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Linde Heavy Trucks

Division
Service Training 357-05

Linde Material Handling

Kessler Drive Axle Assembly

Linde Material Handling

357-05 Kessler Drive Axle Assembly

35705

Linde Material Handling

357-05 Kessler Drive Axle Assembly

SERVICE TRAINING
KESSLER DRIVE AXLES
357-05

Linde Material Handling

357-05 Kessler Drive Axle Assembly

KESSLER AXLES ARE MANUFACTURED TO THE


HIGHEST STANDARDS IN THE TOWN OF AARLEN
IN GERMANY. THEIR QUALITY AND RELIABILITY
HAVE BEEN PROVEN OVER MANY YEARS USE IN
THE LINDE PRODUCT.

THE FOLLOWING SLIDES DETAIL THE REBUILD


PROCEDURE TO ADOPT SHOULD REPAIR WORK
BE REQUIRED ON D101 & D102 DRIVE AXLES.

Linde Material Handling

357-05 Assembling the Differential

Assemble the spider with the differential gears with their bearings, place the bearing
washers
on the half shaft gears. The bearings must be lubricated with oil during assembly.
Notice the holes in the bearing washers and the tabs on the differential gear bearings, these
are to prevent rotation.

Linde Material Handling

357-05 Kessler Drive Axle Assembly

Assemble the crown wheel to the differential half aligning the fixing holes, have the matching
differential half and bearings ready.

Linde Material Handling

357-05 Assembling the Differential

Assemble the differential gears into the cage half, note the lock tabs.

Linde Material Handling

357-05 Assembling the Differential

Join the two differential cage halves together, there is a stamped mark in each cage for alignment
shown here as a chalk mark. Fit and tighten the differential cage and crown wheel fixing bolts.
Fit the bearing halves, these may need heating to 100C to facilitate fitting.

Linde Material Handling

357-05 Assembling the Differential

Assembly of the bearing shell into the differential housing requires the measuring and placement of
a shim behind the shell to control the depth of pinion mesh.

Linde Material Handling

357-05 Assembling the Differential

A theoretical dimension exists for all


components.
S = 3.1mm
B = 40 mm
A = Stamped on the crown wheel as + or -.
To ascertain the shim thickness the bearing
must be measured, assume this to be 39.95
The difference is therefore +.05.
Look at the dimension stamped on the
end of the pinion at A. Assume this is -.1
The difference between these is -0.05.
This must be deducted from the
theoretical S dimension, IE 3.1mm
-0.05 = 3.095. This is the thickness of
the shim that must be fitted at S.

Linde Material Handling

357-05 Assembling the Differential

Measure the thickness of the bearing using 40mm as the datum.

Linde Material Handling

357-05 Assembling the Differential

Note the correction dimension stamped on the cone face of the pinion.

Linde Material Handling

357-05 Assembling the Differential

Fit the shim and the bearing shell.

Linde Material Handling

357-05 Assembling the Differential

The shim thickness C to be fitted


between the pinion bearings must be
measured.
Again this is calculated from a number of
dimensions.
The dimension A is the distance between
the front face of both bearings.
The dimension B is the length of the pinion
from the back of the gear cone to the front face
where the shim fits.

C=A-B

Linde Material Handling

357-05 Assembling the Differential

It is important that the flange and nut are fitted without the oil seal as this may interfere with
the torque required to rotate the pinion.
Tighten the nut to 850Nm before testing.

Linde Material Handling

357-05 Assembling the Differential

Test the torque to rotate the assembly without the seal fitted, if this is correct, 0.8 to 1.2 Nm
mark the position of the nut as this will make assembly easier.
Remove the nut and flange, fit the seal and the flange and retighten the nut to the correct torque.
Observe the mark on the nut.

Linde Material Handling

357-05 Assembling the differential

When the torque to rotate is correct remove the nut and flange, fit the oil seal in its housing
and fit and secure the housing in position. Fit the flange and nut and tighten to the correct
torque. Ensure that the marks on nut and pinion align.

Linde Material Handling

357-05 Assembling the differential


The differential crown wheel and
cage can now be fitted into the the
housing, the vernier adjusting
nuts must be fitted with care to
avoid cross threading.
There are now three settings to
consider, these are.
1 Backlash in the crown wheel.
2 Torque to rotate the differential
3 Tooth contact.

Linde Material Handling

357-05 Assembling the Differential

Fit and tighten the vernier nut


caps.Tighten the vernier nuts so
there is a resistance to rotation in
the differential cage.
Place a dial indicator on a gear
of the crown wheel and test the
backlash at every 3 -4 teeth around
the gear. At the tightest point the
backlash must not be less than
0.15 mm and the maximum must
not be more that 0.3 mm.
When the backlash is correct test
the torque to rotate the differential
cage again, this should be 2 - 3
Nm.

Linde Material Handling

357-05 Assembling the Differential

This shows the perfect tooth marking


That can be achieved with care.
The mark is central in the tooth in all
planes.
Errors in setting become obvious with
this test and should be corrected as
described on the next slides.

