Universal Joints and Drive Shafts {3108, 3251, 3253} Caterpillar

Articulated Truck

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Integrated Toolcarrier

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Landfill Compactor

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Off-Highway Truck/Tractor

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Soil Compactor

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Wheel Dozer

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Wheel Loader

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Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Illustration 1	g02139237

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The “WARNING” Safety Alert Symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

The purpose of this guideline is to help in the reusability of universal joints and drive shafts. Usually, the question of reusability will not be an issue. If the joint or the shaft has any number of abnormal problems, the joint or the shaft should be replaced. However, if the cause of that problem is not corrected, the replacement part will also have a shortened life. Use the information to help in determining the reusability of the part. Also, use the information to help correct the problem before installing new parts.

The beginning of the guideline describes the inspection of universal joints and drive shafts. The section follows this section on the assembly of the U-joints and drive shafts.

The suggestions on reusing universal joints and drive shafts in this guideline should be followed. Before installing a new part, correct any conditions that may have caused the original failure or wear.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Inspection for Reusability

Note: Do not disassemble U-joints solely for making decisions on reusing the joints.

Note: Do not remove bearing caps solely to look for washers.

During the disassembly and the assembly procedure, contamination or damage often occurs without the knowledge of the technician to the damage. This damage can substantially reduce the remaining service life of the U-joint. Reduction of the remaining service life will lead to a failure after inspection. The potential for the problems is so high that a criterion for the inspection during disassembly has not been offered.

Note: When reassembling be sure that bearing cap seal is in correct position when cap is reassembled.

Inspection

If one U-joint on a drive shaft requires replacement and the U-joint on the other end of the shaft has the same time of service, replace both U-joints.

Cleaning

Note: Do not submerge the drive shaft in water or cleaner. The water and the cleaner can destroy the seals and internal components of the drive shaft if the drive shaft is submerged. Water and cleaner may only be used to clean the surface.

Remove the drive shaft from the machine. Remove the U-joint from the drive shaft before cleaning and inspection. Use caution for removing the U-joints. The bearing caps on the U-joint may fall. Do not reuse bearing caps that have been dropped. Clean the surface with a solvent that has a petroleum base. Remove excess solvent with a clean, dry paper towel to remove any deposits or oil.

Leaks

Spider Assemblies Without Grease Fittings

Do not use the part again if there is evidence of grease that is leaking past the seals.

Note: After the first 500 hours there may be some grease on the outside of the seals that was left from the original assembly of the spider and bearing. Some assemblies are overfilled with grease.

Spider Assemblies With Grease Fittings

Normal lubrication procedures for spider assemblies with grease fittings force old grease out of the bearings past the seals. The forcing of old grease past the seals purges the old grease and contamination out of the bearing.

Note: Fill with new grease until new grease is visible past all 4 bearings and seals.

Free Play

Do not use the part again if there is excessive free play in the U-joint. If necessary, compare the free play with a new U-joint.

Roughness

The part should not be reused if the universal joint is not smooth. If necessary, compare the smoothness of movement with a new U-joint.

Bolt Torque

Be sure that all bolts are tightened correctly to the specified torque. The bolts should be tightened in an alternating X pattern at assembly.

Cracks

Visually inspect the bearing caps, the cross shaft, and yokes for cracks. Do not reuse any parts that are cracked.

Remove the drive shaft from the machine and the U-joints from the drive shaft before cleaning and inspection. During removal, the bearing caps on the U-joint may fall. Do not reuse bearing caps that have been dropped due to contamination.

Liquid Fluorescent Inspection

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Tooling for this method consists of a 4C-4804 Penetrant and a 4C-4805 Developer. A 1U-5566 Ultraviolet Lamp Gp will also be used. The surface must be clean and dry to use this method. Follow the steps below to use the liquid fluorescent inspection to check for cracks.

1. Refer to"Cleaning"to clean the drive shaft assembly properly. Cleaning must be done prior to inspection.

2. Spray the 4C-4804 Penetrant on the surface under inspection. Allow the penetrant to remain on the surface for 5 to 30 minutes. This will allow the penetrant to penetrate the smallest cracks.

3. Once the 4C-4804 Penetrant is allowed to settle into the cracks, the excess penetrant must be removed from the surface. Use a clean moist paper towel to remove the penetrant. Take care not to wash the surface excessively. If too much Penetrant has been removed, repeat from Step 1.

4. Tap the surface with a clean, dry paper towel without lint to remove excess water.

5. Check the surface with a 1U-5566 Ultraviolet Lamp Gp. This will highlight the location of any cracks or damage.

6. Spray and coat the developer onto the entire dry surface. Use compressed air to reduce drying time. Once the developer has been applied and the developer has dried, a minimum time for developing of 10 minutes is required. During this time, the developer will draw the penetrant from the cracks to the surface. Cracks should become visible during the 10 minute time for developing.

