RE - Atlas Copco - Upbox W2465 - 2 - en PDF

Repair and Maintenance
Atlas Copco
Upbox (W2465.2)
Edition 08/2016
Original
Service Manual

© Kessler & Co. GmbH & Co.KG
All rights reserved

Copyright ©
No part of this work may be reproduced, copied,
adapted, or transmitted in any form or by any means
Firma Kessler & Co. GmbH &Co.KG 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.

All rights reserved 02.04.2011

Chapter
Important information
1.15

Table of contents
Table of contents .................................................................................................................................... 1
Important information ........................................................................................................................... 2
Checking of screw connections, safety devices and corrosion ......................................................................................................................................................... 2
Customer service ............................................................................................................................................................................................................................. 2
Ordering replacement parts .................................................................................................................... 3
Warranty ......................................................................................................................................................................................................................................... 3
Ordering .......................................................................................................................................................................................................................................... 3
Identification plate .......................................................................................................................................................................................................................... 3
Necessary to contact Kessler & Co. GmbH & Co.KG ........................................................................................................................................................................ 4
Warnings, signal words and symbols ....................................................................................................... 5
All rights reserved -1- 2011‐07‐08

Chapter
1.15

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.
• 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 supporting components (e.g. housings) are not

permissible for reasons of operational safety and leaks.
Supporting components with cracks must be replaced!
Customer service
• Assembly and disassembly may be carried out only by trained specialists.
• Repair welding is permissible only after consulting Kessler & Co. GmbH & Co.KG!
• To remove the transmission from the vehicle, read the instructions in the vehicle
manufacturer's manuals. The following descriptions assume that the transmission
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.

Chapter
1.15

Ordering replacement parts

Warranty
Kessler & Co. GmbH & Co.Kg provides a warranty only for the original delivered replacement parts.
Please be aware that the use of other than original replacement parts can have a negative effect on the
design properties of the axle, therefore making it unsafe.
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:
1. Part number (no. on the installation drawing) → see rating plate
2. Serial number → see rating plate
3. Vehicle manufacturer
4. Name of replacement part
5. Replacement part number (drawing or DIN no.)
6. Quantity
7. Mode of dispatch

Identification plate
¾ Close to the identification plate, you will also find the gearbox serial number of the gearbox
stamped into the housing.

Chapter
1.15

Necessary to contact Kessler & Co. GmbH & Co.KG
¾ In case of questions, contact Kessler & Co. GmbH & Co.KG.
¾ In case of major repairs or overhaul work, it is advisable to send the entire transmission to Kessler &
Co. GmbH & Co.KG.

Chapter
1.15

Warnings, signal words and symbols
There is immediate danger of death or severe injury in case of failure to comply with this
Danger: safety notice.
¾ highest danger level
There is possible danger of death or immediate danger of severe injury in case of failure to
Warning: comply with this safety notice.
¾ second highest danger level
There is danger of minor injury or property damage in case of failure to comply with this
Caution: safety notice.
¾ third highest danger level
Notice: There is danger of property damage in case of failure to comply with this safety notice.
Tip: Offers additional information to facilitate working.

2
Chapter
Lubrication specifications and maintenance instructions
2.15
Table of contents
General lubrication instructions .............................................................................................................. 2

Filling quantities .............................................................................................................................................................................................................................. 2
Oil change ....................................................................................................................................................................................................................................... 2
Lubrication for storage .................................................................................................................................................................................................................... 2
Prior to operation of the transmission ............................................................................................................................................................................................ 2
Lubrication points............................................................................................................................................................................................................................ 3
Lubricants – Lubrication intervals – Relubrication ........................................................................................................................................................................... 4
Recommended hypoid transmission oil grades ............................................................................................................................................................................... 5
General maintenance instructions .................................................................................................................................................................................................. 6

All rights reserved -1- 08/11/2011
2
Chapter
2.15
General lubrication instructions

Filling quantities
Result from oil overflow at the oil level checking screws.
Oil change
1. Make sure vehicle is level.
2. Drain oil only when warm. Clean all lubricating points prior to opening screws. Open oil drain
plugs on the transmission.
3. Drain oil.
4. Re-insert oil drain plugs.
5. Open oil filler screws and oil level checking screw on the transmission.
6. Fill with oil.
7. Watch oil level at checking screw (to prevent overflow).

Wait several minutes.
If the oil level drops, add
oil until the oil level is
constant.
Lubrication for storage
 Replace breather with a screw plug to prevent oil from leaking and water from entering the
transmission.
 Fill the components completely with oil.

 Bare surfaces (e.g. flange mounts) must be additionally treated with corrosion protection.
Prior to operation of the transmission
 Remove storage oil and fill transmission with suitable oil to correct oil level.
 Check sealing ring contact surfaces for corrosion. Check seals for leaks immediately after putting into
operation. In case of leaks, replace sealing rings if necessary.
 The corrosion protection on bare surfaces (e.g. flange mounts) must be completely removed when
the transmission is put into operation.
 Check supporting components for corrosion, especially if stored for several years.

2
Chapter
2.15
Lubrication points
Helical gear W1616.2

Upbox
Figure 1
I = Oil fill plug

2
Chapter
2.15
Lubricants – Lubrication intervals – Relubrication
gearbox operation
Lubrication at ambient Lubrication
Lubricant Remarks
point (outside) interval 1.)
temperatures
after every min.
125 1000 1x per
hours hours year
Hypoid – gear oil per

MIL-L2105B/API GL5
Hypoid – gear oil in multi

range characteristic per
MIL-L2105 C/D/API GL5 Oil change
Transmission SAE 90
from -10°C – to +30°C or
multi grade oils
⊕ ⊕ ⊕
Check oil level
SAE 75 W – 90
at control
continuously under -10°C or
SAE 75 W - 85 points monthly
SAE 140
continuously above +30°C or
multi grade oils
Figure 2
(hours = hours of operation)
1. The value which is reached first always applies.

2
Chapter
2.15
Recommended hypoid transmission oil grades
Recommended hypoid transmission oil grades in accordance with

MIL-L 2105 B/API GL 5 or MIL – L 2105 C/API GL 5
 ARAL transmission oil Hyp 90
 AVIA transmission oil Hypoid 90 EP
 BP multi-purpose transmission oil EP SAE 90
 ELF - Tranself type B 90 / Tranself type B 80 W - 90
 ESSO transmission oil GX - D 90
 FINA - Pontonic MP SAE 85 W - 90
 FUCHS - Renogear Hypoid 90
 MOBIL - HD 90 - A
 SHELL - Spirax MB 90 / HD 90
 TEXACO - Multigear EP SAE 85 W / 90
 AGIP - Rotra MP / Rotra MP DB
Never use "normal" transmission oils!

