80-1072 - Allied Systems Company
Contents
1. bearing 1 Insert the two outer rings of the taper roller bearings into the differential carrier 2 Calculate the thickness C of the spacer disc d SCN N S N p Nol N WERE Kes N a Place the two inner rings of the taper roller bearings in their outer rings Measure A b Measure the dimension B of the roller bearing c Measure the dimension D of the spacer bushing d Thickness of the spacer disc C A B D 3 Heat the drive pinion side taper roller bearing to about 100 C and install it on the drive pinion shaft Drive on completely after it cools 4 Install the spacer bushing and the spacer disc on the pinion shaft EZ Sek Ld 277 5 Install the drive pinion into the differential carrier Heat the taper roller bearing inner ring at undersize to about 1002 and install it with tube onto the drive pinion shaft 6 Install the drive flange onto the drive pinion shaft Tighten the safety nut according to sheet 3 5 For tightening fix the differential carrier and block the drive flange 7 Measure the roll resistance of the bearings by using a torque wrench If the measured value is not the prescribed 1 5 to 2 5 Nm adjust the resistance by modification of the thickness of the spacer disc After arriving at the adjustment of the bearing back off the safety nut and draw off the drive flange 8 Install the radial sea2. 1 bar 750 torr All rights reserved Revised 01 10 2012 Page 1 of 1 E E 9 3 4 1 General instructions for correct assembly and disassembly htening torque wheel nut with thrust collar Ti Tightening torque Tightening torque Wheel nut with thrust collar Wheel nut with thrust collar Galvanized Phosphourus darkened Service Revised 01 10 2012 Kessler amp Co GmbH amp Co KG All rights reserved General instructions for correct assembly and disassembly 25 Section ES Tightening torques for castle nuts and adjusting nuts Tightening torques for castle nuts on ball joints for track rods and ram Cone size Thread Torque d2 mm Nm M 20 x 1 5 200 220 cylinders The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality S6 Kessler amp Co GmbH amp Co KG All rights reserved Service Revised 01 10 2012 Page 1 of 2 General instructions for correct assembly and disassembly 25 Section ES Tightening torque of the adjusting nut resp slotted nut at flanges resp Thread Torque di mm Nm M 24 x 1 5 gearwheels ect Service Revised 01 10 2012 Kessler amp Co GmbH amp Co KG All rights reserved Page 2 of 2 Section Service tools 3 6 1 Tools When ordering maintenance tools please provide Part number no of instal
3. measure dimension X of the disk set install disks A and B according to the table gt if necessary grind off 109 2873 P1 P2 or order specific disks A and B according to the table check set value 63 72 to 64 29 Kessler amp Co GmbH amp Co KG All rights reserved HESSLER CO disk A disk B for your information disk thickness 109 2873 P1 4 75 mm 109 2873 P2 4 2 mm 109 2873 P3 3 8 mm Service Revised 17 02 2011 Assembly of the hub assembly Service Revised 18 02 2013 Kessler amp Co GmbH amp Co KG All rights reserved LOP uonoeg Service Hevised 15 04 2014 Assembly of the hub assembly Hub assembly drive axle x O I O o x TD gt o o X lt x oy Section Assembly of the spacer ring Coat the seat of the spacer ring on the steering knuckle resp axle spindle with Loctite 572 Heat the spacer ring to about 100 C and push it by gently striking onto the steering knuckle resp axle spindle The steering knuckle resp axle spindle must be free of corrosion Oil the seal ring tread onto the spacer ring Loctite 572 Service Kessler amp Co GmbH amp Co KG All rights reserved i 0 Bavised 01 09 2007 Assembly of the differential and carrier assembly onto the axle housing 5 3 1 Section
4. Coat the contact surface of the axle housing with Epple 33 at version through drive with Loctite 510 and mount the complete drive assembly The axle housing being placed in a horizontal position secure the screws with Loctite 262 Mount the pol wheel if present onto the axle shaft see 5 1 7 Engage the axle shaft into the axle housing The axle shaft should be able to be moved easily by hand in the toothing of the differential side gear At version with differential lock on the outside D 71 D 109 the differential lock must always be actuated when assemble or disassemble the axle shaft Direction Actuating of the differential lock is necessary to prevent the sliding sleeve to drop out of the shifter fork into the axle housing when pulling out or sliding in the axle shaft This would entail disassembly of the axle Service Revised 18 02 2013 Kessler amp Co GmbH amp Co KG All rights reserved Assembly hub assembly OQ Section Assembly of the spacer ring if present see sheet 5 1 6 e Install the brake onto the axle spindle be careful of the brake control position and bolt it At version with disc brake install the brake carrier if present then mount the wheel hub with the brake disc and after this operation install the brake e Prepare and mount the wheel hub see chapter 5 5 Attention Hold the wheel hub with a hoist until the outer bearing with ring gear carrier is mounted Ass
5. amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Section Ces vy i WU Disassembly of planetary gear Knock the locking pin 20 resp 21 completely to the inner side of the planetary pin Press the planetary pin in direction of arrow out of the planetary housing Attention Because of the difference of diameter of 0 1 mm do not press the planetary pin against the direction of arrow out of the planetary housing to prevent damaging the bore Remove the planetary gears with the thrust discs and needle bearings b Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Assembly disassembly cageless needle bearing planetary gear bearing Section deu Om 7 U outer mounting bushing cyl rollers needles inner mounting bushing Version 1 Assembly Version 1 Version 2 Hint Disassembly Install the needle bearing with mounting bushings into the planetary gear thereby the outer mounting bushing will be stripping Insert the planetary gear with thrust discs into the planetary housing Press in the planetary pin thereby the inner mounting bushing will remove Place one thrust disc on the work bench place on the planetary gear and insert the mounting bushing Insert the cylindrical rollers needles alternately with the rings according to the desi
6. Co KG All rights reserved 225 RS 3 U L L 1 L Ch NG 15 14 Sealing ring Sealing ring 15 16 17 Spring Screw Seal ring 18 19 20 Screw plug O ring Face seal 21 Screw 22 Tube 23 24 Bushing Screw Service Revised 01 09 2007 Assembly of the piston seals N Section Assembly of the piston seals Place piston with the larger diameter downwards Note succession of the sealing parts at fitting Install o rings free of torsion and loops Assembly of o ring and supporting ring 1 large supporting ring 2 large o ring 3 small o ring 4 small supporting ring E AE E OE Pressure gt Install the supporting rings to the averting side of pressure Assembly of the Omegat seal kit 1 large o ring 2 small o ring 3 large supporting ring 4 small supporting ring Pressure gt Install the PTFE profile rings with small diameter to pressure side Service Kessler amp Co GmbH amp Co KG All ri rights reserved 5 f H 0 Revised 28 03 2011 N Section Assembly of the piston gt lubricate cylinder bore apply the thread holes at wet disc brakes with Loctite Wet disc brake X270 X340 X460 X550 X650 dimension X Loctite 243 Loctite 262 install and screw the bushing if present gt place the piston onto the brake carrie
7. DIN 51825 The dust protection cap is fitted with a vulcanized in steel ring which is used to press it through the locating hole For exchanging lever out the ring using a suitable tool The new dust protection cap must be pressed in with the aid of a suitable mounting ring and screw clamps or a lever press Mount the brake in accordance with the above procedure into the vehicle at the axle 4 3 General Any discovered defects or damage to parts not listed here must naturally be re paired or replaced using original parts For any other information not contained in these instructions or for more detailed instructions please contact the vehicle or brake manufacturer 8 Technical information TM 63 97 Brake disc N Section Go m Network ike formation of cracks admissible B Radial shaped crack not admissible C Uneven brake surface characteristics below 1 5 mm admissible D Continuous cracks not admissible E Radial cracks max 0 5 mm width admissible Service 8 1 H e 0 Revised 09 06 2010 Kessler amp Co GmbH amp Co KG All rights reserved K 05 H 0 Service Manual Kessler amp Co GmbH amp Co KG All rights reserved
