drive train maintenance management

Drive Train ManagementEquipment Management Series

Marcial Jr. R. Militante PS Mktg

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

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: ???

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!

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.

Drive Train Parts Drive train

• Transmission• Torque converter• Driveshaft• Differential• Final drive• Brakes

Power train• Engine + drive train

Factors with the Largest Influence on O&O Costs

Maintenance Operating Technique and Application Repair Management

Factors with the Largest Influence on O&O Costs

Maintenance Operating Technique and Application Repair Management

Maintenance Practices Daily Inspections

• Visual• Operational

Preventive Maintenance• Oil• Filters• Grease

S.O.SSM Fluids Analysis Contamination Control

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

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

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

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

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

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

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

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

Drive Train Oil Recommendations

Use the oil that best meets your requirements

Transmission / Drive Train Oils

Questions?

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

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

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

Combination Compartments• Many machines have combination

compartments:• transmission • differential • final drive• brakes• auxiliary hydraulic oil

• Follow the O&M Manual

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

Filters

Questions?

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

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

Greasing the U-Joint, Slip Shaft, and Mid-Ship Bearing

Caterpillar recommends lithium-based grease

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

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

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

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

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

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

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

Cat S•O•S Fluids Analysis

Questions?

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

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!

Contamination Control Customers are demanding:

• More power• Faster cycle times• Easier operation

Caterpillar is responding with:• Higher system pressures• More sophisticated and productive

machines

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!

What is Contamination?

Dirt Metals Products from oil

oxidation Heat Paint flakes

Sealing materials Grease Weld spatter Air Water Rag fibers

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

Contamination Prevention

Housekeeping Oil storage and transfer Parts handling and storage Component repair and assembly Particle count monitoring

Contamination Prevention

General housekeeping• Sweep floors daily• Clean up spills immediately• Keep work benches uncluttered and free of debris• Limit use of floor storage

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

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

Particle Count

Detects oil cleanliness• New machines (field assembly or attachments

added)• Before and after service repairs

Complements other oil analyses

Contamination Control

Questions?

Factors with the Largest Influence on O&O Costs

Maintenance Operating Technique and Application Repair Management

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

Operating Technique

Implement:• Adequate warm-up• Periodic and proper shifting• Attention to warning lights• Daily walk-around inspections

Application

Environment• Ambient temperatures• Water

Layout• Haul roads• Repetitive and high speed load and carry

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

Operating Technique and Application

Questions?

Factors with the Largest Influence on O&O Costs

Maintenance Operating Technique and Application Repair Management

Repair Management

Daily Inspections• Visual • Operational

Repair Indicators• Planned• Problem

Repair Management

Daily Inspections• Visual • Operational

Repair Indicators• Planned• Problem

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!

Repair Management

Daily Inspections• Visual • Operational

Repair Indicators• Planned• Problem

Planned Indicators

Follow the recommendations from the Operation & Maintenance Manual

Adjust the procedures to your application and practices

S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide

Planned Indicators

S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide

Planned Indicators

Technical Analysis

Complete, in-depth inspections 1000 and 2000 hour intervals 2 levels Recommends maintenance

& repairs Controls costs and

downtime

Planned Indicators

S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide

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

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

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

Maintenance Tips

Axle oil cooler Axle temperature indicators –

G-Series wheel loaders Brake clearance measurement

Use your experience as an indicator!

Planned Indicators

S•O•S Oil Analysis Technical Analysis Service Meter Hours Service History Experience Overhaul Management Guide

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.

Repair Management

Daily Inspections• Visual • Operational

Repair Indicators• Planned• Problem

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

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

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

Transmission/Final Drive Repair Management

Repair options concept - lower your operating costs by integrating:

• maintenance management practices • before-failure repair options

Level I Drive Train Parts

Fastest wearing parts – not reusable• Anti-friction bearings• Seals

Level II Drive Train Parts Slower wearing parts - reusable

• Plates• Discs

• Ring gears• Final drive gears

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

Life Cycle of Drive Train Parts

Level III

Level II

Level I

Time

% W

orn

100%

0%

Life Cycle of Drive Train Parts

Level III

Level II

Level I

Time

% W

orn

100%

0%

Selecting Drive Train Repair Options

Final drive reseal Rebearing and reseal Before-failure overhaul

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

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

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!

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.

Summary -Factors with the Largest Influence on

O&O Costs

Maintenance Operating Technique and Application Repair Management

Maintenance

Seven elements of drive train systems management• Preventive maintenance• SOS fluid analysis• Inspections• Repair management• Training• Scheduling• Record keeping

Preventive Maintenance

Follow Operation & Maintenance Manual• Oils• Filters• Grease• SOS Fluids Analysis

Adjust to your application and practices Control contamination

SOS Fluids Analysis

Use a program that analyzes:• Maintenance• Operating practices• Component condition• Oil condition

Inspections

Visual Operational

Catch small problems before they become major catastrophes!

Repair Management

Repair Indicators• Planned• Problem

Repair Options• Find your best value - lower O&O costs

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

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

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

Operating Technique & Application

Be aware of the operator impact on your machines

Consider the application when performing your preventive maintenance

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

Effective equipment management will have the greatest impact on

your profitability!