User Manual
Contents
1. loosen nut F14 and bolt F13 and gently drift the lever from spline 7 Remove 6 M6 cap head bolts E21 per side and withdraw cover E18 spring E16 and brake lever LH or RH F12 8 Repeat steps 6 and 7 for the opposite hand Note The cap spring and brake lever are handed and on rebuild must be fitted to the same side of the axle Page 14 615 Service Manual 9 Check the condition of the brake lever bush E22 bore If this requires replacing drift it through the main case Ensure the replacement is fitted square 10 To reassemble reverse the above procedure replacing the brake lever bush o rings E19 E20 with the brake lever bush E20 Page 15 615 Service Manual NOTE F COMPONENTS ARE STRUCTURED WITHIN THE GENERAL PARTS 615 Service Manual 5 6 Section F General parts g e K n N MN AADNNNONN NNN Description Axle shaft Cover wheel hub seal Axle arm Bolt M12 Dowel pin Annulus Sun gear Brake spacer plate Brake disc Brake plate Brake lever RH Brake lever LH Bolt M10 Nyloc Nut M10 ASSEMBLE IN TO AXLE MAINCASE Page 17 615 Service Manual SAFETY Prior to removal of an axle arm we recommend that lifting tackle is available due to the weight of the associated components 1 Making sure the weight is fully supported remove the bolts F4 around the flange of the axle arm connecting it to the maincase and withdraw the a2. pinion setting up procedure Record the following information of the original components in the following sequence a The pinion A3 mounting distance etched on the head b The overall bearing width of pinion head bearing A7 A8 c The shim thickness A4 d a b c If replacing the pinion A3 or pinion head bearings A7 A8 the following procedure needs to be carried out Record the following information of the new components to be fitted as follows e The pinion A3 mounting distance etched on the head f e f g The new shim thickness A4 to be determined New shimming Shim thickness Old pinion head Brg amp shim New pinion head Brg h d Page 5 615 Service Manual 12 13 14 16 17 18 19 20 21 22 To assemble the unit reverse the above procedure and proceed as follows Pinion assy must be fitted before crown wheel diff assy Tighten the new pinion nut A10 until the new spacer A6 collapses and all the end float between the pinion bearings is taken up Drag torque 1 92 2 48Nm 17 22 lb in Spin over several times and recheck torque Note the tightening torque to collapse the spacer should not be less than 245 Nm 180 Ib ft This equates to a pre load of 59 98N 13 2 22lbf for new bearings or 29 5 59N 6 6 13 2lbf for used bearings is obtained The pre load is measured by binding a piece of string around the coupl
3. Axle Backlash Figures Axles Series 615 Assy 618 9820 Assy 619 9820 Pin wheel 618 2000 618 2010 619 2000 619 2010 Drive Flange 615 2180 HS 1410 617 2180 HS1410 Metric 618 2180 HS 1510 915 2180 1480 Yoke 615 2180 HS1416 617 2180 HS1410 Metric 618 2180 HS 1510 915 2180 1480 Yoke Page 3 95 30 95 30 120 66 108 05 95 30 95 30 120 66 108 05 Backlash 0 31 0 39 0 31 0 39 0 39 0 47 0 47 0 55 0 31 0 39 0 31 0 39 0 39 0 47 0 47 0 55 615 Service Manual 615 AXLE ASSEMBLIES 5 1 Section A Crown wheel and Pinion Assembly Qty 1 1 1 As required As required As required ND ND ND SECTIONAL VIEW SEE MAINCASE ASSY Description Spiral bevel wheel Input drive flange Spiral bevel pinion Shim 0 25mm Shim 0 3mm Shim 0 4mm Seal Collapsible spacer Bearing cup Bearing cone Plain washer Nut M20 Seal cover DOO TOO Page 4 615 Service Manual Removing amp Servicing the Crown Wheel and Pinion 11 12 Remove the drain plug E6 and drain the axle oil Remove both axle arm assembly s by removing 12 bolts per side F4 page 17 Withdraw the planet carrier assy see Section C and sun gear F7 Remove annulus F6 using extractor tool or pinch bars Remove the brake spacer plate F8 and the other brake components F9 amp F10 See Section E Use pinch bars at the