8. drive assembly The position is dependent from the respective axle version Drive assembly with throughdrive Version with interaxle differential Fill 1 5 liter oil at for first time filling and for refilling Drop gear D51 D108 only at version with separately oil space Cardan shaft intermediate bearing Oil fill plug Oil drain plug I Oil level control plug IV Grease nipple O Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 29 09 2012 Page 1 of 1 N Section N N N Ch a a N No Lubrication intervals and maintenance instructions Lubrication points The binding lubrication points have to be taken from the according installation drawing of the axle Hub assembly with planetary gear drive Lubrication points at universal joint and brake shaft If not maintenance free Hub assembly with wet disc brake Tumbler bearing Oil drain plug Oil fill plug IV Grease nipple I Oil level control plug Service Kessler amp Co GmbH amp Co KG 5 I Revised 29 09 2012 Page 1 of 1 Section Lubrication intervals and maintenance instructions Lubricants and lubrication intervals Lubrication nen Lubricant Lubrication intervals 1 after every every at least at least 100Bh 500Bh 1000Bh 1x per 1x in 1000Km 5000Km 10000Km ear 2 years ome fol fell del
9. following work steps may deviate or differ from the actual product component Drawings graphics pictures and photos are generally not true to scale This manual was developed for technicians who have been trained by KESSLER for the repair and servicing of KESSLER axles transmissions wheel gears and non drive wheels The manual must be stored where it is available to the technicians at all times The company will not be liable for damages and consequential costs resulting from improperly executed work by third parties This also applies if spare parts other than those specified by KESSLER are used KESSLER offers customer service tools that make working on axles transmissions wheel gears and non drive wheels easier and safer Kessler amp Co GmbH amp Co KG Introduction Service Manual All rights reserved 23 09 2013 ATEN Kessler amp Co GmbH amp Co KG All rights reserved General information 23 09 2013 General information Axles transmissions wheel gears and non drive wheels from KESSLER may be used only in technically flawless condition and as specified in a safety and hazard conscious manner and in compliance with the manual Defects especially those that could impair safety must be remedied immediately It is likewise prohibited to use defective or improperly serviced repaired or modified axles transmissions and non drive wheels In addition to and having priority over the warning and safety information in
10. head screw Shaft nut with cheese head screw and bushing Shaft nut with set screw Loctite 243 Shaft nut with counter nut Kessler amp Co GmbH amp Co KG All rights reserved Version 9 Oo 2 5 Security Remarks Cheese head screw amp Loctite 270 Cheese head screw amp Loctite 270 Set screw amp Loctite 243 262 Back off set screw rotation after tightening Molykote Security spline amp counter nut amp Loctite 243 Service Revised 01 09 2007 Assembly of the face seal OQ Section 1 Sealring 2 Rubber toric ring 3 Housing retaining lip 4 Housing ramp 5 Seal ring housing Seal rings torics and housings must be clean and free of any oil film dust or other foreign matter Use a solvent that evaporates quickly leaves no residue and is compatible with the rubber toric rings The recommended solvent is Isopropanol Ring and housings should be wiped with a solvent soaked lint free cloth or paper towel After all components have been wiped clean the torics should be installed on the metal seal rings so that they rest in the radius on the tail of the metal ring Insure that the torics are not twisted by inspecting the mold flash line on the outside diameter of the toric for true circumferential tracking around the seal Twisted torics will cause nonuniform face load that can result in leckage of lubricant and pumping of debris past the toric If a t
11. seal detail of the seal DS OO JO Om P GO Faulty seals must be exchanged in accordance with the instructions below 1 Stand the vehicle on an even surface and secure against rolling away 2 Release the parking brake by applying the necessary release pressure 3 Release the screw cap and unscrew 4 Release the lock nut size 24 or 30 and turn the adjusting screw with socket wrench size 8 or 10 manually counter clockwise until the adjuster screw is flush with the inner side of the piston 5 Push backthe thrust bolt until it has contact with the piston Following actuate the hand brake valve no pressure must be in the piston chamber The bank of cup springs is now completely depressurized 6 Unscrew the pressure hose and remove the brake 7 Release the circlip and remove the pressure ring of the housing 8 Release the bank of cup spings and the piston Caution Pay attention to the mounting direction of the seal rings otherwise leaks can occur Use for mounting the new seal rings a suitable mounting needle with roun ded edge Be careful Technical information TM 63 97 T Maintrance and repair instruction 63 97 KN OTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 9 Change all seals and mount the parts of the brake in other way round order By mounting the piston the sliding and sealing surfaces must be greased li ghtly using lubricating grease to
12. this manual the applicable national safety and environmental regulations also apply Maintenance repairs or modifications may be performed only by trained specialists The manual must be read prior to starting maintenance repairs or modifications In case of ambiguities and uncertainty always consult KESSLER When performing maintenance and repairs comply with the safety regulations and the statutory requirements for preventing injuries and damage to the product Persons who perform these tasks are obligated to become familiar with and comply with these regulations These persons are responsible for the occupational safety After conducting maintenance and repairs the product must be inspected to ensure that it is functioning properly In case of major repairs and overhauls it is recommended to send the entire components axle gear wheel gear and non drive wheel to KESSLER All maintenance instructions in the KESSLER manual must be complied with Assembly and disassembly must be carried out in a clean work area Use special tools from KESSLER for the work Before reinstalling used parts they must be inspected for damage undamaged contact surfaces and wear It is especially important to ensure that no chips or other foreign objects remain in the axles transmissions wheel gears and non drive wheels To remove the components axle gear wheel gear and non drive wheel from the vehicle read the instructions of the vehicle manufac
13. 100 Tightening torque of the nut for steering stop 300 Approximate value for the thigthening torque for screw plug Thread Tightening torque Tightening torque Approximate value Screw plugs with O Ring M14x1 5 ca 45 45 M16x1 5 ca 60 M22x1 5 ca 100 100 M24x1 5 ca 120 M30x1 5 ca 160 M42x1 5 ca 260 M45x1 5 ca 280 Kessler amp Co GmbH amp Co KG All rights reserved Service Revised 01 10 2012 Page 2 of2 General instructions for correct assembly and disassembly Units Comparison table for units 25 40 mm 1mm 1 kg kilogram 9 81 Nm 1 1 356 Nm 0 138 kpm 1 bar 1 02kp cm 0 070 bar 0 071 1 Litre 4 456 Litre 1 Litre 3 785 Litre 1609 344 m 0 C Celsius 1 C Celsius 0 C Celsius 1 C Celsius Names of the legal units Torque Moment of Newton force ish Kessler amp Co GmbH amp Co KG T Nm LETT Kapitel 3 3 1 1 in inch 0 0394 in inch 2 205 Ib pounds 7 233 lbf x ft pound force foot 1 lbf x ft pound force foot 14 5 psi pound force per square inch Ibf in 1 psi Ibf in 0 264 Gallon Imp 1 Gallon Imp 0 220 Gallon US 1 Gallon US 1Mile land mile 32 F Fahrenheit 33 8 F Fahrenheit 273 15 Kelvin 274 15 Kelvin Conversion Comment Nm 1 kpm 9 81 Nm F N x r m 1 02 at 1 02 kp cm
14. 12 Section Assembly of differential and carrier assembly Service Revised 20 01 2014 Kessler amp Co GmbH amp Co KG All rights reserved Assembly of differential and carrier assembly Is section Adjustment of contact pattern of bevel gear teeth NOTICE search for the production numbers of the drive pinion and the ring gear It is only possible to achieve an optimal contact pattern if Production numbers No production numbers on drive pinion marked on the end face on drive pinion on ring gear marked on the face of the ring on ring gear gear The production numbers of the drive pinion indiscriminate use of drive pinion and ring and ring gear must match gear is possible only mount in pairs no pairing necessary Kessler amp Co GmbH amp Co KG All rights reserved Service Revised 23 05 2012 page 1 of 2 Assembly of differential and carrier assembly Section Checking the contact pattern of the gear teeth 1 Coat the teeth of the ring gear with spotting paste and then turn it several times until you can see pressure marks from the drive pinion on the coated teeth 2 Check the contact pattern pressure marks and compare them with the illustrations in the following table 3 If necessary make adjustments as shown in the table Optimal contact pattern Contact pattern too high Reduce drive pinion distance by correcting thic