2
Chapter
2.15
General maintenance instructions
Inspection and Comment Maintenance intervals 1)

maintenance points
after after every every at least

50 hours 100 500 1,000
hours hours hours 1 time
500 km every
1,000 km 5,000 km 10,000 year
km
Screws/drive flange Inspect and tighten

Nuts/gear mounting screw (check for tight fit) ⊕ ⊕ ⊕ ⊕
Screw connections
check occasionally ⊕
(e.g. transmission housing)
Seals check occasionally monthly

Figure 3
(hours = hours of operation)
1. The value which is reached first always applies.

Chapter
Assembly/disassembly
Tools
3.15

Table of contents
Assembly/disassembly ........................................................................................................................... 2
Disassembly .................................................................................................................................................................................................................................... 2
Assembly ......................................................................................................................................................................................................................................... 2
Use of Loctite and auxiliary materials ..................................................................................................... 3
Use of Loctite and auxiliary materials ............................................................................................................................................................................................. 3
Use of Loctite and auxiliary materials ............................................................................................................................................................................................. 4
Use of Loctite and auxiliary materials on the transmission ............................................................................................................................................................. 5
Units ...................................................................................................................................................... 6
Comparison table for units .............................................................................................................................................................................................................. 6
Names of the legal units.................................................................................................................................................................................................................. 6
Torques (Nm) ......................................................................................................................................... 7
Metric coarse‐pitch thread .............................................................................................................................................................................................................. 7
Metric fine‐pitch thread .................................................................................................................................................................................................................. 7
Galvanized screws and nuts ............................................................................................................................................................................................................ 8
Adjusting nuts or slotted nuts on drive flanges, gearwheels, etc..................................................................................................................................................... 8
Tools ...................................................................................................................................................... 8

Chapter
Tools
3.15

Disassembly
• Disassembly is the same as the assembly procedure in reverse order.
• Prior to disassembly, drain oil and check for abrasion.
• Mark matching parts prior to disassembly.
• Never use force to separate parts which fit tightly together. Use suitable pull-off devices for
disassembly of roller bearings, drive flanges and similar components.
• For proper disassembly, the use of special tools is recommended.
• Prior to disassembly, destruction of bearings and other components, always check whether
the disassembly, destruction of bearings and other components is necessary.
• In case of disassembly, always replace worn shaft seal rings, O-rings and roller bearings, if
necessary.
• Clean or replace corroded components.
• Do not place parts on a dirty surface.
Assembly
• Clean parts prior to installing.
• Bearing points which run in oil must be oiled prior to assembly.
• During the assembly of radial seal rings, make sure there is sufficient overlapping in the
housing bore. Make sure the radial seal ring is seated flatly. Do not allow Loctite to get onto
the sealing lips!
• Radial sealing rings, especially sealing rings with a dust lip, must be filled with grease.
• Sealing ring running surfaces on flanges, shafts, etc. must be protected with Castrol Rustilo
DWX 32 prior to installing.
• Fill with oil after assembly!

Chapter
Tools
3.15

Use of Loctite and auxiliary materials

¾ The surfaces or screws and threaded holes to be bonded must be free of paint, grease and oil
(washed). The Loctite adhesives used harden under the following conditions:
¾ Exclusion of air
¾ Metal-to-metal contact
¾ Warmth
¾ Only a very short time (5 - 10 min.) can be allowed between pre-assembly and controlled tightening.
¾ Parts prepared with Loctite for bonding can be exposed to air for up to 1 hour.
Exception: Parts made of non-ferrous metal may be exposed only for one minute.
¾ Connections subjected to mechanical loads must be allowed to harden at least 24 hours.
¾ Quantity of Loctite:
For screws: For parting surfaces:
1 bead Make sure parts are coated sufficiently!
Figure 1

Chapter
Tools
3.15

Type Colour Use

1. LOCTITE 243 blue Screw retention, light
262 red Screw retention, medium
270 green Screw retention, high-strength
270 green Increase of friction coefficient in parting surfaces
510 orange Sealing compound
572 white Special seals
638 light Splicings with a large gap
5926 blue Sealing compound
and 209
2. EPPLE 33 grey Sealing compound
3. DIRKO grey Elastic seals

Figure 2

Chapter
Tools
3.15

Use of Loctite and auxiliary materials on the transmission
Securing parts Connection Loctite Auxiliary materials
Flange Master system - Dirko grey
Housing Parting surface 510
Bleeding Thread 572
Oil pipe / oil pipe screw Parting surface /

270
connection screws
Gearwheel Screws 270

Figure 3

Figure 4

Chapter
Tools
3.15

Units
Comparison table for units
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)
1609.344m = 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 5
Names of the legal units
Term Symbol New Old Conversion Comment
Nm T (Nm) =
Torque T kpm 1 kpm = 9.81 Nm
(Newton meter) F (N) x r (m)
Nm M (Nm) =
Moment of force M kpm 1 kpm = 9.81 Nm
(Newton meter) F (N) x r (m)
1.02 at = 1.02 kp/cm2 =

Pressure p bar at
1 bar = 750 torr
Figure 6

Chapter
Tools
3.15

Torques (Nm)
µ = 0.14
Metric coarse-pitch thread
Screw Nut Screw Nut Screw Nut

Thread
8.8 8 10.9 10 12.9 12
M4 3.0 4.4 5.1
M5 5.9 8.7 10
M6 10 15 18
M8 25 36 43
M 10 49 72 84
M 12 85 125 145
M 14 135 200 235
M 16 210 310 365
M 18 300 430 500
M 20 425 610 710
M 22 580 830 970
M 24 730 1,050 1,220
M 27 1,100 1,550 1,800
M 30 1,450 2,100 2,450
Figure 7
Metric fine-pitch thread
Screw Nut Screw Nut Screw Nut

Thread
8.8 8 10.9 10 12.9 12
M8x1 27 39 46
M 10 x 1 55 81 95
M 10 x 1.25 52 76 90
M 12 x 1.25 93 135 160
M 12 x 1.5 89 130 155
M 14 x 1.5 145 215 255
M 16 x 1.5 225 330 390
M 18 x 1.5 340 485 570
M 20 x 1.5 475 680 790
M 22 x 1.5 650 920 1,050
Figure 8

Chapter
Tools
3.15

Galvanized screws and nuts
Use reduced torque for galvanized screws and nuts!

