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GMK 5180
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Kessler Power
Train

General description .................................................................................................................. 1

1. Transfer case ................................................................................................................. 1
1.1 Differentials................................................................................................................ 1
1.1.1 Standard differential............................................................................................. 1
1.1.2 Additional drive differential ................................................................................. 1
1.1.3 Inter-axle differential ............................................................................................ 2
2. Power train layout ........................................................................................................ 2
3. Principle of transfer case power flow.......................................................................... 3
4. Detail of range selection mechanism ........................................................................... 4
5. Standard Differential.................................................................................................... 5
6. Additional Drive Differential ....................................................................................... 6
7. Inter-axle Differential................................................................................................... 7
RC April 99

GMK 5180. Training Information. Kessler Power Train. April 99

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General description
Search The power output from the transmission is connected to a transfer case, which gives
proportional power distribution to the axle differentials to ensure equal power train loading
Prev. (fig.2). The differentials, depending on type, may transmit full, partial or no power until
selected.
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1. Transfer case
Fit Page Output drive from the Allison transmission is connected via a drive shaft to a VG 2500
transfer case. The transfer case consists of drop gears, which give two selectable drive ratios
Fit Width and a neutral position (fig.2).
Selection is via an integral air cylinder, with one fixed and one floating piston; both are
attached to the selector shaft. This arrangement gives three positions via sequential air
delivery from three external air solenoid valves, which are energised by cab mounted push
button control switches to give the desired ratio or neutral position. The selector shaft is held
in the selected position by a detent ball & spring, allowing only momentary actuation of the
control solenoids while the control buttons are pressed (fig.3).
Highway & low range are both indicated by warning lights in the drivers cab. Neutral
position does not have any warning light. An integral longitudinal inter-axle power divider
with a power split of 1:2 gives the necessary proportional power division to the drive axles,
33% being to the front and 66% to the rear. An internal longitudinal inter-axle differential
lock can be engaged in case of traction being lost.
Operation of the differential lock is via an integrated air cylinder, which is actuated by an
external solenoid valve, when selected with the drivers cab switch. The longitudinal/inter-
axle locking is now common to the transfer case; the fourth axle longitudinal/inter-axle
differential lock and the second axle additional drive selection.
Switches are installed to indicate longitudinal/inter-axle differential lock status via a common
warning light in the drivers cab. See electrical group =41/5.2.
Lubrication to the transfer case is by an internal oil pump. As the oil pump only operates in
the forward direction, the crane should not be driven any avoidable distance in reverse gear.
1.1 Differentials
Three versions of differential are installed on a GMK 5180.
1.1.1 Standard differential
This is fitted to the first and fifth axle lines and incorporates a transverse/cross differential
lock (fig.4). This is operated by an integrated air cylinder, which engages a sliding dog
coupling to inhibit the differential function when selected via the drivers cab switch. A
switch is installed within the differential to indicate engagement. See electrical group =41/5
& 6.
1.1.2 Additional drive differential
This is fitted to the second axle line and in normal highway operation the drive passes through
the differential to the first axle (fig.5). When the longitudinal/inter-axle locks are engaged by
switch operation from the drivers cab, an integrated air cylinder engages a sliding dog
coupling to connect the second axle to the drive train. The differential also incorporates a
transverse/cross differential lock. Switches are installed in the differential to indicate
engagement of additional drive or cross locks. See electrical group =41/5 & 6.

GMK 5180. Training Information. Kessler Power Train. April 99. Page 1
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1.1.3 Inter-axle differential
Search This is fitted to the fourth axle line and incorporates a power divider/differential on the input
section, which splits the incoming drive power and routes 50% to drive itself, and transmits
Prev. the remaining 50% through an output shaft to drive the fifth axle.

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The power divider/differential contains a longitudinal/inter-axle lock. A transverse/cross lock
is fitted to the transverse differential. Both are selected by integrated air cylinders, which
Fit Page
engage sliding dog couplings to inhibit the differential functions. Switches are installed in the
differential to indicate engagement of inter-axle or cross locks. See =41/5 6.
Fit Width NOTE: All longitudinal/inter-axle differential locks, additional drive and transverse/cross
differential locks have separate cab control switches respectively. The function of
longitudinal/inter-axle locks, additional drive and all the transverse/cross locks being common
to their respective control switches.
The use of all differential locks, additional drive is also conditional on the transfer case being
in low range with the suspension key switch engaged.

2. Power train layout

Input from VG 2500

transmission Transfer case

33% 33% 66% 33%

Standard Additional drive Inter-axle Standard

differential differential differential differential
first axle line second axle line fourth axle line fifth axle line

Figure 1. Overview of powertrain layout. 10 x 8 x 10

The view above shows power distribution in highway travel. The second axle line is not
connected to the drive power. To engage the second axle drive, low range must be selected in
the transfer case. For standard drive 10 x 6 x 10, the standard differential would be removed
from the first axle line and the additional drive differential in the second axle line would be
mechanically engaged.
NOTE: Axle & transfer case differential locks should only be used when traction is lost.
While in use, the vehicle should be steered in a straight line with minimum power. Use of
differential locks above standard axle weights, on non-skid ground or turning may cause
component failures.

GMK 5180. Training Information. Kessler Power Train. April 99. Page 2
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3. Principle of transfer case power flow
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The vehicle must be stationary.
When changing gear range, should the gear range
Fit Width
selector dog-teeth not make immediate alignment,
move the transmission gear range selector briefly to
reverse gear at low engine revs.

Do not select forward drive as this can damage the

gear selector dog-teeth in the transfer case.

Highway gear Low gear

range range

Gear
range
selector

Inter-axle
differential/power
divider

Figure 2. Transfer case power distribution

GMK 5180. Training Information. Kessler Power Train. April 99. Page 3
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4. Detail of range selection mechanism
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Solenoid function 41-Y1 41-Y2 41-Y3
Highway range O X X
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Low range X O O S7 low S70 highway
Neutral X O X range range
Fit Width
X = Air pressure
O = No air pressure

Solenoids
Y3 Y2 Y1

1. Shift cylinder
2. Fixed piston
3. Floating piston
4. Detent pin

Figure 3. typical cross-section of range selector & solenoid pneumatic input configuration

See Kessler VG 2500 service manual for specific details

GMK 5180. Training Information. Kessler Power Train. April 99. Page 4
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5. Standard Differential
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Applicable to first & fifth axle line 10 x 8 x 10

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Differential cross lock warning light switch

Figure 4. Cross-section of standard differential

GMK 5180. Training Information. Kessler Power Train. April 99. Page 5
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6. Additional Drive Differential
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Applicable to second axle line 10 x 8 x 10

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Additional drive warning light switch

Differential cross lock warning light switch

Figure 5. Cross-section of additional drive differential

GMK 5180. Training Information. Kessler Power Train. April 99. Page 6
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7. Inter-axle Differential
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Applicable to fourth axle line

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Inter-axle lock warning light switch

Differential cross lock warning light switch

Figure 6. Cross-section of inter-axle differential

GMK 5180. Training Information. Kessler Power Train. April 99. Page 7