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Service-Manual Atlas Copco ST 1030 (101.1642.3 – 101.1643.3)
Version 06/2011 Original
Copyright © Firma Kessler & Co. GmbH &Co.KG
No part of this work may be reproduced, copied, adapted, or transmitted in any form or by any means without written permission from the company Kessler & Co. GmbH & Co.KG.
The information contained in this training manual was current at the time of printing and is subject to change without notice and liability.
© Kessler & Co. GmbH & Co.KG All rights reserved
02.04.2011
Table of contents
101.1642.3 Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter
1 2 3 3 4 5 6 7
Important remarks Lubrication intervals and maintenance instructions General instructions for correct assembly and disassembly Service tools Assembly drive assembly Assembly hub assembly Assembly planetary gear drive Assembly service brake
See the special table of contents of chapter 1 See the special table of contents of chapter 2 See the special table of contents of chapter 3 See the special table of contents of chapter 3 See below See below See below See the special table of contents of chapter 7
Chapter 5 5.1.6 5.3 5.3.1
Assembly of the spacer ring Hub assembly drive axle 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 gear meshing of Gleason gears 4.0.2 Securing of the striking nut 4.39 Drive assembly D81 4.39.1 Adjustment of drive pinion distance 4.39.2 Assembly of the drive pinion bearing 4.1.3 Assembly of the Differential 4.1.4 Assembly of drive assembly 4.39.3 Limited-slip differential
Chapter 7
Chapter 6
See the special table of contents of chapter 7
6.3 6.0.1 6.0.1 6.1.2 6.3.1 6.3.1 6.1.4 6.1.5
© Kessler & Co. GmbH & Co.KG All rights reserved
Planetary gear drive Assembly of the ring gear and ring gear carrier Assembly of the sun gear Assembly of the planetary gear Assembly of the planetary housing Adjustment of the axial clearance Disassembly of planetary gear Assembly / disassembly of cageless needle bearing (planetary gear bearing)
Service Revised 20.04.2011
Service Manual
© Kessler & Co. GmbH & Co.KG All rights reserved
Table of contents
101.1643.3 Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter
1 2 3 3 4 5 6 7
Important remarks Lubrication intervals and maintenance instructions General instructions for correct assembly and disassembly Service tools Assembly drive assembly Assembly hub assembly Assembly planetary gear drive Assembly service brake
See the special table of contents of chapter 1 See the special table of contents of chapter 2 See the special table of contents of chapter 3 See the special table of contents of chapter 3 See below See below See below See the special table of contents of chapter 7
Chapter 5 5.1.6 5.3 5.3.1
Assembly of the spacer ring Hub assembly drive axle 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 gear meshing of Gleason gears 4.0.2 Securing of the striking nut 4.15 Drive assembly D81 4.15.1 Adjustment of drive pinion distance 4.15.2 Assembly of the drive pinion bearing 4.1.3 Assembly of the Differential 4.1.4 Assembly of drive assembly
Chapter 7 See the special table of contents of chapter 7
Chapter 6 6.3 6.0.1 6.0.1 6.1.2 6.3.1 6.3.1 6.1.4 6.1.5
© Kessler & Co. GmbH & Co.KG All rights reserved
Planetary gear drive Assembly of the ring gear and ring gear carrier Assembly of the sun gear Assembly of the planetary gear Assembly of the planetary housing Adjustment of the axial clearance Disassembly of planetary gear Assembly / disassembly of cageless needle bearing (planetary gear bearing)
Service Revised 20.04.2011
Chapter
Important remarks
1.20
Table of contents of important remarks Important remarks ................................................................................................................................. 2 Check of all of bolted assemblies and all of the important safety locks such as .............................................................................................................................. 2 Check of brakes ............................................................................................................................................................................................................................... 2 Service instructions ......................................................................................................................................................................................................................... 2
Instructions for ordering spare parts ....................................................................................................... 3 Warranty ......................................................................................................................................................................................................................................... 3 Ordering .......................................................................................................................................................................................................................................... 3 Indentification plate ........................................................................................................................................................................................................................ 3 Required consultation with Kessler & Co. GmbH & Co.KG. .............................................................................................................................................................. 4
© Kessler & Co. GmbH & Co.KG All rights reserved
-1-
02.04.2011
Chapter
Important remarks
1.20
Important remarks Check of all of bolted assemblies and all of the important safety locks such as For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as.
•
Wheel nuts
•
Nuts of axle mounting bolts
•
Bolts on the steering components and the brake system parts; if the screws are tight able, the Loctite contact breaks loose and remounting is necessary. The locking devices of bolted or keyed assemblies have to be checked according to instructions, in case of doubt, consult Kessler & Co. GmbH & Co KG.
•
Corrosion and cracks on the carrier elements (for example as the axle spindle) are not acceptable for operational safety reasons. Replace carrier elements with cracks!
Check of brakes
•
Inspect regularly as well as wear of brake system parts.
•
In case of signs of excessive heating, consult a brake specialist or the manufacturer.
Service instructions
•
The assembly is to be accomplished only by trained personnel.
