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Kessler Axle 101 Service Manual
Kessler Axle 101 Service Manual
Atlas Copco
ST 1030 (101.1642.3-101.1643.3)
Version 03/2013
Original
Service Manual
© Kessler & Co. GmbH & Co.KG
All rights reserved
Copyright ©
Reproduction and dissemination of this documentation in
any form (photocopying, printing or electronic
Firma Kessler & Co. GmbH &Co.KG dissemination) is prohibited without the written
permission of Kessler & Co. GmbH & Co.KG.
This documentation is not subject to revision. We
reserve the right to make modifications without prior
notice.
© Kessler & Co. GmbH & Co.KG
All rights reserved 08.06.2011
Service Manual
© Kessler & Co. GmbH & Co.KG
All rights reserved
Table of contents
Chapter 2 Lubrication intervals and maintenance instructions See the special table of contents of chapter 2
Chapter 3 General instructions for correct assembly and disassembly See the special table of contents of chapter 3
Chapter 7 Assembly service brake See the special table of contents of chapter 7
Chapter 5
5.1.6 Assembly of the spacer ring
5.3 Hub assembly drive axle
5.3.1 Assembly of the drive axle onto the
axle housing
5.3.2 Assembly of hub assembly
5.5.15 Prepare and mount wheel hub
5.7.1 Adjustment of wheel bearings
5.7.1 Wheel safety nut
5.8.1 Assembly of the face seal
5.8.2 Assembly of the face seal
5.8.3 Assembly of the face seal
5.8.4 Assembly of the face seal
Chapter 4
4.0.1 Adjustment of contact pattern of bevel
gear teeth
4.0.1 Checking the contact pattern of bevel gear
teeth
4.0.2 Securing of the striking nut
4.0.2 Removing of the striking nut
4.39 Drive assembly D81
4.39.1 Adjustment of drive pinion distance
4.39.1 Sample calculations (dimensions in mm)
4.39.2 Assembly of the drive pinion bearing
4.1.3 Assembly of the Differential Chapter 6
4.1.4-81 Dimension of backlash
4.1.4-81 Adjustment of backlash 6.3 Planetary gear drive
4.39.5 Limited-slip differential 6.0.1 Assembly of the ring gear and ring
gear carrier
6.0.1 Assembly of the sun gear
6.1.2 Assembly of the planetary gear
6.3.1 Assembly of the planetary housing
6.3.1 Adjustment of the axial clearance
Chapter 7 6.1.4 Disassembly of planetary gear
6.1.5 Assembly / disassembly of cageless
See the special table of contents of chapter 7 needle bearing (planetary gear
bearing)
Chapter 2 Lubrication intervals and maintenance instructions See the special table of contents of chapter 2
Chapter 3 General instructions for correct assembly and disassembly See the special table of contents of chapter 3
Chapter 7 Assembly service brake See the special table of contents of chapter 7
Chapter 9 Chapter 5
9.1 Wear dimension of oscillation 5.1.6 Assembly of the spacer ring
(housing) fixation 5.3 Hub assembly drive axle
5.3.1 Assembly of the drive axle onto the
axle housing
5.3.2 Assembly of hub assembly
5.5.15 Prepare and mount wheel hub
5.7.1 Adjustment of wheel bearings
5.7.1 Wheel safety nut
5.8.1 Assembly of the face seal
5.8.2 Assembly of the face seal
5.8.3 Assembly of the face seal
5.8.4 Assembly of the face seal
Chapter 4
4.0.1 Adjustment of contact pattern of bevel
gear teeth
4.0.1 Checking the contact pattern of bevel gear
teeth
4.0.2 Securing of the striking nut
4.0.2 Removing of the striking nut
4.39 Drive assembly D81 Chapter 6
4.39.1 Adjustment of drive pinion distance
4.39.1 Sample calculations (dimensions in mm) 6.3 Planetary gear drive
4.39.2 Assembly of the drive pinion bearing 6.0.1 Assembly of the ring gear and ring
4.1.3 Assembly of the Differential gear carrier
4.1.4-81 Dimension of backlash 6.0.1 Assembly of the sun gear
4.1.4-81 Adjustment of backlash 6.1.2 Assembly of the planetary gear
6.3.1 Assembly of the planetary housing
6.3.1 Adjustment of the axial clearance
Chapter 7 6.1.4 Disassembly of planetary gear
6.1.5 Assembly / disassembly of cageless
See the special table of contents of chapter 7 needle bearing (planetary gear
bearing)
Ordering .......................................................................................................................................................................................................................................... 3
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.
