hamworthy transmissions division rigid axle type 1000
Contents
1. Q LIN3A3ONVUUV IVNOIIO23S X 3 A AUR FA ER 112 MDC Vsus TA CX jJ SZ Lv 9v Sv vv Ov 6 mei 5 MAJO LN3 A39NV3BV TVNOIL23S INTENTIONALLY BLANK PAGE2. 24 Hamworthy HAMWORTHY TRANSMISSIONS DIVISION RIGIDAXLE TYPE 1000 WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS 44 0 1204 854650 44 0 1204 854663 parts winget co uk service winget co uk www winget co uk INTRODUCTION This Service Manual applicable to the Hamworthy 1000 Series Rigid Drive Axle is a re print of the manual last published in 1978 The procedures described within this manual should enable experienced service personnel to strip repair and re build the Hamworthy 1000 Series Axle fitted to some early models of Winget Site Dumpers and Masted Forklift Trucks in a safe and competent 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 amp Safety Regulations which should be applied but the following should act as a reminder This is not an exhaustive list Whenever possible any repairs or service should be carried out in a clean environment If work must be carried out on site or in the field steps should be taken to ensure that dirt or foreign materials cannot enter the assembly Ensure all tools are in good condition and only use the correct tool for the job in hand Always wear safety spectacles or goggles when using soft or hard faced hammers chisels drifts or when using air tools Wear safety spectacles when
3. ONY 73437 10 _ 591 03318 O9EI SH LINS OL LONI NMOHS NOILDJYXIQ NI 13AYuULl 53 19 L dNI 3SIMX20712 ILNY AN3AWLSNCOV 3 Y 88 123443 OL O3ulnO3H 32NvislQ VIO 699 21 sa10H Y 6 vid LEZ _ 64 48 432 59 956 195 530 74 GAH U3AO 927 049 54 2 GNH OOLI 26 8 31xv 10N 133HA _ 9 1 26 9 16 NO 50015 91 soz x SI 9 add 408 91000 37XY 26 0 31Xv JAYO 01915 JO 9 sev X Y NOI1235 41 WW WO 2IL3NOYW Lun 8330 ANN 2 8 5 0333 9 033718 ONY 73431 10 7133HM OSEI SH oer 105 OL 1 0011 AN votz _ NAOHS NOIJ238IO0 13AYdL S3AID 3SIA4920712 5 3Xv88 123443 01 Q3ulnO3uH 32NVLSIO viO 699 21 s330H as 5 E zo Bl h 4 52 55 28 T a 59 _ 4 66 v 5435 8 856 8 1 85 Im 35Nv1J H3 AO 9271 71 049 3 54 5 00 1 l o SECTION 1 DESCRIPTION INTRODUCTION T
4. 6 If dimension approaches the maximum of 24 mm 0 95 in brake plates 5 and 6 are worn out New plates must be fitted as detailed under Assembly Brake Plates Remove the worn brake plates as follows 1 Withdraw drive shaft 15 as detailed in the preceding Hub Section 2 Remove setscrews 87 and washers 88 and 9 and axle casing cover 2 3 Remove retaining 3 and cover 12 if fitted and tap out torque pin 4 complete with O ring 11 if fitted 4 Remove brake plates 5 and 6 5 Replace defective components and assemble as detailed under Assembly Brake Plates 4 3 Differential NOTE The differential may be dismantled if necessary by carrying out the operations 1 to 3 inclusive in the preceding Hub Section and after draining the differential oil both operations in the preceding Brake Section under heading Brake Plates numbered 7 to 4 Spiral Bevel Wheel and Cage Support the outer end of mounting arm 13 14 then remove setscrews 10 washers 9 With the aid of the 2 10 x 1 5 mm pitch extractor holes in the flange withdraw arm 13 14 3 Remove setscrews 78 and spring washers 79 and withdraw differential bearing housing 84 complete with adjusting nut 83 bearing cup 85 and pin 82 both sides supporting the differential cages and 5 bevel wheel 77 4 Spiral bevel wheel 77 with differential cages 90 and 97 bearing cones 86 and differential
5. N N NO NH BP zc Ld NNNNN OL Item No Description 56 Cylinder 57 Cap end 56 58 Spring 56 59 Nut 52 60 Nut lock 59 61 Piston 62 Spacer 54 53 63 Seal oil 64 64 Flange coupling 65 Washer 66 66 Nut 76 67 Cup bearing 68 Cone bearing 69 Shim 70 05 mm 002 in 69 Shim 70 08 mm 003 in 69 Shim 70 13 mm 005 in 70 Spacer 68 73 71 Shim 76 05 mm 002 in 71 Shim 76 13 mm 005 in 71 Shim 76 25 mm 010 in 72 Cup bearing 73 Cone bearing 74 Setscrew 56 75 Washer spring 74 76 Pinion spiral bevel 77 Whee spiral bevel 78 Setscrew 84 79 Washer spring 74 80 Bolt 90 97 81 Nut 80 82 Pin roll 83 Nut adjusting 85 86 84 Housing 85 86 85 Cup bearing 86 86 Cone bearing 89 95 87 Setscrew 2 88 Washer spring 87 89 Washer 87 90 Cage differentia recessed 91 Pin roll 91 92 Pinion 93 Trunnion spider 94 Plug level 95 Wheel 96 Washer thrust 95 97 Cage differential bossed 98 Dowel 28 99 Dowel 31 Items Not Shown Plug 5 in 5 Plug magnetic drain Breather 4 15 z As Req d As Req d As Req d 1 As Req d As Req d As Req d OO
