User Manual
Contents
1. Page 12 5 6 Section F Axle Arm Assembly Page 14 5 7 Section G Hydrostatic Dropbox Assembly Page 15 6 CROWN WHEEL AND PINION ASSEMBLY HYDROSTATIC VERSION Page 17 7 SPIRAL BEVEL GEAR TOOTH CONTACT 415 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 415 series axle is 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 whee2. 69 86 101 50 415 Service Manual Backlash 0 27 0 36 0 22 0 30 0 21 0 28 0 23 0 32 0 19 0 26 0 29 0 38 5 415 AXLE ASSEMBLIES 415 Service Manual 5 1 Section A Pinion Cartridge Assembly rrr E RoR D 3 Qty 1 1 1 As required As required As required 1 1 2 2 1 1 1 Description Input pinion cartridge Input drive flange Spiral bevel pinion Shim 0 25mm Shim 0 3mm Shim 0 4mm Spiral bevel wheel Spacer collapsible for non hydrostatics Bearing cup Bearing cone Plain washer Nut M20 Oil seal NB Not valid for hydrostatic version STRUCTURED WITHIN THE MAINCASE ASSY COLOCO Page 4 415 Service Manual Removing 8 Servicing the Pinion Cartridge Assembly 10 11 Remove the drain plug E6 and drain the axle oil Remove both axle arms assy by removing bolts F4 Withdraw the sun gear F7 Remove 10 bolts E3 around the pinion cartridge Using the M10 extraction bolts not supplied remove the crown wheel differential assembly through the pinion cartridge aperture Remove the pinion nut A10 from the pinion shaft A3 along with the washer AQ and the coupling A2 Inspect the bearings A7 A8 for wear and damage If the inner bearing on the pinion shaft needs replacing use a bearing puller to extract the cone taking care not to damage the shims positioned behind the bearing cone If the bearing cups or oil seals need replacing they can be presse
3. Page 9 Qty 1 5 or 6 5 or 6 AA AA AND 415 Service Manual Section D Hub Assembly Description Hub i e per side Wheel stud Wheel nut Bolt M10 x 30mm Dowel pin Bearing Bearing Oil seal Spacer Lock washer Locknut CDA CACH SEE GENERAL PARTS Page 10 415 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 off its support bearings Examine all bearings and oil seals for damage and wear and replace if necessary The bearing cups 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 Ifthe 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 rubbing surface Apply Loctite grade 601 to both the arm and seal housing diameters only before assembly Clean off any r
4. distance only available the preferred procedure would be to carry out the following procedure 1 2 10 Repeat steps 1 10 Record the following information of the current and new components as follows a Current fitted pinion A3 mounting distance etched on the head b New pinion A3 mounting distance etched on the head c The new overall width of the pinion head bearing A7 A8 d Note 415 axle mounting distance constant 110 35 e Shim thickness A4 f Difference in a amp b Note Overall length of the slave setting spacer A6 24 30 Press or drift home the new pinion head bearing cone A7 A8 Calculate shims as follows Record the difference in a mounting distance and b mounting distance If a is greater than b subtract the difference f If a is less than b add the difference f For 415 axle use pinion cartridge mounting distance d 73 00 e d f c Fit new shims A4 at new thickness e into pinion cartridge head bore and press or drift home bearing cup A7 A8 into bore trapping shims Press new bearing cup A7 A8 into pinion cartridge head bore Fit new slave bearing setting spacer A6 of 24 30mm pre determined length This will enable end float to exist Follow points 19 to 22 24 to 26 28 30 31 33 34 Attach a dial test indicator to drive flange and apply hand pressure in forward and reverse direction and check movement i e end float and re
