drive train maintenance management
TRANSCRIPT
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Drive Train ManagementEquipment Management Series
Marcial Jr. R. Militante PS Mktg
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Why Drive Train Management? Maintenance has the greatest
impact on customer profitability Lowers owning and operating costs
• by extending component life• by reducing scheduled repair cost
Controls service intervals• reduces unexpected, costly
repairs from failure
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Cat 980 Final Drives
Maintenance Cost Comparison
Customer “A” After Failure Repair
Overhaul: 17,000 hours Cost of repair: $27,800 Cost/hour $1.64 Days out of production: ???
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Cat 980 Final Drives
Maintenance Cost Comparison
Customer “A” Customer “B”After Failure Repair Before Failure Repair
Overhaul: 17,000 hours 15,000 hoursCost of repair: $27,800 $12,800Cost/hour $1.64 $0.85Days out of production: ??? ???
The extra 2,000 hours cost $7.50/hr!
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Drive Train Functions
• The drive train transfers engine power to the ground.
• Two primary components:• Transmission - takes the output from the engine and
manipulates it to control speed, direction, and torque.• Final Drive - reduce speed and increase torque.
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Drive Train Parts Drive train
• Transmission• Torque converter• Driveshaft• Differential• Final drive• Brakes
Power train• Engine + drive train
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Factors with the Largest Influence on O&O Costs
Maintenance Operating Technique and Application Repair Management
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Factors with the Largest Influence on O&O Costs
Maintenance Operating Technique and Application Repair Management
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Maintenance Practices Daily Inspections
• Visual• Operational
Preventive Maintenance• Oil• Filters• Grease
S.O.SSM Fluids Analysis Contamination Control
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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Transmission/Drive Train Oil
Transmission Oil(TO-4, TO-4M)
Engine Oil(CH-4, CG-4, SJ)
UNIVERSAL OIL(CD/TO-2)
1980’s Current
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Transmission/Drive Train Oil
Importance of TDTO over non TO-4 Oil
Be sure to use the correct oil
Insufficient lube caused adhesive wear (scouring) on the gear surfaces
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Transmission/Drive Train Oil
Cat TDTO• Eliminates transmission slippage caused by many
CD/TO-2 commercial engine oils• Increases clutch disc life up to 45%• Controls brake chatter• Provides greater machine rimpull
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Transmission/Drive Train Oil
Cat TDTO (TMS)• Multi-viscosity oil• For use in extreme low and/or high ambient
temperatures• Improved transmission performance in cold
weather for machines with electronic controls• Extended oil drain capability
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Transmission/Drive Train Oil
Cat Multipurpose Tractor Oil (MTO)• Developed specifically for rear axles of backhoe
loaders and for Challenger tractors• Benefits:
Better wet brake control Wear protection Water tolerance
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Drive Train Oil
Cat Final Drive and Axle Oil (FDAO)• Developed specifically for gears and bearings in
bevel gears, differentials, final drives and axles that DO NOT contain friction material..
• Benefits: Protects highly loaded components Designed for components in continuous operation Better protection in high ambient temperatures
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Drive Train Oil Recommendations
Use the oil that best meets your requirements
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Transmission / Drive Train Oils
Questions?
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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Use the Correct Filter
What is your filter purchasing criteria? Caterpillar filters are specifically designed
for the application:• Sediment capacity• Collapse test• Burst strength• Pressure fatigue
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High Efficiency Filters
For use when:• Drive train system is open for maintenance and
repair• S•O•S particle count numbers indicate a need
Use for 250 hours after contamination Return to standard filters
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Combination Compartments• Many machines have combination
compartments:• transmission • differential • final drive• brakes• auxiliary hydraulic oil
• Follow the O&M Manual
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Oil Change Recommendations Tips
• Drain when agitated and warm• Use a filtered transfer cart• Install and remove filters carefully• Keep filter in package until ready for use• Cut open old filter and inspect
• Follow O&M Manual for recommended intervals • Tailor to your conditions and application
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Filters
Questions?