6. Gasket to the mounting arm journal in the area of the distance piece 17 Lightly oil the oil seal recess in the distance piece If either the hub 22 or bearings 20 21 23 24 have been renewed it will be necessary to re set the bearing pre load as the existing shims 48 may not now suitable Do not therefore re fit the oil seal 181 at this stage but proceed to rebuild the hub 22 as follows Using 8 suitable plate either press or knock intqosition the two bearing cups 21 and 23 making sure that they are both fully home Place the hub 22 on its outer face on the bench and proceed to fit a new set of wheel studs 45 Note The stud heads will be uppermost Care must be taken that the studs are pressed squarely into the hub flange Position the inner bearing cone 20 on the mounting arm 13 14 4 10 11 Position the hub assembly square on the mounting arm 13 14 and whilst holding it square tap assembly into position with soft hammer Position the outer bearing cone 24 onto mounting arm 13 14 then still holding the hub 22 square tap the cone fully home F it special tool ST 1015 005 onto the mounting arm 13 14 securing with old setscrews 47 Lightly and evenly clamp the three setscrews against bearing cone 24 Take readings A D as shown in illustration The shim pack 48 required is determined by the formula Shim pack A B C D 05 mm 0 002 in 22
7. 47 ST 1015 005 HUB BEARING SETTING Dimensions A B C D 05 mm 022 in Shims 48 required Peel off the laminated shims 48 to give the above value Remove special too ST 1015 005 and dismantle hub 22 and bearing cones 20 and 24 Fit seal 18 lubricating the O rings with operating oil Both surfaces must be absolutely clean and free from contamination Refit bearing cone 20 followed by hub 22 and outer bearing cone 24 Position shim pack 48 and spacer 49 on the annulus 28 and retain with pin 25 4 11 17 20 21 22 23 CHECKING HUB BEARING FOR ZERO END FLOAT Position annulus against Mounting arm 13 14 It is important that the three 12 mm diameter dowel holes are aligned with the Mounting arm dowels nd not the three larger 12 5 mm diameter bolt holes Incorrect fitting could result in the dowels working and Causing damage to annulus and mounting arm Tap 3 dowels fully into position Fit a new lockplate 32 and secure the annulus with three setscrews 47 Apply Loctite 241 or 245 to the setscrew threads before fitting ensuring all threads are perfectly clean Note Early designs have setscrews 47 fitted with Nyloc thread locking insert Where this is the case discard the original setscrews and fit the later design with no undercut beneath the head and fit also lockplate 32 Torque load setscrews 47 to 12 m 89 5 6 and bend over tab of lockpla
8. B4 complete with bearing cups 85 NOTE Locking pin 82 must be removed 8 Clamp bearing housings 84 to axle casing 1 with setscrews 78 and spring washers 79 9 Tighten adjusting nut 83 to eliminate end float in bearings COUPLING FLANGE HOLDING SPANNER 4 5 10 12 Check the gap between the gauge journal and the end face of pinion 76 The gap should be 0 641 mm 0 025 in plus or minus the figure etched on the pinion i e if the etched figure is minus 0 13 mm 0 005 in the gap must be 0 628 mm 0 020 in If the gap is too large add the equivalent thickness of shims 71 behind the inner bearing cup 72 Conversely if the is too small the equivalent thick ness of shims 71 must be removed This requires the differential assembly to dismantled as described earlier in the text If a setting gauge is not available fit the initial thickness of 5 71 and refer to the tooth contact diagram for adjustment procedure Remove bearing housing setscrews 78 and spring washers 79 Remove bearing housings complete with adjusting nuts 83 and bearing cups 85 Withdraw setting tool ST 1015 001 and remove bearing cones 86 Spiral Bevel Wheel and Cage 12 Refit spiral bevel wheel 77 onto differential cage 90 4 pinion differential only Fit bearing cones 86 to differential cages 90 and 97 Place wheel 77 and cage on the bench on the cage end face Position a new thrus