•
Repair weldment is only allowed after consultation with Kessler & Co GmbH & Co.KG!
•
In order to remove the axle unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle.
•
Observe all national regulations and do not perform any service task in case it does not apply with these.
© Kessler & Co. GmbH & Co.KG All rights reserved
-2-
02.04.2011
Chapter
Important remarks
1.20
Instructions for ordering spare parts Warranty The company Kessler & Co. GmbH & Co.KG only accept liability for the original spare parts supplied by ourselves. We express clearly that the utilisation of other parts than the form us prescribed original spare parts, can change unfavourably the characteristics of the axle prescribed by the construction and that thereby the safety can be affected. For damage caused by the utilisation of not original spare parts and accessories, any liability of the Kessler & Co. GmbH & Co.KG is excluded. Please bear in mind that special manufacturing and delivery specifications apply to own as well as to foreign parts and that we always offer spare parts to the up - dated technical conditions and the up - dated legal prescriptions.
Ordering When ordering Kessler spare parts, please furnish the following information: 1. Order number (installation drawing no.) → see identification plate 2. Fabrication number → see identification plate 3. Vehicle producer 4. Description of the spare part 5. Spare part number (drawing - resp. DIN no.) 6. Number of pieces 7. Kind of delivery
Identification plate
¾
The position of the identification plate on the axle is mostly beside of the drive assemly on the side of the oil fill plug.
¾
Close to the identification plate the serial number of the axle is also stamped into the axle housing.
© Kessler & Co. GmbH & Co.KG All rights reserved
-3-
02.04.2011
Chapter
Important remarks
1.20
Required consultation with Kessler & Co. GmbH & Co.KG. ¾
In case of doubt, consult Kessler & Co. GmbH & Co.KG.
¾
For major repairs or overhaul, it is recommended that the complete axle assembly be returned to Kessler & Co. GmbH & Co.KG.
© Kessler & Co. GmbH & Co.KG All rights reserved
-4-
02.04.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
Table of contents of lubrication intervals and maintenance instructions General lubrication instructions .............................................................................................................. 2 Fill levels .......................................................................................................................................................................................... 2 Oil change ....................................................................................................................................................................................... 2 Preservation of Kessler axles for an extended storage period ........................................................................................................ 2 Before putting the axle into operation ............................................................................................................................................ 2 Lubrication points ........................................................................................................................................................................... 3 Lubrication points ........................................................................................................................................................................... 4 Lubricants – lubrication intervals .................................................................................................................................................... 5 Recommendable hypoid gear oils corresponding ........................................................................................................................... 6 General maintenance instructions .................................................................................................................................................. 7
© Kessler & Co. GmbH & Co.KG All rights reserved
-1-
01.06.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
General lubrication instructions Fill levels ¾ Are checked at the level control plugs.
Oil change 1. Place the vehicle in a horizontal position. 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 4. Replacement of the oil draining plugs 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. 8. Clean the grease nipples before lubrication.
Preservation of Kessler axles for an extended storage period ¾ Replace the breather with a screw plug with a sealant in order to avoid water intrusion and oil leakage. ¾ Fill axles completely up with oil, the same applies to wet disc brakes. ¾ Protect machined surfaces (for example: rim surface, steering cylinder, brake disc, ….) with additional anticorrosive.
Before putting the axle into operation ¾ Drain storage oil. Fill the axle with suitable oil (see service manual Kessler & Co. GmbH & Co.KG) ¾ To the required oil level. ¾ Check sealing contact surfaces for corrosion. Check the seals immediately after start-up for leakage and renew them if leaking.
¾ 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.
© Kessler & Co. GmbH & Co.KG All rights reserved
-2-
01.06.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
Lubrication points
Axle
101.1642.3
I = Oil fill plug
© Kessler & Co. GmbH & Co.KG All rights reserved
II Oil level control plug
III = Oil drain plug
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Chapter
Lubrication intervals and maintenance instructions
2.21
Lubrication points
Axle
101.1643.3
I = Oil fill plug
© Kessler & Co. GmbH & Co.KG All rights reserved
II Oil level control plug
III = Oil drain plug
-4-
01.06.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
Lubricants – lubrication intervals
Axle and gearbox operation Lubrication point at ambient (outside) temperatures
Lubricant
Remarks
Lubrications intervals 1.) after 125 hours
min. 1x per year
every 1000 hours
Hypoid – gear oil per MIL-L2105B/API GL5
Drive assembly Wheel hub planetary gear drive
Hypoid – gear oil in multi range characteristic per MIL-L2105 C/D/API GL5
Oil change higher -10°C
lower +30°C
Drop gear / gear boxes
SAE 90 or multi grade oils
continuously lower -10°C
SAE 75 W – 90 or SAE 75 W - 85
continuously higher +30°C
SAE 140 or multi grade oils
Wheel bearing oil lubricated
Wet disc brake
See chapter – 7-
⊕
⊕
⊕
Check oil level at control points monthly
external cooled oil change
dependent on: - tank volume - cooling system - operation conditions (hours = hours of operation)
1.
