Shell Lubricants 1

TRENDS HD TRANSMISSION OILS KEY DRIVERS, CONSEQUENCES, FIELD EXPERIENCES

Frank Machatschek Product Application Specialist

2

Key Drivers For Transmission Oil Development

Total Cost of Ownership

Measures to improve TCO also affecting transmission oil

Transmission oil needs to be robust against mechanical and thermal load

over extended oil drain intervals and compatible with new materials

3

Longer drain intervals

Today: 400k-500k km

Mid-term: 750k km, Long-term: 1 Mio km... Fill-for-Life

Increased power density

High demand on cooling and wear protection capability at high load

Higher operating temperatures

Higher power density

Smaller oil volumes

Reduction by 30-50% for lower churning losses

New Developments

4

New Developments

Improved Fuel Economy

0,5 1,5% higher efficiency through less friction losses

Eg Gear box: 75W-9075W-80, Axle: 80W-9075W-85

Improved, durable and constant shifting quality

Special oils for special applications (operation, climate)

Mining, off-raod, hot climate: Volvo 97315 SAE 75W-90 Protection

Long haul: lower viscosities Efficiency

New materials

Plastic material compatibility

Carbon synchronizer

5

Carbon Synchronizer

Many EU OEMs moved to carbon in recent years

Benefits compared to Molybdenum:

Longer service life, higher loads higher temperatures

More shift cycles, improved shift comfort

Less vulnerable against faulty shifting

Carbon can be used to replace Mo synchro at

repair/maintenance refer to manuel instructions

New oil spec to prevent synchro failure due to oil

carbon: ZF TE-ML 01

Shell Spirax S6 GXME 75W-80 approved against ZF

TE-ML 01L

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New Developments Require Advanced Lubricant Solutions

Base oil

Improved thermal stability and oxidation/deposit control

More high quality synthetic base oils Gr III or Gr IV

OEMs: global availability and supply security

Additives

Higher shear stabililty advanced VI-Improver

Advanced EP/AW to compensate for lower viscosity

Anti-Foam: higher durability

Finished formulation

Improved compatibility ela/synchro

OEM tailored formulations

DRAIN INTERVAL

VOLUME EFFICIENCY

& DURABILITY

OIL

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OEM AXLE TRANSMISSION

ArvinMeritor O76 (SAE J2360, MIL-PRF-2105E)

O81

DANA/Eaton SHAES 254 SHAES 256 Rev C

PS-164 Rev 7

ZF TE-ML 05, 12 TE-ML 02

Volvo 97310 97312

97305 97307

Iveco SAE J 2360 (MIL-PRF-2105E) TE-ML 02 DAF (GL-5) TE-ML 02 MAN Typ 342/3343 Typ 341/3343 Scania STO 1:0

STO 2:0A STO 1:0

STO 2:0G Mercedes-Benz 235.0, 235.6

235.8, 235.9 , 235.20 235.1, 235.11 235.4, 235.5

Various OEM Requirements Cannot Be Met By One Product

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Additive Chemistry (EP/AW)

FUEL ECONOMY

GL-5

GL-4

75W-90 75W-80

THER

MA

L ST

ABI

LITY

SAE viscosity grade

STO 2:0G API GL-5

SAE 75W-90

STO 2:0G API GL-5

SAE 75W-80

STO MTF API GL-4

SAE 75W-80

commercially available under development

Various OEM Requirements: Scania Transmission Oil

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SPIRAX MB 90 SPIRAX S3 AD Transmission MB SPIRAX S5 ADE

85W-90 80W-90 75W-90 75W-85

FUEL ECONOMY

Various OEM Requirements: Mercedes-Benz Axle Oil

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5x Eaton gear box RTSO 1234..

Test duration: 500k km

Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80

Fe

[ppm]

Cu

[ppm]

Oil Milage [km]

11

Some more examples: DAF, MAN, Volvo

Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80

Shell Lubricants 12

?

?

Axle Oil Drain Intervals In EU Approach Fill-For-Life

???

