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Pelco NEWAGE 410 manual

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Table of contents for the manual

  • Page 1

    NE WA GE 410 WI N G E T L IM I TE D PO BOX 41 EDGEFOLD I NDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS Tel:++ 44(0)1204 8 54650 Fax :++44(0 )1204 854663 www.win get . co .uk SERVICE MA NUA L U.K . SERIES A XLE E-mai l serv ice@w inget. co.uk[...]

  • Page 2

    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 CONTAC[...]

  • Page 3

    Section 1 INTRODUCTION[...]

  • Page 4

    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, repai[...]

  • Page 5

    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 notific[...]

  • Page 6

    Section 2 GENERAL DESCRIPTION[...]

  • Page 7

    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 t[...]

  • Page 8

    Section 3 IDENTIFICATION[...]

  • Page 9

    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 b[...]

  • Page 10

    Section 4 GENERAL SERVICE INFORMATION[...]

  • Page 11

    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/[...]

  • Page 12

    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 followi[...]

  • Page 13

    NEWAGE TRANSMISSIONS: TORQUE VALUES FOR FASTENERS WITH CLEAN & DRY THREADS METRIC IN NEWTON/METRES (Nm) COATED THREADS, ZINC & ZINC PASSIVATED IMPERIAL IN POUNDS-FEET (LBF-FT) COATED THREADS, ZINC & ZINC PASSIVATED GRADE S GRADE V GRADE X 13 10 14 606 696 515 829 12 17 19 14 23 26 19 28 71 1 23 30 35 26 41 47 35 50 43 48 55 40 65 75 55 [...]

  • Page 14

    Section A PINION HOUSING[...]

  • Page 15

    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 as[...]

  • Page 16

    Section B DIFFERENTIAL ASSEMBLY[...]

  • Page 17

    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 [...]

  • Page 18

    Section C PLANET CARRIER ASSEMBLY[...]

  • Page 19

    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 ge[...]

  • Page 20

    Section D AXLE ARM & HUB ASSEMBLY[...]

  • Page 21

    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 [...]

  • Page 22

    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 a[...]

  • Page 23

    Section E BRAKES[...]

  • Page 24

    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[...]

  • Page 25

    Section F SETTING PROCEDURE CROWNWHEEL & PINION[...]

  • Page 26

    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[...]

  • Page 27

    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. Retighten the adjusting ring nuts to take up the[...]

  • Page 28

    Section G SPIRAL BEVEL GEAR TOOTH CONTACT[...]

  • Page 29

    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 co[...]

  • Page 30

    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[...]

  • Page 31

    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 [...]