FACING PAGE SERVICE MANUAL NEWAGE 200 SERIES
Contents
1. NEWAGE 200 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 uk CONTENTS INTRODUCTION GENERAL DESCRIPTION IDENTIFICATION GENERAL SERVICE INFORMATION EXPLODED VIEW PARTS LIST SECTION A PINION HOUSING SECTION B DIFFERENTIAL ASSEMBLY SECTION C PLANET CARRIER ASSEMBLY SECTION D AXLE ARM AND HUB ASSEMBLY SECTION E BRAKES SECTION F SETTING UP CROWNWHEEL AND PINION SECTION G SPIRAL BEVEL GEAR TOOTH CONTACT 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 200 series axles fitted to Winget 2B 4B and 4S range site dumpers in a safe and competant manner The procedures are not intended to be used by personnel who are unfamiliar with the product or mechanically inexperienced It is assumed that personnel are aware of the Health and Safety Regulations which should be applied but the following should act as a reminder Whenever possible any repairs or service should be carried out in a clean environment If work must be ca2. Hub assemblies HUB STUD wheel BEARING hub inner SEAL V ring SEAL oil SLEEVE HOUSING oil seal FOR PART NUMBERS REFER TO RELEVANT PARTS MICROFICHE OR OPERATORS HANDBOOK Qty N 2233323 gt gt gt AAD MORON ANNNDN ONONNOON NNNNNNN AXLE 200RF Type 3210 shown number of brake plates and disc s is dependant on the Axle Code No i e 3213 axles have fewer brake plates and disc s AXLE 200RF Item No Description Qty AXLE type 200RF14S3210 shown Hub assemblies continued 52 CIRCLIP 2 53 SPACER 2 54 BEARING hub outer 2 55 SPACER 2 56 WASHER locking 2 57 LOCKNUT 2 58 STUD 16 59 NUT nylon insert 16 Main casing 60 CASING main 1 61 PISTON brake 2 62 SEAL O ring 2 63 SEAL O ring 2 64 NUT 2 65 HOUSING bearing 2 66 PLATE locking 2 67 SCREW 6 68 NUT 6 69 DOWEL 2 70 ADAPTOR brake pipe 4 71 SCREW set 12 72 WASHER spring 12 73 SEAL bonded 4 74 VALVE breather 1 75 PLUG socket 2 76 VALVE brake bleeding 1 77 BEARING cup amp cone kit 2 General parts 80 SHAFT axle 2 81 DOWEL 4 82 ANNULUS 2 83 SPACER 2 84 PLATE brake 4 85 PLATE disc 4 86 GEAR sun 2 The number of Brake Disc s and Plates is dependant on the Axle Code Number l e 3213 axles have fewer disc s and plates fitted Axle arms 2 90 CASING axle arm 20 91 STUD 26 92 NUT nylon insert 2 93 SHIELD 100 NUT wheel 12 FOR PART NUMBERS REFER TO RELEVANT PARTS MICROFICHE OR OPERAT
3. are fitted check the crownwheel pinion backlash see Section F Crownwheel Pinion Set up If a new pinion or housing is being fitted refer to Section F before proceeding any further To reassemble the housing reverse the above procedure fitting a new collapsible spacer install the pinion shaft through the innermost bearing cone and fit the rear bearing over the pinion shaft Carefully fit the new oil seals and pack with one of the recommended greases Refit the flange coat the inner surface of the flat washer with silicone sealer and loosely refit the washer and self locking nut Prevent the flange from turning and tighten the nut until the spacer begins to collapse and all the end float between the pinion bearings is taken up but without pre loading the bearings Slowly continue to tighten the nut frequently checking the preload until a preload of 6 10kg 13 2 22lbs for new bearings or 3 6Kg 6 61 13 2lbs for used bearings is obtained The preload is measured by winding a length of string round the flange and measuring the load required to turn the flange with a spring balance Care should be exercised when tightening the pinion nut otherwise the required preload will quickly be exceeded If the old bearings have been reused coat the mating surfaces of the centre casing and pinion housing with the recommended sealant and refit the housing to the axle If new bearings have been fitted refer to Section F making a note of the pinion prel
4. brake components it will be necessary to refer to sections D and C and remove the axle arms and planet carriers Withdraw the sun gears annulus and brake spacer plate lift out the brake friction discs and brake fixed plates plain Withdraw the brake piston from the cylinder machined into the case and remove the seals The brake piston seals should be replaced even if visually in good condition ensure replacement seals are suitable for use with mineral hydraulic fluid Examine all parts for wear or damage under normal operating conditions the brake plates should last several years but should be replaced if blued distorted or badly scored or the wear exceeds the limits given below Blueing of the brake plates indicates that the brakes have been overheating and slipping Both sets of plates plain and sintered bronze should be replaced and the piston seals renewed Distortion normally occurs in conjuction with blueing and again indicates that the brakes have been overheating and slipping Both sets of plates plain and sintered bronze should be replaced and the piston seals renewed Scoring of the plates indicates that there are loose particles or foriegn material suspended in the oil The axle casing should be thoroughly cleaned out and if necessary the source of the particles or material should be investigated Both sets of plates plain and sintered bronze should be replaced and the axle refilled with clean oil Wear if the sintered