5. solved by the equation e e old X Y Z Note use information 10 Fit new shims A4 of new thickness c into pinion cartridge head bore and press or drift home new bearing cup A7 A8 into bore trapping shims Press new bearing cup A7 A8 into pinion cartridge tail bore Fit new bearing setting spacer A6 of overall length e over pinion diameter up to new bearing fitted at pinion head end Drift bearing cone over pinion tail end Refit new crown wheel to diff case and secure by tightening the new nyloc nuts to recommended tightening torque Loosely screw the new bearing adjusting nuts to retain diff assy in pinion cartridge Clean maincase pinion cartridge and transfer case joint face using recommended Ambersil F10 Solvent on joint face Apply thin continuous bead of the recommended sealant to the maincase joint face and LH transfer case joint face Fit crownwheel differential assy through pinion cartridge aperture Fit LH transfer case over pinion cartridge and tighten new nyloc nuts to recommended tightening torque Refit output wheel over pinion spline with inner part of the roller bearing fitted to the gear and outer fitted with RH transfer case Refit input pinion with bearings fitted to LH transfer case half Clean transfer case joint faces using recommended Ambersil F10 Solvent Apply a thin continuous bead of the recommended sealant to the LH transfer case joint face Refit the RH case this
6. NEWAGE Driveline Solutions SERVICE MANUAL 415 Series Axle Issue 1 January 2002 415 Service Manual CONTENT TINTRODUCTION iia IA es Peg be owes Ae E i bok Made Bes ded aoe Page 1 2 GENERAL DESCRIPTION Page 1 S IDENTIFICATION iii gt acta eee Ad ea head Hee BAG SRG AA Page 1 4 GENERAL SERVICE INFORMATION Page 2 4 1 Routine Maintenance cee tenets Page 2 4 2 Lubricants ii etaawie eae ey haw eed ee ea a EE aa Page 2 4 3 Glases chic i ce ai ind Soke Bee eek ete he tht aie eee bet ka Page 2 4 4 Brake Fluid IMPORTANT Page 2 4S gud Sealant 430 ste IA oleae Oboe eee BEES EOE ee ed Page 2 4 6 Fasteners Tightening Torque Page 2 4 Axle Backlash FIQures sowie saves dhs Lobe keene Gee dg dae pM ee ed Se Page 3 5415 AXLE ASSEMBLIES ii ence aay Sea Aaa Page 4 5 1 Section A Pinion Cartridge Assembly Page 4 5 2 Section B Differential Assembly Page 7 5 3 Section C Planet Carrier Assembly Page 9 5 4 Section D Hub Assembly risit siani a ni i eee nee eens Page 10 5 5 Section E Brake Assembly
7. RTANT The axle brakes operate with a mineral hydraulic fluid SO 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 Pinion Cartridge Maincase amp 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 stud M10 56 Nm 42 Ibf ft e Differential assy nut M10 56 Nm 42 Ibf ft e H B End end cover cap bolts M6 28 Nm 20 Ibf ft e Differential brg adjuster nuts 21 Nm 15 Ibf ft e Pinion cartridge main case bolts M10 56 Nm 42 Ibf ft e Axle arm main case bolts M10 56 Nm 42 Ibf ft e Coupling nut M20 340 Nm 250 Ibf ft Hydrostatic only e Wheel nuts 5 8 B S F 245 Nm 180 Ibf ft e Wheel nuts 18mm 270 Nm 200 Ibf ft e Wheel hub bolts M10 56 Nm 42 Ibf ft Page 2 4 7 Axle Backlash Figures Axles Series 415 Assy 415 9820 Pin wheel 415 2000 250 2010 Drive Flange 419 2180 419 2181 421 2180 HS1410 415 2180 415 2181 416 2180 416 2181 HS1310 420 2180 420 2181 DIN90 417 2180 417 2181 DIN100 418 2180 418 2181 HS1100 422 2180 DIN120 Page 3 95 30 79 40 74 50 84 00
8. anet carrier assembly see Section C 2 Remove the annulus gear F6 and brake spacer plate F8 The oil immersed brake discs F9 and the brake fixed plates F10 can now be removed Count the number of plates taken out as the quantity can very with different axle specifications 3 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 wear or heat discolouration on fixed plate 4 The brake piston E11 can be removed from the cylinder and the seals E10 E12 checked for damage and wear 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 6 To remove hand brake operating lever E13 loosen nut F14 and bolt F13 and withdraw from spline 7 Remove 6 M6 cap head bolts E21 and withdraw cover E18 spring E16 and brake cam F12 8 Repeat steps 6 and 7 for the opposite hand Note The cap spring and brake cam are handed 9 Toreassemble reverse the above procedure replacing brake cam O rings E19 and E20 Page 12 OENE EDENE DA 415 Service Manual 5 6 Section F Axle Arm Assembly Ite Qty Description F1 1 Axle shaf
9. cord movement Reverse the procedure up to 8 Page 19 11 12 415 Service Manual Subtract the end float recorded from the slave bearing setting spacer A6 24 30mm 0 025mm end float and fit new spacer of the calculated length Note 0 025mm subtracted to obtain pinion bearing pre load Follow points 23 to 35 37 38 39 40 amp 41 to rebuild the unit Page 20 415 Service Manual 7 SPIRAL BEVEL GEAR TOOTH CONTACT 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 7 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 21 415 Service Manual 7 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 22
