errors or ommissions. The procedures described within this manual should enable experienced service personel to strip, repair and re-build Newage 410 series axles fitted to Winget 4S range site dumpers in a safe and competant manner.
410 Series axles are designed to operate under arduous conditions and providing they are regularly and correctly maintained they will provide long trouble free service. Whilst every effort is made to ensure the contents of this manual are accurate Winget Limited and Newage Transmissions reserve the right to alter specification without prior notification and certain sections of this manual may then no longer apply.
Section 2 GENERAL DESCRIPTION
General Description The 410 series is a double reduction drive axle with integral long life oil immersed multiplate disc brakes. Housed within the central housing is the spiral bevel crownwheel and pinion assembly. The crownwheel is mounted on a four pinion differential. The planetary reduction gears and brake plates are housed within the ends of the axle arms. The axle half shafts are fully floating and the wheel hubs run on opposed taper roller bearings. The approximate weight is 220KG (485lb).
Section 3 IDENTIFICATION
Identification A plate is attached to the centre housing of each axle on which are stamped details of the axle specification (see illustration below) and the axle serial number. If you require spares, both numbers on the plate should be quoted together with the machine model and serial number. The model number allocated to each axle describes the basic specification as follows:Axle Model Series 410 Fixed Pads R Rigid Drive F Code Number 14 Reduction Ratio 14.
Section 4 GENERAL SERVICE INFORMATION
General Service Information Routine Maintenance Check Interval For oil leaks around joints and seals Weekly/50 hours Wheel nut tightness Daily/8 hours Hub bearing adjustment 12 Monthly/1000 hours Axle arm/centre case bolts Weekly/50 hours Halfshaft securing nuts Weekly/50 hours Propshaft nuts and bolts Weekly/50 hours Brake pipe connections Weekly/50 hours Lubricants The oils used must have the correct additives to be compatible with the mineral oil braking system, therefore, only those lubr
Brake Fluid The oil immersed brakes are operated using a mineral hydraulic fluid. On no account must a vegetable based brake fluid be used otherwise all braking system seals will be damaged. Whenever the brakes are serviced it is essential that the cylinder bores, pistons and seals are cleaned before assembly and lubricated using one of the following mineral oils or their equivalent.
19 35 55 84 168 294 696 17 30 48 73 146 255 606 5/16 3/8 7/16 1/2 5/8 3/4 1" 515 217 124 62 40 26 829 349 200 100 65 41 23 11 7 14 NOM. MIN. 953 402 230 115 75 47 26 13 MAX. GRADE V 704 297 170 85 55 35 19 10 MIN. 1004 423 243 121 79 50 28 14 NOM. 1155 487 279 140 91 58 32 16 MAX. GRADE X NOM.
Section A PINION HOUSING
Servicing the Pinion Cartridge Assembly Section A Place a suitable container below the axle drain plug underneath the axle centre housing, remove the plug and drain the oil. Dispose of the oil safely in accordance with local bylaws and national regulations. Remove the setscrews securing the pinion cartridge to the centre housing and lift off the assembly. The cartridge is located to the centre housing on dowels and will require carefully prising free using a small pry bar or similar suitable tool.
Section B DIFFERENTIAL ASSEMBLY
Servicing the Crownwheel and Differential Assembly Section B Refer to Sections A, D and E and remove the pinion cartridge, axle arm assemblies, sungears and brake plates. Withdraw the brake pistons and discard the “O” rings. Remove the cap headed screws and brake pipe adaptors retaining the brake cylinders into the centre casing, mark both the cylinders and casing so that the cylinders can be refitted in their respective ends of the casing on re-assembly.
Section C PLANET CARRIER ASSEMBLY
Servicing the Planet Carrier Assembly Section C To gain access to the planet carrier refer to Sections D and E and remove the axle arm, sun gear and brake plates. Withdraw the brake spacer plate from within the axle arm and lift out the planet carrier assembly. Check the teeth on the planet gears, sun gears and annulus gears for wear. The planet gears should run freely on the planet pins without excessive radial play.
Section D AXLE ARM & HUB ASSEMBLY
Hub, Stub Axle and Axle Arm Assembly Section D The Hub, Halfshaft and Stub Axle can be serviced with the Axle in situ on the machine. The Hub Assembly Remove the ring of nyloc nuts round the halfshaft securing the shaft to the hub, withdraw the shaft and check the splines for wear or damage. Check the shaft for signs of twist or distortion (A drip tray placed below the hub will catch any oil which runs from the hub).
Axle Arm Removal It is recommended that the axle is first removed from the dumper before the axle arm is removed. Drain the oil from the axle as described under section A, remove the halfshaft as described previously. Support the weight of the axle arm and remove the ring of bolts around the flange of the arm. Place a drip tray below the axle arm and case to catch any oil which may run out. Carefully withdraw the arm away from the centre housing taking care with the brake plates, discs, sun gears etc.
Section E BRAKES
BRAKES Section E Note: the brakes operate on a mineral hydraulic fluid. On no account must a vegetable based brake fluid be used otherwise all braking system seals will be damaged. To gain access to the brake components it will be necessary to refer to Section D and remove the axle arm assemblies. Remove the brake friction and fixed plates from the sun gears and withdraw the sun gears from the planet carriers.
Section F SETTING PROCEDURE CROWNWHEEL & PINION
Setting Up The Crownwheel And Pinion Section F A) When a new Spiral Bevel Pinion is fitted. Assemble the pinion and bearings into the cartridge and adjust the bearing preload as described on Section A, note the Mounting Distance “MD” stamped on the front face of the old and new bevel pinons. The shim pack thickness used with the old pinion must be adjusted to suit the new bevel pinion as follows:a) If the new MD is less than the old figure decrease the shim pack thickness by the difference.
Select a shim pack of the correct thickness and fit to the pinion cartridge, slacken the differential bearing adjusting ring nuts and install the pinion cartridge to the maincase ensuring the crownwheel and pinion are correctly meshed. Retain the pinion cartridge to the main case using two setscrews.
Section G SPIRAL BEVEL GEAR TOOTH CONTACT
Spiral Bevel Gear Tooth Contact Section G The illustration shown below is intended as a reminder to those who are unfamiliar with the terminology applied to Spiral Bevel Gear Teeth Convex Flank Concave Flank The markings on a crownwheel which is correctly meshed with the pinion should resemble those shown on the illustration below:- Although the contact point on both flanks of the teeth may vary slightly, generally speaking when correctly setup the markings on both the convex and concave flanks will be i
If when comparing the contact markings they appear similar to the illustrations below the corrective action indicated is required. Pinion Too Far Out of Mesh Convex Flank Contact markings closer to toe and tip than factory markings Concave Flank Contact markings closer to heel and tip than factory markings. Remedy:175 series Re-check and increase shims behind head of pinion. 200 series Re-check and increase shims behind head of pinion. 210 series Re-check and increase shims behind head of pinion.
Pinion Too Far into Mesh Convex Flank Contact markings closer to heel and root than factory markings Concave Flank Contact markings closer to toe and root than factory markings. Remedy:175 series Re-check and decrease shims behind head of pinion. 200 series Re-check and decrease shims behind head of pinion. 210 series Re-check and decrease shims behind head of pinion. 220 series Re-check and decrease shims behind head of pinion.
