ay Service Handbuch Inhaltsverzelchnis Table of contents 1 Wichtige Hinweise Important remarks 2 ‘Schmiervorschriften und Wartungshinweise Lubrication intervals and maintenance instructions 3 ‘Allgemeine Hinweise zur fachgerechten Montage und Demontage Kundendienstwerkzeuge Goneral instructions for correct assembly and disassembly ‘Service tools 4 Montage Achsantrieb Assembly drive assembly 5 Montage Radseite ‘Assembly hub assembly 6 ‘Montage Planetengetriebe ‘Assembly panelary gear drive i Montage Betriebsbremse Assembly service brake 8 Montage Festselbremse Assembly parking brakeService Manual it remart For safety reasons, the operator should verify and service at regular intervals all ofthe bolted assemblies and all ofthe important safety locks such as : = Wheel nuts = Nuts of axle mounting bolts ~ Bolts on the steering components and the brake system parts ; ifthe screws are tightable , the Loctite contact breaks loose and remounting is necessary . ~ Corrosion on the cartier elements ( such as the axle spindle ) is not acceptable for operational safety reasons = Verity seals , oil levels and lubrication at regular intervals Brakes = Ingpect brake lining and brake drum / brake disk regulary as well as wear of brake system parts. - Inspect the free movement of brake system rods . - In case of signs of excessive heating , consull a brake specialist or the manufacturerJe disconnect Operation of cr “The operation ofthe creep gear in the transfer case may be necessary for 2 reasons 4) For ow speed operation , normally on good ground. In this case the connection of further cive ‘axles and expecially the operation of cross axle differential locks must be prevented because of possible wind up and possible damage on the drive line parts b) Operation of he creep gear inthe transfer case becaue af loose of traction on cificut, siepPery ground condition . Under these circurnstances operation of ock should only be made stop by s'eP and only if realy require = iftraction is not sufficent then connection of futher drive axles , on further traction problems ‘operation of inter axle differential lock - Ifnecessary as a next step operation of cross dif. ack Genere mer Operation of df, locks may cause overloading of drive line parts Special attention is necessary - Operation of diff. lock only in ficult ground condition ( sand , gravel , mud ) - Dif locks must only be operated shortly before the obstacte and must be disconnected immediately after - Difflock should only be operated at stand stil and under no circumstances when wheels are spinning - No steering Is allowed during operation of cross dif. lock . With operated interaxle dif. lack steering may be done under great caution Operation of dif. lock only in the transport conditions of the machine or when the machine weight not helgher. Dill lock should not be operated during a bull up concition with additional weighs = Dive carefully : not jerky and not with fll engine power - With operated dif. lock never drive longer distances or on normal , good driving condition scabin must inform about the operation of inter axle and cross diff. lock ol light should show with already the first lock operated , even if the 0 already disconnected ( electrical installation parallel ) ‘A control light in the di separately . Further tt ‘other locks are not!Service Manual Instructions for ordering spare parts ‘We oniy accept liability for the original spare parts supplied by ourselves . We express clearly that the utilisation of other parts than the from us prescribed original spare parts , can change infavourably the characteristics of the axle prescribed by the construction and that thereby the safety can be affected . For damage caused by the utlisation of not original spare paris and accessories , any liability of the Kessler & Co GmbH 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 . }. Order number ( installation drawing no . ) -» see identification plate Fabrication number > see identification plate Vehicle producer . Description of the spare part . Spare part number ( drawing - resp. DIN no. ) Number of pieces Kind of delivery ‘TELO7366 / $132 FAXO7366 / 8169, 73453 ABTSGMUND | GERMANY ‘Order Nr Fabrik Nr OIL: MIL-L-2105 B SAE 90 In case of doubt , consult Kessler & Co, For major repairs or overhaul, itis recommendet that the complete axle assembly be returned to Kessler & CoService Manual General lubrication instructions Lubrication points _see sheet 2.2 resp. installation drawing Lubricants see sheet 23 Fill tevels: ‘Are checked at the level control plugs ll change Place the vehicle in a horizontal position . Draining of the oil is to be ‘accomplished only in warm condition . Clean all lubrication points before ‘opening them . Open the drain holes on the carrier assembly , on the wheel assemblies , and if present , on the interaxée differential and drop oar housing . On the hub assemblies , the drain plug should be turned downward. Oil draining Replacement ofthe ol draining plugs lemove the oil filer plug 2s well as the oll evel control plug on the carrier assembly , on the wheel assembly , and , if present on the interaxle ciferental and drop gear housing . ( see sheet 2.2 > lubrication points ) il fting Check the ci level atthe ol level plug hole ( Overflow control ) . Wait a few ‘minutes . I the ol level falls, add oll until the level remains constant . Clean the grease nipples before lubrication . Lubrication intervals see sheat 2.3. Important ! (On the axles with self locking differentials , a noise is produced if normal cils are used - In case of abnormal noises and in case of operation under bumpy conditions , use gear oil EP with additives of the , Limited Slip . type conforming to specification M2C - 104 A. Incase of prolonged non - operation of the vehicle , itis recommended to start - up and operate all of the parts of the