• Wheel nuts
• Tightening screws on housing joints will break the Loctite bond, which means the
screws have to be reinstalled!
Secure screw connections and joints in accordance with specifications; in case of
doubt, contact Kessler & Co. GmbH & 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!
Check of brakes
• Inspect regularly as well as wear of brake system parts.
Service instructions
• Assembly and disassembly may be carried out only by trained specialists.
• 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.
Kessler & Co. GmbH & Co.KG will not be liable for any damages resulting from the use of other than original
replacement parts and accessories. Please be aware that special production and delivery specifications
exist for proprietary or third-party parts and that our replacement parts comply with the most recent
standards as prescribed by law.
Ordering
When ordering original Kessler replacement parts, please provide the following information:
3. Vehicle manufacturer
6. Quantity
7. Mode of dispatch
Identification plate
The position of the identification plate on the axle is mostly next to the drive assemly on the
same side as the oil fill plug.
Close to the identification plate, you will also find the axle serial number of the axle stamped into
the axle housing.
Oil change
2. 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.
3. Oil draining
5. 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).
6. Oil filling
7. Check the oil level at the oil level plug hole (Overflow control). Wait a few minutes. If the oil level
falls, add oil until the level remains constant.
Axle 101.1642.3h
I = Oil fill plug II Oil level control plug III = Oil drain plug
Axle 101.1643.3k
I = Oil fill plug II Oil level control plug III = Oil drain plug
dependent on:
external cooled - tank volume
Wet disc brake See chapter – 7-
oil change - cooling system
- operation conditions
(hours = hours of operation)
On the 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.
ESSO - Gearoil GX - D 90
MOBIL - HD 90 - A
SHELL - Spirax MB 90 / HD 90
Check- and
Remarks Maintenance intervals 1.)
maintenance points
at
after after after after after every every least
50 100 1000 4000 8000 500 1000
hours hours hours hours hours hours hours 1x per
year
Inspect, if necessary
Wheel bearing
readjust wheel bearing
⊕ ⊕ ⊕ ⊕
Bolted connections
(for example: Check from time to time ⊕
drive assembly)
Section
service tools
Chapter
service tools
3.21
Application of Loctite and operating supplies of wet disc brake spring load design ...................................................................... 5
Application of Loctite and operating supplies of drive assembly .................................................................................................... 6
Service tools of the wet disc brake spring load design .................................................................................................................. 12
Service tools for drive assembly .................................................................................................................................................... 13
Service tools for drive assembly .................................................................................................................................................... 14
Chapter
service tools
3.21
• Never use a hard object to separate tightly fitted assemblies. To remove bearings, drive
flange and similar parts, use adequate pull-off tools.
• Before disassembly, the destruction of bearings and other components must check, if it is
necessary to destroy it.
• 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!
• 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.
Chapter
service tools
3.21
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.)