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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Grease Grease drive shaft points according to Operation
& Maintenance Manual• Generally every 250 hours• Adjust to conditions and application
Grease points:• U-Joints• Slip shaft• Mid-ship bearing
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Greasing the U-Joint, Slip Shaft, and Mid-Ship Bearing
Caterpillar recommends lithium-based grease
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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Customer “A” Before Failure Repair
Overhaul: 7,200 hours Cost of repair: $3,400 Cost/hour: $0.37 Days out of production: ???
Oil Analysis Cost ComparisonD7H Transmission
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Customer “A” Customer “B”Before Failure Repair After Failure Repair
Overhaul: 7,200 hours 12,175 hoursCost of repair: $3,400 $13,725Cost/hour: $0.37 $1.12Days out of production: ??? ???
4,975 extra hours cost Customer “B” $2.22/hour!
Oil Analysis Cost ComparisonD7H Transmission
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How do you rate your oil analysis program?
No sampling program
Report on oil condition
only
Trend analysis
Forecast wear
related problems
Provide recommendations on maintenance procedures and
operating practices
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Quality Oil Analysis Program Benefits
Detect early problems Shorten repair time Avoid unscheduled downtime Realize maximum component life Monitor maintenance practices Increase value of used equipment
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All Oil Analysis Programs Are Not the Same!
Other oil analysis programs• Focus on oil condition
Cat S•O•S oil analysis• Focuses on component condition, maintenance,
and operating practices• And on oil condition
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Cat S•O•S Fluids Analysis
Four standard analysis tests• Wear rate • Oil cleanliness • Oil condition• Water, fuel and glycol tests
Expert analysis and interpretation• Trend analysis - forecasts wear problems• Data interpretation and recommendations
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Cat S•O•S Fluids Analysis
Questions?
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Preventive Maintenance Follow schedule in Operation &
Maintenance Manuals• Tailor intervals to your application and conditions
Covered under PM:• Transmission/drive train oils• Filters• Grease• S.O.S Fluids Analysis• Contamination control
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How much contamination exceeds Caterpillar standards for cleanliness?
In a 55-gallon drum of oil, how much “dirt” is allowed before quality standards are exceeded?A teaspoon?A tablespoon?A quarter cup?
1/4 teaspoon. That’s it!
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Contamination Control Customers are demanding:
• More power• Faster cycle times• Easier operation
Caterpillar is responding with:• Higher system pressures• More sophisticated and productive
machines
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Contamination Control Controlling contamination is more critical than ever
• Tighter clearances• Fluid systems are more sensitive to contamination
Contaminated fluid systems:• Reduce efficiency and cycle times• Shorten component and fluid life• Lead to catastrophic failure & costly downtime and repairs
Contamination control is no longer an option – it’s a necessity!
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What is Contamination?
Dirt Metals Products from oil
oxidation Heat Paint flakes
Sealing materials Grease Weld spatter Air Water Rag fibers
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Effects of Contamination on Drive Train Components
Shifting problems from plugged control valves Premature clutch wear from spinning Leaks or premature wear Premature bearing wear/failure Premature gear wear
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Contamination Prevention
Housekeeping Oil storage and transfer Parts handling and storage Component repair and assembly Particle count monitoring
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Contamination Prevention
General housekeeping• Sweep floors daily• Clean up spills immediately• Keep work benches uncluttered and free of debris• Limit use of floor storage
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Oil Storage and Transfer Filter new oil Store oil drums on their sides Use drum covers Use “kidney-loop” system Use high efficiency filters
for extra filtration
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Parts Handling and Storage
Keep components packaged until ready to install
Return parts to storage in packaging
Protect in-process components Wash finished components
before assembly using a 2 micron fuel filter
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Particle Count
Detects oil cleanliness• New machines (field assembly or attachments
added)• Before and after service repairs
Complements other oil analyses
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Contamination Control
Questions?