Whichever occurs first.
© Kessler & Co. GmbH & Co.KG All rights reserved
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01.06.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
Recommendable hypoid gear oils corresponding
Recommendable hypoid gear oils corresponding
MIL-L 2105 B/API GL 5 alternatively
MIL – L 2105 C/API GL 5
¾
ARAL - Gearoil Hyp 90
¾
AVIA - Gearoil Hypoid 90 EP
¾
BP - Multiuse - Gearoil EP SAE 90
¾
ELF - Tranself Typ B 90 / Tranself Typ B 80 W - 90
¾
ESSO - Gearoil GX - D 90
¾
FINA - Pontonic MP SAE 85 W - 90
¾
FUCHS - Renogear Hypoid 90
¾
MOBIL - HD 90 - A
¾
SHELL - Spirax MB 90 / HD 90
¾
TEXACO - Multigear EP SAE 85 W / 90
¾
AGIP - Rotra MP / Rotra MP DB
On no account use „normal“ gear oils!
© Kessler & Co. GmbH & Co.KG All rights reserved
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01.06.2011
Chapter
Lubrication intervals and maintenance instructions
2.21
General maintenance instructions
Check- and maintenance points
Remarks
Maintenance intervals 1.) after
after
after
after
after
every
every
min.
50 hours
100 hours
1000 hours
4000 hours
8000 hours
500 hours
1000 hours
1x
⊕
⊕
⊕
Wheel bearing
Inspect, if necessary readjust wheel bearing
Wheel nuts
Check and tighten with a torque wrench (after tire change after 50km and 200km)
⊕
⊕
⊕
Screws/drive flange Nuts/axle mounting bolts
Check and retighten (Verify the adjustment)
⊕
⊕
⊕
Wet disc brake - spring load design
Check lining wear
Bolted connections (for example: drive assembly)
Check from time to time
Seals
Check from time to time
Year
⊕
⊕ ⊕
⊕ monthly (hours = Hours of operation)
1. Whichever occurs first.
© Kessler & Co. GmbH & Co.KG All rights reserved
-7-
01.06.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Table of contents of general assembly / disassembly instructions and service tools General instructions for correct assembly and disassembly ..................................................................... 2 General instructions for disassembly .............................................................................................................................................. 2 General instructions for assembly ................................................................................................................................................... 2
Application of Loctite and operating supplies .......................................................................................... 3 Remarks for working up Loctite and operating supplies ................................................................................................................. 3 Application of Loctite and operating supplies ................................................................................................................................. 3 Application of Loctite and operating supplies of hub assembly ...................................................................................................... 4 Application of Loctite and operating supplies of wet disc brake spring load design ...................................................................... 5 Application of Loctite and operating supplies of drive assembly .................................................................................................... 6 Application of Loctite and operating supplies of drive assembly .................................................................................................... 7
Dimension unit ....................................................................................................................................... 8 Comparative table of dimension unit .............................................................................................................................................. 8 Denomination of standard dimensions ........................................................................................................................................... 8
Tightening torques (Nm) ......................................................................................................................... 9 Metric standard thread ................................................................................................................................................................... 9 Metric fine pitch thread .................................................................................................................................................................. 9 Approximate value of screwing of screw plugs ............................................................................................................................. 10 Wheel nut with thrust collar (for rims with centerring) ................................................................................................................ 10 Tightening torque of the adjusting nut responsible slotted nut at flanges responsible gearwheels…… ....................................... 10
Service tools ......................................................................................................................................... 11 Service tools of the hub assembly ................................................................................................................................................. 11 Service tools of the wet disc brake spring load design .................................................................................................................. 12 Service tools for drive assembly .................................................................................................................................................... 13 Service tools for drive assembly .................................................................................................................................................... 14
© Kessler & Co. GmbH & Co.KG All rights reserved
-1-
26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
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 be used for disassembly.
•
Before disassembly, the destruction of bearings and other components must check, if it is necessary to destroy it.
•
Systematically 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 •
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!
•
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!
© Kessler & Co. GmbH & Co.KG All rights reserved
-2-
26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Application of Loctite and operating supplies Remarks for working up Loctite and operating supplies
¾ Threads and surfaces have to be cleaned and free from colour, oil and grease before applying Loctite. Loctite will harden under following conditions: ¾
Exclusion of air
¾
Metal contact
¾
Increased temperature
¾ Pre - assembly and control tightening must do in a short time (5 to 10 min.) ¾ 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. ¾ Assembled parts must remain unloaded for at least 24 hours. ¾ Loctite quantity: At screws:
At contact surfaces: 1 bead
Pay attention for a sufficient Loctite application!