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:
Figure1
5926 and
blue Surface gasket
209 125
Chapter
service tools
3.21
Safety blocked
Joint Loctite Operating supplies
parts
in planetary
Grommet 270 -
housing
Ring gear
Screws 270 -
retainer
Radial seal rings
Contact surface 270 -
Steel casing
Planetary
housing / wheel Screws 243
hub
Figure 4
Chapter
service tools
3.21
Application of Loctite and operating supplies of wet disc brake spring load
design
Safety blocked
Joint Loctite Operating supplies
parts
Figure 6
Chapter
service tools
3.21
Safety blocked
parts
Joint Loctite Operating supplies Axle
Drive flange Nut surface -
Epple 33 alternative 101.1642.3
Dirko grey
209125
Differential
Contact surface and
carrier
5926
Differential
Screw 262
carrier
Differential
Screw 262
housing
Lock plate /
Screw 262 -
setting ring
In differential
Ring 270
housing
Figure 8
Chapter
service tools
3.21
Safety blocked
parts
Joint Loctite Operating supplies Axle
Drive flange Nut surface -
Epple 33 alternative 101.1643.3
Dirko grey
209125
Differential
Contact surface and
carrier
5926
Differential
Screw 262
carrier
Differential
Screw 262
housing
Lock plate /
Screw 262 -
setting ring
Figure 10
Chapter
service tools
3.21
Dimension unit
Comparative table of dimension unit
25,40 mm = 1 in (inch)
1 mm = 0,0394 in (inch)
1 bar (1,02kp/cm2) = 14,5 psi (pound force per square inch lbf/in2)
formula
definition new old conversion note
symbol
Nm (Newton T (Nm) =
Torque T kpm 1 kpm = 9,81 Nm
meter) F (N) x r (m)
Moment Nm (Newton M (Nm) =
M kpm 1 kpm = 9,81 Nm
(force) meter) F (N) x r (m)
1,02 atü = 1,02 kp/cm2 =
Pressure pü bar atü
1 bar = 750 torr
Figure 12
Chapter
service tools
3.21
Chapter
service tools
3.21
M 22 x 1,5 650 Nm
Figure 16
M 45 x 1,5 850
M 52 x 1,5 950
Figure 17
Figure 18
Chapter
service tools
3.21
Service tools
When ordering service tools, please provide
031.0072.0-2
Figure 19
Figure 20
Chapter
service tools
3.21
056.031.0-1
Figure 21
1 U 5933
Figure 22
Chapter
service tools
3.21
Axle
101.1642.3
Figure 23
031.168.0-3
Figure 24
Chapter
service tools
3.21
Axle
101.1643.3
Figure 25
031.168.0-3
Figure 26
Version 1 Version 2
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!
page 1 of 2
Section
Assembly of differential and carrier assembly
4.0.1
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.
page 2 of 2
Section
Assembly of differential and carrier assembly
4.0.2
4
Securing of the striking nut
Figure 1
Figure 2
page 1 of 2
Section
Assembly of differential and carrier assembly
4.0.2
4
Removing of the striking nut
Figure 3
Figure 4
Figure 5
page 2 of 2
Section
Drive assembly D 71
4.15
theoretical B 40
Page 1 of 2
Section
Assembly of differential and carrier assembly A71
4.15.1
4
Version 1 Version 2
Theor. Required
adjustment Measured bearing Tolerance at drive adjustment
Calculation of the required adjustment disk thickness
disk width pinion disk
thickness thickness
Version 1
Fit corresponding disc and outer rings of the taper roller bearings.
Page 2 of 2
Section
Assembly of drive pinion bearing
4.15.2
7. Measure the resistance of the bearings by using a torque wrench. If the measured value is not
the prescribed 0,8 to 1,2 Nm, adjust the resistance by modification of the thickness of the spacer
ring. After arriving at the adjustment of the bearing, back - off the safety nut and draw off the
drive flange.
8. Install the radial seal ring with Loctite 572 applied into the cover. Fill the radial seal ring with
bearing grease. Install the o - ring into the slot of the cover, fit the cover on the differential carrier
and tighten the screws. Fit the carrier of the parking brake (if present) on the differential carrier
and tighten the screws. Slip on 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.
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).
Page 1 of 2
Section
Assembly of differential and carrier assembly A71
4.1.4-71
4
Adjustment of backlash
Version 1 Version 2
Tighten the differential strap bolts by hand. By a
counter rotation of the two thread rings, move the
differential until the backlash is correct.