9. kerosene gasolene or a suitable solvent prior to inspection used O rings oil seals Dowty and thrust washers lock washers and seif locking nuts should discarded and new ones fitted on re assembly Remove any traces of Jointing compound joint faces 4 4 E xamine all components for cracks corrosion wear distortion or any other damage and renew any part found defective Pay particular attention to the teeth of the annulus planet gears sun gear at the end of the drive shaft spiral bevel wheel and pinion differential centre gears and to the trunnion arms bearings brake plates and brake actuator ASSEMBLY Pinion 1 Tap inner and outer bearing cups 67 and 72 evenly into the bore of casing 1 with the initial thickness of shims 71 between the inner cup and casing If removed tap inner bearing cone 73 onto pinion 76 3 Position the pinion and bearing cone in axle casing 1 4 Place casing 1 onto the face of cover 2 and tap into position outer bearing cone 68 5 Position coupling flange 64 on the pinion splines and tap into position 6 Fit washer 65 and old nut 66 Lightly tighten nut whilst holding flange 64 with Special Spanner ST 1015 004 NOTE Thepinion must be rotated frequently whilst nut is being tightened 7 Press differential cage bearing cones onto setting gauge ST 1015 001 Position setting gauge in axle casing 1 and place in position differential bearing housings
10. plates 5 and 6 are to be renewed the drive shaft should be left in position as this will keep brake plates 5 and 6 correctly located 7 Knock back the tabs of lockplate 32 and remove setscrews 47 Note If lockplate 32 was not originally fitted reassemble with a new lockplate 32 and setscrews 47 Consult Spares Manual for ordering instructions 8 With the aid of the 2 MIO x 1 5 mm pitch extractor holes in the annulus flange withdraw the annulus 28 complete with three dowels 98 and pin 25 9 Remove bearing spacer 49 complete with shim pack 48 10 Hold hub 22 square to the axle then tap off with a soft hammer against the hub flange This will remove hub 22 complete with bearing cups 21 and 23 and outer bearing cone 24 Note Take care not to let the outer bearing cone 24 drop to the ground as it is pulled away from axle arm 13 or 14 11 Tap seal housing 17 sauarely off mounting arm 13 14 enabie removai of seal 18 and bearing cone 20 12 With a suitable drift tap out bearing cups 21 and 23 4 1 BRAKES in the event of brake inefficiency carry out the following procedures before dismantling any brake components First remove level plug 94 and magnetic drain plug and drain the oil Brake Adjustment Check the brake adjustment for correct setting as follows Unscrew and remove brake cylinder cap 57 complete with spring 58 Remove locknut 60 Fully
11. OUTINE MAINTENANCE Every 50 Hours Every 200 Hours Every 500 Hours Every 1000 Hours gt Recommended Torque Figures SECTION 4 HUBS BRAKES AND DIFFERENTIAL General DISMANTLING Hubs Brakes Brake Adjustment Cylinder Seals Brake Plates Differential Spiral Bevel Wheel and Cage Pinion CLEANING AND INSPECTION ASSEMBLY Pinion Spira Bevel Wheel ind Cage Brakes Brake Plates Cyiinder Seals Mounting Arms and casina Hubs Special Tools Spare Parts LIST OF PARTS HUBS BRAKES AND DIFFERENTIAL Page 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 2 2 3 1 3 1 3 1 3 1 3n 41 41 4 2 4 2 4 2 4 2 4 4 4 4 4 4 4 5 4 6 4 9 4 9 4 9 4 10 4 10 4 13 4 13 4 14 LIST OF ILLUSTRATIONS General Arrangement Checking Brake Plate Wear Coupling Flange Holding Spanner Spiral Bevel Wheel and Pinion Tooth Checking Spira Bevel Wheel and Pinion Backlash Correct Fitting of Brake Cylinder Seals and Brake Plates Hub Bearing Setting Checking Hub Bearing for Z ro End Fiost Sectional Arrangements of Hubs Brakes and Differential 3 4 3 4 5 4 7 4 8 4 9 4 11 4 12 End of Book ud 8 0001 3dAL ser NOLL23S 55 1Yu3N39 6540 ME WO 2IL3NOYM WINSIX ANN 2 8 0334