Figure1
Application of Loctite and operating supplies
1. LOCTITE
2. EPPLE
Type
colour
Application
243
blue
Lightly locked screws
262
red
Middle locked screws
270
green
Highly locked screws
270
green
Increased coefficient of friction in contact surfaces
510
orange
Surface gasket
572
white
Special gasket
638
light-green
Gluing with big width of slit
5926 and blue 209 125
Surface gasket
33
grey
Surface gasket
grey
Elastic gasket
3. DIRKO Figure 2
© Kessler & Co. GmbH & Co.KG All rights reserved
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Application of Loctite and operating supplies of hub assembly
Safety blocked parts Spacer ring
Joint
Loctite Operating supplies
Contact surface
572
-
Grommet
in planetary housing
270
-
Grommet
in sun gear
270
in axle spindle
270
-
Screws
270
-
Contact surface
270
-
Screws
243
Disc Ring gear retainer Radial seal rings Steel casing Planetary housing / wheel hub
Wheel safety nut → see chapter 5 → page 5.7.1 Figure 3
Figure 4
© Kessler & Co. GmbH & Co.KG All rights reserved
-4-
26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Application of Loctite and operating supplies of wet disc brake spring load design
Safety blocked parts Thread bushing
Joint thread
Loctite Operating supplies 262
-
Figure 5
Figure 6
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Application of Loctite and operating supplies of drive assembly
Safety blocked parts
Joint
Loctite
Operating supplies
Drive flange
Nut surface
-
Epple 33 alternative Dirko grey
Drive pinion
Nut thread
Differential carrier
Contact surface
209125 and 5926
Differential carrier
Screw
262
Differential housing
Screw
262
Lock plate / setting ring
Screw
262
Retaining clip
Screws
262
Ring gear
Screws
262
-
Ring gear
Contact surface
270
-
In differential housing
270
Screw
262
Ring Cover
Axle 101.1642.3
assembly paste with MoS2
-
Figure 7
Figure 8
© Kessler & Co. GmbH & Co.KG All rights reserved
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Application of Loctite and operating supplies of drive assembly
Safety blocked parts
Joint
Loctite
Operating supplies
Drive flange
Nut surface
-
Epple 33 alternative Dirko grey
Drive pinion
Nut thread
assembly paste with MoS2
Differential carrier
Contact surface
209125 and 5926
Differential carrier
Screw
262
Differential housing
Screw
262
Lock plate / setting ring
Screw
262
Retaining clip
Screws
262
Ring gear
Screws
262
-
Ring gear
Contact surface
270
-
Screw
262
Cover
Axle 101.1643.3
-
Figure 9
Figure 10
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Dimension unit Comparative table of dimension unit
25,40 mm
=
1 in (inch)
1 mm
=
0,0394 in (inch)
1 kg (Kilogram)
=
2,205 lb (pounds)
9.81.Nm (1 kpm)
=
7,233 lbf x ft (pound force foot)
1,356 Nm (0,138 kpm)
=
1 lbf x ft (pound force foot)
1 bar (1,02kp/cm2)
=
14,5 psi (pound force per square inch lbf/in2)
0,070 bar (0,071 kp/cm2)
=
1 psi (lbf/in2)
1 Litre
=
0,264 Gallon (Imp.)
4,456 Litre
=
1 Gallon (Imp.)
1 Litre
=
0,220 Gallon (US)
3,785 Litre
=
1 Gallon (US)
1609,344 m
=
1Mile (land mile)
0°C (Celsius)
=
+32°F (Fahrenheit)
1°C (Celsius)
=
+33,8°F (Fahrenheit)
0°C (Celsius)
=
273,15 Kelvin
1°C (Celsius)
=
274,15 Kelvin
Figure 11
Denomination of standard dimensions definition
formula symbol
new
old
conversion
note
Torque
T
Nm (Newton meter)
kpm
1 kpm = 9,81 Nm
T (Nm) = F (N) x r (m)
Moment (force)
M
Nm (Newton meter)
kpm
1 kpm = 9,81 Nm
M (Nm) = F (N) x r (m)
Pressure
pü
bar
atü
1,02 atü = 1,02 kp/cm = 1 bar = 750 torr
2
Figure 12
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Tightening torques (Nm) μ = 0,14
Metric standard thread
thread
M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30
screw
nut
8.8
8
3,0 5,9 10 25 49 85 135 210 300 425 580 730 1100 1450
screw
nut
screw
nut
10.9 10 4,4 8,7 15 36 72 125 200 310 430 610 830 1050 1550 2100
12.9 12 5,1 10 18 43 84 145 235 365 500 710 970 1220 1800 2450
screw
screw
Figure 13
Metric fine pitch thread
thread
M8x1 M 10 x 1 M 10 x 1,25 M 12 x 1,25 M 12 x 1,5 M 14 x 1,5 M 16 x 1,5 M 18 x 1,5 M 20 x 1,5 M 22 x 1,5
screw
nut
8.8
8
27 55 52 93 89 145 225 340 475 650
nut
10.9 10 39 81 76 135 130 215 330 485 680 920
nut
12.9 12 46 95 90 160 155 255 390 570 790 1050
Figure 14
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Approximate value of screwing of screw plugs
tightening torques (approximate value)
thread
tightening torques (screw plugs with o-ring)
M24x1,5
ca. 120
-
M42x1,5
ca. 260
-
Figure 15
Wheel nut with thrust collar (for rims with centerring)
dimensions
Phosphorus darkened
M 22 x 1,5
650 Nm
Figure 16
Tightening torque of the adjusting nut responsible slotted nut at flanges responsible gearwheels……
thread
Tightening torque
d1 (mm)
(Nm)
M 45 x 1,5
850
M 52 x 1,5
950
Figure 17
Figure 18
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Service tools When ordering service tools, please provide ¾
Order number (installation drawing number)
alternatively ¾
Fabrication number → see identification plate
