Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050} Caterpillar


Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050}

Usage:

MT700 018

Information for equipment:


POWER TRAIN
AXLE GP

Tool and Specification Chart for Conventional Duo-Cone Seal Groups {0599, 7561} Tool and Specification Chart for Conventional Duo-Cone Seal Groups {0599, 7561}

Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050} Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050}
Torque Converter, Divider, Drive Line, and Drive Axle Reuse and Salvage Manual Contents {0374, 3000, 3050, 3100, 3250, 3251, 3253, 3258} Torque Converter, Divider, Drive Line, and Drive Axle Reuse and Salvage Manual Contents {0374, 3000, 3050, 3100, 3250, 3251, 3253, 3258}

Proper Oil Changing Procedures {1000, 1308, 1316, 1325, 1348, 3000, 3004, 3005, 3030, 3064, 3067, 3080, 3081, 4000, 4001, 4050, 4051, 5050, 5056, 5068, 5095} Proper Oil Changing Procedures {1000, 1308, 1316, 1325, 1348, 3000, 3004, 3005, 3030, 3064, 3067, 3080, 3081, 4000, 4001, 4050, 4051, 5050, 5056, 5068, 5095}
Obtaining Oil Sample for Analysis {1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542} Obtaining Oil Sample for Analysis {1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542}
Procedure for Filtering Final Drives, Rear Axles, and Differentials on Caterpillar Machines {0680, 0768, 3258, 3260, 4050} Procedure for Filtering Final Drives, Rear Axles, and Differentials on Caterpillar Machines {0680, 0768, 3258, 3260, 4050}


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Introduction

Table 1
Revision  Summary of Changes in SEBF8728 
17  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
Removed Repair Process Engineering old point of contacts.
Added Repair Process Engineering new point of contact.
NENG2500 , "Dealer Service Tools Catalog", canceled replaced by , PERJ1017 , "Dealer Service Tools Catalog". 
16  Reworded Torque Turned fastener section. 
15  Removed irrelevant image. 
14  Added Expanded Mining Products. 

© 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.

Summary

This guideline covers fasteners that are used in transmissions, drivelines, and differentials. Most of the fasteners are common bolts. Since special bolts are used in some assemblies, the requirements for these bolts are also covered. Both the common special types of fasteners are used in any application. Most of the common bolts are reusable. Common bolts will provide equal services as new bolts. Reused bolts will provide equal service requirements as newer bolts. However, single use or common bolts that are indicated in this guide should not be reused. Any additional information on fasteners may also be found in the reference publications.

------ WARNING! ------

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.


References

Table 2
References 
References  Title 
PERJ1017  "Dealer Service Tool Catalog" 
SEBD1868  "Reusability of Phoshate/Oil Coated and Zinc-Plated Fasteners" 
SEBF8301  "Inspection and Reuse of Critical Fasteners Used in All Engines" 
SEBV0545  "Threaded Fasteners Applied Failure Analysis" 

Tooling and Equipment

Table 3
Required Tools 
Part Number  Part Description 
4C-8648  Cleaner 
5P-1720  Seal Pick 
8S-2257  Eye Loupe As 

Cleaning

Bolts should be cleaned prior to inspection, except if bolts are bent, or damaged. Cleaning and inspecting ensures that no damage is hidden by grease or dirt. Use a wash tank or a coarse brush with a mild petroleum-based solvent. Cleaning the adhesive lock bolts will remove the coat of oil from the bolt, so these bolts should not be reused.

Be sure that the solvent does not have any water contamination. Also, never use a chlorinated solvent. Surface pitting can be caused by either water or chlorine. Pits can cause areas of highly concentrated stress. These areas are called stress risers. Stress risers are more likely to result in failure of the bolt.

A good solvent for a wash tank and hot tanks is 4C-8648 Cleaner. This cleaner is a strong alkaline cleaner, which will not damage aluminum parts. The cleaner is available in 19 L (5.0 US gal) and 208 L (55.0 US gal) containers.



Illustration 1g03858781
Nomenclature
(1) Threads
(2) Shank
(3) Fillet
(4) Washer Face
(5) Head

Inspection

Refer to Illustration 1 for the nomenclature of the bolt and areas that need thorough inspection. Illustration 2 indicates areas of highest stress, which should be examined especially closely.