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Factors with the Largest Influence on O&O Costs
Maintenance Operating Technique and Application Repair Management
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Operating Technique
Operator impact• Discuss practices that can help limit
drive train wear with your operators. Avoid:
• High speed direction changes• Backing over stumps or off lowboy• Frozen undercarriage• Extreme braking
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Operating Technique
Implement:• Adequate warm-up• Periodic and proper shifting• Attention to warning lights• Daily walk-around inspections
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Application
Environment• Ambient temperatures• Water
Layout• Haul roads• Repetitive and high speed load and carry
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Training
Operator and Service Technician Training• Provided on site or at dealership• Reduces operator error• Reduces failures from faulty maintenance
Helps you lower your owning and operating costs
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Operating Technique and Application
Questions?
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Factors with the Largest Influence on O&O Costs
Maintenance Operating Technique and Application Repair Management
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Repair Management
Daily Inspections• Visual • Operational
Repair Indicators• Planned• Problem
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Repair Management
Daily Inspections• Visual • Operational
Repair Indicators• Planned• Problem
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Daily Inspections Visual
• Leaks & loose bolts
Operational• Strange noises• Slippage• Overheating• Brake chattering• Control module diagnostics (VIMS)
Catch small problems before they become major catastrophes!
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Repair Management
Daily Inspections• Visual • Operational
Repair Indicators• Planned• Problem
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Planned Indicators
Follow the recommendations from the Operation & Maintenance Manual
Adjust the procedures to your application and practices
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S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide
Planned Indicators
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S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide
Planned Indicators
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Technical Analysis
Complete, in-depth inspections 1000 and 2000 hour intervals 2 levels Recommends maintenance
& repairs Controls costs and
downtime
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Planned Indicators
S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide
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Preventive Maintenance SchedulesService Meter Hours
Low sprocket tractors & power shift track loaders
10-hour or daily• walk-around inspection
250-hour or monthly • check final drive oil level
500-hour or quarterly• change fluid filters• S•O•S fluid samples
1000-hour or six-month• change oil on both sides• check magnetic plug
2000-hour or annually• adjust sprocket hub bearing
and valves• change final drive oil
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Wheel Loaders & Integrated Toolcarriers
10-hour or daily• walk-around inspection• check lube levels for leaks
250-hour or monthly• check final drive oil level
500-hour or quarterly• change fluid filters• inspect magnetic plug for particles• S•O•S fluid samples
2000-hour or annually• change differential and
final drive oils• clean all differential and
final drive drain plugs
Preventive Maintenance SchedulesService Meter Hours
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Elevated Sprocket Tractors & Pipelayers
10-hour or daily• walk-around inspection
250-hour or monthly• check final drive oil level• inspect magnetic plug
Check your Operation & Maintenance Manual for specific recommendations.
500-hour or quarterly• S•O•S fluid samples• change fluid filters
2000-hour or annually• change final drive oils
Preventive Maintenance SchedulesService Meter Hours
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Maintenance Tips
Axle oil cooler Axle temperature indicators –
G-Series wheel loaders Brake clearance measurement
Use your experience as an indicator!
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Planned Indicators
S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide
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Overhaul Management Guide Identify operator or maintenance
factors that can improve component life
Determines best time to perform before-failure overhaul based on:• machine’s load factor and • operating and maintenance habits.