4. a double reduction unit with oil immersed multi plate disc brakes The centre casing houses the 1st reduction spiral bevel pinion and crown wheel fixed to a 4 pinion differential the oil immersed brakes and the 2nd reduction planetary assembly The axle shafts are fully floating i e not subjected to wheel loads with the wheel hubs supported on opposed tapered roller bearings 3 IDENTIFICATION If spares are required please quote the axle series and the vehicle machine model and serial number Newage axles are produced with a variety of track widths mounting centres wheel hub centres ratios and input couplings to suit individual customer requirements therefore it is important to identify the axle correctly The part number allocated to each axle describes the basic specification as below AXLE MODEL CUSTOMER CODE NUMBER 615 PB 16 X12 1 PB WILL INDICATE PARK APPROX REDUCTION RATIO VARIANT AND SERVICE BRAKE Page 1 615 Service Manual 4 GENERAL SERVICE INFORMATION 4 1 Routine Maintenance e Check for oil leaks around joints and seals Weekly e Check wheel nut tightness Weekly e Check wheel hub bearing adjustment 1 000 hours e Check axle Arm Maincase joint securing bolts Monthly e Check Half Shaft bolts Monthly e Check Prop Shaft Nuts Monthly 4 2 Lubricants Only those lubricants shown below or their direct equivalents must be used e MOBIL FLUID 422 The oil is added via the combined filler level plug po
5. back of the brake piston E11 to extract Unscrew and remove 4 shoulder screws E9 and extract the Diff Bearing Carrier E3 through the bore of the Maincase E1 Feed Diff and crown wheel assembly through bore of the Maincase IMPORTANT It is essential that a protective sleeve is used over the parts being withdrawn through the bore to prevent damage to the piston location bore Failure to observe this procedure will result in a loss of brake efficiency or complete brake failure To remove tab washers E4 securing the diff housing release the two screws 2 screws E23 from Diff adjusting nut E2 Unscrew brg adjuster nuts E2 and push brg cups E8 out of bores While reacting against drive flange to prevent it from turning release the nut A10 and remove the washer AQ from the pinion shaft A3 Remove the flange A2 Using a soft drift remove the pinion taking care not to damage the teeth Inspect the bearings A7 A8 for wear and damage If replacing the inner bearing on the pinion head use a bearing puller to extract the cone Discard collapsible Spacer A6 Drift out Brg Cups A7 8 from the main case bore taking care not to loose shims A4 located behind the Brg cup of the pinion head bore IMPORTANT Once dismantled it is necessary to reset the pinion backlash to ensure the correct meshing of the crown wheel pinion Always use new collapsible spacer A6 and a new nut A10 See section F for the crown wheel
6. wheel A5 can now be drifted off diff case The assembly will split into 2 halves Taking care not to lose internal components Inspect all gears bearings and spider for damage and wear Replace if necessary 10 To reassemble reverse the procedure Important Great care must be taken when refitting the reassembled diff back into the main Clearance is very limited and to avoid personal injury it is advisable lower the fully assembled diff into the case using a sling made from strong twine Note To reset the back lash see page 5 taking note of para 5 also Page 9 615 Service Manual 5 3 Section C Planet Carrier Assembly Note This procedure assumes the axle is stripped down to the main assembly only with planetary Remaining in place 1 The planet carrier assembly can now be removed from the centre casing Take care not to withdraw the floating sun gear 2 Check the planet gears and the mating gear teeth on the annulus and sun gear for damage and wear The planet gears should run free in the planet pins without excessive radial play Replace if worn Note When servicing the planet assembly we recommend all three gears and bearings are replaced See section A 3 To replace the planet gears pins or bearings drift the spring dowel C8 which locates the planet pins C2 through the planet carrier C1 lightly drift the planet pins through the planet carrier Remove the loose planet gears C4 thrust washe