12. SEALS AND BRAKE PLATES 4 9 Cylinder Seals 5 6 Grease the internal sea 54 and carefully position in brake cylinder bore 56 See illustration F it spacer 62 Grease external seal 55 and carefully position in brake cylinder bore 56 Note Ensure that the sealing lip on each of the seals 54 and 55 is positioned as shown in the illustration Lightly oi the piston 61 position it in the cylinder bore 56 then carefully push it through the seals 54 and 55 taking great care not to damage the seal lips Fit the pull rod nut 59 Set brake adjustment as detailed in Section 4 Brake Adjustment on page 4 2 paras 10 8 Mounting Arms and Casing Hubs Apply sealing compound 10 the face of mounting arm 13 14 and position over drive shaft 15 onto the axle casing 1 making sure that the torque pin hole lines up with the recess in the brake plates Fit mounting arm washers 9 and setscrews 10 Torque load setscrews to 4 7 kg m 34 Ib ft Tap torque pin 4 complete with a new O ring 11 if applicable lightly oiled into position Fit plug 12 if applicable into torque pin hole Apply jointing compound around the opening of axle casing cover and position cover 2 with washers 88 89 and setscrews 87 Torque load setscrews to 2 3 kg m 17 Ib ft Refit the magnetic drain plug If removed refit the distance piece 17 onto the mounting arm 13 14 after applying Loctite Plastic
13. and torque load nut 66 to 37 kg m 275 Ib ft Note The pinion should be rotated frequently whilst this nut is being tightened 31 Fasten a piece of cord to the coupling flange wrap it around the journal with the other end attached to small spring balance Ignoring the initial force required to turn the assembly an even pull of 0 45 to 0 91 kg f 1 to 2 Ibf must be registered on the spring balance If the reading is too low reduce thickness of shims 69 whilst if the reading is too high increase the thickness of shims 69 When correctly set remove the spring balance Note Alter the thickness of shims 69 to correspond with the pinion adjustment shims 71 ie 12 mm 005 in of shims 71 is added also add 12 mm 005 in of shims 69 32 Remove coupling flange 64 as previously described and fit a new oil seal 63 squarely in casing 1 by means of a suitable plate Lubricate the sealing lip with roller bearing grease BRAKES Brake Plates a If removed refit pull rod 52 to actuator 7 by means of pin 50 locked in position with circlip 51 2 Position brake plates 5 and 6 and actuator in the order shown on the arrangement drawing 3 Fit drive shaft 15 to locate brake plates correctly 4 Apply sealing compound to the face of brake cylinder 56 and position on axle casing 1 with washers 75 and setscrews 74 Torque load setscrews to 2 3 kg m 17 Ib ft CORRECT FITTING OF BRAKE CYLINDER
14. are thus ideally suited to off highway applications The centre casing has been designed to give adequate oil capacity for heat dissipation For ease of servicing both the sintered bronze brake plates which are splined to the drive shafts and their mating steel plates can be removed through an access hole in the centre casing after partial removal of the drive shaft and extraction of the torque pin as described in the Brake Dismantling Section 1 1 SECTION 2 LUBRICATION Differential Only a high quality Hypoid mineral oil containing limited slip and anti squawk additives for the brake plates of the following viscosity must be used S A E 80 For ambient temperatures between minus 10 15 F and 30 C 90 F S A E 75 For ambient temperatures between minus 25 C 15 F and minus 10 C 15 F See Lubrication Chart for details of the various grades recommended Oil is entered through the combined filler and level plug 94 situated in the axle casing cover 2 a magnetic drain plug being situated at the bottom After the first 200 hours running drain the oil while the axle is warm and refill with fresh oil Allow a few moments for the oil level to settle Top up the oil level after every 50 hours running Drain and refill with fresh oil after every 1000 hours running Hub Reduction Gears and Hub Bearings The same oil specified for the differential must be used for the hubs To fill stop the machi
15. centre gears may now be removed Take note on which side wheel 77 is installed to aid re assembly To dismantle the assembly proceed as follows Position the assembly on the bench with bossed cage 97 uppermost 2 Remove nuts B1 and tap out bolts BO 3 Separate differential cages 80 and 97 to enable removal of the differential centre gears For two pinion differentials first remove spiral bevel wheel 77 With a pin punch remove pin 91 4 To remove the wheel 77 tap off the bearing cone 86 then with a soft hammer tap the wheel 77 off the cage register Pinion 1 Remove coupling flange nut 66 and washer 65 Hold flange with Special Spanner 1015 004 2 Whilst supporting pinion 76 use a soft hammer tap the pinion from the threaded end into the casing Inner bearing cone 73 will come away with it Remove coupling flange 64 4 Remove spacer 70 and discard A new Spacer must be fitted on assembly if it is of the collapsible type Retain spacer if itis fitted with shims 69 5 Remove oil seal 63 to allow removal of outer bearing cone 68 6 f the bearings are to be renewed tac cups 67 and 72 out of casing 1 with the aic of a suitable drift Take care to maintain the thickness of shims 71 behind the inner bearing cup to aid re assembly Also remove inner bearing cone 73 from the pinion 7 Remove the axle casing breather CLEANING AND INSPECTION Thoroughly clean all components in