(The illustrations are not binding for the design)
Service tools of the hub assembly
Spanner for wheel safety nut
031.0072.0-2
Figure 19
Seal ring sleeve driver
038.1350.0-3 (seal ring dimension 220x250x16)
Figure 20
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Service tools of the wet disc brake spring load design
Centring tool for discs
056.031.0-1
Figure 21
Installation tool for face seal
1 U 5933
Figure 22
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Chapter
General assembly / disassembly instructions service tools
3.21
Service tools for drive assembly
Axle 101.1642.3 Seal ring sleeve driver
031.450.0-3 (seal ring dimension 105x130x12)
Figure 23
Spanner for thread rings (Differential bearing)
031.168.0-3
Figure 24
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26.04.2011
Chapter
General assembly / disassembly instructions service tools
3.21
Service tools for drive assembly
Axle 101.1643.3 Seal ring sleeve driver
031.265.0-3 (seal ring dimension 85x105x12)
Figure 25
Spanner for thread rings (Differential bearing)
031.168.0-3
Figure 26
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26.04.2011
© Kessler & Co. GmbH & Co.KG All rights reserved
Section
Assembly of drive assembly
Service Revised 01.09.2007
Section
Adjustment of gear meshing of Gleason gears
4.0.1
It is only possible to achieve a perfect gear meshing, if the fabrication number of the drive pinion (marked on the end face) and the ring gear (marked on the circumference) are corresponding.
Perfect marking.
The following figures show improper gear meshing marks of the ring gear. The text alongside gives the corrections to obtain correct gear meshing. The dark colored arrows in the sketch of the drive pinion and ring gear indicate the direction towards which the drive pinion has to be moved. The clear arrows indicate the direction towards which the ring gear has to be moved, to get further more a correct backlash. Gear meshing too deep. Increase the drive pinion distance by correction of the adjustment disc thickness. Regulate the backlash by inwards moving of the ring gear.
Gear meshing too high. Decrease the drive pinion distance by correction of the adjustment disc thickness. Regulate the backlash by outwards moving of the ring gear.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Securing of the striking nut
4.0.2
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.
Use of Loctite and other operating supplies
1. Striking nut at drive flange •
In thread: assembly paste with MoS2 (exception: through drive pinion see point 2).
•
Front side contact surface: sealing compound (Epple 33 or equivalent).
2. Striking nut at through drive pinion •
In thread: Loctite 262.
3. Striking nut at gear wheels, bearings etc. •
In thread: assembly paste with MoS2.
Removing of the striking nut
Bend away the nose and screw the nut off.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Drive assembly D 71
4.15
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 03.02.2009
Section
Adjustment drive pinion distance
4.15.1
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 “Adjustment of gear meshing of Gleason gears”) (S theor. = 3,2mm).
*) A = Set value for correct pinion support. This dimension is written on the end face of the pinion in millimetres. It indicates the deviation from the theoretic distance (set point dimension). **) B = Measured width of the taper roller bearing (B theor. = 40 mm). Calculation example to ascertain the thickness S from the adjustment disc: A = + 0,10; B = 39,95 S=
3,20 mm (theor.) + 0,05 mm → B = 0,05 mm smaller than B theor. = 3,25 mm - 0,10 mm → drive pinion value A = 3,15 mm → necessary thickness of the adjustment disc
Fit corresponding disc and outer rings of the taper roller bearings. *) Hint: If value A is positive (e.g. + 0,1) the adjustment disc has to be 0,1 mm thinner than theor. S. If value A is negative (e.g. – 0,1) the adjustment disc has to be 0,1 mm thicker than theor. S. **) Hint: If value B is positive (e.g. 40,05) the adjustment disc has to be 0,05 mm thinner than theor. S. If measure B is negative (e.g. 39,95) the adjustment disc has to be 0,05 mm thicker than theor. S.
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Service Revised 01.09.2007
Section
Assembly of drive pinion bearing
4.15.2
1. Insert the two outer rings of the taper roller bearings into the differential carrier. 2. Calculate the thickness C of the spacer ring. a) Place the two inner rings of the taper roller bearings in their outer rings. Measure A. b) Measure the dimension B of the drive pinion. c) Thickness of the spacer ring C = A - B. 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 ring on the pinion shaft. 5. Install the drive pinion into the differential carrier. Heat the taper roller bearing inner ring at undersize to about 100°C and install it with a 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 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.