7. 1 Bearing D7 1 Bearing D8 1 Hub seal D9 1 Spacer D10 1 Lock washer D11 1 Locknut SEE GENERAL PARTS Page 12 615 Service Manual Servicing the Hub Assembly The hub assembly can be serviced with the axle arm still connected to the maincase Procedure is as follows 1 Remove bolts D4 that secures the axle shaft F1 to the hub and withdraw the shaft Inspect the spline form for damage and wear Flat on hub is provided to aid extraction Straighten locking tab ears on lockwasher D10 undo lock nut D11 remove lockwasher D10 and bearing spacer D9 The hub D1 can now be withdrawn from the axle arm stub Care must be taken not to drop the loose brg cone Examine all Brg cups amp cones for wear or damage replace as necessary Note We recommend the hub oil seals are always changed when the hub has been removed The bearing cup D6 amp D7 can be drifted out of the hub D1 if they need replacing When fitting new cups D6 amp D7 ensure that they are aligned squarely to the bores before pressing in Note If the brg D7 is replaced oil seal D8 will also need replacing If the oil seal shield F2 needs replacing it can be drifted off the axle arm When drifting on the replacement care must be taken not to damage the oil seal running diameter Before refitting the seal housing ensure all of the original sealant is removed this may require use of a solvent Apply Loctite grade 601 to bot
8. NEWAGE SERVIGE MANUAL 615 Series Axle Issue 1 February 2002 615 Service Manual CONTENT 1 INTRODUCTION 2 GENERAL DESCRIPTION 3 IDENTIFICATION 4 GENERAL SERVICE INFORMATION 4 1 Routine Maintenance 4 2 Lubricants 4 3 Greases 4 4 Brake Fluid IMPORTANT 4 5 Liquid Sealant 4 6 Fasteners Tightening Torque 4 7 Axle Backlash Figures 5 615 AXLE ASSEMBLIES 5 1 Section 5 2 Section B Differential Assembly 5 3 Section C Planet Carrier Assembly 5 4 Section D Hub Assembly 5 5 Section E Axle Maincase Assembly 5 6 Section F General Parts 6 SPIRAL BEVEL GEAR TOOTH CONTACT A Crown Wheel and Pinion Assembly 615 Service Manual 1 INTRODUCTION Spare parts for Newage axles may only be obtained from the original equipment manufacturer and not directly from Newage Always quote your vehicle machine serial number and axle serial number see section titled Identification If possible the repair service should be carried out in a clean environment Where this is not possible and the work must be completed on site appropriate measures must be taken to ensure that dirt or foreign matter does not enter the unit Newage axles are designed to operate in the arduous conditions found in the construction industry providing they are maintained regularly they will provide the service our customers expect from Newage products 2 GENERAL DESCRIPTION The 615 series axle is
9. eak level return spring E17 1 Handbrake lever cover RH E18 1 Handbrake lever cover LH E19 2 Handbrake lever O ring E20 2 Handbrake lever O ring E21 12 Screw M6 E22 2 Brake lever bush E23 4 Screw M6 IMPORTANT The axle brakes operate with a mineral hydraulic fluid ISO VG32 Specification DO NOT USE Vegetable based brake fluid SAE J1703 should not be used 1 To gain access to the brakes the procedure is the same as previously described in section B 2 When removing the brake plates count them as the number can vary with axle models Under normal operating conditions the brakes should last several years The condition of the brakes can be checked as follows e Sintered brake disc F9 not less than 4mm thickness e Fixed brake plate F10 not less than 2mm thickness Check for uneven surface wear or heat discolouration on fixed plate 4 The brake piston E11 can be gently removed from the cylinder using pinch bars in a scissor fashion locating them behind the piston Check o rings E10 E12 for wear or damage Note All brake components must be free of damage amp remain clean at all times if in doubt change the appropriate parts 5 To reassemble reverse the above procedure Ensure that piston bores are clean and the brake plates are assembled on the sun gear spline F7 with the oil feed holes in the sintered plates correctly aligned for oil circulation 6 To remove hand brake operating lever E14