16. cleaning components or when grinding Do not misuse airlines and be aware of the damage compressed air can cause if misused Always ensure lifting equipment is in good condition and the Safe Working Load S W L exceeds the weight of the component to be lifted Always use suitable supports i e axle stands or baulks of timber in conjunction with hydraulic jacks etc Never rely on hydraulic jacks alone to support the weight of 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 do not allow it to drain onto the ground or dispose of it down drains or watercourses Whenever possible always disconnect the battery or battery isolator when working on the equipment 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 thinners or other solvents to clean the skin Health and Safety is a matter of common sense If common sense is applied correctly the risk of accidents can be reduced The contents of this manual although correct at the time of publication in 1978
17. es for the brake plates Oils marked meet the specification MIL L 21058 AP1 GL5 CLASS Should the climatic conditions vary from those listed above please consult our more detailed Lubrication Book 2 2 SECTION 3 ROUTINE MAINTENANCE Every 50 Hours Check tightness of road wheel mounting nuts 46 to the correct tightening torque of 30 42 Kg m 220 Ib ft Every 200 Hours Remove clean and refit the axle casing breather Inspect the area around the pinion oil seal housing planet carriers hub oil seals and brake cylinders for any oil leakage If there is any sign of leakage fit a new oil seal or make good the joint as appropriate Every 500 Hours Check tightness of all external nuts and bolts in accordance with the torque figures given in the following text Every 1000 Hours Check hub bearing adjustment as detailed in Section 4 Assembly Hubs Brakes and Differential RECOMMENDED TORQUE FIGURES Item No Torque Fig Kg m Ib ft 10 4 7 34 37 7 9 58 46 30 42 220 47 12 89 74 2 15 78 4 7 34 81 4 7 34 87 2 15 SECTION 4 HUBS BRAKES AND DIFFERENTIAL General The item numbers in the text refer to components shown on the Sectional Arrangement Drawing and List of Parts at the end of this Section The hub and planet gear assembly brake actuation assembly and brake plates may be removed with the axle still in place however for convenience and ease in Carrying out some of this
18. h on bevel whee 77 and zero the i indicator See Illustration The backiash must be a minimum of 0 15 mm 0 006 in and a maximum of 0 20 mm 0 008 in checked with the bevel wheel in three different positions if the backlash is too high the bevel wheel mesh with the p must be moved further into inion Conversely if The backlash is too low the bevel wheel must be moved further out of mesh Adjustment of the bevel wheel is obtained by unscrewing the nut 83 on the side the wheel is to be moved towards whilst screwing up the second nut 83 by a similar amount Note Movement of nut is 2 mm 0 078 in for one revolution 4 6 Spiral Bevel Wheel and Pinion Tooth Contact CORRECT ENGAGEMENT OF SPIRAL BEVEL WHEEL AND PINION NO ADJUSTMENT REQUIRED LENGTH OF CONTACT TO 4 OF TOOTH WIDTH SPIRAL BEVEL PINION TOO FAR OUT OF MESH MOVE PINION CLOSER TO WHEEL IT ISNECESSARY TO INCREASE THICKNESS OF SHIMS 71 AND RE ADJUST BACKLASH SPIRAL BEVEL PINION TOO CLOSEL Y IN MESH MOVE PINION AWAY FROM WHEEL IT IS NECESSARY TO DECREASE THICKNESS OF SHIMS 71 AND RE ADJUST BACKLASH NOTE THESE ARE OERLIKON GEARS NOT GLEASON IT IS IMPORTANT THAT THESE GEARS GIVE THE CORRECT TOOTH CONTACT SEE FIG 1 FOR QUIET RUNNING AND LONGER LIFE 4 7 20 2i 22 N 27 29 CHECKING SPIRAL BEVEL WHEEL AND PINION BACKLASH Tap bearing cone 68 onto spiral bevel pinion 76 Using a suitable sleeve fit a new