Figure 9
Adjusting nuts or slotted nuts on drive flanges, gearwheels, etc.
Thread Tightening torque:

d1 (mm) (Nm)
M 52 x 1.5 950
Figure 10
Figure 11
Tools
When ordering maintenance tools, please provide the
¾ Part number (no. on the installation drawing)

and
¾ Serial number → see rating plate.
¾ The ordering numbers for tools are specified as follows.
¾ The illustrations in the manual are not binding for the actual design.

Helical gear
W2465.2

Table of contents
General information on assembly and disassembly of the differential and carrier assembly 4
Information on warnings ................................................................................................................................................ 4
Required tools and mounting devices ......................................................................................... 5

Radial seal ring .............................................................................................................................................................. 5
Cylindrical roller bearing ................................................................................................................................................ 6
Tapered roller bearing ................................................................................................................................................... 7
To press parts ................................................................................................................................................................ 8
General demounting ...................................................................................................................... 9

Release the adjusting nut .............................................................................................................................................. 9
Disassembling the bearings ....................................................................................................... 11

By destruction of bearings ........................................................................................................................................... 11
Conserving the bearings .............................................................................................................................................. 12
Assembling the bearings ............................................................................................................ 12

By heating .................................................................................................................................................................... 12
Overview of parts ......................................................................................................................... 13
Overview of parts ......................................................................................................................... 14
Assembling the helical gear assembly ...................................................................................... 15

Upbox.1.A – Preparing the housing (36) ..................................................................................................................... 15
Upbox.2.A – Mounting the breather in the housing (36) ............................................................................................. 16
Upbox.3.A – Mounting the bearings in the housing (36) ............................................................................................. 17
Upbox.4.A – Mounting the oil supply in the housing (36) ............................................................................................ 19
Upbox.5.A – Mounting of gear wheel (3) ..................................................................................................................... 22
Upbox.6.A – Mounting of gear wheel (15) ................................................................................................................... 29
Upbox.7.A – Mounting of gear wheel (48) ................................................................................................................... 37
Upbox.8.A – Mounting of oil pump (22) ....................................................................................................................... 42
Upbox.9.A – Insertion of pre-mounted gear wheels .................................................................................................... 50
Upbox.10.A – Measuring axial play between cylindrical roller bearing (13) and cover (50) ....................................... 52
Upbox.11.A – Preparing the cover (50) ....................................................................................................................... 53
Upbox.12.A – Mounting the oil supply in the cover (50) .............................................................................................. 55
Upbox.13.A – Assembling the transmission ................................................................................................................ 56
Upbox.14.A – Mounting and measuring of rolling resistance on the shaft (4) ........................................................... 58
Upbox.15.A – Mounting and measuring of rolling resistance on the shaft (48) .......................................................... 62

Upbox.16.A – Mounting of sealing ring (10) on shaft (4) and drive flange (11) ......................................................... 64
Upbox.17.A – Mounting of drive flange (11) on shaft (4) ............................................................................................ 65
Upbox.18.A – Mounting of the pre-mounted oil pump ................................................................................................. 67
Upbox.19.A – Mounting of sealing ring (37) on input shaft (48) ................................................................................. 71
Demounting of parts of the helical gear assembly ................................................................... 72

Upbox.1.DA – Demounting of oil pump (22) ................................................................................................................ 72

General information on assembly and
disassembly of the differential and carrier
assembly
Information on warnings
WARNING: Danger of injury – rotating parts
During rotation of the part, it can tilt or sway uncontrolled

due to its intrinsic weight. There is a danger of injury to
the limbs.
Actions:
 Fasten part securely to lifting gear. (Example:
eye bolt)
 Guide part with free hand.
 During rotation of the part, ensure that no one is
underneath the part.
WARNING: Danger of injury – moving parts
Proceed cautiously and slowly when moving pre-

mounted parts. Do not place limbs between the parts to
be installed. This can cause severe injuries to the limbs.
Actions:
 Fasten part securely to lifting gear.
 Do not release lifting gear suddenly or
prematurely. Do not release the lifting device until
the part has been completely lowered.
 During movement of pre-mounted parts, ensure
that no one is underneath the pre-mounted parts.
WARNING: Danger of being crushed
Proceed slowly when assembling two parts. Do not place

limbs between the parts. This can cause severe injuries
to the limbs.
Actions:
 Fasten part securely to lifting gear.
 Do not release lifting gear suddenly or
prematurely. Do not release the lifting device until
the part has been completely lowered.

Required tools and mounting devices
Radial seal ring
Mounting tool
031.299.0-3
(Radial seal ring dimension 105x130x12)
Figure1
Mounting tool
031.052.0-3
( Radial seal ring dimension 70x95x12)
Figure2
Punch
071.007.0-4
( Radial seal ring dimension 60x72x7)
Figure3

Cylindrical roller bearing
Mounting tool
031.291.0-3
(Cylindrical roller bearing - dimension 90x190x43)
Figure4
Punch
071.005.0-4
Figure5
Punch
071.006.0-4
Figure 6

Tapered roller bearing
Punch
071.001.0-4
Figure 7 Figure 8 (Tapered roller bearing - dimension 75x160x37)
Punch
071.002.0-4
(Tapered roller bearing - dimension 75x160x37)
Figure 9
Punch
071.004.0-4
(Tapered roller bearing - dimension 75x160x37)
Figure 10

To press parts
Mounting tool
071.0003.0-3
(press gear)
Figure 11

General demounting
Release the adjusting nut
1. The secured adjusting nut
Figure 12
TIP: Use a screwdriver or a straight bit to bend back the

retainer.
2. Make sure that the screwdriver is between the pinion and the
retainer of the adjusting nut and hammer to knock open the
retainer.
Figure 13
NOTICE: Make sure that the retainer is complete released.

Otherwise during the demounting of the adjusting nut the
pinion will be damaged.
3. The released retainer from the adjusting nut.
Figure 14

4. Use a spanner socket and a rattle gun to loosen the adjusting
nut.
Figure 15
5. The correct loosened adjusting nut.
Figure 16

All rights reserved - 10 - 25/08/2016
Disassembling the bearings
By destruction of bearings
The following description in assembly / disassembly of bearings is universal.