5. pins which retain the planet pins into the centre of the pins and lightly drift the planet pins out of the carrier The axle shaft thrust washer is retained by a circlip which can be removed to allow inspection of the washer Before re assembling the unit remove the old spring dowels from the planet pins and ensure new spring dowels are fitted on assembly If necessary the annulus which is retained in the casing by dowels can be withdrawn If the annulus is replaced the dowels should also be replaced ensure the annulus is fitted squarely into the case on assembly Locate the planet carrier back in the centre casings engaging the teeth on the annulus and sun gear Refit the shield Refit the axle arm assembly as described in section D Remove the combined filler level plug and top up the axle with oil Section D AXLE ARM amp HUB ASSEMBLY Servicing the Axle Arm and Hub Assembly Section D The hub assembly and halfshaft can be serviced with the axle still in situ on the machine however it is recommended that the axle be removed from the machine before the axle arm is removed The Hub Assembly Remove the self locking nuts securing the halfshaft to the hub and withdrawn the shaft A drip tray placed below the hub will catch any oil which runs from the hub Inspect the splines for wear or damage and the shaft for signs of twist or distortion Straighten the locking tabs on the lockwasher securing the ring nut undo the the
6. ORS HANDBOOK Section A PINION HOUSING Servicing the Pinion Housing Assembly Section A Place a suitable container below the axle drain plug underneath the 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 housing to the centre casing and lift off the assembly The housing is located on dowels and will require carefully prising apart from the centre casing using a pry bar or other suitable tool Prevent the flange from turning and undo and remove the self locking nut and flat washer securing the flange to the pinion using a suitable puller or drift remove the flange and gently drift the pinion shaft out through the housing Take care to avoid damaging the gear teeth splines or threads Prise the oil seals out of the housing slide the old collapsed spacer off the shaft and discard the spacer Note A new spacer should always be fitted Inspect the bearings for wear or damage check the teeth on both the crownwheel and pinion and make a visual check through the differential of the wheels If the front bearing race on the pinion shaft needs replacing use a suitable bearing puller to avoid damaging either the shaft or the shim pack sandwiched between the pinion head and bearing If the outer cones require replacing thay can easily be drifted out of each end of the housing Important If new pinion bearings
7. ab into the nut to secure the ring nut in place Coat the mating surfaces of the hub and halfshaft with the recommended sealant Refit the halfshaft it may be necessary to turn the hub slightly to engage the splines on the halfshaft with the planet carrier within the axle case Torque up the self locking nuts Remove the combined filler level plug and top up the axle oil Axle Arm Removal It is recommended that the axle is removed from the machine before the axle arm is removed Drain the oil from the axle as described under section A whilst it is possible to remove the axle arm with the halfshaft in place it is strongly recommended that the halfshaft be removed as previously described Support the weight of the axle arm and remove the ring of self locking nuts round the flange of the axle arm Place a drip tray below the axle and case to catch any oil which may run out Withdraw the axle arm taking care not to lose the shield fitted in front of the planet carrier or dislodge the planet carrier Reverse the procedure to reassemble coating the mating surfaces of the axle arm and casing with the recommended sealant Torque up the self lock nuts Remove the combined filler level plug and top up the axle oil 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
8. below should be lubricated and packed with grease during overhauls or repairs 1 Hub oil seals between the V ring seal and hub oil seal 2 Input pinion oil seals Using one of the following greases or their equivalents Mobil grease MP Esso Beacon 2 Total Multis EP2 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 equivalent Total Azzola Z846 Total Azzola ZS22 Shell Tellus 27 Mobil DTE 24 Esso Nuto H32 Liquid Sealants On assembly the following mating surfaces should be coated as indicated Under no circumstances should Silicone RTV Compound be used on the Pinion Housing Cartridge or the Axle Arm to Case Joints Pinion Housing Cartridge to Maincase Hermatite Axle Arm to Main Centre Housing Hermatite Stub Axle to Axle Arm Hermatite Where applicable Halfshaft to Hub Silicone RTV Compound Tightening Torques Description Torque Kpm Ibft Differential Assembly Nuts 5 6 40 Nuts and Bolts Differential Bearing Housing to Maincase 5 6 40 Pinion Housing to Maincase Setscrews 5 6 40 Axle Arm to Maincase Nuts 5 6 40 Halfshaft to Hub Nuts 5 6 40 Description Torque Kpm Ibft Hub Assembly Ring Nut 14 100 Wh
