Ok Chapter-3 549322 Axle Manual Service En

8/12/2019 Ok Chapter-3 549322 Axle Manual Service En

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Service-Manual

PausPMKT 10.000-20 (82.3673.3)

Edition 12/2010


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ServiceRevised 01.09.2007

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

Assembly of drive assembly S e c t i o n


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4.0.1


Ad ears S e c t i o n

justment of gear meshing of Gleason g

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 drivepinion 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.


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4.0. nut S e c

t i o n


Securing of the striking2

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 suppli es

1. Striking nut at drive flange

In thread: assembly paste with MoS 2 (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 MoS 2.

Removing of t he striking nut

Bend away the nose and screw the nut off.


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4.4


Drive assembly D 108 S e c t i o n


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4.4.1


Ad inion distance S e c t i o n

justment of drive p

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 theadjustment 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 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 (set point dimension).

**) B = Measured width of the taper roller bearing (B theor. = 33,5 mm).

***) C = Distance measured from the contact surface of the adjustment disc to the contact surface of

the pinion housing (C theor. = 13,5 mm).

Calculation example to ascertain the thickness S from the adjustment disc :

A = + 0,10; B = 33,40 ; C = 13,45

S = 3,00 mm (theor.)

+ 0,10 mm B = 0,10 mm smaller than B theor.

= 3,10 mm

+ 0,05 mm C = 0,05 mm smaller than C theor.

= 3,15 mm

- 0,10 mm drive pinion value A

= 3,05 mm necessary thickness of the adjustment discFit 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. 33,55) the adjustment disc has to be 0,05 mm thinner than theor. S.

If value B is negative (e.g. 33,45) the adjustment disc has to be 0,05 mm thicker than theor. S.

**) Hint: if value C is positive (e.g. 13,55) the adjustment disc has to be 0,05 mm thinner than theor. S.

If value C is negative (e.g. 13,45) the adjustment disc has to be 0,05 mm thicker than theor. S.


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S e c t i o n


Assembly of the drive pinion bearing 4.4.2

1. Heat the cylindrical roller bearing inner ring to

about 100C and install it on the stud of the drive

pinion. (Drive on completely after it cools). Press

the cylindrical roller bearing outer ring into the

differential carrier.

2. Insert the two outer rings of the taper roller

bearings into the pinion housing.

3. Calculate the thickness C of the spacer bushing.

a. Place the two inner rings of the taper roller

bearings in their outer rings. Measure A or C.

b. Measure the dimension B of the taper roller

bearing.

c. Thickness of spacer bushing C= A B.

4. Heat the drive pinion side taper roller bearing to

about 100C and install it on the drive pinion

shaft. (Drive on completely after it cools):

5. Install the spacer bushing on the pinion shaft.6. Install the pinion housing onto the drive pinion.

Heat the taper roller bearing inner ring at

undersize to about 100C and install it with a

tube onto the drive pinion shaft.

7. Install the drive flange onto the drive pinion

shaft. Tighten the safety nut by turning the

pinion housing according sheet 3.5. For

tightening, place the drive pinion in a vice using

soft jaws or clamp the drive flange with the fork

support in the vice.


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4.4.3

Kessler & Co. GmbH & Co.KGall rights reserved

Assembl S e c t i o n

y of the drive pinion bearing

8. Measure the roll resistance of the bearings by using a torque wrench. If the measured value is

not prescribed 1,0 to 1,5 Nm, adjust the resistance by modification of the thickness of the spacer

bushing. After arriving at the adjustment of the bearing, back - off the safety nut and draw off thedrive flange.

9. Install the radial seal ring with Loctite 572 applied into the pinion housing. Place the O-ring into

the slot of the pinion housing and install the pinion housing on the differential carrier. Fill the

radial seal ring with bearing grease. Fit the carrier of the parking brake (if present) on the pinion

housing resp. 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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4.1.3

Kessler & Co. GmbH & Co.KG Al rights reserved

Assembl of the Differential S e c t i o n

y

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 100C

and install them by using a sleeve.


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4.2.3


Assembl ort bolt S e c t i o n

y of the ring gear supp

1. Glue the cap with Loctite 270 onto the support bolt.

2. Coat the support bolt with Epple 33.

3. Screw the support bolt with cap by hand to contact to the ring gear, without exerting pressure.

4. Screw the counter nut onto the support bolt.

5. Turn back the support bolt max. 15.

6. Tighten the counter nut, during this operation the support bolt must not move.

In tightened condition the clearance between the ring gear surface and the contact surface of the

support bolt amounts about 0,1 mm.

At ten ti on :

The support bolt has to be sealed again when adjusting timely.


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Documents

Ok Chapter-3 549322 Axle Manual Service En