10. d or drifted out of the cartridge housing Unpein 2 adjuster nuts E2 and remove Differential assembly will now be free to remove from the pinion cartridge IMPORTANT If any components are replaced a new collapsible spacer A6 amp pinion nut A10 must be used and the crown wheel pinion backlash will need checking see Section F crown wheel pinion set up If the pinion A3 or pinion head bearings A7 A8 are replaced the following procedure needs to be carried out Record the following information of the current components fitted as follows a The new pinion A3 mounting distance etched on the head b The new overall bearing A7 A8 width of pinion head bearing c Pinion cartridge A1 mounting distance constant for 110 35mm d Shim thickness A4 100 85 a b To assemble the unit reverse the above procedure Ensure the brake plates when fitted are aligned on the sun gear spline giving oil access through the holes Tighten the pinion nut A10 until the spacer A6 collapses and all the end float between the pinion bearings is taken up Drag torque 1 92 2 48Nm 17 22 Ib in Note the tightening torque should not be less than 245 Nm 180 lb ft Continue to tighten the pinion nut until 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 coupling A2 and measuring the load to turn t
11. e Manual 5 3 Section C Planet Carrier Assembly 1 To gain access to the planet carrier assembly remove the axle arm assy F3 by removing the bolts F4 around the flange connecting it to the centre casing The axle shaft F1 will now be exposed and the spline projecting from the axle arm should be examined for wear and damage If it needs replacing see section A 2 The planet carrier assembly can now be removed from the centre casing Check the planet gears and the mating gear teeth on the annulus and sun gear for damage and wear If the latter needs replacing see section A 4 The planet gears should run freely on the planet pins and without excessive radial play To replace the planet gears pins or bearings drift the spring dowel C8 which locates the planet pins C2 into the planet carrier C1 lightly drift the pins through the planet carrier 6 Before reassembling the unit remove the old spring dowels C8 from the planet pins C2 and fit new spring dowels C8 after reassembling the unit 7 Locate the planet carrier assembly back into the centre casing and fit the axle arm assy ensuring the recommended sealing agent is uniformly applied to the sealing faces NOTE When servicing planetary sets all three gears and bearings must be replaced ltem Qty Description C1 1 Planet carrier C2 3 Planet pin C3 3 Needle bearing C4 3 Planet gear C5 6 Thrust washer C6 1 Circlip C7 1 Spacer C8 3 Spring dowel
12. esidual on fitment Do not apply any to the oil seal diameter This must be kept clean from any foreign ingress To reassemble the hub unit reverse the above procedure using a new lockwasher D10 Note Fit a new locking tab washer D10 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 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 11 415 Service Manual 5 5 Section E Brake Assembly See Diagram on page 11 ltem Qty Description E9 1 Bleed screw E10 2 Piston O ring E11 2 Brake Piston E12 2 Piston O ring E13 14 2 External operating lever E15 1 RH return spring E16 1 LH return spring E17 1 RH hand brake cover E18 1 LH hand brake cover E19 2 Brake cam O ring E20 2 Brake cam O ring E21 12 M6 Cap head bolt F8 2 Brake spacer plate F9 4 or 2 Sintered brake disc F10 4 or 2 Fixed brake plate F11 1 RH Brake cam F12 1 LH Brake cam F13 2 Lever Clamp bolt F14 2 Lever Clamp nut IMPORTANT The axle brakes operate with a mineral hydraulic fluid ISO VG32 Specification On no account must a vegetable based brake fluid SAE J1703 be used 1 To gain access to the brakes the procedure is the same as the pl
