DT; Equip Mgmt; CCR (1)

Preventive Maintenance

Power Train

Marcial Jr. R. MilitantePS Marketing

Internal Sales Specialist

Whayne Supply January, 2009

Preventive Maintenance

Good Preventive Maintenance program closely follows manual recommendations

Advantages Prevents small problems from

becoming major failures Allows scheduling downtime

and planning for costs Helps maximize equipment life Increases resale value Keeps equipment on the job

longer Improves profits Saves money


Same Look. Same Build. Same Performance?

All Filters Look Alike


Filter Cleanliness


Acrylic Beads

Prevents BunchingMaximizes Media Surface

Area Utilization


Spiral Roving

Reduces Pleat Flex and FatigueMaximizes Media Surface UtilizationIncreases Contamination Retention


Molded End Caps

One-piece DesignMedia Molded into Urethane

Eliminates Possible Leak Paths


Non Metallic Center Tube

Stronger than MetalMaximum Cleanliness


• Provides Structural Strength• Eliminates Potential Leak Paths• Aluminum Top Plate - No Metallic Contamination

One-Piece Canister & Top Plate


Lube Filter Efficiency Options

• Standard 30 to 40 Microns

• Advanced 10 to 30 Microns

• Ultra High 6 to 10 Microns


• HE secondary fuel filter– Captures the most harmful

particles those 5 – 10 micron in size

– Series or parallel filtration• Fuel Filter Efficiency Options

Standard (10 microns and up) Advanced (4 to 10 microns) Ultra High ( 4 microns *)

Install ONE FULL TURN* Currently < 4 Micron unmeasurable

Increasing Injector Life


0% WornLevel III

100% Worn

Level II

Level I

Time

Life Cycles of Power Train Parts


Life Cycles of Power Train Parts

0% WornLevel III

100% Worn

Level II

Level I

Time


Level I & II Parts - Engine

Level II - Slower wear, reusable– Pistons– Liners– Valves– Camshafts

Level I - Fastest wear, not reusable– Piston rings– Main, rod bearings– Valve guides– Turbo bearings– Turbo seals


Level I & II Parts - Drive Train Level II - Slower wear,

reusable – Plates– Discs– Ring gears– Final drive gears

Level 1 - Fastest wear, not reusable – Anti-Friction bearings– Seals


Level III Parts - Engine

Longest life– Blocks/Housings– Covers/Oil Pan– Manifolds– Crankshafts


Level III Parts - Drive Train Life of Machine

– Transmission cases, shafts, carriers, and gears

– Final drive cases, hubs, and shafts


2 Types of Repair Indicators

– Planned

– Problem


Problem Indicators

Smoke Low power Unusual Noise Vibration Overheating Oil Consumption Leaks Slippage Debris in Filter Brake chatter


Drive Train Problem Indicator Examples

Transmission - debris in filter–Possible causes

•Dirt entry•Wrong oil used•Extended oil change period•Worn gears or bearings•Disc disintegration

–Options•Check S•O•S for wear trends•TA Inspection

Differential - unusual noises (when traveling straight)

–Possible causes•Worn gears or bearings•Ring & pinion require adjustment•Dirt entry•Low fluid level

–Options•Check SOS for wear trends•TA inspection

PEPJ 0042


Planned Indicators

S·O·S fluid analysis Machine service meter hours Service history Experience Fuel Consumption VIMS/ET Inspections Site Operation and Maintenance

Advisor


Are Caterpillar parts different from the rest?


Engine Parts


Integral Seals

Volume vacuum (Plastic support) Joined edges (Metal support)

Advantages• Virtually eliminates leaks from gaskets.

• Improves bolt torque retention, compared to flat gaskets

• Easy assembly, compared to flat gaskets


– Forged steel– Lack of aluminum flap– No separation occurs– Lack of bushings– New oil inlet– Larger piston chamber– New ring gasket

Features

3408/3412/3500/ All the ACERT One-piece steel piston


2 Types of Repair Indicators

– Planned

– Problem


Water openings oversized, without screw thread, omitted

Competitors Appropriate machining

Caterpillar

Cylinder Heads


Blocked conduitsCompetitors

Rigorous cleaning processCaterpillar

Cylinder Heads


Cylinder JacketsCompetitors They have not been friction polished. The flange thickness does not comply with specifications The ring seal grooves are not beveled Greater risk of cracking

Caterpillar Friction polished Control of flange thickness The ring seal grooves are beveled Heat treatment