9. eel Nuts g BSF 25 180 Wheel Nuts 18mm 28 200 Brake Pipe Adaptor 2 8 20 veel v89L voy LEOL COVE Occ 262 2901 rvL 98601 611 9601 Ev9 5 NIV Id WN SJYLIW NOLM N NI OIHLIWN 5 NIV Id 13 487 L334 SANNOd NI IVIEIANI SOVIYHL AHG 10 SHANALSV4 SINTVA 3NOYOL SNOISSINSNVHL 39VM3N Section 5 EXPLODED VIEWS AXLE 200RF Type 3210 shown number of brake plates and disc s is dependant on the Axle Code No i e 3213 axles have fewer brake plates and disc s Item No XXX 15 16 17 18 19 20 21 22 23 24 25 30 31 32 33 34 35 36 37 45 46 47 48 49 50 51 AXLE 200RF Description AXLE type 200RF14S3210 shown Bevel Wheel Housing amp Pinion Assembly HOUSING pinion BEVEL WHEEL amp PINION not available as separate items FLANGE input assy with item 6 WASHER NUT COVER seal part of item 3 BEARING SPACER SEAL oil SHIM 0 25mm SHIM 0 30mm SHIM 0 40mm Differential assembly CASING L H differential CASING R H differential WHEEL differential PINION differential WASHER thrust differential wheel WASHER thrust differential pinion SPIDER PIN spirol STUD STRIP locking NUT Planet Carrier assemblies CARRIER planet gears GEAR planet PIN planet gears SPACER axle shaft CIRCLIP BEARING needle roller WASHER thrust DOWEL
10. g the teeth with both the annulus and sun gear refit the shield Refit the axle arm as described in section D Remove the combined filler level plug and top up the axle oil Section F SETTING PROCEDURE CROWNWHEEL amp PINION Setting up the Crownwheel and Pinion Section F A When a new Spiral bevel Pinion is fitted Note the mounting distance M D stamped on the front faces of the old and new bevel pinion s The shim thickness used with old pinion which is placed between the head of the pinion and the front bearing race must be adjusted to suit the pinion as follows 1 If the new MD is less than the old one increase the thickness of the shim pack by the difference 2 If the new MD is more than the old one decrease the thickness of the shim pack by the same amount Assemble the pinion into the housing and preload the bearings as described in Section A B When old MD is not available or a New Pinion Housing is fitted Fit the front inner bearing assembly into the pinion housing and sit the assembly on a flat inspection surface bearing down apply a downward force to the housing directly above the bearing whilst rotating the housing to ensure that the bearing is correctly seated Accurately measure the distance between the inspection surface and the underside of the pinion housing mounting flange i e mating suface This is dimension A Add this dimension A to the dimension MD sta
11. groove of the bronze brake disc is worn down to a depth of 025 inch 0 6mm or less then the plates have reached the end of their working life and should be replaced Care should be taken when examining the plain brake plates for over a long period of operation these can show a greater degree of wear than the sintered bronze disc Do not assume because the bronze disc is well within the wear limits that all the brake plates are in an acceptable condition Replacing the plain brake plates may prolong the working life of the brakes and restore their efficiency Lubricate all the components with one of the recommended mineral oils carefully refit the brake piston taking care not to nip the O rings Refit the brake plates into the axle ensuring that a plain fixed plate is installed first up against the brake piston note the fixed discs locate on the dowels in the walls of the case followed by a friction disc alternate the disc s ensuring a plain fixed disc is between each friction disc ensure that the last plate fitted is a friction disc which will butt up to the brake spacer plate when fitted Align the splines and oil feed holes in the friction disc s and insert the sun gear through the disc s ensure it engages fully into the differential Refit the brake spacer plate locating over the dowels in the walls of the case Install the annulus gear ensuring it is aligned squarely with the case and dowels Refit the planet carrier engagin
12. hinners or other solvents to clean skin Health and Safety is a matter of common sense If common sense is applied correctly the risk of accidents can be reduced Spares for Newage Axles fitted to Winget Equipment can only be obtained from Winget Limited or one of our authorised distributors and not from Newage Transmissions Limited Always quote your machines serial number and model together with axle serial number and model when ordering spare parts 200 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 200 Series is a double reduction drive axle with integral long life oil immersed multiplate disc brakes The central casing houses the spiral bevel crownwheel and pinion assembly the crownwheel being mounted on a two pinion differential The central casing also contains the oil immersed brake assemblies and the planetary reduction gears The axle half shafts are fully floating and the wheel hubs run on opposed taper roller bearings The approximate weight is 114kg 25016 Section 3 IDENTIFICATION Identificat
