CLASS.No.

l2O54O suB l o o 61 z(t/S)

No

MODEL

DRAWNG
No.

UNIVERSAL JOINTS INSTRUCTION MANUAL

3r.\*9'tv)e

4y

hm+&-=rfr,EE*

crlrcs
Ref No.

BJ

UJ No.

41AGU
415G90

89230072A
892 30073A

410&95
415G95 413G97

892300744 892300774
892 30081A

MARK

REVISION

APPROVED

REVIEWED APPROVED

DRA!ryN

DATE

S.Ehata Y.Oshb
T. To kito u/H. H a sh im

NIIGATA POWER SYSIEMS CO. . LTD,

REVIEWED
DRA\^/NI

ENGINEER/AIG & TECHNOLOGY CENTER

KFRM.2O78

oto

DATE

16 / Sep./ 2004

(9802)

GlUS

TE CHMCAL DE S CRIPTIOIY Edition 2002 concernrng the mounting, maintenance and repair of propshafts with flanged joints
1. General hints
Assembly, disassembly, maintenance and repair of propshafts should be performed only by qualified personnel. ln addition, for repair work we recommend our own service to ensure professional workmanship, the use of original spare parts, technical equipment, guarantee etc. The propshafts lve manufacture are supplied ready for installation and operation. All are lubricated, base painted and the surf-ace ofthe fianges are protected against corrosion. The propshafts have been dynamically balanced to ensure perfect smooth running. The balance plates attached to the drive shaft tubes or thejoint drivers must not be removed as they are essential for the vibration-free running ofthe propshaft. For the same reason. the joints must not be exchanged with one another. When a propshafl is being installed care must be taken to ensure that the engraved indicating arrows coincide so that the two joints are located within one plane, as required lbr perfect motion.

Fig.

inner forks ofjoint

arking arrows The propshaft should be set-up according to the installation instmctions issued by the final manulacturer. For safety reasons, propshafis used in hazardous environments should be suitably guarded. High-speed propshafts should be guarded by saf'ety bands to avoid damage in the event ofshaft release or fracture. The relevant national regulations concerning industrial safety and protective efficiency are to be observed. During transport and storage, the propshafts should be handed caref'ull' and be protected against impacts and shocks in order to guarantee the balance quality. Propshafts should preferably be transported and stored horizontally. Ani neglect of these instructions may lead to an impairment of functional reliability.
2. Assembly Before the propshaft is installed, the faces ofthe two flanges (shaft flange and connecting flange) are to be cleaned, i.e. the faces and centring surface must be tiee ofburrs, dirt, paint and grease. The axial and radlal run out tolerances admissible for the connecting flange are to be maintained. otherwise the correct running of the propshaft may be affected (Fig 2 and Table l). r1g.

Radial run out

t'ft

,l fi ".t,l i--i
.'t

PropShaft

tolerance

il

t:'
,

tpm .-l mln Up to

500 500 to 3.000

for d
h8

Radial Run out

KR 0,

axial Run out

KS 0. I 8/t 00 0, I 0/r 00

'ii

li
,l

l5

'*l
axial run out
Table
I

h]
h6

0,08

More
than 3.000 0.05
0,071 100

DRW.No.

20540-00612 (215 |
Pagetof4

Gelenkwellenwerk Stadtllm GmbH Weimarische Strasse 56 D- 99326 Stadlilm Tel +49 3629 640 0 Fax +49 3629 800002 qewes@gewes.dewww.qewes.de

gtus
Both flanges are connected by means ofhexagon bolts according or similar to ISO 4014 ofproperfy class 10.9 and hexagon nuts according to ISO 7042-V ofproperty class 10.
The hexagon bolts cannot be inserled from thejoint end on all types ofpropshafts. Particular attention should be given to tighten the flange connecting bolts in order to achieve the necessary frictional torque transfer. Suitable spanners are to be used, but in every case the torque is to be checked with a torque wrench. The specified tightening torques given in table 2 are to be followed.

Fis.