Page 2 of 2
Section
Assembly of differential and carrier assembly
Version 1 Version 2
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!
page 1 of 2
Section
Assembly of differential and carrier assembly
4.0.1
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.
page 2 of 2
Section
Assembly of differential and carrier assembly
4.0.2
4
Securing of the striking nut
Figure 1
Figure 2
page 1 of 2
Section
Assembly of differential and carrier assembly
4.0.2
4
Removing of the striking nut
Figure 3
Figure 4
Figure 5
page 2 of 2
Section
Drive assembly D 81
4.39
Page 1 of 2
Section
Assembly of differential and carrier assembly A81
4.39.1
4
Version 1 Version 2
Theor. Required
adjustment Measured bearing Tolerance at drive adjustment
Calculation of the required adjustment disk thickness
disk width pinion disk
thickness thickness
Version 1
Fit corresponding disc and outer rings of the taper roller bearings.
Page 2 of 2
Section
Assembly of the drive pinion bearing
4.39.2
7. Measure the roll resistance of the bearings by using a torque wrench. If the measured value is not the
prescribed 1,0 to 1,5 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 seal ring with Loctite 572 applied into the cover. Fill the radial seal ring with bearing
grease. Install the o - ring into the slot of the cover, fit the cover on the differential carrier and tighten the
screws. Fit the carrier of the parking brake (if present) on the differential carrier and tighten the screws. Slip
on 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.
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).
Page 1 of 2
Section
Assembly of differential and carrier assembly A81
4.1.4-81
4
Adjustment of backlash
Version 1 Version 2
Tighten the differential strap bolts by hand. By a
counter rotation of the two thread rings, move the
differential until the backlash is correct.
Page 2 of 2
Section
Limited-slip differential
4.39.5
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.
Section
onto the axle housing 5.3.1
5
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).
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.
• 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.
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.
Press in outer rings of taper roller bearings (2 + 3), do not hammer them. Install inner ring of taper
roller bearing (3).
Press the radial seal ring (4) with Loctite 572 (rubber cage) resp. Loctite 270 (steel cage) applied
into the wheel hub (5). Fill the radial seal ring with bearing grease.
Install the face seal (6) into the wheel hub (5) (see 5.8).
Push the pre - assembled wheel hub (5) parallel onto the axle spindle resp. steering knuckle.
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 below) 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.
1. Seal ring
4. Housing ramp
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 twist 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).
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 ring (1)
with toric ring (2). Lower the rings into a container
with Isopropanol until all surfaces of the toric (2)
are wet.
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.
The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated
adjustment hook.
A thin film of 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.
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 vacuum
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.
Section
Assembly of the sun gear 6.0.1
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 after installation of
the fast planetary gear stage, reverse the ring gear
has to be disassembled before disassembly of the
fast planetary gear stage.
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.
Section
Adjustment of the axial clearance 6.3.1
Press the thrust disk (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)).
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 =
Mount the correctly dimensioned thrust disc (if necessary, make final correction on a lathe) into the
planetary housing. Secure with Loctite 270.
Place o - ring (30) into the slot of the planetary housing. Install the preassembled planetary housing
(22) and bolt it.
Knock the locking pin (20 resp. 21) completely to the inner
side of the planetary pin.
Attention:
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
7.51.20 Installation and basic setting of the lining wear indicator ............................................................................................... 12
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
Overview of parts
Safety notes
7.51.1 WARNING!
Before commencing work on the brake, ensure that no unintended machine movement can happen
when the braking effect is removed.
- Danger to life! -
7.51.2 DANGER!
The brake is under spring tension. Parts could become loose and fly out suddenly if improper brake
assembly resp. disassembly.
- Danger to life! -
The loading resp. unloading of the springs must not be realized by the brake housing screws, it has to
be made with a suitable press and device.
7.51.3 WARNING LABEL
7.51.4 Important remarks
Do not contact or expose inner and outer disks to water!
7.51.5 General remarks
During the assembly and disassebly of a wet disk brake, dirt and abraison particles must not get
into the brake or into the grooves of sealings. All parts which are subject to assembly or
disassembly, e.g. brake carrier (1) or brake housing (2), need also to be cleaned on their outside.