13. ion 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 Fixed Pads Code Number Series 200 R F 14 3210 ee N Rigid Drive Reduction Ratio 14 8 1 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 nuts 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 lubricants shown below or their direct equivalents must be used Mobil Fluid 422 Agricastrol As Special Esso Torque Fluid 56 or 62 Gulf Universal Tractor Oil Total Universal Plant Oil Total Transmission Mp The oil is added via the combined filler level plug located in the face of the centre housing on the oposite face from the input flange The oil capacity is approximatley 3 5 Litres 6 pints Greases The areas listed
14. mped on the front face of the pinion and subtract the total from the constant 98 67 the remainder is the shim thickness required Assemble the pinion as described in Section A and preload the bearings With the crownwheel and differential assembled into the centre case as described in Section B fit the assembled pre loaded pinion housing assembly on to the case retaining with two set screws Tighten the differential bearing ring nuts to take up any end float in the bearings and lightly preload the bearings Continue to adjust the ring nuts until the correct backlash is obtained between the teeth on the crownwheel and pinions 1310 Hardy Spicer 4 bolt flange 0 22 0 30mm The backlash is best checked via a dial gauge indicator clock located against a drive flange hole or located against the head of a nut and bolt which is secured in one of the holes within the flange Equally tighten both ring nuts by the same amount to give the correct bearing preload it is important that the correct backlash is maintained The preload is measured by winding a length of string round the pinion flange and measuring the load required to turn the flange with a spring balance The preload for the differential bearings must be added to the preload figures obtained for the pinion bearings in section A Additional Differential New Bearings Old Bearings Bearing Preload 1 0 2 0KG 0 5 1 0KG 2 20 4 4lbs 1 10 2 20lbs After setting the preload fo
15. oad setting as it will be required later Refit the drain plug and tighten remove the combined filler level plug located midway up the face of the centre housing and fill the axle with one of the recommended oils Refit and tighten the level plug Section B DIFFERENTIAL ASSEMBLY Servicing the Crownwheel and Differential Assembly Section B Refer to sections A C D and E and remove the pinion housing axle arm planet carrier and brakes Undo the nuts and bolts securing the bearing housings and withdraw the bearing housings The housings are provided with threaded holes into which jacking screws can be inserted to aid removal of the housing unless new differential bearings are to be fitted do not disturb the position of the bearing adjusting nuts with the bearing housings The differential crownwheel assembly can be removed through the pinion housing opening in the centre case Mark the centre casing so that the differential assembly is correctly re assembled into the same end of the centre casing Assembling the crownwheel into the opposite end of the centre casing from which it was removed will result in the rotation of the axle being reversed Free the locking washers and undo the nuts securing the crownwheel to the differential remove the crownwheel and pull the two halves of the differential apart To strip the differential gears drift out the dowel pin and push out the spider Examine the bearings wheels pinions thrust washe
16. r the differential bearings recheck the crownwheel pinion backlash Remove the pinion housing and brush some Engineers Blue onto a few crownwheel teeth and refit the pinion housing Rotate the pinion flange a few complete rotations in both directions and remove the housing Examine the contact markings on both flanks of the crownwheel teeth and compare the markings to the illustrations in section G or the original factory markings If the marking is different refer to the notes in Section G Spiral Bevel Tooth Contact and make the necessary adjustments Secure the adjusting ring nuts with the locking devices and reassemble the remainder of the axle as described in Sections A C D and E Remove the combined filler level plug and top up the axle with oil 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 in the centre of the tooth form and can still be considered to be correct if on both flanks the markings are towa