19. he Hamworthy type 1000R rigid drive axle is of the double reduction type having primary reduction by spiral bevels and secondary reduction through planetary gears in the hub ends GENERAL DESCRIPTION Axle Casing and Mountina Arms The axle casing and mounting arms are manufactured from separate S G Iron castings spigotted and bolted together In this way the axle width may be varied whilst stil retaining the standard centre casing Differential The differential is of the two bevel pinion type with the exception of some early axles which may be fitted with four pinions Both the spiral bevel wheel and pinion are mounted on taper bearings Drive is transmitted from the spiral bevel wheel via the pinions through the drive shafts and the planetary hub gears Hub Assemblies The hub gears are three pinion epicyclic spur type mounted on bush type bearings in the early design and needle roller bearings in the later design axles The gears run in the annulus gear which is bolted and dowelled to the axle arm The hubs run on high capacity long life taser roller bearings Face type hub oil seals are fitted and are designed to eliminate the oil sealing problems usually associated with lip type seals Brake Assemblies The brake assemblies are oil immersed multi plate disc type mounted within the centre casing and are operated hydraulically As they are enclosed and running in oil they are free from the ingress of dirt and foreign matter and
20. l Pinion Oil Seal Fitting Tool Planet Carrier Extractor 023 ST 1015 005 ST 1015 006 ST 1015 007 Spare Parts When ordering spare parts or in any correspondence relating to the axle the number stamped on the axle nameplate must be quoted Also give the Item Number and full Description as specified in the LIST OF PARTS 4 13 LIST OF PARTS R1000 HUBS BRAKES amp DIFFERENTIAL Item No WH 34 Description Casing Axle Cover 1 Pin retaining 4 Pin torque Plate middle Plate intermediate Actuator Not Applicable Washer spring Bolt 13 14 O ring 4 Cover 4 Arm mounting Arm mounting L H Shaft drive Not Applicable Piece distance 18 Seal oil O ring SPARES ONLY Cone bearing 21 Cup bearing 22 Hub Cup bearing 22 Cone bearing 21 Pin 49 Not Applicable Not Applicable Annulus Pin 31 10 mm O D Pin 31 6 O D Carrier planet Plate retaining Button thrust Plug 31 1 8 B S P T Pin 40 O ring 35 Capscrew 31 Washer spring 37 Washer side 40 Gear planet Spacer 42 Rolier needle 40 Bush 40 Pis retaining 35 Stud wheel Nut wheel Setscrew 28 Shim pack Spacer Pin brake Circlip 50 Rod pull Screw bleed Seal internal 56 Seal external 61 4 14 Qty
21. may be have been subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused Winget Limited operate a policy of continuous product development Therefore some illustrations or text within this publication may differ from your machine WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS TEL 44 0 1204 854650 FAX 44 0 1204 854663 E mail service winget co uk parts winget co uk www winget co uk 2 Hamworthy APRIL 1978 HAMWORTHY TRANSMISSIONS DIVISION RIGID AXLE TYPE 1000 TRANSIVIISSIONS DIVISION OMBRE SES UU SiS Tt x E E E RENE SCIES NINE PT SERVICE MANUAL RIGID DRIVE AXLE TYPE 1000 HAMWORTHY ENGINEERING LIMITED TRANSMISSIONS DIVISION POOLE DORSET 7LA Telephone 020 13 5123 Telex 417195 TDH 9116 3 April 78 27 CONTENTS SECTION 1 DESCRIPTION INTRODUCTION GENERAL DESCRIPTION Axle Casing and Mounting Arms Differential Hub Assemblies Brake Assemblies SECTION 2 LUBRICATION Differential Hub Reduction Gears and Hub Bearings Oil Capacities Recommended ture SECTION 3 R
22. ne so that the combined hub oil filler and level plug 34 is in the correct position at the bottom Remove plug 34 and charge with oil until it overflows Allow few moments for the oil level to settle Top up the oil level every 50 hours running Drain and refill with fresh oil every 1000 hours running Oil Capacities Hub one side 0 571 1 Imp pint Differential 57V 10 Imp pints 2 1 RECOMMENDED LUBRICANTS AXLES WITH OIL IMMERSED MULTI PLATE BRAKES di AMBIENT TEMPERATURE RANGE COMPANY From 25 C 15 F to 10 C 15 F From 10 C 15 F to 30 C 90 F Tractran 9 Top Up Only B P Hydraulic TF 8 CASTROL Agricastrol AS DALTONS No suitable grade available DUCKHAMS No suitable grade available Hypoid 90 DL ESSO 2082 IL 2082 Agricastro MD Agrifina Oil FT Gulf Universal Tractor Fluid Gulf Multi purpose Tractor Oil 20W 30 Mobilube HD 75 OR Mobilfluid 427 Mobilube 80 OR Mobilfluid 422 5 7224 Initial Fill Spirax HD 75 Top Up Only Donax Initial Fill Spirax EP 80 Top Up Only No suitable grade available ETL 2039 WALKERS Centlube E 76 Compound Centlube F 76 Compound ante sont NOTE 72 oils arc Extreme Pressure Lubricants containing limited slip and anti trone Pr squawk additiv