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Service Revised 01.09.2007
Section
Assembly of the Differential
4.1.3
Before assembly all of the bevel gears and the thrust rings should be well oiled. 1. Place one differential side gear with the side gear thrust washer in the differential case. 2. Install the spider with differential gears and differential pinion thrust washers in the differential case. 3. 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) 4. 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. 5. Check that all differential pinions can rotate easily. 6. 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. 7. Heat the two taper roller bearings to about 100°C and install them by using a sleeve.
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Service Revised 01.09.2007
Section
Assembly of drive assembly
4.1.4
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.) Tighten the differential strap bolts by hand. By a counter rotation of the two thread rings, move the differential until the backlash is correct. (The smallest admissible value at the closest place is marked on the ring gear). Therefore hold the drive pinion at the drive flange. Check the backlash by careful forwards and rearwards 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 gear meshing according to sheet “Adjustment of gear meshing of Gleason gears”. 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.
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Service Revised 01.09.2007
Section
Drive assembly D 81
4.39
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 25.09.2009
Section
Adjustment of drive pinion distance
4.39.1
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 “adjustment of gear meshing of Gleason gears”) (S theor. = 3,2 mm).
*) A = Set value for correct pinion support. This dimension is writed on the end face of the pinion in millimetres. It indicates the deviation from the theoretic distance (setpoint dimension). **) B = Measured width of the taper roller bearing (B theor. = 45 mm). Calculation example to ascertain the thickness S from the adjustment disc: A = + 0,10; B = 44,95 S=
3,20 mm ( theor. ) + 0,05 mm → B = 0,05 mm smaller than B theor. = 3,25 mm - 0,10 mm → drive pinion value A = 3,15 mm → necessary thickness of the adjustment disc
Fit corresponding disc and outer rings of the taper roller bearings. *) Hint: if value A is positive (e.g. + 0,1) the adjustment disc has to be 0,1 mm thinner than theor. S. If value A is negative (e.g. – 0,1) the adjustment disc has to be 0,1 mm thicker than theor. S. **) Hint: if value B is positive (e.g. 45,05) the adjustment disc has to be 0,05 mm thinner than theor. S. If value B is negative (e.g. 44,95) the adjustment disc has to be 0,05 mm thicker than theor. S.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of the drive pinion bearing
4.39.2
1. Insert the two outer rings of the taper roller bearings into the differential carrier. 2. Calculate the thickness C of the spacer disc. 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. 5. Install the drive pinion into the differential carrier. Heat the taper roller bearing inner ring at undersize to about 100 °C and install it with a 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 1,0 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.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Limited-slip differential
4.39.4
¾ if necessary grind off 71.7074.4 ¾ **) if disc thickness are not sufficient, exchange 71.9838.4 by 71.3131.4 and grind off if necessary (don`t fall below minimum values!)
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 03.11.2009
Section
Assembly of the Differential
4.1.3
Before assembly all of the bevel gears and the thrust rings should be well oiled. 1. Place one differential side gear with the side gear thrust washer in the differential case. 2. Install the spider with differential gears and differential pinion thrust washers in the differential case. 3. 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) 4. 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. 5. Check that all differential pinions can rotate easily. 6. 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. 7. Heat the two taper roller bearings to about 100°C and install them by using a sleeve.
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Service Revised 01.09.2007
Section
Assembly of drive assembly
4.1.4
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.) Tighten the differential strap bolts by hand. By a counter rotation of the two thread rings, move the differential until the backlash is correct. (The smallest admissible value at the closest place is marked on the ring gear). Therefore hold the drive pinion at the drive flange. Check the backlash by careful forwards and rearwards 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 gear meshing according to sheet “Adjustment of gear meshing of Gleason gears”. 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.
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Service Revised 01.09.2007
© Kessler & Co. GmbH & Co.KG All rights reserved
Section
Assembly of the hub assembly
Service Revised 01.09.2007
Section
Assembly of the spacer ring
5.1.6
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.
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Service Revised 01.09.2007
Section
Hub assembly drive axle
5.3
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 17.09.2009
Section
Assembly of the drive axle onto the axle housing
5.3.1
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.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of hub assembly
5.3.2
• Assembly of the spacer ring (if present) see sheet 5.1.6. • 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. • 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. • Assembly of the planetary gear drive see chapter 6. • 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 & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Prepare and mount wheel hub
5.5.15
Prepare wheel hub 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). 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).
Mount wheel hub Push the pre - assembled wheel hub (5) parallel onto the axle spindle resp. steering knuckle.
Attention: Be careful not to damage the radial seal ring (4).
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Adjustment of wheel bearings
5.7.1
Tightening torque of the wheel safety nut
axle series
readjustment used bearings (Nm) new bearings (Nm)
D 101 / D102
600 to 650
750
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 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.
Designation
Shaft nut with cheese head screw
© Kessler & Co. GmbH & Co.KG All rights reserved
Version
Security/ Remarks
Cheese head screw & Loctite 270
Service Revised 26.04.2011
Section
Assembly of the face seal
5.8.1
1.
Seal ring
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 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).
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of the face seal
5.8.2
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.
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) under the retaining lip (3) of the housing (5).