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Repair Management
Daily Inspections• Visual • Operational
Repair Indicators• Planned• Problem
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Problem Indicators Low power complaints High operating temperatures Leaks, vibrations Excessive oil, fuel consumption Overheating Unusual noise Debris in filters, screens, plugs Slippage or hesitation
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Summary of Repair IndicatorsIndicator Possible CausesSOS Insight to internal transmission
wear & potential failure
Debris in filter or onmagnetic screen
Dirt entryWrong oil usedExtended oil change periodWrong gears or bearingsDisc disintegration
Hesitation / Slippage Worn plates and discsWrong oil usedIncorrect pressure settingsLow fluid level
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Summary of Repair IndicatorsIndicator Possible Causes Overheating Wrong oil used
Plugged radiatorWrong pumpWorn pressure relief valve, damaged sealsWorn / dirty control valve
Unusual noises Dirt entryWrong gears or bearingsAerationLow fluid level
Vibration Bent drive shaftGear failureBearing failure
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Transmission/Final Drive Repair Management
Repair options concept - lower your operating costs by integrating:
• maintenance management practices • before-failure repair options
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Level I Drive Train Parts
Fastest wearing parts – not reusable• Anti-friction bearings• Seals
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Level II Drive Train Parts Slower wearing parts - reusable
• Plates• Discs
• Ring gears• Final drive gears
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Level III Drive Train Parts
Longest life – should never have to be replaced!• Transmission cases, shafts, carriers and gears• Final drive cases, hubs and shafts
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Life Cycle of Drive Train Parts
Level III
Level II
Level I
Time
% W
orn
100%
0%
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Life Cycle of Drive Train Parts
Level III
Level II
Level I
Time
% W
orn
100%
0%
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Selecting Drive Train Repair Options
Final drive reseal Rebearing and reseal Before-failure overhaul
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Repair Options
Your assurance for getting the best value and lowest owning and operating cost• Guaranteed price• Guaranteed turnaround• Field service exchange• Equipment transportation• Reduced costs • Repair warranty
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Using “Correct” Parts
Avoid “will-fits”Avoid “will-fits”• Unknown qualityUnknown quality• Uncertain specsUncertain specs• Possible contaminationPossible contamination
Caterpillar parts are engineered to work and wear together
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Maintenance Made Easy Daily Inspections Preventive Maintenance
• Oils and filters• Grease
S•O•S Fluids Analysis Contamination Control
Simplify with a customized Customer Support Agreement!
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Customer Support Agreement
No unexpected maintenance & repair costs
Optimizes drive train life Maximizes availability
Helps you understand and manage the owning & operating costs of your equipment.
If 20% or more of your drive train repairs are after failure, you can benefit from a
CSA.
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Summary -Factors with the Largest Influence on
O&O Costs
Maintenance Operating Technique and Application Repair Management
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Maintenance
Seven elements of drive train systems management• Preventive maintenance• SOS fluid analysis• Inspections• Repair management• Training• Scheduling• Record keeping
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Preventive Maintenance
Follow Operation & Maintenance Manual• Oils• Filters• Grease• SOS Fluids Analysis
Adjust to your application and practices Control contamination
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SOS Fluids Analysis
Use a program that analyzes:• Maintenance• Operating practices• Component condition• Oil condition
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Inspections
Visual Operational
Catch small problems before they become major catastrophes!
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Repair Management
Repair Indicators• Planned• Problem
Repair Options• Find your best value - lower O&O costs
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Training Helps you lower O&O costs We can offer:
• Meetings and seminars• Individual or group instruction• Materials• Routine maintenance training• Operation/maintenance training• Software instruction• Experienced instructors
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Scheduling
Comprehensive scheduling• Maintenance, inspections, & planned repairs
Prevent drive train failures• From overlooked maintenance• Catch problems when they’re small
Scheduling resources• Record-keeping and control systems manual• MCS software• PMP software
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Record Keeping Document component history
• Component life & cost information
Locate problem areas• Reduce and control costs, and decrease downtime
Increase machine resale value Use record keeping resources
• Record-keeping and control systems manual• Time and cost record booklet• Work order systems manual• MCS software, PMP software
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Operating Technique & Application
Be aware of the operator impact on your machines
Consider the application when performing your preventive maintenance
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Repair Management
Use daily inspections to find repair indicators
Identify repair indicators• Planned - Oil analysis, SMU, OMG, etc...• Problem - leaks, vibrations, noise, etc...
Know your repair options and manage your repairs
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Effective equipment management will have the greatest impact on
your profitability!