23. o the planet carrier 31 to hub mating face then offer up the planet carrier assembly to the hub 22 first engaging the bottom planet gear 40 with the annulus gear 28 and teeth of the drive shaft 15 It is then possible to line up the teeth of the remaining two gears 40 by slowly rotating the hub 22 Care should be taken to ensure that the dowe holes in the planet carrier 31 are lined up with the respective holes in the hub 22 Fit three 37 and washers 38 lightly to maintain alignment 26 Fitsix new dowels 99 with their chamfered end inwards Tap planet carrier assembly fully into position 27 Fit remaining capscrews 37 and washers 38 Torque load capscrews to 7 9 58 Ib ft 28 Position the hub assembly filler level plug 34 in its correct position as described earlier in the text then refill with fresh oil of the correct grade as shown in Section 2 Lubrication 29 Fit filler level plug 34 30 Remove the filler level plug 94 and refill with fresh oil of the correct grade as shown in Section 2 Lubrication 31 Fit filler level plug 94 32 Fitroad wheel nuts 46 Torque nuts to 30 42 kg m 220 Ib ft 33 If removed refit the axle to the chassis and re connect brakes and coupling flange Special Tools Pinion Setting Gauge 4 68 ST 1015 001 Differential Bearing Adjusung Nut Spanner ST Sco Pinion Flange Holding Spanner Hub Bearing Setting Too
24. oil seal 63 Smear the seal lip with grease Position coupling flange 64 onto the pinion splines and retain with washer 65 and nut 66 Do not tighten nut at this stage Clamp special tool ST 1015 004 to the coupling flange 64 Fasten acord around the journal of coupling flange 64 with the opposite end attached to a spring balance Tighten nut 66 until spacer 69 is felt to collapse Take a reading on the spring balance keeping the coupling flange rotating Note Ignore the initial force required to overcome friction A reading of 3 8 4 5 kg 8 10 ib is required f the reading is too low further tighten nut 66 Note If the reading is found to he too high then the spacer 59 must be discarded and the procedure repeated with a new spacer 69 Retit spiral bevel wheel and associated components as previously described ensuring that the correct backlash figure is maintained After tightening nuts 83 lock with pins 82 Note The following paragraphs 27 32 apply to axles fitted with spacer 70 and shims 69 Fit spacer 70 with the initia amount of shims 69 onto the spiral bevel pinion 76 and replace in the casing Tap bearina cone 68 onto spiral bevel pinion 76 Do not fit oil seal 63 at this stage as this will cause drag 4 8 30 Position coupling flange 64 on the pinion splines and retain with washer 65 and nut 66 Hold flange with Special Spanner ST 1015 004
25. t washer 96 if applicable in the cage bore Fit one of the bevel wheels 95 Position the trunnion 93 complete with bevel pinions 92 onto bevel wheel 95 Fit the remaining bevel wheel 95 complete with washer 96 if applicable into mesh with pinions 92 Position the differentia cage 97 making sure that the mating marks line up Align the holes in differential cage 90 and trunnion 93 Secure trunnion with retaining pin 91 2 pinion differential only Refit spiral bevel whee 77 onto the differential cage 90 2 pinion differential only Fit bolts 80 and nuts 81 Torque load nuts to 4 7 kgm 34 Ib ft Support spiral bevel wheel 77 and differential cages 90 and 97 in axle casing 1 ensuring the wheel is at the correct side see Installation Drawing Fit differential bearing housings 84 into axle casing 1 and secure with spring washers 79 and set screws 78 Ensure that bearing adjusting nuts 83 are free before torque loading to 4 7 34 1b Using speciai spanner 57 1015 002 screw the nuts 83 into contact with the bearing cups 85 With the aid of a dial indicator mounted on the Casing Check spiral bevei wheel 77 run out This must nct exceed 0 1 mm 0 004 and the cause found and rectified if found to be above this figure the must be removed Move the dial indicator so that the spindle is in contact and at right angles to one of the teet