The representations of the parts on the pictures do not necessarily correspond to parts of this statement.
CAUTION: Injury to eyes.
Eyes can be injured from flying metal parts.

Action:
 Wear protective goggles
1. Separate retainer
of tapered roller bearing.
Figure17
Figure18
2. Bend retainer up using a screwdriver.
3. Remove retainer and rollers.
Figure19
CAUTION: Danger of being burned
During heating, there is a danger of the limbs being

burned.
Action:
 Wear fireproof gloves.
4. Place gear wheel on a

suitable mounting device.
Figure20 5. During heating of the tapered

roller bearing, turn the gear
wheel quickly until the inner
ring automatically separates.
Figure21

Conserving the bearings
1. Use a pull-off device to remove the bearing.
Figure22
Assembling the bearings

By heating
CAUTION: Danger of being burned
Parts become very hot. This can result in injury to limbs.

Actions:
 Wear fireproof gloves.
Tip: Water test: pour a little water on the bearing and

watch to see if it vaporizes.
Figure23
1. Heat bearing on a hotplate to ca. 100 to 120°C.
NOTICE: Bearing must be able to be mounted without

force and must be seated straight on the collar at the
bottom.
2. Join hot bearing to counterpart.
3. After the bearing cools, it is firmly seated and you can

continue with assembly of the other parts.
Figure24

Overview of parts
Figure25

Overview of parts
1 tapered roller bearing 30 angle piece
2 hexagon socket screw 31 pipe
3 gear wheel 32 sealing ring
4 shaft 33 hexagon socket screw
5 thrust washer 34 cover
6 O-ring 35 O-ring
7 cover 36 housing
8 hexagon socket screw 37 radial seal ring
9 ring 38 retainer
10 radial seal ring 39 hexagon socket screw
11 drive flange 40 pipe
12 adjusting nut 41 retainer
13 cylindrical ball bearing 42 pipe
14 hexagon socket screw 43 pipe
15 gear wheel 44 screw fitting
16 shaft 45 tapered roller bearing
17 ball 46 gear wheel
18 O-ring 47 hexagon socket screw
19 hexagon socket screw 48 shaft
20 flange 49 thrust washer
21 radial seal ring 50 cover
22 oil pump 51 cylindrical pin
23 flange 52 hexagon socket screw
24 hexagon socket screw 53 screw plug
25 cover 54 sealing ring
26 hexagon socket screw 55 O-ring
27 sealing ring 56 cover
28 screw plug 57 hexagon socket screw
29 screw fitting

Assembling the helical gear assembly
Upbox.1.A – Preparing the housing (36)
TIP: For complete assembly, a swivelling mounting device

is useful.
Figure27 1. Mount the housing (36) on a mounting device which is

suitable for the assembly process.
Figure26
TIP: Use a light (electric torch) for testing.
NOTICE: Oil ducts must be free of all foreign matter and

dirt particles.
Figure 28
2. Check all oil channels in the housing (36).
NOTICE: Grooves in covers must be aligned with the oil

ducts in the housing.
Figure 29 3. Mount the cover (34) with the O-Ring (35) insert.
NOTICE: Check position of grooves from the cover.

Grooves are marked by a centre punch mark on the top
side.
4. Screw and tighten hexagon socket screws (33).
 Torque 50 Nm
Figure 30

Upbox.2.A – Mounting the breather in the
housing (36)
NOTICE: Threads must be sealed with Loctite.
Figure 31
Figure 32
1. Assemble breather parts. Put a bead of Loctite on the threads

of the angle piece (30) and the threads on the pipe (31).
 Loctite 572
2. Screw in the assembled breather (30/29/31) with the sealing

ring (32) into the housing (36).
Position according to the installation drawing of
Kessler & Co GmbH & Co.KG.
Figure 33

Upbox.3.A – Mounting the bearings in the
housing (36)
1. Turn the housing (36).
NOTICE: Oil ducts must be free of all foreign matter and

dirk particles.
Figure 34
2. Check all oil channels in the housing (36).
NOTICE: Apply clean oil to bearing seat.
3. Lubricate the bearing seat of the tapered roller bearings

(1/45) and the cylindrical roller bearing (13).
 Oil grade: same as transmission oil
4. Insert the outer bearing race of the tapered roller bearings

(1/45).
NOTICE: With mounting of a cylindrical roller bearing the

delivered mating must be kept by the manufacturer
absolutely.
TIP: Component parts to each other mark.
Figure 35
5. Insert the cylindrical roller bearing (13) into the lubricated,
undamaged housing (36).

6. Tap in cylindrical roller bearing (13) using
mounting device (031.291.0-3) without tilting, evenly and
without damaging it, as far as it will go.
 Mounting device 031.291.0-3
Figure 36
NOTICE: Use only brass or copper punch!
7. Tap in outer bearing race of the tapered roller bearing (1/45)

using a soft material, without tilting, evenly and without
damaging it, as far as it will go.
Figure 37

Upbox.4.A – Mounting the oil supply in the
housing (36)
Figure 38
NOTICE: Note, short pipe length on the pipe (43) – mount

short length toward the screw fitting (44) – necessary for
free movement of the gear wheel. (3).
1. Screw the screw fitting (44) with mounted pipe (43) into the
housing (36).
Figure 39
2. Apply Loctite to end of pipe (43).
 Loctite 270
Figure 40

NOTICE: Watch out for countersink on retainer (41) –
otherwise, a tight seal cannot be ensured!
TIP: The fit of the pipe in the retainer can be improved by

tapping lightly with a hammer, if necessary.
3. Mount retainer (41) in the pipe (43).
Figure 41

 Loctite 270
6. Fasten the completely mounted oil pipes (43/40) and retainer

(38/41) by inserting and tightening the hexagon socket crews
(39).
 Loctite 270
 Torque 10 Nm
Figure 42
7. Tighten screw fitting (44) with an open-end wrench.
Figure 43

Upbox.5.A – Mounting of gear wheel (3)
1 tapered roller bearing

2 hexagon socket screw
3 gear
4 shaft
Figure 44
1. Place tapered roller bearing (1) on

mounting device (071.001.0-4).
Figure 45
2. Place tapered roller bearing (1) on mounting device

(071.002.0-4).
Figure 46

3. Lubricate shaft (4) on both bearing seats for tapered roller

bearings (1).
Figure 47
4. With the tapered roller bearing (1) on the mounting device,

insert lubricated shaft (4) with the profile side into the tapered
roller bearing (1).
Figure 48

5. Prepared components for pressing in the tapered roller
bearing (1).
Figure 49
NOTICE: Apply clean oil to gear wheel seat.
6. Lubricate gear wheel seat (3) on shaft (4).
Figure 50
NOTICE: Make sure you have the correct gear wheel.
NOTICE: Apply clean oil to inner diameter.
7. Lubricate gear wheel (3) in inner diameter gear wheel seat

(3).
Check: Gear wheel has 43 teeth.