gear train every 6 months . For this purpose , maintain the proper oil level which also protects the axle against water intrusion “The surfaces of the brake areas are to be preserved in humid locations . On start - up , a break «in of the braking system by intermittent operation is indispensable De ee elService Handbuch ‘Schmierstellen / Lubrication points Die verbindliche Schmierstellenposition ist der achszugeh6rigen Einbauzeichnung zu entnehmen ‘The binding lubrication points has to be taken from the according installation drawing of the axle ‘Achsantrieb einfach ‘Single drive assembly * Position ist von jewelliger AchsausfUhrung abhngig “The positon is dependent from the respective axle version ‘Achsantrieb mit Durchtrieb Drive assembly with throughdrive * Ausfohrung mit Zwischenachsdifferential anit” 1,5 Liter O1 bei Erst - und Neubefillung einfallen | * Version with interaxte diferential fi 4,5 re oil at 1+ I * for first - time filing and for refiling ! Vorgelege D 51D 108 Drop gear D51/D 108 * IT nur bei Ausfihrung mit separatem Olraum * IT only at version with separately oil space Kardanwellenzwischenlager Cardan shatt intermediate bearing jeinfullschraube / oi fil plug 111 = Olablagschraube / ol drain plug ‘Okontrolischraube / oil level control plug IV = Kegelschmiernippel / grease nipple usRadseite mit Planetengetriebe Hub assembly with planetary gear drive ‘Schmierstellen an Doppelgelenkwelle und Bremswelle ‘al nih waringetel) {Ubeaton pat a unnersa int and brake shat (if aot maintenance - free ) Radseite mit Nasser Lamellen Bremse Hub assembly with wet disk brake Pendellagerung Tumbler bearing 1 = Oleinfalischraube / oi fil plug IM = OlablaBschraube / of arin pu |= Okontrolschraube/ ol level contro plug srgel/ anata IV = Kegelschmiemippel/ grease nippleService Manual 2.3 Lubricants and lubrication intervals Lubrication Lubricant Remarks Lubrication intervals 1.) point. apap aaa Dive assembly [ett RE a 5 | Olchanos ® ele inert Rn RE Se Le Winco hub plane- liste sishe Typenschild . ( Die Abbildungen sind fur die Ausfahrung nicht verbindlich ) ‘When ordering service tools please provide order number {installation drawing no. ) , resp. fabrication umber — see identification plate . ( The illustrations are not binding for the design ) SS a Schissel for Radsicherungsmutter Spanner for wheel safety nut ‘Schlissel fr Nutmutter ( Radseite ) ‘Spanner for splined nut ( hub assembly )aesslen-co]| Service Handbuch | 3.6.2 Kundendienstwerkzeuge Dichtringaufsetzer Seal ring sleeve driver ‘Schidssel far Gewinderinge (Ditferentiallagerung ) ‘Spanner for thread rings ( differential bearing ) ‘Schldssel far Kontermutter (Planetengetriebe ) Spanner for counter nut (planetary gear drive ) Montagekonus far O - Ring ( Differentialsperre ) yY Assembly cone for 0 - ring (differential lock )Zentriervorrichtung far Lametien Centering tool for dises inseteworkzoug fur Gt arotiery Installation tool for face:Service Handbuch Montage Achsantrieb Assembly drive assemblyService Manual gears of the drive pinion To became a perfect gear meshing is only possible if the fabrication number of pastes (marked on the end face ) and the ring gear ( marked on the circumference ) are 2 The following figures are showing 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 are indicating the direction towards which the drive pinion has to be moved . The clear arrows are indicating the direction towards which the ring gear has to be moved , to get further more a correct backlash Gear meshing to deep Increase the drive pinion distance by correction of the adjustment disk thickness Regulate the backlash by inwards moving of the ring gear « ze tT Gear meshing to high Decrease the drive pinion distance by correction of the adjustment disk thickness Regulate the backlash by outwards moving of the ring gear » 3 L Adjustment of gear meshing of Gleason‘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 ‘Using of Loctite and other operating supplies 41, Striking nut at drive flange - In thread : assembly paste with MoS, ( exception through clive pinion see point 2) = Frontside contact surface: sealing compound (Epple 33 or equivalent) 2) Striking nut at through drive pinion -Inthread : Loctite 262 34 Striking nut at gear wheels, bearings etc. - In thread : assembly paste with MoS, ‘Removing of the striking nut Bend away the nose and screw off the nut= ~ aan Service Handbuch | 4.1 Achsantrieb D 51 Drive assembly D 54Service Manual Adjustment drive pinion distance To obtain the proper tooth flank contact, adjust the axial postion of the drive pinion with the thickness of the adjustment disk . The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement ( s28 calculation example ) The finat thickness of the adjustment disk can be fixed during the checking of gear meshing at the assembled drive assembly ( see page . Adjustment of gear meshing of Gleason gears") *)A= Set value for correct pinion support . This dimension is writed on the end face of the pinion in millimeter . It indicates the deviation from the theorelic distance ) (setpoint dimen: **) B= Measured width of the taper roller bearing Calculation example to ascertain the thickness S from the adjustment disk : A=+0,10; B= 37,95 $= 3,00mm ( theor. ) +£0.05 mm -> B = 0,05 mm smaiier than B theor. 3,05 mm, 0.10 mm -> drive pinion value A = 2,95 mm —> necessary thickness of the adjustment disk Fit corresponding disk and outer rings of the taper roller bearings *) Hint if value A Is posiiv (f. ©. + 0,1 ) the adjustment disk has to be 0,1 mm thinner than theor. S . It value Ais negativ (fe. —0,1 ) the adjustment disk has to be 0,1 mm thicker than theor. S **) Hint : if measure B is posit (f. e. 38,05 ) the adjustment disk has to be 0,05 mm thinner than theor. S . fmeasure B is negatv (fe. 37,95 ) the adjustment disk has to be 0,05 mm thicker than theor. §