10. h the to seal housing location point of the arm and to the seal housing diameter immediately prior to reassembly Ensure the seal diameter is free from dirt and damage Prior to reassembly of the hub Brgs apply a recommended quality grease to ensure the Brgs are lubricated on the initial start up To reassemble the hub assembly clean off the original silicone sealant with a solvent Reapply a continuos bead of silicone sealant and reseal the axle shaft joint to the hub using the same silicone sealant reverse the above procedure using a new lockwasher D10 Note To adjust the hub bearings e Tighten the lock nut D11 to a torque of 140 Nm 100 Ib ft When checking the torque setting turn the wheel hub a few turns in each direction to ensure the bearings have seated correctly and recheck tightening torque Repeat this procedure 3 times e Slacken the nut back a distance equal to 2 tabs of the lock washer D10 e Bend ear of lock washer over to secure the nut Page 13 615 Service Manual 5 5 Section E Axle Maincase Assembly See Diagram on page 16 Item Qty Description E1 1 Maincase E2 2 Bearing Adjustment Nut E3 1 Diff bearing carrier E4 2 Lock plate E5 1 Breather E6 2 Drain plug E7 2 Bonded seal E8 2 Bearing cup 2 Bearing cone E9 4 Shoulder screw E10 1 O ring small E11 1 Brake piston E12 1 O ring large E13 1 Bleed valve E14 2 Hand brake operation lever E15 1 Break level return spring E16 1 Br
11. ing A2 and measuring the load to turn the coupling with a spring balance see drawing below This must be carried out with the crown wheel pinion mesh disengaged Fit diff bearing cups E8 into the maincase E1 and diff Brg carrier E3 Screw Brg adjuster nut E2 loosely to retain Brg cups in housing bores It is advisable to stand maincase on its end with the brg cup E8 on the bottom Lower differential assembly complete with crown wheel through main bore until the bottom bearing E8 seats in the bearing cup E8 See para 5 on page 5 Fit Diff Bearing Carrier E3 so that the 2 tapped holes for locating screws are towards the brake feed holes on the maincase This is important as it will allow good oil circulation to other internal components Ensure that the shoulder screw holes align with the holes in the maincase Apply silicone sealant to under the head prior to fitment of the shoulder screw E9 and repeat three times Torque to the recommended figure Insert bearing cone through Diff Bearing Carrier E3 and loosely fit bearing adjuster nut E2 Position Maincase E1 so bore is horizontal Adjust both bearing nuts E2 to obtain the required pinion amp wheel backlash Tighten to the recommended tightening torque See section 4 7 Locate two new tab washers E4 to both adjusting nuts E2 fit two screws E23 and tighten to the recommended torque Ensure all joints are clean and free of the original jointing c
12. ompound and reseal Locate each axle arm assembly on the dowels positioned in the main case refit the 12 bolts F4 and tighten to recommended tightening torque Refit drain plug E6 and refill to the correct level with recommended oil Page 6 615 Service Manual 5 2 Section B Differential Assembly Item Qty Description B1 1 Diff case LH 1 Diff case RH B2 2 Diff wheel B3 2 Diff pinion B4 2 Thrust washer B5 4 Thrust washer B6 2 Diff spider half B7 8 Bolt M10 B8 8 Nyloc nut M10 87 SEE CW amp PINION ASSY STRUCTURED WITHIN THE MAINCASE ASSY Page 8 615 Service Manual Servicing the Differential Assembly 9 Note This procedure assumes the axle is stripped down to main case assembly only To remove the annulus F6 using an extractor tool or pinch bars located behind the annulus in a scissor fashion Remove the brake spacer plate F8 and the brake components F9 F10 See Section E Using pinch bars at the back of the brake piston E11 to extract Remove the 4 shoulder screws E9 and extract the Diff Bearing Carrier E3 through the bore of the Maincase E1 Feed Diff and crown wheel assembly through bore of the Maincase Note See para 5 page 5 Remove 2 screws E23 securing the diff Brg housing tab washer E4 to the diff Brg adjuster nut E2 Unscrew brg adjuster nuts E2 and push Brg cups E8 out of bores Remove the 8 nuts amp bolts B7 B8 The crown