Figure 51

TIP: Use 2 set screws as centering aid during mounting of
gear wheel.
8. As a centring aid for connecting the gear wheel (3) and the
shaft (4), screw 2 headless pins into the shaft (4), offset 180°.
Figure 52
NOTICE: Make sure the position of the gear wheel is

correct.
9. The bevel on the inner diameter of the gear wheel (3) must
point in the direction of the bearing surface of the shaft (4).
Figure 53 Join the gear wheel (3) to the shaft (4).
10. Check gear wheel (3) to make sure it is centered.
Figure 54
11. Place mounting device (071.003.0-3) on prepared unit for

pressing in the tapered roller bearing (1) and gear wheel (3).
Figure 55

12. Place prepared unit under the press and press on the gear
wheel (3).
Figure 56
13. Shaft (4) with pressed-on gear wheel (3) and tapered roller
bearing (1).
Figure 57
14. Remove the 2 set screws .used as centering aid.
Figure 58
15. Screw in hexagon socket screws (2).
 Loctite 270
Figure 59

16. Tighten hexagon socket screws (2).
 Torque 125 Nm
Figure 60
17. Place tapered roller bearing (1) on short shank of shaft (3).
Figure 61
18. Place mounting device (071.001.0-4) on taper (1). Place

prepared unit under the press and press on the tapered roller
bearing (1).
Figure 62

19. Pressed-in tapered roller bearing (1) on shaft (4).
Figure 63
20. Place bearing shell on both tapered roller bearings (1).
Figure 64

13 cylindrical roller bearing

15 gear wheel
16 shaft
Figure 65
1. Shaft (16).
Figure 66

absolutely.
2. Remove inner bearing race of cylindrical roller bearing (13).
Figure 67

3. Place inner bearing race of cylindrical roller bearing (13) in
mounting device (071.005.0-4).
Figure 68
4. Lubricate shaft (16) on both seats for cylindrical roller

bearings (13).
Figure 69
5. Insert lubricated shaft (16) with the „long shank side“ into
bearing inner race on mounting device.
Figure 70

NOTICE: Apply clean oil to gear wheel seat.
6. Lubricate gear wheel seat (15) on shaft (16).
Figure 71

gear wheel.
7. As a centering aid for connecting the gear wheel (15) and the
shaft (16), screw 2 set screws into the shaft (16), offset 180°.
Figure 72
8. Lubricate gear wheel (15) in inner diameter.
Figure 73

NOTICE: Make sure the position of the gear wheel is
correct.
Join the gear wheel (15) to the shaft (16).
Figure 74
10. Check gear wheel (15) to make sure it is centered.
Figure 75
11. Place mounting device (071.003.0-3) on prepared unit for

pressing the inner bearing race.
Figure 76

12. Shaft (16) with pressed-on gear wheel (15) and inner bearing
races.
Figure 77
13. Remove the 2 set screws used as centering aid.
Figure 78
 Loctite 270
Figure 79
 Torque 125 Nm
Figure 80

absolutely.
Figure 81
16. Remove inner bearing race of cylindrical roller bearing (13).
17. Place inner bearing race on short shank of shaft (16).
Figure 82
18. Place mounting device (071.006.0-4) on top.
Figure 83
19. Press in inner bearing race and remove mounting device.
20. Pressed-in inner bearing race on short shank of shaft (16).
Figure 84

21. Turn unit and insert unit with short shank side into the
cylindrical roller bearing (13).
Figure 85
22. Turn the unit.
Figure 86

absolutely.
23. Place cylindrical roller bearing (13) onto pressed-in inner

bearing race.
Figure 87

24. Pre-mounted shaft (16).
Figure 88


46 gear wheel
48 shaft
Figure 89
1. Shaft (48).
Figure 90
2. Lubricate shaft (48) on both bearing seats for tapered roller

bearings (45).
Figure 91

3. Insert lubricated shaft (48) with the short shank side into the
tapered roller bearing (45) on the mounting device..
Figure 92
4. Lubricate gear wheel (46) in inner diameter.
Figure 93

gear wheel.
5. As a centring aid for connecting the gear wheel (46) and the
shaft (48), screw 2 set screws into the shaft (48), offset 180°.
Figure 94

Join the gear wheel (46) to the shaft (48).
Figure 95
7. Place prepared unit under the press and press on the gear
wheel (46).
Figure 96
8. Remove the 2 set screws used as a centring aid.
Figure 97

 Loctite 270
 Torque 125 Nm
Figure 98
11. Place tapered roller bearing (45) on long shank of shaft (48).
Figure 99
12. Place mounting device (071.004.0-4) on tapered roller

bearing (45)
13. Place prepared unit under the press and press.
Figure 100

14. Place bearing shell on both tapered roller bearings (45).
Figure 101
15. Completed shaft (48).
Figure 102

Upbox.8.A – Mounting of oil pump (22)
17 ball
20 flange
21 radial seal ring
22 oil pump
23 flange
25 cover
Figure 103
1. Lubricate oil pump (22-A / 22-B).
 Grease: Multi-purpose grease
Figure 104
NOTICE: Grooves must align.
2. Check grooves in oil pump (22-A / 22-B).
Figure 105

3. Flange (20).
Figure 106
4. Installation position of radial seal ring (21) in flange (20).
Figure 107
5. Place radial seal ring (21) on mounting device (071.007.0-4).
Figure 108
6. Mount radial seal ring (21) in flange (20).
Figure 109

7. Use a rubber hammer to tap in radial seal ring (21), on
mounting device, without tilting, evenly into the flange (20).
Figure 110
8. Mounted radial seal ring (21) in flange (20).
Figure 111
9. Check whether there is play between the oil pump (22) and the
cover (25).
10. Place the oil pump (22-A) in the lower depression of

intermediate piece (23).
Figure 112
11. Use a depth gauge to measure the distance between the oil
pump (22-A) and the contact surface of the intermediate piece
(23).
TIP: Set depth gauge to zero.
Figure 113

12. Measure the depression in the cover (25).
Dimension is larger Dimension is smaller
There is play There is no play
Execution OK Further assembly is not possible
Figure 114
13. Lubricate depression in cover (25) completely.