Thread
:

Tightening
torque

Thead mm

Tightening
torque

mm

Nm
9
15

Nm
300 410 600
800

M5 M6 M8

M16

Mr8
M20

35

Ml0 Mt2 Ml4

Shaft

l0
t2a
200

M22

flange

Table 2

connecting flange

3. Maintenance
Propshafts without grease nipples are greased fbr 1if-e and therefore require no fufiher lubrication. Ilhigh pressurc equipment is used for cleaning, it is important not to direct thejet directly onto the seal. For propshafts fitted with a tape red grease nipple (acc. to DIN 71412) or flat grease nipple (acc. to DIN 3404) it is possible

to lubricate thejoints rvith a grease gun (see Fig. 4),

The grease nipples must be cleaned before a grease gun is applied. The 4 bearings ofeachjoint are lubricated by one central grease nipple. Complete lubrication is achieved when grease can be obsened coming from the bearing seals. For shafts with regreaseable shaft length compensation, l0 - 30 g ofgrease should be sufficient depending on shaft size. Grease guns must be operated smoothly. at pressures not exceeding 2 MPa to prevent any damage to the seals. The maintenance intervals ofthe propshafts in special areas ofapplication (mass produced parts), are to be agreed with the final customer. For general applications, the following directions are recommended: Propshafts employed in: Maintenance interval - road motor vehicles 50,000 km or I year - off'-road motor vehicles 30,000 km or I year - rail vehicles 3,000 hours or t/2 yea - stationary plant 500 operating hours Regreasing is necessary after cleaning with high pressure equipment. It is important not to direct thejet directly onto the seal. Shorter maintenance intervals will be required where the propshafis are operated in extremely adverse conditions. Propshafts taken out ofpro-longed storage (6 months and more) should be lubricated before being installed. Suitable lubricants recommended: Lithium-saponified lubricating greases of penetration class 2 with epoxy additives. No greases containing Mo52 to be used for the joint bearings. When the application temperature limits exceed the normal range of +80 oC to -25 "C. special-purpose greases of the abovementioned specilication should be used.

DRW.No.

20540-00612 ( 315
de
Page: ofa

Gelenkwellenwerk Stadtilm GmbH Weimansche Strasse 56 D- 99326 Stadtilm Tel +49 3629 640 0 Fax *49 3629 800002 gewes@qewes.de ivww.qewes

gtus
,1.

Reconditioning

The propshafts can be reconditioned with the aid of simple auxiliary tools, as the joints can be completely disassembled and the length-compensating attachment can be exchanged. The principal points ofwear are: Joint bearr'ng: Perceptible play in the bearings; damaged sealings or bearing housings; wear marks and indications ofpitting on the bearing surfaces. Profile length-compensating joint: Perceptible play permitting twisting and/or tilting; indications of pitting at profile flanks and at the head periphery; damaged seals. DISASSEMBLY of the propshaft starts with the dismantling of the two half shafts, with the profile length-compensating joint being pulled apart. For disassembly of the joints, the locking rings placed in the drivers are to be removed flrst, with the aid of a special pair of pliers. The bearing bushes can then be dismantled, according to Fig. 5. Ifthe bearing bush cannot be removed by hand after the push out operation, the release from the bore can be affected by light tapping against the yoke driver.

tsro l

Flansch

Auxiliary tool
The other bearing bushes are to be dismantled in similar manner(Fig. 6).