© Kessler & Co. GmbH & Co.KG
All rights reserved -4- 26/03/2013
7
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
1. Install the o - rings (1) into the slots of the intermediate piece (4)
2. Install the profile seal rings (2) with stepped side to the piston showing into the slots of the intermediate piece (4)
3. Install the guide ring (3) into the slot of the intermediate piece
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
2. Place the brake carrier onto the springs (3), thereby note the position of the brake
connections.
3. Squeeze together the brake carrier and brake housing (5) by using a press and device,
which is suitable for the brake be load.
4. Detach the thread bolts and screw in and tighten the screws (6).
6. Install the warning label on the brake and stamp in the corresponding preload.
DANGER!
The brake is under spring tension. Parts could become loose and fly out suddenly if improper brake
assembly resp. disassembly.
- Danger to life! -
The loading resp. unloading of the springs must not be realized by the brake housing screws, it has to
be made with a suitable press and device.
Preferably the assembly/ disassembly should be done by Kessler & Co. GmbH & Co.KG
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
1. Screw in the bleeder with connection piece and seal ring as well as the screw plugs with seal ring.
Hint: with increased disc wear and hence it resulting less spring tension the brake torque will be reduced
9. Install o - ring (brake carrier/ axle spindle resp. steering knuckle) free of torsion and loops (inapplicable at one-
piece design brake carrier).
10. Install the complete brake on the axle (coat the contact surface with Loctite 270) (inapplicable at one-piece
design brake carrier).
11. Mount face seal see chapter 5.8.
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
1. The centring of the inner discs at wet disc brake has to be realized by using a centre tool (see chapter 3.6).
2. To this the disc set has to be released by hydraulic pressure.
3. After centring clamp the disc set by releasing the hydraulic pressure (spring load effect).
Hint: To save the centering of the disc set in case of disassembly the wheel hub, the hydraulic pressure
should be released, so the disc set will be clamped (spring load effect).
After assembly of the wheel hub with the face seal and adjusting of the wheel bearings check the
tightness of the cooling oil room.
The pressure drop after a period of 10 minutes must not exceed 0,1 bar.
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
Disassembly of brake
7.51.17 Disassembly of brake
WARNING!
Before commencing work on the brake, ensure that no unintended machine movement can happen
when the braking effect is removed.
- Danger to life! -
• The complete brake can be removed from the axle spindle after unscrewing of the screws (1)
Hint: To safe the centring of the disc set in case of disassembly the wheel hub, the hydraulic
pressure should be released, so the disc set will be clamped (spring load effect).
DANGER!
The brake is under spring tension. Parts could become loose and fly out suddenly if improper brake
assembly resp. disassembly.
- Danger to life! -
The loading resp. unloading of the springs must not be realized by the brake housing screws, it has to
be made with a suitable press and device.
Preferably the assembly/ disassembly should be done by Kessler & Co. GmbH & Co.KG.
• Before unscrewing the screws (2) of the brake, the brake has to squeeze together by using a press
and device (3), which are suitable for the brake preload (see warning label). After removing of all
screws lift the press ram slowly till the springs are released.
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
Viscosity:
Check measure: 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 maximum
wear dimension, unconditional consult Kessler & Co. GmbH & Co.KG.
After working at the brake, bleed the brake hydraulic system and check for tightness!
Chapter
Assembly of service brake
wet disc brake – spring load design – 4460
7.51
1. Install the o-rings (13) and the circlip (15) onto the indicator pin (14)
2. Push the indicator pin (14) lightly greased, into the thread bushing (12)
3. Actuate the brake and screw in and adjust the thread bushing (12) (Loctite
262 in thread) to a standout x (see below) of the indicator pin (14) according
4. Nominal dimension
5. Wet the thread and the mounting flange of the cap nut (10) with Molykote
1. The check must realize then the indicator pin (14) is assembled
3. Detach the cap nut (10) and push the indicator pin (14) to the inside
4. The standout x of the indicator pin (14) shows the maximum allowed
5. If the end face of the indicator pin (14) is flush with the end face of
the thread bushing (12), the maximum lining wear has been reached
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Service Manual
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