Small cracks are permitted in the welded areas. The small cracks are shallow cracks in the weld that do not affect the integrity of the drive shaft. If any other cracks that will affect the integrity of the drive shaft are found, do not reuse the part.

Assembly of the U-joints and Drive Shafts

Phasing

Correct phasing of the spiders on each end of the shaft is important. Phasing prevents driveline vibration, failure of the torque converter, and failure of the transfer gear housings. Phasing also prevents other similar damage. Refer to Illustration 3.

Illustration 3	g03734172
Correct phasing of components in a drive shaft (1) Missing tooth splines (2) Timing marks for alignment

On most off-highway trucks with rigid frames, many Caterpillar Inc. drive shafts can be assembled only when all the parts are correctly aligned. Commonly, the tubes of drive shafts have a missing spline tooth and a pin in the yoke assemblies to ensure correct alignment. Check that drive shaft assemblies that do not have splines with missing teeth are correctly phased during assembly. Correct phasing is completed by aligning the timing marks (arrows) on the tubes and yoke assemblies. Check drive shafts that are repaired by independent rebuilders to ensure that the drive shafts have been correctly phased.

Balancing

Note: This section defines acceptable limitations for balancing drive shaft assemblies on the following Caterpillar off-highway trucks, articulated trucks, wheel loaders, compactors, and tractors.

Table 3 through Table 11 defines acceptable limitations for balancing the listed Caterpillar models.

1. Drive shafts with slip joints and drive shafts with welded yokes must meet acceptable symmetry conditions. 2.29 mm (0.0902 inch) symmetry is considered within criteria of acceptance.

2. Balancing should be completed at the speed rpm that is defined in Table 3 through Table 11.

3. The imbalance that is permissible must be in accordance with the criteria that is defined in Table 3 through Table 11, or the imbalance that is permissible must be in accordance with the criteria that is specified on the print.

4. The planes of correction must be as close to the end of the drive shaft assembly as practical.

5. Weights that are welded to the tubing must not be positioned closer than 25.4 mm (1.00 inch) from the center of the radial weld. Positioning is shown in Illustration 3.

6. Weights must not be stacked on each other.

7. Weights must be aligned with the axis of the drive shaft and electrode to prevent metal expulsion. Heating that is not uniform may alter the adhesion and mechanical characteristics of the weld.

8. Distortion, runout, or unbalance can be caused by excessive heat. The excessive heat is generated from repeated welding of the same balance weight. Therefore excessive heat shall be avoided.

9. Drive shafts with slip joints should be balanced with a fully collapsed spline connection unless the print states otherwise.

10. Eight is the maximum number of balance weights that should be applied to correct imbalance.

11. Drive shafts, that do not need the application of balance weights, must be identified with a B. The letter B should be stamped on the flange diameter of the drive shaft. Illustration 3 shows the location for stamping the letter.

Illustration 4	g01404379
(A) The balance weight must be placed no closer than 25.4 mm (1.00 inch) from the center of the radial weld on both ends of the drive shaft. Area (A) is 25.4 mm (1.00 inch) in length. (B) Stamp the letter B in the indicated location if no balance weights are necessary.

Temperature recorder install

Illustration 5	g06261813
Location of 8T-2823 Recorder (1)

Illustration 6	g06261814
8T-2823 Recorder (1)

1. Install temperature recorder (1) onto both front spider and bearing group (A) and rear spider and bearing group (A). Replace spider and bearing group (A) if the temperature recorder (1) gets to 127° C (260.6° F).

2. Inspect for grease loss from spider and bearing group (A).

   Note: Some grease purge from spider and bearing group (A) during the first 500 hours of service.

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   Illustration 7	g06261811

3. Inspect for discoloration of the paint on spider and bearing group (A) as shown in Illustration 7.

4. Inspect Slip Joint for any broken or missing balance weights.

Illustration 8	g03734174
Articulated Trucks with two rear drive shafts.

Illustration 9	g03734178
Articulated Trucks with three rear drive shafts.

Note: Usually, drive shafts with non-slip joints and welded couplings do not require balancing if the length is 180 mm (7.0 inch). Refer to the print for balancing requirements.

Lubrication

Use 2P-9066 Lubricant for U-joints. Use 266-8566 Grease for the drive shaft splines. The intervals should depend on the application and the severity of the environment. Only on drive shafts and U-joints with grease fittings, use the correct amount and the correct type of uncontaminated lubricant during assembly to prevent the following problems:

• Repeated joint bearing failures

• Failures during low hours

• Failures in the support bearings

• Slip spline galling

• Seizure

Note: Only use NGLI Class 2 rated grease.

Note: DO NOT use grease containing Molybdenum in u joints.