Boosting Safety and Efficiency on Kessler D-Series Axle Maintenance

Introduction

In underground mining, equipment reliability, accuracy, and safety are critical to productivity.
Many mine-site vehicles — such as the Atlas Copco MT6020, Epiroc MT5020, and Sandvik TH663 — use Kessler D-Series planetary drive axles, known for their strength and load capacity.

However, servicing brake-pack assemblies on these axles has long challenged maintenance teams. Tight clearances make it difficult to apply torque safely and accurately, often increasing manual effort, fatigue, and risk of component damage.

Partnering with Byrnecut Australia, Norbar Torque Tools engineered a custom torque reaction arm and torque-multiplier system that removes manual strain and delivers precise, repeatable torque across multiple Kessler-axle vehicle types.

The Challenge

Underground maintenance magnifies every challenge. Crews working on Kessler D111 axles in articulated dump trucks face:
• Minimal clearance and limited reaction points around the brake pack
• High manual torque requirements exceeding 1100 Nm
• Operator fatigue from two-person wrench operation
• Increased risk of incorrect torque or strain-related injury

Byrnecut’s goal was clear — reduce manual handling, improve torque accuracy, and shorten maintenance downtime without compromising safety.

The Solution

Norbar’s engineering team designed a custom-fit reaction arm assembly that interfaces directly with the Kessler D111 axle housing.

When paired with the Norbar SPL833 or SPL838 Torque Multipliers, the system provides the stability, control, and precision required for high-torque brake-pack servicing in underground environments.

Key benefits:
• Dedicated reaction surface that protects axles and brake packs from stress damage
• Single-operator functionality, reducing labour costs
• Accurate, repeatable torque delivery with even load distribution
• Faster turnaround times and improved fleet uptime

Scalable to All Kessler-Axle Mining Vehicles

While originally designed for the Atlas Copco MT6020, the same Kessler D-Series axle design is widely used across underground fleets, including:
• Articulated dump trucks: Atlas Copco MT6020, Epiroc MT5020, Sandvik TH663
• Load-haul-dump (LHD) machines using Kessler D106 and D111 axles
• Utility and service vehicles such as personnel carriers, fuel trucks, and maintenance rigs
• Shield haulers and other heavy transport equipment

Because torque values and bolt geometry are consistent across these axles, Norbar can adapt the same reaction-arm design to fit any Kessler-based vehicle, delivering:
• Standardised torque processes across multiple machines
• Simplified operator training and reduced tooling costs
• Reliable torque verification for compliance and audit reporting

Results

After deployment across Byrnecut’s underground workshops, the Norbar custom torque system delivered measurable performance improvements:
• Up to 60 % faster brake-pack removal and installation
• Zero manual-handling injuries since implementation
• Consistent torque accuracy, verified through digital calibration
• Reduced downtime and higher productivity for maintenance crews

Operators reported the tool as lighter, easier to handle, and more efficient in the confined spaces typical of underground mining.