15. 90 min residual thickness 1 0 mm per lining pad 6 mm carrier plate thickness FSG 100 min esidual thickness 2 0 mm per lining pad 8 mm carrier plate thickness Note Only Knott original spare lining plates may be used If any other spare parts are used no warranty claims will be accepted either for the brakes or their functional characteristics 1 Stand the vehicle on an even surface and secure against rolling away 2 Release the parking brake by applying the required release pressure 3 Release the screw cap and unscrew 4 Release the lock nut size 24 or 30 and turn the adjusting screw with socket wrench size 8 or 10 manually clockwise until it lies flush with the inside of the piston 5 Press back the thrust bolt using a suitable screwdriver until it has contact with the piston Technical information TM 63 97 5 Maintrance and repair instruction 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles Bild 4 2 Exchanging the lining pads 1 guide bolt 2 lining pad 3 lining pad 4 permanent magnet o castellated nut safety splint 6b safety clip f US 6 Depending on the free space available release one of the two guide bolts re moving the safety splint unscrewing the castellated nut and pulling the guide bolt out of the brake anchor plate Now the brake lining pads can be removed tangentially to the brake disk Note In
16. Oil seal rings and particularly the anti dust lip seals must fill with grease The universal joint shafts and the axle shafts must forcibly mounted they must slide Seal ring treads on flanges shafts and so on must preserve with Castrol Rustilo DWX 32 before mounting Refill oil after assembly Service Revised 01 10 2012 General instructions for correct de assembly and disassembly An Application Loctite and operating supplies Application of Loctite and operating supplies DEER O fm p poes ato mm aaner ess ignrgreen Gluing wih big with or si 5926 and 2 EPPLE 33 0 2 Surface gasket Surface 3 DIRKO oe Elastic gasket Remarks for working up Loctite and operating supplies gt Threads and surfaces have to be cleaned and free from colour oil and grease before applying Loctite Loctite will harden under following conditions Exclusion of air Metal contact Increased temperature Pre assembly and control tightening must do in a short time 5 to 10 min gt The time between gluing and mounting of the parts should be shorter than 1h Exception parts made from nonferrous metal have to be glued within one minute Assembled parts must remain unloaded for at least 24 hours Loctite quantity At contact surfaces Pay attention for a sufficient Loctite application Kessler amp Co GmbH amp Co KG All rights reserved Service
17. Revised 01 06 2010 Page 1 of 1 General instructions for correct de assembly and disassembly iz Application of Loctite and operating supplies of hub assembly prre ERIC ES EU Poem mp m oe axle spindle Adjusting screw in planetary mm nut EN See retainer Pol wheel Contact surface os f Steering lever Track rod lever uz Steering lever Contact surtace surface MM rod lever Radial seal rings Contact surface Rubber casing Radial seal rings Contact surface 270 Steel casino Wheel safety nut see chapter 5 Adjustment of wheel bearings Kessler amp Co GmbH amp Co KG all rights reserved Service Revised 01 10 2012 Page 1 of 1 General instructions for correct de assembly and disassembly e Application of Loctite and operating supplies of differential and carrier assembly oafety blocked Epple 33 alternative a Dirko Shifter cylinder Contact surface 572 Diff lock Diff carrier Through drive Epple 33 alternative 24 5926 209125 Through drive Contact surface COVer pm Hing gear ewm o fem Ring gear Thread Epple 33 alternative support Dirko gre Kessler amp Co GmbH amp Co KG all rights reserved Service Revised 01 10 2012 Page 1 of 1 General instructions for correct assembly and disassembly 33 Kap
18. Service Manual Axle Edition 05 2014 Original Allied Form 80 1072 K 05 H 0 Service Manual Kessler amp Co GmbH amp Co KG All rights reserved Copyright Reproduction dissemination of this documentation any form photocopying printing or electronic Firma Kessler amp Co GmbH amp Co KG dissemination is prohibited without the written permission of Kessler amp Co GmbH amp Co KG This documentation is not subject to revision We reserve the right to make modifications without prior notice O Kessler amp Co GmbH amp Co KG All rights reserved 08 06 2011 K 05 H 0 Service Manual Kessler amp Co GmbH amp Co KG All rights reserved IEEE Introduction Axles transmissions wheel gears and non drive wheels from Kessler amp Co GmbH amp Co KG hereinafter referred to as KESSLER are designed and manufactured in accordance with the state of the art and the recognised technical safety regulations This documentation describes the state of the art at the time the documentation was created Although the documentation was created with great care KESSLER accepts no liability for any errors with respect to the depiction and description This documentation is not subject to revision service We reserve the right to make modifications without prior notice Due to continuous developments and technical improvements of our products the depictions in the
19. ary housing 22 Because of the difference of diameter of 0 1 mm press the planetary pin 17 resp 18 in direction of arrow Be sure that the bore hole of the locking pin in the planetary pin and planetary housing are aligned After inserting secure the planetary pin with the locking pin 20 resp 21 NI n Service 1 0 Revised 01 09 2007 m Assembly of the planetary housing Adjustment of the axial clearance Section Assembly of the planetary housing 23 Press the thrust disc 32 into the sun gear 8 secure with Loctite 270 Press the sun gear 8 into the planetary housing 23 secure with Loctite 270 Install the circlip 33 into the slot of the sun gear Insert the preassembled planetary housing 23 into the hub assembly fix on the sun gear 7 and in the ring gear 3 Adjustment of the axial clearance The axial clearance between sun gear 8 and thrust disc 27 in the planetary housing 22 must be 0 6 0 9 mm Measure distances Dimension A Dimension B Required disk thickness A B axial clearance 0 6 0 9 mm Mount the correctly dimensioned thrust disc if necessary make final correction on a lathe into the planetary housing Secure with Loctite 270 Assembly of the planetary housing 22 Place o ring 30 into the slot of the planetary housing Install the preassembled planetary housing 22 and bolt it secure the screws with Loctite 262 Kessler
20. component permits gt Make sure that the oil has cooled before draining it gt Make sure that rotating parts have cooled before starting to remove them gt Wear fireproof gloves During all machining work on metal parts during which there is a danger of splinters abrasive cutting deburring cleaning with compressed air etc flying metal parts can cause eye injuries gt Wear protective goggles It is prohibited to wear loose clothing and long open hair when working on axles transmissions wheel gears and non drive wheels Oils and greases can cause allergic skin reactions Wear suitable protective clothing NOTICE Always observe the technical data brake connections tightening torques of screws and wheel locking nuts etc Compliance with these specifications is very important for the safety of other people For information on connections see installation drawing For information on tightening torques see Important Information For information on the drive assembly see Drive assembly For information on the hub assembly see Hub assembly For information on the planetary gear drive see Planetary gear drive For information on the brakes see Brakes Kessler amp Co GmbH amp Safety information Service Manual All rights reserved page 4 of 4 18 11 2013 Table of contents Kessler amp Co GmbH amp Co KG All rights reserved Important remarks Lubrication int
21. cuum fill technique for the lubricant It is recommended the compartment be filled to the correct level with lubricant and then rotated slowly several revolutions to seat the seals A vacuum test will catch big seal damage such as broken seal rings or cut torics that may be caused in the last phases of assembly The Duo Cone seal is not designed to seal air so some leakage can be expect using such a procedure Following these guidelines and recommendations should insure optimum performance from the Duo Cone seals Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Section Assembly of planetary gear drive Service Kessler amp Co GmbH amp Co KG All rights reserved i 0 Bavised 01 09 2007 uonoes mE LH a gt p lt TA N KZ SS ne IT SoA KM N Nec nn gt T UOTE Planetary gear drive Cee see 9 n A AA Assembly of the ring gear and ring gear carrier Assembly of the sun gear Section Prepare the ring gear and the ring gear carrier Heat the taper roller bearing inner ring with cage 1 to about 100 C and install it onto the ring gear carrier 2 Place the ring gear 3 onto the ring gear carrier Bolt the retainer 5 with the screws 4 secure the screws with Loctite 270 At PL417 510 the ring gear has to be mounted aft
22. djustment dimension A Deviating dimension defined during production is marked on the locating face of the pinion It indicates the deviation from the specified dimension Without inscription on the locating face of the pinion the deviating from the specified dimension is O Example Deviation 0 1 Example Deviation 0 Sample calculations dimensions in mm Theor Required adjustment Measured bearing Tolerance at drive l adjustment disk width pinion Calculation of the required adjustment disk thickness disk thickness thickness Version 1 theor deviation deviation disk from from thickness bearing pinion required disk thickness ANN 10 deviation from the theoretical dimension deviation from the theoretical dimension 0 15 theor deviation deviation DEE E disk from from uc thickness bearing pinion deviation from the deviation from the theoretical dimension theoretical dimension 0 20 theor deviation deviation disk from from thickness bearing pinion required disk thickness deviation from the deviation from the theoretical dimension theoretical dimension 0 10 0 10 Fit corresponding disc and outer rings of the taper roller bearings Kessler amp Co GmbH amp Co KG All rights reserved l Ser vice B3 Revised 30 08 2012 Paae 2 of 2 A Section l A A Assembly the drive