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of the face seal
5.8.3
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 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 “Y” rotate 180°. This causes high pressure at “A”/ “Y” and possible galling. When rotated, points “B”/ “X” has low pressure and possible leakage. Original assembled position
© Kessler & Co. GmbH & Co.KG All rights reserved
Rotated 180°
Service Revised 01.09.2007
Section
Assembly of the face seal
5.8.4
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.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
© Kessler & Co. GmbH & Co.KG All rights reserved
Section
Assembly of planetary gear drive
Service Revised 01.09.2007
Section
Planetary gear drive
6.3
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of the ring gear and ring gear carrier Assembly of the sun gear
6.0.1
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 after 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 & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of planetary gear
6.1.2
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 planetary 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).
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly of the planetary housing Adjustment of the axial clearance
6.3.1
Assembly of the planetary housing (23)
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)).
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 disc 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.
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Service Revised 01.09.2007
Section
Disassembly of planetary gear
6.1.4
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.
© Kessler & Co. GmbH & Co.KG All rights reserved
Service Revised 01.09.2007
Section
Assembly/ disassembly of cageless needle bearing (planetary gear bearing)
6.1.5
Assembly: Version 1:
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.
Version 2:
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 design). Insert the planetary gear with thrust discs into the planetary housing. Press in the planetary pin, thereby the mounting bushing will remove.
Hint:
Note the passage “Assembly of the planetary gear”!
Disassembly: 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:
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Note the passage “Disassembly of the planetary gear”!
Service Revised 01.09.2007
Chapter
Assembly of service brake
7.51
© Kessler & Co. GmbH & Co.KG All rights reserved
-1-
27.04.2011
Chapter
Assembly of service brake
7.51
Table of contents of assembly/disassembly of the wet disc brake spring load design Overview of parts ................................................................................................................................... 3 Safety notes ........................................................................................................................................... 4 7.50.1 WARNING! ........................................................................................................................................................................... 4 7.50.2 DANGER! .............................................................................................................................................................................. 4 7.50.3 WARNING LABEL .................................................................................................................................................................. 4 7.50.4 Important remarks ............................................................................................................................................................... 4 7.50.5 General remarks ................................................................................................................................................................... 4
Assembly of the wet disk brake .............................................................................................................. 5 7.50.6 Assembly of the piston seals ................................................................................................................................................ 5 7.50.7 Prepare the brake housing ................................................................................................................................................... 5 7.50.8 Assembly intermediate piece ............................................................................................................................................... 6 7.50.9 Assembly piston ................................................................................................................................................................... 6 7.50.10 Assembly springs ................................................................................................................................................................ 6 7.50.11 Assembly of the brake carrier ............................................................................................................................................ 7 7.50.12 Final assembly .................................................................................................................................................................... 8 7.50.13 Check the air gap (pressurized) .......................................................................................................................................... 8 7.50.14 centring of the discs: .......................................................................................................................................................... 9 7.50.15 Check brake hydraulic system for leaks ............................................................................................................................. 9 7.50.16 Check cooling oil room for leaks ......................................................................................................................................... 9
Disassembly of brake ............................................................................................................................ 10 7.50.17 Disassembly of brake ....................................................................................................................................................... 10
Remarks to the wet disc brake .............................................................................................................. 11 7.50.18 Permissible oil for brake with external cooling ................................................................................................................ 11 7.50.19 Check measure ................................................................................................................................................................. 11 7.50.20 Installation and basic setting of the lining wear indicator ............................................................................................... 12 7.50.21 Check lining wear ............................................................................................................................................................. 12
© Kessler & Co. GmbH & Co.KG All rights reserved
-2-
27.04.2011
Chapter
Assembly of service brake
7.51
Overview of parts
1.
Brake carrier
13. Spring set
2.
Brake housing
14. Connection piece
3.
Intermediate piece
15. Seal ring
4.
Piston
16. Bleeder valve
5.
Inner disc
17. Sealing set
6.
Outer disc
18. Sealing set
7.
O - ring
19. Guide ring
8.
O - ring
20. Screw plug
9.
Screw
21. Seal ring
10. Screw plug
22. Face seal
11. Seal ring
23. Screw
12. O - ring
24. Warning label
© Kessler & Co. GmbH & Co.KG All rights reserved
-3-
27.04.2011
Chapter
Assembly of service brake
7.51
Safety notes 7.50.1 WARNING!
Before commencing work on the brake, ensure that no unintended machine movement can happen when the braking effect is removed. - Danger to life!
7.50.2 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.
Preferably the assembly / disassembly should be done by Kessler & Co.
7.50.3 WARNING LABEL
7.50.4 Important remarks
Do not contact or expose inner and outer disks to water!
7.50.5 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-
27.04.2011
Chapter
Assembly of service brake
7.51
Assembly of the wet disk brake 7.50.6 Assembly of the piston seals
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
7.50.7 Prepare the brake housing 1. Lay the discs (1 + 2) alternately into the brake housing (3)
Hint: The upper disc always has to be an outer disc!