NOTICE: The seal surface must be free of dirt particles

and grease and must be undamaged. Apply Loctite evenly.
14. Apply Loctite to cleaned contact surface of the cover (25) just
before assembly.
 Loctite 510
Figure 115
NOTICE: Observe the installation position of the grooves.
15. Insert lubricated oil pump (22-A) in the cover (25). Grooves on
oil pump (22-A) must align with the threaded hole in the cover
(25)!.
Figure 116
16. Check whether there is play between the oil pump (22-A) and
the intermediate piece (23).
pump (22-A) and the contact surface of the intermediate piece
(23).
TIP: Set depth gauge to zero.
Figure 117

18. Measure the depression the intermediate piece (23).
Dimension is larger Dimension is smaller
There is play There is no play
Execution OK Further assembly is not possible
Figure 118
19. Apply Loctite to cleaned contact surface of the intermediate

piece (23) just before assembly.
 Loctite 510
20. Lubricate depression in intermediate piece (23).

21. Place the intermediate piece (23) on premounted cover (25)

and oil pump (22-A).
Figure 119
NOTICE: Observe the installation position of the grooves.
22. Insert oil pump (22-B).
Figure 120
23. Check alignment of grooves and alignment to the threaded hole

on the mounted intermediate piece (23), cover (25) and oil
pump (22-A / 22-B).
24. Screw mounted unit together using 2 hexagon socket screws

(24).
 Torque 50 Nm
Figure 121

26. Check whether there is play between the oil pump (22-B) and
the flange (20).
pump (22-B) and the contact surface of the intermediate piece
(23).
Figure 122
28. Measure the depression the flange (20).
Figure 123
29. Lubricate the flange (20) with the radial seal ring (21) mounted.
Figure 124

and grease and must be undamaged.
30. Clean sealing surface of flange (20).
Figure 125

and grease and must be undamaged. Apply Loctite evenly.
31. Apply Loctite to cleaned contact surface of the flange (20) just
before assembly.
 Loctite 510
Figure 126
32. Put the flange (20) in place.
33. Check the hole in flange (20); it must align with the grooves.
Figure 127
34. Screw mounted unit together using 2 hexagon socket screws

(19).
Figure 128
 Torque 50 Nm
Figure 129

36. Position of sealing ring lip on radial seal ring (21) in completely
mounted oil pump.
Figure 130
37. Lubricate radial seal ring (21).
Figure 131
38. Lubricated radial seal ring (21).
Figure 132
39. Place the O-ring (18) on the completely mounted oil pump.
Figure 133

Upbox.9.A – Insertion of pre-mounted gear
wheels

46 gear wheel
48 shaft
Figure 134
1. Insert pre-mounted gear wheels using a suitable mounting

device.
Figure 135
13 bearing
15 gear wheel
16 shaft
Figure 136

device.
Figure 137

3 gear wheel
4 shaft
Figure 138

device.
Figure 139
4. Pre-mounted gear wheels in housing (36).
Figure 140

Upbox.10.A – Measuring axial play between
cylindrical roller bearing (13) and cover (50)
NOTICE: The axial play between the cylindrical roller

bearing (13) and cover (50) must be between
0,3 mm and 1 mm.
Dimension A – dimension B = axial play
Figure 141
NOTICE: The axial play between the cylindrical roller

bearing (13) and cover (50) must be between
0,3 mm and 1 mm.
Figure 142
1. Place a square bar with parallel surfaces on the top edge of

the cylindrical roller bearing (13) and use a depth gauge to
measure from the latter to the contact surface of the housing
(36).
2. Set depth gauge to zero.
Figure 143
3. Place a square bar with parallel surfaces on the top edge of

the cover (50) and use a depth gauge to measure from the
latter to the first shoulder in the cover (50).
4. The measured dimension is the axial play between the

cylindrical roller bearing (13) and the cover (50).
Figure 144

Upbox.11.A – Preparing the cover (50)
Cover (50)
Figure 145
NOTICE: Oil ducts must be free of all foreign matter and dirt
particles.
Figure 146 1. Check all oil channels in the cover (50).
2. Remove bearing shells (1/45) and cylindrical roller bearings

(13) from the mounted gear wheels.
Figure 147
3. Lubricate the bearing seat of the tapered roller bearings

(1/45) and the cylindrical roller bearings (13).
4. Insert the outer bearing race of the tapered roller bearing

(1/45) and the cylindrical roller bearing (13) into the
lubricated, undamaged cover (50).
Figure 148

NOTICE: Use only brass or copper punch!
5. Tap in outer bearing race of the tapered roller bearing (1/45)

using a soft material, without tilting, evenly and without
damaging it, as far as it will go.
Figure 149
6. Tap in cylindrical roller bearing (13) using mounting device no

(031.291.0-3) without tilting, evenly and without damaging it,
as far as it will go.
Figure 150

Upbox.12.A – Mounting the oil supply in the
cover (50)
Figure 151
NOTICE: Note, short pipe length on the pipe (42) – mount

short length toward the screw fitting (44) – necessary for
free movement of the gear wheel (3).
1. Screw the screw fitting (44) with the mounted pipe (42) into
the cover (50).
Figure 152

 Loctite 270
NOTICE: Watch out for countersink on retainer (41) –

otherwise, a tight seal cannot be ensured!
TIP: The fit of the pipe in the retainer can be improved by

tapping lightly with a hammer, if necessary.
Figure 153

 Loctite 270
6. Fasten the completely mounted oil pipes (42/40) and retainer

(38/41) by inserting and tightening the hexagon socket
screws (39).
 Loctite 270
 Torque 10 Nm
7. Tighten pipes using an open end wrench only after oil pipe
assembly is complete.