23. el delel dele Hypoid gear oil MIL L 2105 API GL 5 Drive assembly Hypoid gear oil in multi range characteristic per SAE 90 or multi grade oils for control points normal external temperature thl SAE 75 W 90 SERM SAE 75 W 85 for external temperature lower 10 C SAE 140 or multi grade oils Wheel hub plane tary gear drive Interaxle differential Drop gear Gear boxes for external temperature over 30 C Wheel bearing oil lubricated Multi disk parking Hydraulicoil Oilchange brake ISO VG 32 wet running p RCE 90 98 Cardan shaft inter Fuchs Renolit dedi mediate bearing LX NHU 2 dl elo fete Multi use grease maintenance lithium saponified reduced groove penetration eee o e L6 Fuch mese Henolit MP 150 Steering knuckle bearing Steering knuckle bearing Universal joint Track rod Steering cylinder ball head if provided for Spherical plain bearing en mm e ep Attention 2 Lightly greased at brake shoe new assembly if grease Change grease at wheel lubricated hub disassembly e external cooled dependent on tank volume cooling oilchange system operation conditions not external cooled Bh Hours of operation Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 29 09 2012 Brake shaft bearing Brake shoe bearing W
24. el hub 6 parallel onto the axle spindle resp steering knuckle gt Important Be careful not to damage the radial seal rings 7 O Kessler amp Co GmbH amp Co KG Service All right d rights reserve H 0 H 1 Revised 04 02 2014 OQ section Adjustment of wheel bearings Tightening torque of the wheel safety nut series Nm 41 300 51 350 61 400 71 72 400 81 82 450 91 500 109 500 116 500 L101 500 L102 550 D LT 101 102 600 650 106 650 700 111 750 112 1000 Adjusting of wheel bearings The temperature of the axle parts should be between 0 and 20 C at the bearing adjustment Screw on the wheel safety nut Loctite resp Molykote using see page 5 7 2 and adjust and secure as following described Screw on the wheel safety nut and tighten it with a 1 5 2 times higher tightening torque than the finish tightening torque During the tightening turn the wheel hub a few times and knock it with a plastic hammer Untighten the wheel safety nut about 180 back rotation then tighten the wheel safety nut to the tightening torque according to the table At this tightening turn the wheel hub also a few times if there is no possibility for securing the wheel safety nut has to be turned back to next securing possibility Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Wheel safety nut Designation Shaft nut with cheese
25. ely pre tensioned 1 2 9 4 7 Stand the vehicle an even surface and secure against rolling away Release the parking brake by using the required release pressure Release the screw cap and unscrew Release the lock nut size 24 or 30 and turn the adjusting screw with socket wrench size 8 or 10 manually clockwise until the two brake pads make contact with the brake disk Turn the adjusting screw anti clockwise and set the clearance specified in the above table Hold the adjusting screw in position with the hexagonal socket wrench and lock with the lock nut Mount the screw cap and tighten as far as possible manually Actuate the brake valve several times and check the braking efficiency of the par king brake on a slope Technical information TM 63 97 3 Maintrance and repair instruction TM 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles After the failure of the pressure release the parking brake by using following ma nual procedure 3 Emergency release of the parking brake Bild 3 1 Adjusting and assem bly possibilties thrust bolt bank of cup springs adjusting screw screw cap lock nut piston even surface socket wrenchl D OO A 1 The vehicle has to be secured against rolling away 2 Release the screw cap and unscrew 3 Release the lock nut size 24 or 30 and turn the adjusting screw with socket wrench size 8
26. embly of the planetary gear drive see chapter 6 e At version with drum brake mount the brake drum Assembly of the ABS sensor installation if present see 5 1 7 Attention At version with ABS resp ABS preparation the pol wheel is mounted onto the axle shaft the thrust ring of the sun gear in the axle spindle must be dismounted for disassembly the axle shaft Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Assembly of the hub assembly 5 5 12 Prepare and mount the wheel hub NOTICE At irregular assembly of the radial seal ring The sealing of the oil chamber is not guaranteed gt Observe the fitting position of the sealing lip from the radial seal ring gt Do damage the sealing lip Usea special tool seal ring sleeve driver Prepare wheel hub gt Install the wheel studs 1 Press in outer rings of taper roller bearings 2 3 do not hammer them Install inner ring of taper roller bearing 3 Install the o ring 4 into the distance ring 5 Install the distance ring 5 into the wheel hub 6 Y Y VV WV Press the radial seal rings 7 with Loctite 572 rubber cage resp Loctite 270 steel cage applied into the wheel hub 6 Fill the radial seal rings with bearing grease gt Install the face seal 8 into the wheel hub 6 see 5 8 Mount wheel hub gt Push the pre assembled whe
27. er installation of the fast planetary gear stage reverse the ring gear has to be disassembled before disassembly of the fast planetary gear stage Assembly of the ring gear carrier Install the ring gear carrier 2 with ring gear 3 into the wheel hub resp onto the steering knuckle resp axle spindle The oil compensating hole in the ring gear carrier must be on the bottom Subsequent adjust wheel bearings see chapter 5 7 Assembly of the thrust ring Press the thrust ring 6 into the steering knuckle resp axle spindle Secure with Loctite 270 Assembly of the sun gear Slip the sun gear 7 onto the universal joint resp axle shaft install the circlip 9 and push the universal joint resp axle shaft towards the inside until the circlip contacts to the sun gear and the sun gear contacts to the thrust ring Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Assembly of planetary gear Kessler amp Co GmbH amp Co KG All rights reserved section 1 2 Prepare planetary gear Install the needle bearing 10 resp 11 into the planetary gear 12 resp 13 Insert the preassembled planetary gears 12 resp 13 with needle bearings 10 resp 11 rings 16 if present and thrust discs 14 resp 15 into the planetary housing 22 resp 23 planetary housing in horizontal position Place o ring 19 into the slot of the planet
28. ervals and maintenance instructions General instructions for correct assembly and disassembly Service tools Assembly drive assembly Assembly hub assembly Assembly panetary gear drive Assembly service brake Assembly parking brake HESSLER CO Service Revised 01 09 2007 Section Sy I mportant remarks O Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 27 02 2013 I mportant remarks Section 1 1 Important remarks Checking of screw connections safety devices and corrosion For safety reasons the vehicle operator must check and service all important screw connections and safety devices at regular intervals Check of brakes Kessler amp Co GmbH amp Co KG All rights reserved Wheel nuts Nuts of axle mounting bolts Tightening screws on housing joints and steering components will break the Loctite bond which means the screws have to be reinstalled oecure screw connections and joints in accordance with specifications in case of doubt contact Kessler amp Co GmbH amp Co KG Corrosion and cracks on support components e g the axle spindle are not permissible for reasons of operational safety and leaks Supporting components with cracks must be replaced Cracks on steering components are not permissible for reasons of operational safety oteering components with cracks must be replaced Inspect brake lining and brake drum brake disc regulary as well as
29. ervice Kessler amp Co GmbH amp Co KG Al rights reserved i 1 Ee S Section Assembly of differential and carrier assembly A91 A a T Dimension of backlash Place the differential with the outer rings of the taper roller bearings on the differential carrier which is in a vertical position with mounted drive pinion Mount the differential straps and align them with the thread rings During this operation be careful of the alignment marks on the differential straps with respect to the differential carrier Do not interchange the differential straps Backlash Version 1 Version 2 The smallest admissible value at the closest Is no value marked on the circumference of the ring place is marked on the circumference of the ring gear the backlash is depend on the ring gear gear diameter see following table ibid Ring gear Backlash description diameter Drive Kessler amp Co GmbH amp Co KG All rights reserved i Ser vice g H db Revised 23 05 2012 Page 1 of 2 Section Assembly of differential and carrier assembly A91 A E mek Adjustment of backlash Version 1 Version 2 Tighten the differential strap bolts by hand a counter rotation of the two thread rings move the differential until the backlash is correct Therefore hold the drive pinion at the drive flange Check the backlash by careful forwards and rear