17. rds the toe or if crossed slightly e g towards the toe on the convex flank and the heel on the concave flank or vice versa If when comparing the contact markings they appear similar to the illustrations below the corrective action indicated is required Pinion T Far f 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 200 series 210 series 220 series 360 series 410 series Re check and increase shims behind head of pinion Re check and increase shims behind head of pinion Re check and increase shims behind head of pinion Re check and increase shims behind head of pinion Re check and increase shims behind pinion front bearing cone Re check and decrease shims between pinion cartridge and axle case Pinion Too Far into Mesh Convex Flank HEEL 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 200 series 210 series 220 series 360 series 410 series Re check and decrease shims behind head of pinion Re check and decrease shims behind head of pinion Re check and decrease shims behind head of pinion Re check and decrease shims behind head of pinion Re check and decrease shims behind pinion front bearing cone Re check and increase shims between pinion ca
18. ring nut and remove the nut lockwasher and spacer The hub can now be withdrawn off the opposed taper roller bearings Remove the V seal on the circumference of the rear of the hub prise out the oil seal and lift out the rear most bearing race inspect the bearings for damage or wear and replace if necessary The cones can be simply drifted out of the hub however ensure that replacements are square to the bores before refitting The replacement oil seal must be packed with grease and the V ring seal lubricated with a little oil or grease A new oil seal must be fitted regardless of visual condition If the oil seal housing is damaged or the seal contact area worn it can be drifted off the axle arm When fitting the replacement care must be taken not to damage the oil seal contact area or distort the housing Apply loctite grade 601 or equivalent to both the axle arm and seal housing mating surfaces before assembly To reassemble the hub reverse the procedure lightly oil the V seal and bearings before reassembly fit a new lockwasher To Adjust the Hub Bearings Tighten the ring nut upto a torque of 14Kpm 100Ibft Turn the wheel hub in each direction at least three times to ensure the bearings have correctly seated in and re check the torque this operation should be repeated until the locknut no longer turns when rechecking the torque Slacken the ring nut back a distance equal to 1 tab of the lockwasher then turn down a t
19. rried out on site or in the field steps should be taken to ensure that dirt or foreign materials cannot enter the assembly Ensure all work tools are in good condition and only use the correct tool for the job in hand Always wear safety spectacles when using soft or hard faced hammers chisels drifts or when using air tools Wear safety spectacles when cleaning components or when grinding Do not misuse air lines and be aware of the damage compressed air can cause if misused Always make sure lifting equipment is in good condition and the Safe Working Load exceeds the weight of the component to be lifted Always use suitable supports i e axle stands or baulks of timber in conjuction with hydraulic jacks etc Never rely on hydraulic jacks alone to support a machine Be aware of hot surface temperatures and take care when draining hot oils Always dispose of waste oils in accordance with local and national regulations Whenever possible always disconnect the battery or battery isolator when working on the machine to prevent electrical shorts and unauthorised starting Refer to the operators handbook for a guide to the correct sequence for assembling components and sub assemblies Oils fuels silicone sealer etc can cause skin diseases if allowed to contaminate the skin Always apply barrier creams wear suitable protective clothing or when contamination is unavoidable clean the area with soap and water as soon as possible Do not use t
20. rs spider and crownwheel for wear or damage and replace as necessary Assemble in reverse order ensuring that no dirt or foreign objects enter the assembly and replace the spring dowel Align any indent marks on the differential casing halves refit the crownwheel fit new lockwashers torque up the nuts and bend over the lockwashers If new differential bearings have been fitted it is necessary to check both the bearing preload and the crownwheel pinion backlash as described in section F If the bearings are not replaced the bearing housings should be fitted in their original position without turning the adjusting ring nuts and there is then no need to recheck either the backlash or preload Secure the ring nuts with the locking tabs and re torque the nuts and bolts securing the bearings housings Refer to sections A C D and E and reassemble the axle Refill the axle with oil Section C PLANET CARRIER ASSEMBLY Servicing the Planet Carrier Assembly Section C To gain access to the planet carrier remove the axle arm as described in section D Remove the shield and carefully lift out the planet carrier without disturbing the sungear Check the teeth on both the annulus and sun gear for wear or damage Check the planet gear for wear or damage Check the planet gears within the planet carrier the gears should run freely on the pins without excessive radial play To replace the planet gears pins or bearings drift the small spring dowel
21. rtridge and axle case
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