Linde Material Handling

357-05 Assembling the Differential

This shows the correct tooth marking, the mark is in the centre
of the tooth and is oval in shape.

This shows incorrect tooth marking where the crown wheel and
pinion are too far into mesh and must be moved away.

This shows incorrect tooth marking where the crown wheel and
pinion are too far out of mesh and must be moved together.

Linde Material Handling

357-05 Assembling the Differential

When all the settings are correct fit the locking tabs to secure the vernier nuts and
lock them with the bolts.

Linde Material Handling

357-05 Assembling the Differential

In order to assemble the parking brake the input flange must be removed. Fit the parking brake
housing and secure it, also fit the anti vibration O rings in the brake housing holes.

Linde Material Handling

357-05 Assembling the Differential

After fitting the brake housing re-fit the flange and re-torque the bolts to the correct setting, note
the marks made earlier. Upset a small area of the nut lip into the keyway of the pinion shaft to
lock the nut in position.

Linde Material Handling

357-05 Assembling the Differential

The parking brake disc and caliper assembly can be fitted, secure the caliper with bolts,
castellated nuts and split pins.

Linde Material Handling

357-05 Assembling the Differential

Fit the propshaft securing bolts. The differential assembly can now be installed and secured into
the axle casing.

Linde Material Handling

357-05 Assembling the Differential

This cross sectional view of the differential


shows all the major components.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

The brake piston housing must be clean and without burrs and damage prior to assembly.
The holes for brake cooling oil inlet and outlet as well as the brake pressure operating inlet
can be seen.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

The brake piston housing must be clean and without burrs and damage prior to assembly.
The holes for brake cooling oil inlet and outlet as well as the brake pressure operating inlet
can be seen.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly
Fit the seals and anti extrusion rings to
the piston.
It is important that the pressure seals both
face inwards to seal the pressure area
between them.

This shows better how the seals must be fitted.


The pressure area is between the seals.
It is possible that other types of seal may be fitted
not just O rings

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Prepare the components to fit the piston to the piston housing.


Two alignment sleeves and their screws.
Eight pairs of push of springs and their screws.
Four long screws for alignment during assembly.
The large cap screws are for fastening the piston housing to the brake assembly.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Prepare the brake housing for assembly, ensure it is clean and free of burrs or damage.
Place the correct number of pairs of discs into the housing always beginning with the friction disc.
The last disc in will always be a plain steel pressure disc.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Insert the alignment bushes and fix them in place with the screws.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Fit the piston into its housing over the alignment bushes, use two long screws to assist in
the alignment.
Use care when fitting to avoid damaging the seals.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Fit the push off springs and screws.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Ensure the piston is fully pressed home and measure the stand off dimension from the piston to the
housing.
Call this dimension B.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Measure the dimension from the brake housing face to the last brake disc.
Call this dimension A.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly
The dimensions were taken to calculate the brake
air gap dimension.
The dimension measured in the brake piston B is
deducted from the dimension measured in the brake
housing A.
The resulting dimension is the air gap dimension.
A - B = Air gap.
The air gap must be within the acceptable
tolerance for a new brake IE.
On a 7 disc brake it must be 3.0mm =0.5 / -0.1
On a 8 disc brake it must be 3.3mm =0.5 / -0.1

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Apply a small amount of grease to all the O ring groves.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Fit all the O rings in position.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Fit the piston and housing assembly into the brake housing ensuring the bolt holes align.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Insert and tighten the cap screws.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Insert an air supply into the brake piston supply


port with a gauge and valve in circuit.
Pressurise the brake chamber to 120bar and turn
the valve to lock the air in the brake chamber.
Observe the gauge for a period of 15 minutes.
An air loss of 2% to 117.5 bar is the maximum
permitted.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

With the air pressure still applied the


brake check dimension should be
measured.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

Stamp the check dimension measured onto the housing adjacent to the measuring hole.
The check dimension is when the brake is new, as the brake wears this dimension will
increase.
If the dimension on a 7 disc brake has increased by 2.8 mm the brake is nearly worn out.
If the dimension on a 8 disc brake has increased by 3.2 mm the brake is nearly worn out.
This
dimension
is always
measured47.4mm
with thestamped
brake under
pressure.
Example
of a check
dimension.
on brake
housing of an 8 disc brake.
Add 3.2 mm = 50.6mm. If this dimension is measured the brake discs are worn.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly

The brake assembly is now completed and ready for assembly to the drive axle.