Corrosion is wear that can have two different causes. One is the result of chemical or electrochemical reaction on metal surfaces. Example is surface rust or pitting rust. The other cause is the result of movement between the surfaces of the bolts and mating parts. Movement between the surfaces causes microwelding among each of the surfaces. Microwelding can be caused by loosening bolts or abnormally high forces near the bolts contact points. Microwelding can also happen if the clearance of the bolt and the tapped holes do not line up. These conditions result in pitting, or fretting.

The 8S-2257 Eye Loupe As is useful in close inspection of surface irregularities, which includes lines and pitting.



Illustration 2g03858787
Three areas of highest stress on bolts
(6) First thread root and shank
(7) First thread root above nut or tapped hole
(8) Fillet

Threads

Check the full diameter of bolt threads for damage. Verify the bolt for nicks, cracks, corrosion, or stripped threads. Examine the bolt for any structural overstressing. Excessive stress may also cause rolling of the threads or stripping. Pay particular attention to areas (6) and (7) in Illustration 2. The first full thread at the shank, and the first thread above the nut or tapped hole. Do not reuse bolts with signs of yielding or other thread damage.

Shank

The shank is to be checked for corrosion, deep pitting, cracks, or wear from surface contact. These factors are called stress risers, which decrease the effective strength of the bolt. Check the shank also for plastic deformation and scrap any bolts with this condition. Next, check for bending which may not be obvious. Check the bolt for bending, by rolling the bolt on a smooth table with the head just off the edge, and watching for wobble. Replace any bolts that do not roll smoothly.

Forging lines or small pits, that are on the shank of a bolt, will cause few problems. These lines or small pits can form on the shaft of a bolt. These lines or small pits are the result of forging. Lines must not be opened as a crack. Also, lines must not extend into the face of the washer. Salvage of a bolt is not recommended, when dragged pits catch on 5P-1720 Seal Pick.

Fillet

Properly machined bolts have clearance holes with a chamfer at the top. Avoid any machined bolts with sharp edges. A sharp edge in this area can cut into the fillet of the bolt when the bolt is tightened. When this sharp edge is tightened, the sharp edge will groove a circular nick. This circular nick is a stress riser, which can initiate a crack and lead to separation of the bolt head. As inspected, the fillet can have a shiny scribed circle, but the radius must be smooth and even around the full diameter of the bolt.

Washer Face

The washer must be perpendicular to the center-line of the bolt, so the washer seats on the full diameter of the bolt. Check the face for burrs, nicks, or corrosion. There must also be no visible lines on the face of the shank. These lines can be separations which can be the result of bad techniques in forging. Any damage near the shank is a potential stress riser and indicates that the bolt should be scrapped.

Head

Check for cracking, chipping, or rounding of hex corners. If any of these conditions are seen, do not reuse the bolt. Damage on the top of the head will not prevent the bolt from being reused. If, damage prevents the proper fit of sockets or wrenches, do not reuse the bolt. The bolt can be reused.

Ground Body Bolts

Hardened shanks of the bolts are used with tightly controlled clearance holes. These tightly controlled clearance holes are used for precise locations of parts such as differential ring gears. The surface condition of the shank is especially important with these bolts. In addition to thread and inspections of the head, carefully inspect the shank for fretting or other damages on the surface. The surface texture of the shank should be approximately 1.6 µm (63 µinch). Closely check the face of the washer and the undercut of the shank, for any cracks or other damage. Replace any damaged bolts.

Adhesive Lock Bolts

Since cleaning solvents remove the adhesive, these bolts should not be reused regardless of appearance.

Torque and Turn Required Bolts

The bolts that are torque turned are sometimes used in machine applications because extra clamping force is needed between components. Bolts that are torque turned are efficient when there is a limited space. When, space is limited bolts that are torque turned can sometimes have a reduced diameter of the shank. Increasing forces from controlled stretching of the shank prevent torque turned bolts from being reused.

Patch Lock Bolts

Patch lock bolts are used in applications with severe vibration. These bolts use a nylon insert in the threads which absorbs vibrations. The nylon insert in the thread is also used to maintain bolt torque. Patch lock bolts may be reused. The bolt is not to be reused if the bolt has minimal resistance during tightening. The nylon material will usually wear out after the fourth life of the bolt.

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