Cylinder Jackets

Competitors Random crisscross

pattern

Caterpillar Uniform crisscross pattern


Brakes – Friction Material


Significant product improvement – 2 x Glazing Resistance– 2 x -4 x Longer Life

Performance data supports advantages

Brake Repair Kits Retrofit capabilities Exclusive use in Reman wheel

stations Lower owning & operating costs Value priced

Relative Life of Brake Friction MaterialsResults May Vary Depending on Application & Severity

0

1

2

3

4

5

Failure Mode

Rel

ativ

e Li

fe

Current Mat'l

New Mat'l

Glazing* Wear*

*The Glazing and Wear Lives of Current Material are not Equal

2x - 4x Longer Life

Cat Extended Life Friction Material


Cat Extended Life Brake Disc - Usage– Current Coverage

• OHTs– 769, 771, 773, 775, 777, 785

789, 793, 797– OHT Brake Repair kits

» 769 thru 797 OHTs • Large Wheel Loaders

– 980, 988, 990, 992 • Wheel Dozers

– 824, 834, 844, 854




ApplicationWheel Station

Overhaul

Wheel Station

Overhaul

Wheel Station

Overhaul

Fewer Friction Discs

Consumed*

Labor Hrs

Savings *

Friction Material Cost Comparison Cat Extended Life Standard Cat Disk

Friction Disk Replacement Only

Light

Friction Disk Replacement Only

Severe

33% None

40%

57%

64-102

128-204

Normal

T I M E

* Percentages reflect fewer friction discs consumed over three wheel station overhaul cycles using the Cat Extended Life Discs over Standard Discs. Labor hour savings based on brake replacements performed outside of normal wheel station overhaul cycle and may vary based on machine type (Models 777-789).


789B Off-Highway Truck (Washington, USA)– Full Maintenance Contract (good records)– Application

• Haul coal from mine• 50% downhill haul• High rolling resistance• Runs of 1 to 1.5 miles at grades of 8-10%

– Previous brake history in application• 3,600 – 9,700 SMU (mostly in 8-9,000 range)

Installed Extended Life Brake Discs– Conducted operator training

Test results– Front discs removed at 18,000+ SMU (Averaged 6% wear)– Rear discs removed at 20,000+ SMU (Averaged 14% wear)

Cat Extended Life Brake Discs Field Test


Friction MaterialsCat friction materials meet all braking codesAssures performance and safetyMaximize component life by utilizing reusability guidelines

Total System Design = Built to Cat specs for Cat machines


Gears


CaterpillarRounded rootLarge area for tension relief

Competitors Flat root Small area for tension relief Concentrations of tension

Gear design – Angle geometry


Gear design – Convex profile

No crown Tension at the ends Contributes to

accelerated wear

• Has a crown• Distributes pressure under

tension • Protects tips of the teeth

Caterpillar Competitors


Gear Metallurgy - Heat Treat

The right process means longer life

Induction (Through) Hardened

Case Carburizing Hardened

Nitride Hardened


Through Hardening- Heat Treat

High bending strength

No need for high pitting resistance

Increased core strength

Heat Treat Furnace


Nitriding Improved wear

characteristics

High hardness

Very low heat treat distortion.

Nitiriding Furnace


Standard Case Carburizing

High bending strength

Pitting and scoring resistance

Gears being carburized


Gear Metallurgy - Heat Treat

Not all Carburizing Processes are Equal!

Caterpillar Standard Carburized Structure

Caterpillar Carbide Process Structure

Competitor StandardCarburized Structure

Soft Constituents

500X Mag.

500X Mag..

500X Mag.


Material and Heat Treatment… Gear life: The most important factor is spalling resistance(the gear tooth profile is very important and will be dealt with further on)

3 characteristics affect spalling resistance: ŒHardness of the surface – Rc 59+ Hardness of the sub-surface – Rc 35+ core ŽDeficiencies in the microstructure


Example of material and heat treatment… Cemented gear Cat Original Competition

Hardness of the surface Rc 64 – 59 Rc 63 – 58

Dureza a 1,8 mm Rc 48 – 45 Rc 47 – 35

Dureza a 2,8 mm Rc 39 – 34 Rc 38 – 28

Dureza del núcleo Rc 44 – 35 Rc 31 – 19

Bainita B0 – B1 B7

Ferrita F1 – F2 F4




Hardness at 1.8 mm Rc 48 – 45 Rc 47 – 35

Dureza a 2,8 mm Rc 39 – 34 Rc 38 – 28









Hardness of the core Rc 44 – 35 Rc 31 – 19




Gear dimensions

Tolerance of imitation partsEND PRODUCT OUTSIDE THE ORIGINAL SPECIFICATIONS

Tolerance of Cat original parts

(exaggerated scale)

Nominal of imitation parts

Nominal of Cat original parts (Ideal)


Gear Tooth Profile

• Operating noise• Excessive pressure• Premature wear of bearing

• Fractured parts• Pricking / Spalling• Damage to coupling parts

EXCESSIVE SIZE?