13. he coupling with a spring balance see drawing below Refit the cartridge assembly into the main case ensuring the recommended sealing agent is uniformly applied to the flange faces and tighten to M10 bolts tightening torque Refill the axle with the recommended oil Page 5 PLANET CARRIER ASSEMBLY WAMA 415 Service Manual 5 2 Section B Differential Assembly ltem Qty Description B1 1 Diff case LH 1 Diff case RH B2 2 Diff wheel B3 2 Diff pinion B4 2 Thrust washer B5 2 Thrust washer B6 1 Diff spider half B7 8 Bolt M10 SEE PINION ASSY STRUCTURED WITHIN THE MAINCASE ASSY B8 8 Nyloc nut M10 Page 7 415 Service Manual Servicing the Crown Wheel amp Pinion 4 5 Remove the axle arm and sun gear see Section A Remove the pinion cartridge assembly see Section A The pinion cartridge differential assembly can now be withdrawn through the pinion cartridge aperture Unpein and remove adjuster nuts E2 The differential assembly is now free Remove nuts B8 and bolts if necessary B7 The crown wheel A5 is now loose and the differential assembly will split into 2 halves 6 7 8 Inspect all gears and bearings for damage and wear and replace if necessary To assemble reverse the above procedure If new differential bearings E8 are fitted it will be necessary to check the bearing pre load and crown wheel pinion backlash see Section F Page 8 415 Servic
14. it Remove RH case half G17 which will expose the 2 gears Remove pinion G18 and wheel G19 Note that the bearings G7 G8 G9 will still be fitted to the gears Ensure bearing A7 8 does not fall off spiral bevel pinion A3 Check for wear and damage on gears Check for wear on the seal G12 paying particular attention to the small circular spring Remove if necessary Re assembly procedure 1 Clean surface faces of case halves using Ambersil F10 Solvent and remove any remnants of old liquid sealant Replace if necessary seal G12 and all bearings on the 2 gears before the next stage Place input pinion G18 locating bearing in small bore in LH case half G16 and tap home with mallet Fit input wheel G19 locating onto pinion spline and aligning mesh Tap home with mallet Apply continuous bead of liquid sealant to LH case half G16 Fit RH case half G17 locating on the 2 dowels G6 ball bearing G8 and roller bearing G9 Fit and secure 13 case bolts G1 10 off bottom and G2 3 off top and tighten to the specified torque Apply grease to seal G12 and fit coupling G11 and nut A10 Torque to the specified value Page 15 ct leve mmended oil to the corre 8 Remember also to fill with the reco JODO A COMPONENTS STRUCTURED WITHIN THE PINION CARTRIDGE ASSY WEI 415 Service Manual 6 CROWN WHEEL AND PINION ASSEMBLY HYDROSTATIC VERSION The crown wheel and pinion is assembled u
15. l 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 415 PBH 14 X12 1 PB WILL INDICATE PARK APPROX REDUCTION RATIO VARIANT AND SERVICE BRAKE H WILL INDICATE HYDROSTATIC VERSION Page 1 415 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 positioned in the rear of the axle maincase Approximate oil capacity of 6 litres 10 6 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 IMPO
16. sing special purpose tools and electronic measuring equipment It is advisable that in the unlikely event of failure or adjustment the following actions should be taken 1 Remove the drain plug E6 and drain the axle oil from the maincase 2 Follow dis assembly procedure for hydrostatic dropbox on page 15 3 Remove nuts G14 4 Remove L H transfer case G16 5 Remove both axle arm assys by removing bolts F4 Withdraw the sun gears F7 only 6 Using 2 M10 extraction bolts not supplied remove crown wheel differential assy through the pinion cartridge aperture 7 Unpein and remove 2 adjuster nuts E2 Differential assembly will now be free to remove from the pinion cartridge A1 8 Gently tap pinion A3 out of pinion cartridge bore and drift out bearing cups A7 9 NOTE When refitting any of the following new components crown wheel A5 pinion A3 setting spacer A6 pinion bearings A7 A8 and shims A4 the actions in item 10 need to be carried out 10 Record the following information of the current components fitted as follows The pinion A3 mounting distance etched on the head The overall bearing A7 A8 width of pinion head bearing Current shim A4 thickness The pinion head bearing A7 A8 depth from cup to cone The overall length of the bearing setting spacer A6 The pinion tail bearing A7 A8 depth from cup to cone Overall distance measured i e a b c ompapgp Record the follo