© Kessler & Co. GmbH & Co.KG All rights reserved
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Assembly of service brake
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7.50.8 Assembly intermediate piece 1. Fit o-ring (1) onto the brake housing (2) 2. Place on the intermediate piece (3) 3. Take the screw holes position into consideration 4.
It is recommendable to use 2 thread bolts (4) (longer screws without screw head) for fixation
7.50.9 Assembly piston 1. Check the piston treads for intactness. 2. Wet the piston treads with oil. 3. Install the piston (1) into the intermediate piece, take the position of the spring holes and screw holes into consideration.
Hint: The piston must not tilt (danger of seal tread damage!)
7.50.10 Assembly springs 1. Place the springs sets (1) into the piston (2).
© Kessler & Co. GmbH & Co.KG All rights reserved
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Assembly of service brake
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7.50.11 Assembly of the brake carrier
1. Fit the o - ring (1) onto the brake carrier (2). 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). 5. Lift the press ram slowly. 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
© Kessler & Co. GmbH & Co.KG All rights reserved
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Assembly of service brake
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7.50.12 Final assembly 1. Screw in the bleeder with connection piece and seal ring as well as the screw plugs with seal ring. 2. Check brake hydraulic system for leaks (see page 9).
7.50.13 Check the air gap (pressurized) 1. While none actuated brake (piston room pressurized). 2. Measure through the wear inspection hole the distance from the brake carrier to the piston end face – write down the measure = measure A. 3. Actuate the brake (piston room none pressurized). 4. Measure again through the wear inspection hole the distance from the brake carrier to the piston end face – write down the measure = measure B. 5. The difference of the measured distances A and B gives the air gap sL (pressurized). 6. Rated size sL see table. 7. Actuate the brake (piston room none pressurized). 8. Measure through the check hole the distance from brake carrier to the end face and stamp the now ascertained dimension into the brake carrier near by the wear inspection hole.
air gap and wear dimension brake type
axle
Wet disc brake 4460 -
101.1642.3
spring load design Wet disc brake 4460 - 1
101.1643.3
spring load design
air gap sL new (pressurized) [mm]
wear dimension [mm]
2,5 + 0,7/ - 0,1
1,6
2,25 + 1 / - 0,1
1,6
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 onepiece 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.
© Kessler & Co. GmbH & Co.KG All rights reserved
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Chapter
Assembly of service brake
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7.50.14 centring of the discs: 1. The inner discs at wet disc brake have to be realized by using a centre tool (see chapter 3). 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).
7.50.15 Check brake hydraulic system for leaks
1. Before conducting the test, bleed the brake hydraulic system. 2. The pressure drop after applying pressure corresponding to the working pressure of the brake for a period of 15 minutes must not exceed 2%.
Test medium: Motor oil SAE 10 W corresponding to MIL - L 2104.
7.50.16 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. 1. Install an air pressure gauge with shutoff valve. 2. Be load the hub assembly with 1,5 bar pressure air. 3. Turn the hub assembly several times.
The pressure drop after a period of 10 minutes must not exceed 0,1 bar.
© Kessler & Co. GmbH & Co.KG All rights reserved
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Chapter
Assembly of service brake
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Disassembly of brake 7.50.17 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). • The disassembly of the brake has to be realized in reverse sequence.
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.
© Kessler & Co. GmbH & Co.KG All rights reserved
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Chapter
Assembly of service brake
7.51
Remarks to the wet disc brake 7.50.18 Permissible oil for brake with external cooling
Actuation fluid:
Do not use brake fluid at any time! Use a mineral oil base hydraulic oil type fluid only! 1) Motor oil API SE/ CD MIL - L - 46152C/ MIL - L - 2104 C o. D 2) ATF C - 3 or Dexron ® 3) Hydraulic oil HLP DIN 51524 Part 2 Viscosity:
Cooling fluid:
For moderate climate
ISO VG 22 - 32
For extremely cold climate
ISO VG 15
For extremely warm climate
ISO VG 46
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
7.50.19 Check measure
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! © Kessler & Co. GmbH & Co.KG All rights reserved
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Chapter
Assembly of service brake
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7.50.20 Installation and basic setting of the lining wear indicator 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 to the respective wear dimension
4.
Nominal dimension
axle
Brake type
Wear dimension X [mm]
101.1642.3
Wet disc brake 4460‐spring load design
1,6
101.1643.3
Wet disc brake 4460‐1 ‐spring load design
1,6
5.
Attach the seal ring (11)
6.
! Attention ! Screw on and tighten the cap (10) nut hand-tight
7.50.21 Check lining wear 1.
The check must realize then the indicator pin (14) is assembled
2.
Actuate the brake
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 residual lining wear
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 and a brake check is necessary, unconditional consult Kessler & Co. GmbH&Co.KG
© Kessler & Co. GmbH & Co.KG All rights reserved
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Kessler + Co GmbH & Co. KG Huettlinger Straße 18-20 73453 Abtsgmuend Germany
Tel +49 (0) 73 66/81-32 Fax +49 (0) 73 66/81-69 [email protected] www.kessleraxles.com