INSUFFICIENT SIZE?

WITHIN SPECIFICATIONS

GEAR B

GEAR A

OEM GEAR PROFILE

OVERSIZED PROFILE (NOT TO SCALE)

EXCESSIVE TENSION PRICKING / SPALLING


Manufacturing - Gears

Industry Standard–Hobbing–Shaving–Heat Treat

Caterpillar Process–Near Net Forging–CBN grinding–Heat Treat

Industry Std.

Hobb ShaveHeat Treat

Near Net Forge

CBN Grind

Heat Treat

Caterpillar Process

Quality controlled throughout


Anti-Friction Bearings Application driven

– Correct bearing for the application Bearings position other components

– Alignment and tolerances are critical

Improper bearing tolerances will misalign critical

components and cause gear & seal failures!


Anti-Friction Bearings: Application

LoadsOperating speedsTemperature rangeSizePast field performance

–Continuous design updates–Product improvements–Experience base for future designs

Desired design lifeSpecial needs

Total System Design


Caterpillar Competition • Crown distributes loads• Case carburized – hard shell• Tough bearing core• Excellent wear

characteristics

• Propagate cracks• Cause “brittle

fractures”• Roller element

breakage

Anti-Friction Bearings

Discussion


Anti-Friction Bearings Cage Design

Stamped Industry Standard Snap In

BrassRigidNon Metallic

…application driven designs!


Anti-Friction Bearings Balanced Component Wear Life Caterpillar uses special surface textures to modify

performance properties Use of non-genuine parts may compromise balanced wear

resulting in wasted life or potential part failure


Textured Anti-Friction Bearings Developed as way to achieve better balance among componentsUsed in slow-speed, high-load applications (gear boxes, differentials & final drives)2X life improvement for bearings from better maintaining the proper oil film thicknessProprietary technology, Caterpillar exclusive applications


Debris Resistant Anti-Friction Bearings

Industry Std. 13.6

22.2

122

0 20 40 60 80 100 120 140

Debris Res.

Caterpillar Std.

L10 Life (hours)

Lab Test Results (contaminated oil with debris)


Anti-Friction Bearings

“Timken provides anti-friction bearings to Caterpillar for use in the manufacture of Caterpillar equipment and as replacement parts for that equipment. These unique and proprietary design characteristics are intended to give the Caterpillar customer optimum value and service. Caterpillar requires that these bearings be branded and provided to Caterpillar for exclusive distribution through Caterpillar dealers. Caterpillar's unique branded bearings are not available through alternate distribution channels.”


How Bearings Work


Caterpillar Bearing – 5H1901

“X” cage design

Special hardness

Optimized roller crown

Special surface finish

Industry Standard

Pin cage design

Roller groups

For slow speed applications only

Industry Standard

Larger O.D.

Pin lock retention not required

Increased loads on components

Anti-Friction BearingsSame Industry Number – M1210


Features Summary

Caterpillar Standards Special material technologyBuilt to Caterpillar specificationsSpecial case-hardened heat treatment Optimized roller crown profileSmoother surface finishes on bearing racesPrecise tolerances

Industry StandardsIndustry materialsGeneric industry design focusStandard through-hardened heat treatment Standard crown profileStandard surface finish on bearing racesStandard tolerances

vs.


Anti-Friction Bearing Kits

Transmission, final drive and differential bearing kitsCaterpillar part number

–Ensures correct bearing for the application–Availability–Distribution

Savings over individual parts purchase


Caterpillar Parts for the

Performance You Require!


Cat

erpi

llar

Prod

uct S

uppo

rt

Day 1 Purchase

HIGH MODERATE LOW

1) Utilization of equipment

2) Durability in the application

3) Use of the production

EQUIPMENTPRODUCTION

EQUIPMENT SUPPORT (RESERVE)

Original equipment part option

Reman and replacement parts option

CATERPILLAR EQUIPMENT LIFE CYCLE

CCR / CPT


Cat Remanufacturing Services

Is the component rebuilt or remanufactured?


Not the same as Reman….

Typical Rebuild

• Usually retains the component identity• More than a simple repair.• Usually done by dealer, customer or re-

builder.• Restores to near original condition.• May not use genuine Cat parts.• Re-builder assumes the warranty liability.• Requires investments in tools, equip.,

training, etc.• Rebuild and return or exchange – turnaround

time involved.