30. g 1 with toric ring 2 Lower the rings into a container with Isopropanol until all surfaces of the toric 2 are wet Toric sliding on retainer ramp Toric caught on housing retainer lip Toric sliding on seal ramp After dipping the seal assembly in the solvent shake the excess solvent from the seal assembly and immediately pop the seal into the housing with a firm push of the installation tool Remove the installation tool and check the seal stantout height at several places around the circumference of the ring to verify an accurate installation If the seal does not meet the height specification inspect the toric for twists or obvious bulges With all surfaces of the toric ring 2 wet with Isopropanol use the installation tool 9 to position the seal ring 1 and the toric ring 2 squarely against the housing 5 as shown Use sudden and even pressure to pop push the toric ring 2 7 under the retaining lip 3 of the housing 5 2 Kessler amp Co GmbH amp Co KG Service All rights reserved i H 0 Revised 01 09 2007 Assembly of the face seal OQ Secon 6 3 The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated adjustment hook If small adjustments are necessary do not push directly on the seal ring 1 use the installation tool 9 to push down or the adjustment tool 11 to pull up A thin film of
31. gn Insert the planetary gear with thrust discs into the planetary housing Press in the planetary pin thereby the mounting bushing will remove Note the passage Assembly of the planetary gear At the disassembly of the planetary pin the cageless needle bearing will fall asunder if not a mounting bushing will be pushing inwards at planetary pin removing Hint Kessler amp Co GmbH amp Co KG All rights reserved Note the passage Disassembly of the planetary gear Service 1 1 Revised 01 09 2007 Section Assembly of service brake Service Revised 26 07 2011 Kessler amp Co GmbH amp Co KG All rights reserved A 0 d Assembly of the wet disc brake N Section x Pe B Em SES mem gt 2 SE YG r AF EFFET SS D RAA i SS 00908308 HI AAS EI d A M N En EE EE AE ra L Dan mr ar an aa wan am am ag a I CSSS CCSN aar m an ar n an an aram ar ana BE NN ERE CENE a a a a a a a a EE MANA Brake carrier Brake housing Piston Inner disc Outer disc O ring Screw Screw plug d E Seal ring 10 Seal ring 11 Connection peace 12 Breather Kessler amp Co GmbH amp
32. he spring set is released before disassembly of the circlip 1 LA 1 tr K EL Me Nonbinding sketch Kessler amp Co GmbH amp Co KG Service All rights reserved i 0 Revised 01 09 2007 Maintrance and repair instruction 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 1 Construction and funktion Bild 1 1 Parts of the brake housing pressure ring thrust bolt adjusting screw bank of cup springs piston lining pad lining pad gliding bolt Joo P gt The two identical brake pads slide freely on the guide bolt which is fastened in the housing The guide bolts are guided in an additional brake anchor plate which in turn is screwed onto the vehicle i e its axle On actuation the brake generates a clamping force at the brake lining pads which cause a tangential force braking moment to be generated at the brake disk the extent of which depends on the coefficients of friction generated by the linings The clamping force is generated by the bank of cup springs during which the pi ston is moved together with the adjusting screw the thrust bolt and the brake pad towards the brake disk When the brake pad comes into contact with the brake disk the reaction force shifts the housing onto the guide bolts until the brake pad is also pressed against the brake disk The brake i
33. heel bearing Wet disc brake see chapter 7 Page 1 of 2 Section Lubrication intervals and maintenance instructions 2 3 1 Whichever occurs first 2 The bearing point is to be lightly lubricated only to avoid the penetration of grease in the interior of the brake use only hand operated grease gun and remove surplus grease Check regularly the brake shafts and if need correct the lubrication intervals danger of overheating Important if a noise is produced on axles with self locking differentials Onthe axles with self locking differentials a noise is produced if normal oils are used In case of abnormal noises and in case of a jerky roll off of the tyres use gear oil EP with additives of the Limited Slip type conforming to specification M 2C 104 A Service Kessler amp Co GmbH amp Co KG All righ See Hevised 29 09 2012 Page 2 of 2 v N N NONU A Lubrication intervals maintenance instructions Section Recommendable hypoid gear oils corresponding MIL L 2105 B APIGL 5 resp MIL L 2105 C D API GL 5 ARAL Gearoil Hyp 90 AVIA Gearoil Hypoid 90 EP BP Multiuse Gearoil EP SAE 90 ELF Tranself Typ B 90 Tranself Typ 80 W 90 ESSO Gearoil GX D 90 FINA Pontonic MP SAE 85 W 90 FUCHS Renogear Hypoid 90 MOBIL HD 90 A SHELL Spirax MB 90 HD 90 TEXACO Multigear EP SAE 85 W 90 AGIP Rotra MP Rotra MP DB On no account u
34. inflation of tyres Safety information page 2 of 4 Service Manual 18 11 2013 DANGER Comply with tightening torque for wheel nuts gt Retighten wheel nuts after a short operating period Basic safety information Comply with the safety signs on the axle gt They must be kept in legible condition at all times Only tools and equipment of the highest quality may be used tools and equipment must be undamaged and electrical equipment must be approved for use in the respective country gt Never use improvised devices gt Use only original tools from KESSLER Due to the unforeseeable dead weight of the single parts e g wheel hub or complete axles transmissions wheel gears or non drive wheels it is possible that they can fall or tip over during assembly work Always use suitable undamaged and tested cranes and load attachment gear for the respective load Never work or stand under suspended loads Secure parts with a lashing strap and or support Wear safety shoes Movement rotation of different parts can result in the danger of injury to limbs gt Never reach between moving parts with your hands Kessler amp Co GmbH amp Co KG Safety information Service Manual All rights reserved page 3 of 4 18 11 2013 Welding repairs are permitted only in coordination with KESSLER Work on an axle a transmission a wheel gear and a non drive wheel is allowed only if the temperature of the respective
35. itel Tightening torques General instructions for tightening torques Nm 0 14 All tightening torques are rated Nm Tolerance of the tightening torques is 5 assuming a manually operated torque spanner is used Tightening torque of metric coarse pitch thread Screw Nut Screw Nut Screw Nut Thread 8 8 8 10 9 10 12 9 12 4 3 0 4 4 5 1 M5 5 9 8 7 10 M 6 10 15 18 8 25 36 43 M 10 49 72 84 12 85 125 145 M 14 135 200 235 M 16 210 310 365 M 18 300 430 500 20 425 610 710 22 580 830 970 M 24 730 1050 1220 M 27 1100 1550 1800 M 30 1450 2100 2450 Service Revised 01 10 2012 Kessler amp Co GmbH amp Co KG All rights reserved Page 1 of2 General instructions for correct assembly and disassembly 33 Kapitel Tightening torque of metric fine pitch thread Screw Nut Screw Nut Screw Nut Thread 8 8 8 10 9 10 12 9 12 M 8 x 1 27 39 46 M 10 x 1 55 81 95 10 x 1 25 52 76 90 12 1 25 93 135 160 M 12 x 1 5 89 130 155 M 14 x 1 5 145 215 255 M 16 x 1 5 225 330 390 M 18 x 1 5 340 485 5 0 20 x 1 5 475 680 790 22 1 5 650 920 1050 Thigtening torque for galvanized bolts and nuts Regard reduced thightening torque for galvanized bolts and nuts Tightening torque for brake caliper dowel screws greased M 20 x 1 5 400 100 M27x2 900
36. kness of the adjustment disk Adjust the backlash by moving the ring gear out Contact pattern too low Increase drive pinion distance by correcting thickness of the adjustment disk Adjust the backlash by moving the ring gear in Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 23 05 2012 2 of 2 Assembly of differential and carrier assembly Securing of the striking nut NOTICE The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bended on the slot ground Figure 1 Figure 2 Use of Loctite and other operating supplies 1 Striking nu tat drive flange gt In thread assembly paste with MoS2 exception through drive pinion see 2 gt Front side contact surface sealing compound Epple 33 or equivalent 2 Striking nut at through drive nut gt In thread Loctite 262 3 Striking nut at gear wheels bearings ect gt Gewinde Montagepaste mit MoS2 Service Revised 27 06 2012 Kessler amp Co GmbH amp Co KG All rights reserved H 1 page 1 of 2 S Assembly of differential and carrier assembly D ha Removing of the striking nut 1 NOTICE Bend away the nose and screws the nut off 4 The secured striking nut Figure 3 o Applying an applicable flat chisel in the slot between pinion and securing and removing the