Fig. 6
Flange yoke Cross

Fig.7
Bearing bushes
Sleeve

protective cap

Auxiliary tool
On.loints rvith split bearing eye bores the bearing Gap balls should be slackened to allor.v removal of the cap. After all 4 bearing ca ps have been removed, the spider. including the bearing sleeves. can be separated tram the flange yokes. Note! Bearing Gaps and flange yokes are in pairs and must not therefore be interchanged or mounted in a difTerent position during reassembly . The 4 bearing bushes, and protective Gaps if fitted, are to be removed prior to assembly of the new complete spider to allow spider to be placed in flange yoke. The protective caps are then tapped on to the cap scat provided on the bearing spigot: a hollow mandrel is to be used forthe purpose. Subsequently, the bearing bushes should be pressed into the bores ofthe flange yoke, rvith the inserted spider being guided by hand. 'lhe bearing bush must not be canted while it is being pressed in. it should be seated firmly in the bore of the flange yoke. The locking rings must fit snugly into the ring grooves provided. To avoid any deformation" the flange yoke should be supported during the push-in operation, ifpossible. Any adiustment necessary to take-up any play in thejoints or lack of concentricity should be carried out at the same time (permissible tolerance +/- 0.05 mm). Play and press lit. are compensated fbr by using locking rings ofdifferent thickness.
DRW.No.

20540-00612 (

415

GelenkwellenwerkStadtilmGmbH WeimanscheStrasse56 D-99326StadtilmTel +4936296400Fax*493629800002 gewes@qewesdewww.ggwes.de Pageiof4

GTUS
On propshafts with split bearing eye the spider should be inserted in the flange yokes complete and bolted together with the corresponding bearing caps. The bolts should be tightened to the recommended torque depending on the dimension and stength ofthe bolt. Play is adjusted by using endjoumal bearing disks or distance-rings ofdifferent thickness rvithin the bearing sleeve. Ifthe profile length-compensatingioint is to be replaced, the connecting weld betrveen tube and proflle part has to be separated. The separation should preferably be performed on a lathe, with the welding seam to be recessed completely through (Fig.). In every case, the replacement should involve both hubs and splined shafts, as these parts are manufactured in pairs. During assembly, the splined shaft should be ioined to the tube; a fit of 0, I ... 0,3 mm to be provided to avoid any tack welds. The rotational inaccuracy should not exceed 0,5 mm after the push-in operation. At the same time. care must be taken in the assembling process that the inner yoke drivers lie within one plane and that misalignment does not exceed the admissible angle of 3".

Fig.

Splined section

t/ ,/

lathe tool centenng

For a perfect weld to be ensured there are ceftain technological prerequisites to be met, concerning weld preparation and the

welding operation itself

It is essential. in order to comply with welding classilication DIN 8563 -85 I f l, that we are consulted prior to any welding
being carried out on propshafts, or have the rvelding done in a workshop, qualified and having the certification fbr such rve lding. Once the trvo half sha11s have been completed, they should be assembled in the profile length-compensating joint. resulting in the complete propshaft. Subsequently, the propshaft should be aligned; admissible run out must not exceed 0,5 mm. Any repair of propshafts (replacement of complete spiders and profile length-compensating.joint) rvill usually require subsequent balancing. Inadequatelv balanced propshafts may cause harmiul vibrations and excessive stresses af'f'ecting their proper operation. D-vnamic balancing is therefore essential for propshafts at speeds in excess of 500 rpm. The test speed should exceed the maximum operating speed. Balancing to be in accordance with DIN ISO 1940:
balance quality level G 40 - propshafts used fbr general application balance quality level G 16 - propshafts used for special applications.

CIn the flnal visual inspection, particular attention should be given to the all-round smooth movement ofioints, axial movement of the length-compensating joint. and the perfect seating of the locking rings. lf local workshop f-acilities are unsuitable lbr proper repairs (lacking the balancing equipment, for example, or the authorsation for weldingjobs) users should contact one ofour service workshops or our after-sa1es service department, who r.vill be pleased to assist you.

Gelenkwellenwerk Stadtilm GmbH Weimarische Stra8e 56 D-99326 Stadtilm Germany/ Deutschland Phone: ++49 3629 640 0 Fax: ++49 3629 80 00 02
http //wu,'rv. qerves. de
:

DRW.No.

20540-00612 (

515

-Mail:

sewes@gewes.de
Pageroi+

GelenkwellenwerkSladtilmGmbH WeimarischeStrasse56 D-99326StadtilmTel *4936296400Fax+493629800002 qewes@qewes.dewww.gewes.de