26. te 32 If the hub bearing setting as been carried out correctly hub end float wil be zero This may be checked if necessary by MOUNTING dial gauge on the hub as illustrated Rotate the hub 31 the same time pulling and pushing the hub flange No variation of the dia gauge needle should be apparent Should the planet carrier 31 have been dismantled proceed as follows Grease the bore of pianet Gear 40 with roller bearing grease and install two rows of needle rollers 42 each separated by a spacer 41 later Gesign or install bushes 43 early design Note There must be twen ty 20 rollers in each row Repeat with remaining two gears 40 Smear O ring 36 with bearing grease and fit to planet pin 35 Place carrier 31 on its Outer face on the bench then if removed fit new thrust button 33 4 12 24 Position a thrust washer 39 if applicable followed by a gear 40 complete with rollers 42 then another thrust washer 39 if applicable making sure that the washer tabs are located in their respective holes in the carrier 31 Line up the gear 40 and washers 39 if applicable and tap into position the planet pin 35 making sure that the retaining pin hole in the pin 35 is lined up with the correspond ing hole in the carrier 31 Fit the retaining pin 44 Repeat in the other two positions Note planet gears 40 should rotate freely with no signs of any roughness 25 Apply jointing compound t
27. tighten pull rod nut 59 then screw back one and a half complete turns Check that the hubs 22 can stil be turned freely Secure nut 59 in position with locknut 60 Fit spring 58 Apply sealing compound to the face of cylinder cap 57 and screw into cylinder 56 If brake efficiency is still not correct check cylinder seals Cylinder Seals Jack up the machine 3nd run tne axle Apply brakes and check that both sides operate 14 one side fails to operate this could be due to faulty seals 54 or 55 rectify proceed as follows 1 6 Carry out procedures detailed in Brake Adjustment paragraphs 1 and 2 Unscrew nut 59 Withdraw piston 61 with seal 55 Remove spacer 62 and inner seal 54 Replace defective components Reassemble components as detailed on page 4 10 Assembly Cylinder Seals Brake Plates To determine the extent of wear of brake plates 5 and 6 proceed as foiiows Disconnect brake pipe connections Unscrew and remove brake cylinder 57 complete with spring 58 Unscrew and remove locknut 60 and nut 59 Unscrew and withdraw setscrews 74 complete with spring washers 75 Remove brake cylinder 56 Pull brake rod 52 outwards and at the same time measure the dimension from the brake cylinder boss to the head of link pin 50 See Illustration 4 2 CHECKING BRAKE PLATE WEAR A Dimension taken from face of brake cylinder boss to head of link pin
28. work it may be an advantage to remove the axle complete from the machine For servicing the differential components the axle Must be removed from the machine DISMANTLING Hubs 1 Remove wheel stud nuts 46 and withdraw road wheel assembly 2 Remove the magnetic drain plug in axle casing 1 and allow the oil to drain into a suitable receptacle 3 Remove planet carrier capscrews 37 and spring washers 38 4 Planet carrier 31 complete with gears 40 pins 35 bushes 43 early design or washers 39 needle rollers 42 and spacer 41 later design and thrust button 33 may now be withdrawn 8s an assembly using the 3 M10 x 1 5 mm pitch extractor holes in the carrier flange early design or by three cast slots in hub later design Use Special Tool ST 1015 007 to remove carrier 5 Should it be necessary to strip the planet carrier assembly proceed as follows Remove three planet pin retaining pins 44 Place the assembly on the bench on its outer face and gently tap out planet pin 35 complete with 36 Planet gear 40 con plete with needle rollers 42 washers 39 and spacer 41 later design or bushes 43 early design may now be removed Note Take not to lose any of the needle rollers Repeat this procedure in the other two positions 14 thrust button 33 requires renewing turn over planet carrier 31 and tap out the thrust button with a suitable drift 6 Unless drive shaft 15 or brake
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