Upbox.13.A – Assembling the transmission
1. Turn the cover (50).
Figure 154
NOTICE: The seal surface must be free of dirt particles and

grease and must be undamaged. Apply Loctite evenly.
NOTICE: Do not apply Loctite until immediately prior to

assembly.
2. Coat the seal surface of the cleaned and undamaged housing

Figure 155 (36) and cover (50) completely with sufficient Loctite.
 Loctite 510
WARNING: Danger of injury
WARNING: Danger of being crushed
3. Carefully put the cover (50) in place.
Figure 156

4. Fasten cover (50), after it has been completely lowered onto
the housing (36), by means of 2 cylindrical pins (51).
5. Tap cylindrical pins (51) into the hole at least to a depth of

8 mm.
Figure 157
NOTICE: First tighten 2 opposing hexagon socket screws.
6. Screw the cover (50) and housing (36) together using the
hexagon socket screws (52).
Figure 158
7. Tighten hexagon socket screws (52) connecting the cover

(50) and housing (36).
 Torque 125 Nm
Figure 159
8. Close the helical gear assembly with oil plugs.
Figure 160

Upbox.14.A – Mounting and measuring of
rolling resistance on the shaft (4)
1. Place a depth gauge on the top edge of the shoulder of the

cover (56) and measure the depth.
2. Set depth gauge to zero.
Figure 161
NOTICE: Check to make sure the tapered roller bearing is

in complete contact. It may be necessary to tap the bearing
lightly with a rubber hammer to improve the contact.
Check the dimension at a minimum of 2 different locations.
3. Use the depth gauge on the cover (50) to measure from the
contact surface for the cover (56) to the tapered roller bearing
(45).
4. Write down measured dimension.

Figure 162
TIP: For the initial assembly and setting of the rolling

resistance it is advantageous to insert a disk which is
thicker than the measured dimension by a few 0.0X mm.
5. Insert disk (49).
Figure 163
NOTICE: Check position of grooves from the cover.

Grooves are marked by a centre punch mark on the top
side.
6. Mount cover (56).
Figure 164

7. Tighten cover (56) using 4 hexagon socket screws (56).
Figure 165
8. Mount cover (7).
Figure 166
9. Screw on cover (7) using 4 hexagon socket screws (8).

Screw on adjusting nut (12).
Figure 167

TIP: During the measuring process, light taps against the
housing with a rubber hammer can release tension from the
bearing.
NOTICE: The rolling resistance must be set between

2.5 Nm and 3.0 Nm.
Then grind off disk 0,09 mm – 0,12 mm.
10. Calculate rolling resistance.

Figure 168
11. Write down the measured dimension and compare with
specifications.
Rolling resistance:
Ok Higher than 2,5 Nm – 3,0 Nm Lower than 2,5 Nm – 3,0 Nm
Disk must be ground off

Disk must be thinner. Disk must be thicker.
0.09 mm – 0.12 mm!
TIP: 0,01 mm (thickness of disk) = ca. 1 Nm
12. If the rolling resistance is not within the tolerance, a new disk
(5) (with changed thickness) must be inserted and the
adjustment procedure must be repeated.
13. This process must be repeated until the correct rolling

resistance (stated above) is achieved.
Figure 169
NOTICE: Do not continue until the result is within the

tolerance.
14. Place the O-Ring (6) on the cover (7).

Figure 170 15. Mount the cover (7).

16. Tighten cover (7) using hexagon socket screws (8).
 Torque 50 Nm
Figure 171
17. After final assembly:

Check rolling resistance.
Smooth running must be ensured.
Figure 172

Upbox.15.A – Mounting and measuring of
rolling resistance on the shaft (48)
1. Unscrew cover (56) and insert disk (49) with dimension

already calculated.
Figure 173
2. Mount cover (56) and screw tight using 4 hexagon socket

screws (57).
Figure 174
TIP: During the measuring process, light taps against the

housing with a rubber hammer can release tension from the
bearing.
NOTICE: The rolling resistance must be set

between 2.5 Nm – 3.0 Nm.
Then grind off disk 0,09 mm – 0,12 mm.
3. Write down the measured dimension and compare with

specifications.
Figure 175
Rolling resistance:
Ok Higher than 2,5 Nm – 3,0 Nm Lower than 2,5 Nm – 3,0 Nm
Disk must be ground off

Disk must be thinner. Disk must be thicker.
0.09 mm – 0.12 mm!
TIP: 0,01 mm (thickness of disk) = ca. 1 Nm

4. If the rolling resistance is not within the tolerance, a new disk
(49) (with changed thickness) must be inserted and the
adjustment procedure must be repeated.
5. This process must be repeated until the correct rolling

resistance (stated above) is achieved.
Figure 176
NOTICE: Do not continue until the result is within the

tolerance.
6. Insert O-ring (55) in the cover (56). Then mount cover (56).
Figure 177
 Torque 50 Nm
Figure 178
8. After final assembly:

Check rolling resistance.
Smooth running must be ensured.
Figure 179

Upbox.16.A – Mounting of sealing ring (10)
on shaft (4) and drive flange (11)
1. Insert bushing (9).
Figure 180
2. Fill radial seal ring (10) 2/3 full with grease.
3. Place the radial seal ring (10) on the mounting device

(031.045.0-3) carefully and without tilting.

Figure 181
4. Using mounting device (031.299.0-3), tap in radial seal ring

(10) carefully and without tilting until it is 2.0 mm beneath the
top edge of the cover (50).
Figure 182 Figure 183
 Torque 50 Nm
Figure 184

Upbox.17.A – Mounting of drive flange (11)
on shaft (4)
NOTICE: During mounting, be sure not to damage the

sealing ring lip of the radial seal ring.
Tip: During mounting, turn the flange slightly.
TIP: Groove in shaft pointing toward mechanic – recess of

drive flange likewise. This makes it easier to secure the
Figure 185
adjusting nut later.
1. Mount the drive flange (11) onto the shaft (4).
2. Apply a bead of sealing compound to the seal surface

between the drive flange (11) and the adjusting nut (12).
 Sealing compound: DIRKO grey
Figure 186
3. Screw on adjusting nut (12).
Figure 187
4. Tighten adjusting nut (12).
 Torque 950 Nm
Figure 188

NOTICE: Shear off the collar of the adjusting nut only along
the flank of the groove.
Bend the exposed corner to the bottom of the groove.
Secure against the twist-off direction of adjusting nut.
5. Shear the collar of the adjusting nut (12) with a chisel.
Figure 189
6. Correctly secured adjusting nut (12).
Figure 190

Upbox.18.A – Mounting of the pre-mounted
oil pump
17 ball
20 flange
21 radial seal ring
22 oil pump
23 flange
25 cover
Figure 191
1. Lubricate shank of shaft (16).
Figure 192
2. Balls (17) which to be installed.