13. r C5 and planet Brgs C3 Remove circlip C6 which secures the spacer C7 Note the spacer C7 is fitted with the chamfer facing outwards 4 Remove the old spring dowels C8 from the planet carrier C1 To reassemble Replace the spacer amp circlip C6 C7 fit the planet Brgs C3 into planet gears C4 locate the bottom thrust washer place the planet gear on top of the thrust washer and from the underside gently tap the planet pin through the carrier thrust washer amp planet gear Note when you begin this procedure it is important that the cross in the planet pin is aligned with the cross hole in the planet carrier When part way through fit the top thrust washer and continue to drift the planet pin all the way through the carrier until it is flush 6 Secure by fitting new spring dowel C8 and pein over the hole in the planet carrier to prevent the spring dowel from drifting out of position 7 Check for free rotation of the planet gears 8 To refit to the main case engage the spline of the sun gear F Mesh the planet gears with the annulus F6 and push into position Page 10 WD 2 4 Description Planet carrier Planet pin Needle bearing Planet gear Thrust washer Circlip Spacer Spring dowel Page 11 5 4 615 Service Manual Section D Hub Assembly Item Qty Description D1 1 Hub i e per side D2 8 Wheel stud D3 8 Wheel nut D4 10 Bolt M10 x 30mm D5 2 Dowel pin D6
14. sitioned in the rear of the axle maincase Approximate oil capacity of 11 4 litres 20 1 pints 4 3 Greases Pack the gaps between oil seal lips at major overhauls or whenever a repair to these areas is performed e CASTROL SPHEEROL L EP2 4 4 Brake Fluid IMPORTANT The axle brakes operate with a mineral hydraulic fluid ISO VG32 On no account must a vegetable based brake fluid SAE J1703 be used Whenever the brakes are serviced it is essential that the cylinder bores pistons and seals are clean before assembly and may be lightly coated with one of the mineral based fluids shown below e MOBIL DTE24 4 5 Liquid Sealant The Axle Arm Maincase joint faces must be sealed with any of the following e LOCTITE 595 e HERMETITE RED 4 6 Fasteners Tightening Torque e Differential assy bolt M10 Grade 10 77Nm 56 Ib ft e Differential assy nut M10 Grade 10 77Nm 56 Ib ft e Diff bearing carrier shoulder bolt M10 61 Nm 45 Ib ft e Handbrake end cover cap bolts M6 10 Nm 8 Ib ft e Diff Bearing carrier tab washer bolts M6 10 Nm 8 Ib ft e Differential bearing adjuster nuts 21 Nm 15 Ib ft e Axle arm main case bolts M12 96 Nm 71 Ib ft e Coupling nut M20 Drag Torque 1 92 2 48Nm 17 22 Ib in after collapsing spacer e Wheel nuts 7 8 B S F 407 Nm 300 Ib ft e Wheel nuts 18mm 270 Nm 200 Ib ft e Axle shaft Wheel hub bolts M14 156 Nm 115 Ib ft Page 2 615 Service Manual 4 7
15. xle arm F3 Note this can be done with or without the hub assembly fitted to the arm 2 Before refitting the axle arm ensure the mating faces on the axle arm flange and centre case are clean and free of damage Apply a continuous bead of the recommended sealing agent see section 4 5 3 Refill with see page to the correct level 6 SPIRAL BEVEL GEAR TOOTH CONTACT Page 18 615 Service Manual Contact may vary but generally is approximately in the tooth centre equi spaced between root and tip The marking may be towards toe on some gears on both flanks or marking crossed slightly i e towards toe on convex flank and heel on concave flank or vice versa If compared to the factory tooth contact the contact appears as shown below then corrective action should be taken as follows 6 1 ERROR 1 Pinion too far out of mesh Convex flank Contact further to toe and tip than factory marking Concave flank Contact further to heel and tip than factory marking ACTION Recheck and decrease shims below pinion cartridge flange Page 19 615 Service Manual 6 2 ERROR 2 Pinion too far into mesh Convex flank Contact further to heel and root rather than factory marking Concave Flank Contact further to toe and root than factory marking ACTION Recheck and increase shims below pinion cartridge flange Page 20
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