Linde Material Handling

357-05 Assembling the Service Brake


Assembly
This cross sectional view of the Brake
assembly shows all the major components.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

The inner hub reduction assembly must be completed first. This unit has three planetary gears with
needle roller bearings secured by planetary pins and roll pins.
Use caution during disassembly and assembly of the planetary pins as they will only enter from one
end of the housing due to a slight difference in diameter.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
This is the planetary bearing as it is
supplied new with an outer and
inner needle support to aid
assembly.
Push the needle race into the gear
from inside the cardboard outer
guide leaving the inner bearing
support in place.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

With the needle bearing inserted in the planetary gear insert the gear into position in the housing.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Push the planetary pin through the housing from the inside, this will push the needle bearing inner race
support through, this can then be pulled out.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Ensure the roll pin holes in the planetary pin and its housing align and tap the pin through the
housing.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

When the planetary pins have all been fitted and the gears rotate freely lock the roll pins with silicon.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Assemble the thrust bushes into the secondary sun gear.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Insert the sun gear into the inner hub reduction assembly and secure it with the circlip.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

The seal wear ring should be heated to 100C to facilitate fitting to the axle tube.
Sealant should be applied to the clean tube prior to assembly.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
The hub assembly can be
assembled with the inner and
outer bearings and the outer
(blue) seal.
The brake spline can be used as
an assembly tool for aligning the
brake discs prior to assembly to
the hub.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

This shows the brake spline inserted into the brake prior to assembly and being used to set the
brake discs centrally within their housing. Lock the discs with air pressure when correct.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

The brake assembly can be lifted into position and bolted in place, use sealant on the mating faces
and keep the discs locked with air pressure throughout assembly.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
The special seal must be fitted to both
the brake assembly and the hub. The
special tool shown is use to fit the seal.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Dip the seal in Isopropanol prior to assembly into the hub and brake.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Using the special tool push the seal


assembly into the brake assembly.
Carefully remove the special tool
without moving the seal.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Inspect the seal to ensure it is correctly seated, inserted the same amount all the way round and
not twisted in any way.
The metal sealing face must be perfectly clean, do not touch the face with bare hands.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Repeat this procedure with the other half of the seal into the hub, inspect after insertion to ensure
it is correctly seated and clean.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

The hub can now be lifted into position. Note that there are two lifting holes in the hub, one is in
balance when the brake spline is fitted, the other is in balance when it is not.
With the brake still locked with air the hub should require only slight rotation to fit into position.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

With the hub fitted and supported in


position fit the bush in the end of
the axle tube. The annulus gear can
now be fitted with the cone of the
hub outer bearing.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
The annulus gear can be fitted to
the annulus and secured with
keep plates and bolts. The hub
inner bearing is fitted to the
annulus.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Insert the annulus assembly.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

When the annulus is fitted one of the three holes must be at the bottom to allow the oil to flow
freely through the axle. The hub nut can be fitted and tightened. Note the holes for the lock
screws.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Use the special tool to tighten the hub nut to 1000 Nm while rotating the hub and hitting it with
a soft headed hammer to settle the bearings. Loosen the nut by half a turn and tighten again to
the correct torque of 500 Nm also turning the wheel. The axle tube thread must be greased with
Molykote prior to tightening.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

When the correct torque is achieved insert the lock screw using loctite 270 and tighten, if
a lock screw hole does not fully appear in any of the slots the hub nut may be loosened or
tightened very slightly.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Insert the half shaft ensuring that it is fully entered into the the differential.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Fit the sun gear over the half shaft and secure it with its circlip.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Insert the inner hub reduction assembly using a small lever to lift it into position.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
A measurement must be taken
from the end face of the hub outer
to the end of the inner reduction
gear.
Make a note of this dimension X.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly
A dimension must be taken from
the outer face of the planetary
housing to the inner half shaft
stop plug area.
This is dimension Y.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

A bronze thrust disc of the


correct size must be fitted into
the centre of the housing using
loctite 270.
To calculate the dimension of the
thrust disc.
X - Y - Clearance 0.6 - 0.9 mm.
Example.
X = 12 mm
Y = 6 mm
Clearance required = 0.6-0.9mm
12 - 6 - 0.6 = 5.4mm
A thrust disc 5.4mm thick must
be fitted.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Fit the outer planetary carrier hub end plate assembly and secure with screws.
Fill the axle with the correct oil to the proper level.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

This cross sectional view of the hub assembly shows all the major components.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

UTILISATION OF LIQUID GLUES


It is important that the appropriate liquid glue, engineering adhesive, sealant or lubricant are
correctly applied throughout assembly and that the correct torque is applied to all nuts and
fasteners.
The following slides provide tables of information on the application of the above.
Refer to the relevant Linde training manual for definitive information.

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

PART TYPE

JOINT TYPE

LOCTITE

Differential housing
and straps, ring
gears , track rods,
spindles, supports

Screws

262

Axle spindles,
grommets, adjusting
screws with nuts,
ring gear retainers,
radial seal rings in
steel casings, ring
gears, Brass thrust
discs.

Contact surface

270

Spacer ring, Wheel


hub cover, radial seal
Contact surface
rings in rubber
casings.

572

ADHESIVE/SEALANT

Differential carrier,
Ring gear support.

Contact surface

Epple 33, grey

Drive flange.

Nut contact face

Epple 33, grey

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Linde Material Handling

357-05 Assembling the Final Reduction Hub


Assembly

Linde Material Handling

357-05 Kessler Drive Axle Assembly

35705

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