Figure 193
3. Insert balls (17) in the depressions of the shaft (16).
Figure 194
NOTICE: Grooves of the pre-mounted oil pump must align

with each other.
Depiction of the grooves in the oil pump from the direction
of the sealing ring.
4. Check position of grooves in the pre-mounted oil pump.
Figure 195
NOTICE: The grooves of the pre-mounted oil pump must

align with the inserted balls.
Watch out for this throughout the entire mounting of the oil
pump!
5. Use a suitable lifting device to insert the pre-mounted oil

pump slowly and without tilting.
Figure 196

Figure 197

Figure 198

After the oil pump has been lowered completely, remove the
lifting device.
Figure 199
NOTICE: The grooves and balls align with each other after
mounting of the oil pump.
9. Check to make sure that grooves and balls align with each
other.
Figure 200

other.
Figure 201
11. Tighten oil pump using hexagon socket screws (26).
 Torque 50Nm
 Loctite 262
Figure 202
12. If necessary close the oil pump with rubber plugs.
Figure 203
NOTICE: Do not turn the drive flange frequently, since this

will cause excessive grease to enter the oil pump.
13. Check for smooth running of the drive flange (11).

Drive flange (11) must turn easily and the shaft (48) must
also turn at the same time.
Figure 204

Upbox.19.A – Mounting of sealing ring (37)
on input shaft (48)
NOTICE: Cover gear teeth – protection for sealing lips from

the radial seal ring.
1. Cover gear teeth of the shaft (48) with a safety hood.
Figure 205
2. Fill radial seal ring (37) 2/3 full with grease.
3. Push the radial seal ring (37) over the safety hood carefully
and without tilting.
Figure 206
4. Using the mounting device (031.052.0-3), tap in radial seal

ring (37) carefully and without tilting until it is 2,0 mm beneath
the top edge of the housing (36).
Figure 208
Figure 207

Demounting of parts of the helical gear
assembly
Upbox.1.DA – Demounting of oil pump (22)
17 ball
18 O-ring
20 flange
21 radial seal ring
22 oil pump
23 flange
25 cover
Figure 209
1. The mounted oil pump (22).
Figure 210
2. Screw out the rubber plugs.
Figure 211

other.
Figure 212
4. Loosen and remove hexagon socket screws (26).
Figure 213
5. Use a suitable lifting device to remove the oil pump (22)

slowly and without tilting.
Figure 214
6. Use a suitable lifting device to remove the oil pump (22)

slowly and without tilting.
Figure 215

8. Take off the O-ring
Figure 216
9. Take off the flange (20).
Figure 217
TIP: Use 2 auxiliary screws for a better disassembly.
10. Screw in 2 auxiliary screws into the oil pump (22-B).

For example: auxiliary screws M6x…
Figure 218
11. Remove the oil pump (22-B).
Figure 219

Figure 220
13. Remove the flange (23).
Figure 221
TIP: Use 2 auxiliary screws for a better disassembly.
14. Screw in 2 auxiliary screws into the oil pump (22-A).

For example: auxiliary screws M6x…
Figure 222
15. See the dismounted oil pump (22-A).
Figure 223

Service Manual

All rights reserved

Kessler + Co GmbH & Co. KG Tel +49 (0) 73 66/81-32
Huettlinger Straße 18-20 Fax +49 (0) 73 66/81-69
73453 Abtsgmuend service@kessleraxles.com
Germany www.kessleraxles.com

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Repair and Maintenance

• Corrosion and cracks on supporting components (e.g. housings) are not

Ordering replacement parts

1. Part number (no. on the installation drawing) → see rating plate

2. Serial number → see rating plate

4. Name of replacement part

5. Replacement part number (drawing or DIN no.)

Necessary to contact Kessler & Co. GmbH & Co.KG

¾ In case of questions, contact Kessler & Co. GmbH & Co.KG.

Warnings, signal words and symbols

Tip: Offers additional information to facilitate working.

General lubrication instructions .............................................................................................................. 2

Oil change ....................................................................................................................................................................................................................................... 2

Lubrication for storage .................................................................................................................................................................................................................... 2

Prior to operation of the transmission ............................................................................................................................................................................................ 2

Lubricants – Lubrication intervals – Relubrication ........................................................................................................................................................................... 4

Recommended hypoid transmission oil grades ............................................................................................................................................................................... 5

General maintenance instructions .................................................................................................................................................................................................. 6

© Kessler & Co. GmbH & Co.KG

General lubrication instructions

Result from oil overflow at the oil level checking screws.

1. Make sure vehicle is level.

4. Re-insert oil drain plugs.

6. Fill with oil.

7. Watch oil level at checking screw (to prevent overflow).

Lubrication for storage

 Fill the components completely with oil.

Prior to operation of the transmission

© Kessler & Co. GmbH & Co.KG

Helical gear W1616.2

I = Oil fill plug

© Kessler & Co. GmbH & Co.KG

Lubricants – Lubrication intervals – Relubrication

Hypoid – gear oil per

Hypoid – gear oil in multi

1. The value which is reached first always applies.

© Kessler & Co. GmbH & Co.KG

Recommended hypoid transmission oil grades

Recommended hypoid transmission oil grades in accordance with

 ARAL transmission oil Hyp 90

 AVIA transmission oil Hypoid 90 EP

 BP multi-purpose transmission oil EP SAE 90

 ELF - Tranself type B 90 / Tranself type B 80 W - 90

 ESSO transmission oil GX - D 90

 FINA - Pontonic MP SAE 85 W - 90

 FUCHS - Renogear Hypoid 90

 TEXACO - Multigear EP SAE 85 W / 90

 AGIP - Rotra MP / Rotra MP DB

Never use "normal" transmission oils!

© Kessler & Co. GmbH & Co.KG

General maintenance instructions

Inspection and Comment Maintenance intervals 1)

after after every every at least

Screws/drive flange Inspect and tighten

Seals check occasionally monthly

(hours = hours of operation)

1. The value which is reached first always applies.

© Kessler & Co. GmbH & Co.KG

• Prior to disassembly, drain oil and check for abrasion.

• Mark matching parts prior to disassembly.

• For proper disassembly, the use of special tools is recommended.

• Clean or replace corroded components.

• Do not place parts on a dirty surface.