17. t i e per side F2 1 Oil seal shield F3 1 Axle arm F4 12 Arm to Maincase bolts 1 Remove the bolts F4 around the flange of the axle arm connecting it to the maincase and withdraw the axle 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 cleaned using Ambersil F10 Solvent and uniformly apply a continuous bead of the recommended sealing agent see section 4 5 3 Normally the axle arms only need removing to gain access to the components within the maincase and therefore for further information see previous sections Page 14 415 Service Manual 5 7 Section G Hydrostatic Dropbox Assembly See Diagram on page 14 ltem Qty Description G1 10 Bolt M12 x 45 G2 3 Bolt M12 x 70 G3 4 Stud M12 G4 4 Nut M12 G5 1 Bonded seal 2 BSP G6 2 Dowel G7 1 Bearing G8 1 Bearing G9 1 Roller bearing G10 1 Blanking plate for transit G11 1 Coupling G12 1 Oil seal G13 1 Drain plug 2 BSP G14 10 Nut M10 G15 10 Stud G16 1 Transfer case LH G17 1 Transfer case RH G18 1 Input pinion G19 1 Input wheel Dis assembly procedure 1 2 Drain oil by removing drain plug G13 Replace the plug when oil is drained Remove nut A10 and withdraw coupling G11 Remove 10 bolts G1 and 3 bolts G2 Using 2 case bolts in the extraction holes and tighten evenly until the 2 case halves spl
18. will locate on the 2 dowels in one half of the case and will also contain one half of the cylindrical roller bearing and the oil seal Tighten 13 bolts to the recommended tightening torque Smear the recommended grease on input seal Clean drive flange oil seal diameter prior to fitment Fit new nyloc nut amp tighten to recommended torque Page 18 415 Service Manual 35 Check the pinion assy is free to turn by hand prior to the next stage Check pinion bearing drag torque min 1 92 2 49Nm 17 22lbin and no end float exists in assy by using a dial test indicator on the drive flange and applying hand pressure to record any movement i e maximum permitted end float 0 025mm If excessive end float exists on indicator increase the bearing setting spaces by same amount This will require a strip and rebuild to this stage 36 Set crownwheel amp pinion backlash See data sheets for drive flange variants using new adjuster nuts E2 and tighten to 20Nm 15lbft and tab into recess 37 Refit sungears through brake plate amp diff wheel splines 38 Clean both axle arm and maincase joint faces with recommended Ambersil F10 solvent 39 Apply a thin continuous bead of the recommended sealant to the maincase joints 40 Tighten 24 new bolts to the recommended tightening torque 41 Refit drain plugs and fill with the recommended axle oil In the event of the pinion bearings and bearing setting spacer damage with the pinion mounting
19. wing information of the new components fitted as follows a New pinion mounting distance etched on the head b New overall bearing A7 A8 width at pinion head bearing c New shim A4 thickness d New pinion head bearing A7 A8 depth from cup to cone e New overall length of the bearing setting spacer A6 f New pinion tail bearing A7 A8 depth from cup to cone g Overall distance measured i e a b c 11 Record the above information excluding c and e for new components to be fitted 12 Press or drift home pinion head bearing cone A7 A8 onto pinion 13 Calculate the old shim arrangement as follows a b c g Note use information from 10 14 Calculate the new shim c arrangement as follows g a b c 15 Calculate the new bearing setting spacer e as follows Record the difference in new c and old c shims X if new c is greater than old c add X if less than subtract X Page 17 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 415 Service Manual Record the difference in new d and old bearing d depth on tail bearing Y If new d is greater than old d add Y if less than subtract Y Record the difference in new f and old f bearing depth of cup to cone on pinion head Z If new f is greater than old f add Z if less than subtract Z The new bearing setting spacer e length is therefore
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