Shell Lubricants 13

6 x MAN hypoid axle HY-1350

Test duration: 6 years

No oil drain!! No top up!!

Oil Drain Interval Axle: Spirax S6 AXME 75W-90

Shell Lubricants 14

2 axles inspected after 680k km

2 axles inspected after after 1,0 Mio km

4 axles inspected after 1,2 Mio km

Oil Drain Interval Axle: Spirax S6 AXME 75W-90

All oil parameters excellent

Normal wear pattern

No oil sludge

No oil leakages

No failures

Unique test facility at Shell R&D lab Germany

Each lubricant combination Engine-Gearbox-Axle can be tested

Each single FE contribution (engine-gearbox-axle oil) can be measured

Diff Ratio

1:1 / 1:4 / 1:8 /1:16

Power Brake

Generator

Pmax:470kw

Mmax:50.000Nm

Fuel Economy: Shell Driveline Test Rig Evaluation

Gear Box

Shell Lubricants 16

Driveline test with Mercedes-Benz G210-16 gearbox and HL-7 axle

FE improvement 1,5 - 1,7%

Oil temperatures are reduced for longer equipment endurance

Fuel Economy: Shell Driveline Test Rig Evaluation

Reference Shell FE Fluids Axle MTF Axle MTF

SAE 90 80W 75W-90 75W-80

API GL-5 GL-4 GL-5 GL-4

KV40

KV100

VI

184

16,9

97

87

9,9

92

115

15,2

140

56

9,1

143

Decrease in fuel

consumption per

hour

at 65 km/h

at 75 km/h

at 85 km/h average 1,5 ... 1,7%

Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz

Question:

What was the maximum oil drain interval in the MAN field

trial with Shell Spirax S6 AXME in the rear axle ?

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0 2 4 6 8 10

Wet Clutch Friction Stability

Oxidation Stability

Scuffing Protection

Pitting Protection Wear Protection

Synchroniser Performance

Low Temperature Properties

ATF MTF

Performance Requirements MTF vs ATF

Shell Lubricants 19

Technology Leader In Automatic Transmission Oils

Long history of cooperation with OEMs

Range of fully-synthetic ATFs

First Fill business eg ZF, Voith

Longest ODIs

Spirax S6 ATF ZM: 180.000 km

Spirax S6 ATF VM Plus: 180.000 km

Multiple long drain

Spirax S4 HDX: Voith, ZF, Allison

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Shell ATF Products Are Approved For Longest Oil Drains

Allison Spirax S6 ATF 295 300.000

mls

Voith Spirax S6 ATF VM

Plus

180.000 km

ZF Spirax S6 ATF ZM 180.000

km

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Capable for long drain intervals

Today: increase from 30.000 km up to 180.000 km over last 3 decades

Mid-term: Fill-for-life (500.000 km)

Cope with increased mechanical and thermal load

Provide constant friction behaviour over entire oil drain period

Extremely high shear stability

Provide corrosion protection

New Developments

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oil s

ump

tem

pera

ture

[C

]

time

80

90

100

110

120

Euro I

Euro II

Euro II &

articulated

bus

Euro III &

IV

Increasing Oil Sump And Peak Temperatures Drove Development

Euro VI

Oil sump peak: 120C

Torque converter: 140-180C

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Spirax S6 ATF ZM mineral ATF

change of viscosity @ 100C

+ 0,8 mm 2 /s + 16,1 mm 2 /s

sludge No Yes

Oxidation Test @ 170C and 384 h

Superior oxidation stability enables both longest

ODI and high durability of ATs

Oxidation Stability Mineral vs Synthetic ATF

Shell Lubricants 24

Spirax S6 ATF ZM

ZF First Fill Oil

Approved for highest specifications:

TE-ML 14E for Ecomat up to 150.000 km ODI

TE-ML 20 F for Ecolife up to 180.000 km ODI MAN 339 Z13

TE-ML 04D (marine) and 16N (rail)

Benefits compared to other ATFs:

Joint development with ZF

Designed to meet requirements of ZF transmissions

Esp high temperature and long ODI

Excellent low temperature performance

Better viscosity control through high shear stability

Ecolife

Ecomat

Shell Lubricants 25

Donax TZ

Spirax S6 ATF ZM: Excellent Viscosity Control

4,0

6,0

8,0

10,0

12,0

0 50.000 100.000 150.000 200.000 250.000 300.000 350.000

kin. viscosity [mm2/s]

Oil Milage [km]

Shell Lubricants 26

Spirax S6 ATF VM Plus

Voith First Fill Oil

Approved for highest spec: Voith H.55.6336 Section 3

Underwent severe field trials in coop with Voith with continuous oil

analysis and hardware inspections, up to 340.000 km ODI

Only Voith approved oil for max ODI of 180.000 km w/o restrictions

H.55.6336 Section 2: 180.000 km with restictions (eg GVW)

H.55.6336 Section 1: 120.000 km w/o restrictions

Benefits compared to other ATFs:

Joint development with Voith

Designed to meet requirements of Voith transmissions

Excellent low temperature performance

Improved oxidation stability

Better viscosity control through high shear stability

Shell Lubricants 27

Spirax S6 ATF 295

Approved for highest spec: TES 295

HD trucks and buses as well as MD and LD vehicles

Significantly extended ODI compared to TES 389

up to 300.000 ml (480.000 km) or 6.000 hrs

Benefits compared to TES 389 fluids:

Synthetic: better than previous spec (eg Allison C-4)

Improved low temperature performance

Improved oxidation stability

Better viscosity control through high shear stability

Meets GM Dexron-III for steering/hydraulics

Meets specs based on Allison TES 389/295 eg Cat

AT-1 Synthetic ATF

Shell Lubricants 28

TRANSMISSION OILS FOR MINING APPLICATIONS

Carlos Torres Indirect Lubricant Technical Coach

Shell Lubricants 29

Applications

Hydraulic Systems

Power Train

Wet Breaks

Shell Lubricants 30

Mining Sector Trends

Extended Service Intervals

High Loads

Low Environmental

Impact Fine Filtration

Energy Efficiency

Extended Component

Life

Shell Lubricants 31

Off Road Haul Truck Mechanical

Brake & Hoist System

Torque Converter & Transmission

Differential & Final Drives

Steering System

Shell Lubricants 32

Off Road Haul Truck Electric Drive

Traction Motor

Planetary Gears

Omala S4 Wheel

Shell Lubricants 33

Shovels

Omala S3 GP Omala S4 GX

Omala S4 Wheel

Omala S3 GP Omala S4 GX

Omala S4 Wheel

Omala S3 GP Omala S4 GX

Omala S4 Wheel

Shell Lubricants 34

Fuel Economy Transmission Fluids Trends

Load Capacity

Oxidation Resistance

Shear Stability

Viscosity

Friction Coefficient

Heat Dissipation Viscosity Index

Shell Lubricants 35

Shell Spirax Portfolio for Mining FZG Low Speed Wear Test

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1 2 3 CHALLENGE SOLUTION OUTCOME

VALUE 4

Albian Sands Energy in Fort McMurray Canada operates 75 haul trucks Caterpillar 797F.

In 2008, Albian introduced a new fleet of haul trucks and started to experience failures in less than 5000 hrs of operation whereas the expected life was of 20.000 hrs.

Shell, through Shell LubeExpert, made a detailed analysis of the application and proposed the use of a high-performance lubricant for final drives (Shell Spirax S5 CFD M 50).

Together with the change of lubricant, a systematic monitoring of the final drives, a process of contamination control and training of all staff involved was implemented. All these actions delivered a life extension of the lubricant and increased the life of the final drives.

Savings of over USD 160,000.00/year with productivity increasing and life extension of the lubricant Life extension of the lubricant from 2000 hours to 4000 hours Increased the life of the final drives from 5,000 hours to 20,000 hours (expressive values not accounted in this case) Increased the life and reliability of the final drives

The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.

Success Case 01 Albian Sands Energy Shell Spirax S5 CFD M Final Drives of CAT 797F