37. l ring with Loctite 572 applied Fill the radial seal ring with bearing grease Slip the drive flange screw on the safety nut with sealing compound between the contact surfaces Tighten the safety nut according to sheet 3 5 Lock the nut by striking the nut brim into the slot of the pinion Kessler amp Co GmbH amp Co KG Service All rights reserved H H 1 Revised 01 09 2007 Assembly of the Differential 1 Before assembly all of the bevel gears and the thrust rings should be well oiled Place one differential side gear with the side gear thrust washer in the differential case Install the spider with differential gears and differential pinion thrust washers in the differential case Install the other differential side gear and side gear thrust washer At variants with Nospin differential install the Nospin diff instead of the differential gears Install the other half of the differential case over the assembly and observe the alignment marks tighten the differential case bolts Secure with Loctite 262 Check that all differential pinions can rotate easily Coat the contact surface of the ring gear with Loctite 270 and install the ring gear on the differential case by tapping lightly on the circumference Tighten the ring gear bolts Secure with Loctite 262 Heat the two taper roller bearings to about 100 C and install them by using a sleeve S
38. lation drawing number and Serial number see identification plate The illustrations are not binding for the design opanner for wheel safety nut Not Applicable opanner for wheel safety nut Allied Part Number 593401 opanner for splined nut hub assembly Not Applicable O Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 01 10 2012 Section Service tools 3 6 2 Tools When ordering maintenance tools please provide Part number no of installation drawing number and Serial number see identification plate The illustrations are not binding for the design Seal ring sleeve driver Allied Part Numbers 593402 and 593403 opanner for thread rings Differential bearing Allied Part Number 593404 opanner for counter nut Planetary gear drive not applicable Assembly cone for o ring Differential lock not applicable Kessler amp Co GmbH amp Co KG All rights reserved Service Revised 01 10 2012 Section Service tools 3 6 6 Tools When ordering maintenance tools please provide Part number no of installation drawing number and Serial number see identification plate The illustrations are not binding for the design Centering tool for discs Allied Part Number 593405 Installation tool for face seal Allied Part Number 593406 Service Kessler amp Co GmbH amp Co KG PRIUS reserved 5 5 R I Revised 01 10 20
39. light oil should be applied to the seal faces prior to assembly Use an applicator a disposable tissue or a clean finger to distribute the oil evenly Be careful not to get any oil on the rubber toric rings Be sure there is no visible debris on either of the seal faces even a small piece of lint can hold the seal faces apart and cause leakage After successful installation wait one minute for the Isopropanol to dry before assembling the two seal halves in the final loaded position This delay is to allow any excess solvent to dry so that the torics roll rather than slide in the housing as the faceload is increased If the torics slide this can produce a nonuniform load that can result in poor seal performance Results of incorrect assembly Point A and point B remain stationary Points X and rotate 1807 This causes high pressure at Y and possible galling When rotated points B X has low pressure and possible leakage Original assembled position Rotated 180 Kessler amp Co GmbH amp Co KG Service All rights reserved i H 0 Revised 01 09 2007 OQ Section Assembly of the face seal After the unit to be sealed is assembled a post assembly leakage test can be performed to insure the seal is properly installed A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive Many users find this an easy check to combine with a va
40. or 10 manually counter clockwise until the brake disc is free Caution For the emergency release is an actuation torque of 40 Nm respectively 70 Nm required 4 Mount the lock nut the screw cap and tighten both as far as possible ma nually Protection against dirt Caution Now the vehicle do not have any brake function The vehicle must be se cured against moving away with proper means Before putting the vehicle into operation again the brake has to be adjusted again Res Assembly and basic setting regulations 4 Technical information TM 63 97 Maintrance and repair instruction 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 4 Maintenance and repair work 4 1 Maintenance and exchange of brake pads Bild 4 1 Extending the lining 1 piston 2 adjusting screw 3 locknut 4 thrust bolt S socket wrench S1 screwdriver P inside of the piston The brake pads themselves are maintenance free All that is required here is check for damaged parts as well as inspection to ensure that the brake disk remains easy running The thickness of the brake lining must be subjected to a visual inspection at re gular intervals which depend on vehicle usage but every six months at the latest In the event of a minimal residual lining thickness these intervals must be redu ced accordingly in order to avoid major damage to the brake or disk FSG
41. osity For moderate climate ISO VG 22 32 For extremely cold climate ISO VG 15 For extremely warm climate ISO VG 46 Cooling fluid like actuation fluid Important It is necessary to use oils with LS additives Limited Slip according to the recommendation of the oil supplier For example 3 6 Lubrizol LZ 6117 LZ 9990 A or LZ 6279 It is measured through the check hole while actuating the brake The check measure new is marked in the housing below the hole Is the measured dimension bigger than the marked dimension and max wear dimension unconditional consult Kessler amp Co After working at the brake bleed the brake hydraulic system and check for tightness Kessler amp Co GmbH amp Co KG All rights reserved P Service i H 0 Revised 01 09 2007 Section Assembly of parking brake Service Kessler amp Co GmbH amp Co KG All rights reserved i 0 Bavised 01 09 2007 Spring loaded sliding caliper brakes Co Section Safety notes WARNING Before commencing work on the parking brake ensure that no unintended machine movement can happen when the braking effect is removed Danger to life DANGER The parking brake is under spring tension Parts could become loose and fly out suddenly if improper brake opening Danger to life Therefore release the lock nut 2 and turn the adjusting screw 3 counter clockwise until t
42. ovement of the machine DANGER When working on assemblies with spring actuator elements such as brakes and brake cylinders whether service brake or parking brake The assemblies are under spring tension Improper opening can cause parts to suddenly be released and fly off gt In such cases always comply with the safety repair and maintenance instructions of the suppliers DANGER Special care is necessary when working on wet multiple disk brakes They are under high spring tension Improper installation and or removal of the brake can cause parts to suddenly be released and fly off Do not pre tension and release the tension on the springs by means of the brake housing screw connections Open the screw connection of this brake only using a suitable press or mounting device Preferably installation removal should be carried out by KESSLER DANGER Never remain directly in front of the wheel rim during deflation or inflation The pressure inside the tyre could cause parts to suddenly be released and fly off DANGER When removing and mounting wheels on vehicles with clamped rims there is a danger that the tyre pressure can cause damaged parts of the rim to become released explosively when removing the clamped rim which can cause severe or fatal injuries to the mechanic gt Completely deflate the tyre before performing any task gt Never remain directly in front of the wheel rim during deflation or
43. p GmbH amp Co KG n case of questions contact Kessler amp Co GmbH amp Co KG Section n case of major repairs or overhaul it is advisable to send the entire axle to Kessler amp Co GmbH amp Co KG Service Kessler amp Co GmbH amp Co KG ML d Hevised 29 09 2012 Page 2 of 2 Section Lubrication intervals and maintenance instructions Service Revised 01 10 2012 Kessler amp Co GmbH amp Co KG rved d All rights rese Lubrication intervals and maintenance instructions Section 2 1 General lubrication instructions Fill levels gt Are checked at the level control plugs Oil change 1 2 Place the vehicle in a horizontal position Draining of the oil is to be accomplished only in warm condition Clean all lubrication points before opening them Open the drain holes on the carrier assembly on the wheel assemblies and if present on the interaxle differential and drop gear housing On the hub assemblies the drain plug should be turned downward Oil draining Replacement of the oil draining plugs Remove the oil filler plug as well as the oil level control plug on the carrier assembly on the wheel assembly and if present on the interaxle differential and drop gear housing See page 3 lubrication points Oil filling Check the oil level at the oil level plug hole Overflow control Wait a few minutes If the oil level falls add oil un
44. r do not cant it Wet disc brake X270 X340 X460 X550 X650 dimension X press the piston equal by press the piston equal with hand into the brake carrier do mounting screws into the Assembly of the piston brake carrier do not cant it not cant it gt if necessary adjust the piston with easy hammer taps to the thread holes install first the springs then the tubes in the bore holes of the piston Screw in the hexagon head screws with flange Service Kessler amp Co GmbH amp Co KG All rights reserved 5 f H 0 Revised 24 03 2011 Prepare housing and check the air gap RTE N Section lH ui mi m a a LS iA Lay discs into the housing Check the air gap Air gap measure A measure B measured without pressure Rated size about 0 5 mm smaller than the air gap pressurized see table Install o ring brake housing brake carrier free of torsion and loops Kessler amp Co GmbH amp Co KG i All rights reserved 0 Service Revised 01 09 2007 Air gap and wear dimension air gap sL new brake type pressurized mm N Section wear dimension 3270 1 5 0 7 Kessler amp Co GmbH amp Co KG All rights reserved ech O1 Service Revised 26 07 2011 Final assembly N Section Place the brake carrier onto the brake housing and bolt it Mo
45. re conducting the test bleed the brake hydraulic system The pressure drop after applying 120 bar for a period of 15 minutes must not exceed 2 leaving 117 5 bar Test medium Motor oil SAE 10 W corresponding to MIL L 2104 Check cooling oil room for leaks Brake with external cooling After assembly of the wheel hub with the face seal and adjusting of the wheel bearings check the tightness of the cooling oil room Install an air pressure gauge with shutoff valve Beload the hub assembly with 1 5 bar pressure air Turn the hub assembly several times The pressure drop after a period of 10 minutes must not exceed 0 1 bar Brake without external cooling After assembly of the planetary gear drive check the tightness of the cooling oil room Install an air pressure gauge with shutoff valve Beload the hub assembly with 0 5 bar pressure air Turn the hub assembly several times The pressure drop after a period of 15 minutes must not exceed 0 1 bar Kessler amp Co GmbH amp Co KG i Service All rights reserved 1 Revised 01 09 2007 Remarks to the wet disc brake Actuation fluid Check measure N Section Permissible oil for brake with external cooling Do not use brake fluid at any time Use a mineral oil base hydraulic oil type fluid only 1 Motoroil API SE CD MIL L 46152 MIL L 2104 C o D 2 ATF C 3 or Dexron 3 Hydraulicoil HLP DIN 51524 Teil 2 Visc
46. s released by complete pre tensioning of the bank of cup springs Du ring this process through application of the necessary release pressure after overcoming the cup spring force the piston must move back until it comes to rest against the pressure ring The clamping force diminishes with wear of the brake lining and brake disk The brake must be adjusted at the latest at the times indicated by the adjusting speci fication below Technical information TM 63 97 1 Maintrance and repair instruction TM 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 2 Mounting and basic setting regulations Basic brake setting is required after mounting new brake lining plates or brake disks as well as during all repair stages and in the event of insufficient braking performance Bild 2 1 Adjusting and assem bly possibilties thrust bolt bank of cup springs adjusting screw screw cap lock nut piston even surface socket wrench D O1 BR N A LE Note All mounting and basic setting work must be carried out on the brake when cold 2 1 Mounting the brake 1 Stand the vehicle on an even surface and secure against rolling away 2 Release the screw cap 3 Release the lock nut size 24 or 30 and turn the adjusting screw anticlockwi se using a size 8 or 10 socket wrench until the pressure bolt comes to rest against the even surface of the piston In this status
47. se normal gear oils Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 01 10 2012 Page 1 of 1 Lubrication intervals and maintenance instructions General maintenance instructions Check and main Maintenance intervals 1 tenance points after after every every at least 50Bh 100Bh 500Bh 1000Bh 1x per 500Km m E E py Wheel bearing Inspect if necessary readjust wheel bearing Check and tighten with a torque Wheel nuts wrench after tire change after 50km 200km Castle nuts track rod Check and retighten Screws drive flange Nuts axle mounting bolts i Md La TT Check lining wear if necessary Brakes readjust control the proper monthly see also chapter 7 operation of the brake shafts Wet disc brake Check lining wear Wet disc brake spring load design el Steering and trackrod Check and mounting lever bolts Saz seweewe lel for example drive assembly Ring gear support bolt on drive assembly Readjust if necessary Check from time to time monthly Differential lock Check function and the auto monthly matic return in original position Bh Hours of operation If the bolts are moving Loctite brakes loose the lever has to be mounted once more 1 Whichever occurs first Section Service Kessler amp Co GmbH amp Co KG 1 All right d i DS Revised 01 10 2012 Page 1 of 1 Section e General as
48. securing of the striking nut Figure 4 6 The loosened striking nut Figure 5 O Kessler amp Co GmbH amp Co KG Service All right d rights reserve Revised 27 06 2012 page 2 of 2 5 Assembly of differential and carrier assembly 4 44 Differential and carrier assembly D 91 Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 29 01 2014 Assembly of differential and carrier assembly Adiustment of drive pinion distance EN E Xo Drive assembly theoretical S theoretical B deviating deviating dimension dimension O theoretical zero Kessler amp Co GmbH amp Co KG All rights reserved M A Section R Te To obtain the proper tooth flank contact adjust the axial position of the drive pinion with the thickness of the adjustment disc The necessary thickness of the adjustment disc for first time assembly can be obtained by measurement see calculation example The final thickness of the adjustment disc can be fixed during the checking of gear meshing at the assembled drive assembly see page Checking the contact pattern of the gear teeth 4 0 1 Measured width of the taper roller bearing Service Revised 30 08 2012 Paae 1 of 2 Assembly of differential and carrier assembly A Section A A Version 1 Version 2 Adjustment dimension A
49. sembly disassembly instructions e Service tools Service Revised 01 10 2012 Kessler amp Co GmbH amp Co KG All rights reserved A 0 d General instructions for correct assembly and disassembly a Section General instructions for correct assembly and disassembly General instructions for disassembly The disassembly occurs made inverted to the respective assembly instruction Drain oil before removing check for presence of metal particles Mark the parts to each other before dismantle Never use a hard object to separate tightly fitted assemblies To remove bearings drive flange and similar parts use adequate pull off tools It is recommended that the special tools according 3 6 be used for disassembly Before disassembly the destruction of bearings and other components must check if it is necessary to destroy it oystematically replace used seals O rings and if needed bearings on disassembly Replace or clean corroded parts Do not place parts on dirty surface General instructions for assembly Kessler amp Co GmbH amp Co KG All rights reserved Clean parts before reassembly The cages of bearings rotating in oil must coat with oil at reassembly During mounting of radial seal rings pay attention that there is sufficient overlap to the housing bores Pay attention for a plain alignment of the radial seal ring The seal lips may never be encountered Loctite
50. the brake can be moun ted onto the brake disk and fastened 4 Mountthe pressure connection again Apply the necessary release pressure to the brake until the bank of cup springs is completely pre tensioned Following carry out the below described basic setting regulation 2 Technical information TM 63 97 Maintrance and repair instruction 63 97 KN OTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 2 2 Basic setting regulation 1 Turn the adjusting screw manually clockwise until both brake pads make con tact with the brake disk Then it is not longer possible to turn the adjusting screw without exerting a major amount of force Turn the adjusting screw anticlockwise in order to set the following rated clea rances E ae en miewa 89 me mzogwio 20 45 Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut Mount the screw cap and tighten as far as possible manually Stellen Sie Druckanschlu 3 gem der Vorschrift der Achs bzw Getrie behersteller her Mount the pressure connection in accordance with the in structions of the axle gear manufacturer For bleeding the piston chamber use the socket spanner size 13 for the bleeding valve 2 3 Adjusting regulations During this adjusting process the parking brake must be released i e the bank of cup springs must be complet
51. the event of minimal clearance i e itis not possible for space reasons to exchange the brake lining plate in accordance with these instructions the brake must be removed completely To do this pull both guide bolts out of the brake anchor plate Caution Check the pressure hose If the pressure hose is to short it must be uns crewed to remove the brake Before the pressure hose can be released the brake must be emergancy released 7 Exchange the brake pads and insert the guide bolts into the brake anchor you have removed the complete brake you have to amount the brake on both guide bolt again now 8 Check both permanent magnets if they still have sufficient magnetic force to hold the brake lining plates Should this not be the case the permanent magnets must also be changed by using a suitable screw driver 9 Secure the guide bolt with the castellated nut and the safety splint res safety clip Note After mounting new brake lining plates or their repair the brake must be correctly set in accordance with the instructions Adjusting regulations Technical information TM 63 97 Maintrance and repair instruction 63 97 KNOTT Spring applied hydraulic released sliding calliper FSG 90 and FSG 110 Brakes Axles 4 2 Changing the seal Bild 4 3 Change of the sealsl piston adjusting screw lock nut housing circlip seal guide bolt thrust bolt bank of cup spring detail of the
52. til the level remains constant Clean the grease nipples before lubrication Preservation of Kessler axles for an extended storage period the breather with a screw plug with a sealant in order to avoid water intrusion and oil leakage Fill axles completely up with oil the same applies to wet disc brakes gt Protect machined surfaces for example rim surface steering cylinder brake disc with additional anticorrosive Before putting the axle into operation gt Drain storage oil Fill the axle with suitable oil see service manual Kessler amp Co GmbH amp Co KG to the required oil level Check sealing contact surfaces for corrosion Check the seals immediately after start up for leakage and renew them if leaking gt Completely remove the anticorrosive machined surfaces for example rim surface steering cylinder brake disc The rim face must be cleaned from rust or grease in order to secure a correct friction tight with the rim and to prevent loosening of the rim gt Check axle structure for corrosion especially after several years of storage Kessler amp Co GmbH amp Co KG All rights reserved Service Revised 29 09 2012 Page 1 of 1 N N NOS 704 21 K Lubrication intervals and maintenance instructions N Section N Lubrication points The binding lubrication points have to be taken from the according installation drawing of the axle Single
53. turer The following descriptions assume that the component has been removed and mounted on a mounting device for further processing Service Manual Safety Explanation of the warnin information and symbols appearin in the Service Manual DANGER Highest danger level There is immediate danger of death or severe injury in case of failure to comply with this safety notice this arrow indicates the absolutely necessary measures for preventing the specific danger Second highest danger level There is possible danger of death or severe injury in case of failure to comply with this safety notice this arrow indicates the absolutely necessary measures for preventing the specific danger Third highest danger level There is danger of minor injury or property damage in case of failure to comply with this safety notice this arrow indicates the absolutely necessary measures for preventing the specific danger NOTICE Failure to observe this will result in dangers to the machine and its functions 1 Information Offers additional information to facilitate working Kessler amp Co GmbH amp Co KG All rights reserved Safety information page 1 of 4 Service Manual 18 11 2013 KESSLER CO Special types of danger Kessler amp Co GmbH amp Co KG All rights reserved DANGER When working on brakes make sure that releasing the braking force cannot result in unintentional m
54. unt breather with connection piece and seal ring screw plugs with seal rings Check brake hydraulik system for leaks see tightness checking instruction Install o ring Brake carrier axle spindle resp steering knuckle free of torsion and loops Check the air gap pressurized Measure through the check hole the distance from brake carrier to the piston end face while non actuated brake actuate the brake and repeat the measure operation the difference of the measured distances gives the air gap sL pressurized rated size sL see table Measure through the check hole the distance from brake carrier to the piston end face while actuating the brake and knock the measured value with marking punches into the brake carrier Install the complete brake on the axle coat the contact surface with Loctite 270 Mount face seal see chapter 5 8 Alignment of the discs Wet disc brake dimension X270 and X340 The alignment of the discs has to be made at mounting of the wheel hub by itself Wet disc brake dimension X460 and X650 The alignment of the discs has to be made by a mounting device see chapter 3 6 Clamp the discs by actuating the brake hydraulic or air pressure Kessler amp Co GmbH amp Co KG i Service All rights reserved 0 Revised 01 09 2007 Tightness checking instruction for brake hydraulic system and cooling oil room Check brake hydraulic system for leaks N Section Befo
55. wards rotating the ring gear Use a dial indicator Measure the backlash during a few times turns of the ring gear and if need correct the backlash because of the smallest admissible value at the closest place must not be fall short of Adjust the backlash according to sheet Adjustment of contact pattern of bevel gear teeth Tighten screws of the differential straps and lock them with Loctite 262 Adjust the bearing roll resistance trough tightening of the thread rings Set value 2 0 to 3 0 Nm Check the value with a torque wrench If measuring at the drive pinion drive flange take the ratio of the bevel wheel set into account Screw the lock plates for the thread rings and secure with Loctite 270 if need bend the lock plates Kessler amp Co GmbH amp Co KG All rights reserved Ser VI ce g H H Hevised 23 05 2012 Paqe 2 of 2 Limited slip differential GREEN Leesch Ga N DOEN Boegen RF AE RR RR RR CC RC ALA n H il p CR RCRUM nnn SNS SN LE EF CC a Y CC cca i Sree E 63 2 to 64 29 sel value disk set X Section 9 LJ 44 7 A Loctite 2 0 STE H A AERA NNN Ce VW NULS NEN 18 45 to 18 70 mm 18 71 to 18 85 mm 18 86 to 19 25 mm 19 26 to 19 55 mm Operating sequence
56. wear of brake system parts Inspect the free movement of brake system rods In case of signs of excessive heating consult a brake specialist or the manufacturer Service 5 5 R 1 Revised 19 02 2013 Paae 1 of 2 I mportant remarks Section 1 1 Service instructions Kessler amp Co GmbH amp Co KG All rights reserved Assembly and disassembly may be carried out only by trained specialists Repair welding is permissible only after consulting Kessler amp Co GmbH amp Co KG To remove the axle from the vehicle read the instructions in the vehicle manufacture s manuals The following descriptions assume that the axle has been removed and mounted on a jig for further processing Always comply with the safety regulations for your country There is no guarantee that they correspond to the instructions in this manual Service 5 5 R 1 Revised 19 02 2013 Paae 2 of 2 Important remarks 1 2 Section Control light A control light in the drivers cabin must inform about the operation of inter axle and cross diff lock separately Further the control light should show with already the first lock operated even if the other locks are not yet connected or already disconnected electrical installation parallel Kessler amp Co GmbH amp Co KG Service Hevised 29 09 2012 All rights reserved Paae 2 of 2 I mportant remarks 1 3 Necessary to contact Kessler am
57. wist is apparent it can be eliminated by gently pulling a section of the toric radially away from the metal seal ring and letting it snap back Repeating this in several places around the ring will eliminate any twist in the toric ring Put the toric ring 2 on The toric ring 2 can twist if it is not Eliminate toric twist by gently seal ring 1 at the wet all around during installation or if pulling a section of the toric 2 bottom of the seal ring there are burrs of fins on the retaining rapidly away from the seal ring 1 ramp 7 and against lip 3 of the housing 5 and letting it snap back the retaining lip 8 O Kessler amp Co GmbH amp Co KG Service All rights reserved Revised 01 09 2007 ico 6 2 OQ Section Assembly of the face seal Place the installation tool around the seal ring and dip the seal ring into a pan of Isopropanol solvent to lubricate the toric ring It is essential to lubricate the toric with Isopropanol so that the toric will slip past the housing retaining lip and seal uniformly in the housing nose radius Insufficient lubrication can cause poor seal performance due to nonuniform loading twisted torics or cocked seals Use of solvents other than Isopropanol can leave a residue on the toric or ramps and allow the toric to slide rather than roll in seat This can also result in poor seal performance due to nonuniform loading Put the installation tool 9 onto the seal rin
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