This is Reman……

Remanufacture

• Consistent factory environment• Process and quality control• Upgrades to latest engineering changes• Harvest components (loses its original identity)• Uses 100% genuine Cat parts• Cat Reman carries standard parts warranty• Requires cores – exchange only


Cat Reman – Same-as-New Performance & Reliability

Reman includes critical engineering updates to provide like-new performance.Examples include:

–Updating cores to latest engineering specs - ex. – machining cores–Replacing older materials with newer materials – ex. Updated bearings or friction material–Updating software


Support Upgrades through Core Policies

Customer Benefits–Better Performance–Longer Life–Improve Fuel Efficiency–Lower Customer Owning & Operating Costs

Upgrades often available to make it more economical to upgrade to a later design.

Examples:Fabricated to Cast WheelsMUI to EUI EngineNREE Engines793C to 793D brakeCat AST Hydraulic Suspension & Hoist Rods


Cat Reman Low cost repair optionOff-the-shelf availabilitySame-as-new quality & warrantyFraction of the price of newAvailable through your local Caterpillar dealersPartners with Cat Logistics and Cat Dealers for world- class distribution channels


CCR Terminology

CCR = Cat Certified Rebuild- Full Machine Rebuild

CPT = Cat Certified Power Train Rebuild

CPT “Plus” = Cat Certified Power Train Rebuild plus any additional parts, systems or components


What is a Caterpillar Certified Rebuild?

Endorsed by CAT

Only Genuine

CAT parts

Extended Power Train Coverage Available

7,000 New, Remanufactured, Reconditioned

parts

Critical Updates Incorporated

Rebuilt to like NEW

Performs like NEW

Like NEW Appearanc

e

New PIN

Emissions Compliant Engines Available on select

Models.


CCR & CPT Cycle

2 Useful

Lives!!!!End 2nd Useful

life

1/2 Life:

Rebuild Power Train

End 1st Useful life: CAT Certified

Rebuild

1/2 Life:

Rebuild Power Train

Buy New


20 - 25,000 Hours


Like New


high MODERATE low

CATERPILLAR EQUIPMENT LIFE CYCLE

Cat Used option

Cat Classic option

Cat

erpi

llar

Day 1 PurchasePr

oduc

t Sup

port 1) Utilization of

equipment2) Durability in the

application3) Use of the production

EQUIPMENTPRODUCTION

EQUIPMENT SUPPORT(RESERVE)

Original equipment part option

Reman and replacement parts option

CCR / CPT


Cat ® Classic ™ Parts

“ Cat Classic Parts provide owners of older Caterpillar products with low cost repair alternatives that minimize the risk associated with non-genuine parts.”


What are Cat Classic ™ Parts?

Lower priced, newly manufactured parts for older Caterpillar ® equipment.

Approved by Caterpillar engineers, distributed by Caterpillar Dealers in Cat boxes, and backed by the standard Caterpillar warranty.

An additional price point to complement Cat original production and Cat Reman parts.

Same form, fit, and function as original production Caterpillar parts.

Manufactured to industry-standard specifications rather than Caterpillar’s proprietary standards for tolerances, materials, and heat treatments.

As a result, the life expectancy and price of Classic Parts are lower than original parts, but aligned with the needs of customers owning older Cat equipment.


Benefits To You…

• Value-priced, economical repair option

• Offered by the original equipment manufacturer – covered by the standard Caterpillar warranty

• More options now available – Classic repair parts complement Cat original & Reman

• Available from Caterpillar® parts center and/or from local dealer inventory

• Quality controlled by Caterpillar


• Support specific, higher-population aged machine & engine models

• Focus on higher-cost components which tend to drive up overall repair costs…

PC engine, drive train, hydraulics and undercarriage parts

Classic Product Coverage

Track-Type TractorsTrack LoadersWheel LoadersMotor GradersHydraulic ExcavatorsScrapersPipelayers

Level II & III PartsCrankshaftsCylinder HeadsCarriersShaftsGears and more…


Classic Machine Model Coverage…

D3B/C, D4C/D/E, D5/BD6C/D/H, D7E/F/G

D8H/K, D9G/H

941, 951/B/C, 955H/K/L977H/K/L, 983B

920, 930, 950/B/E966B/C/D/E, 980B/C

120/B/G, 12E/F/G, 14D/E/G112/E/F, 130G, 140/B/G

215, 215B, 225, 225B235, 235B, 245, 245B, 320

561C/D, 571F/G572F/G, 583H/K, 594/H

D330/333/3423304/3306PC3304/3306DI D353B/C/D/E,

D379A/B, D398A/B, D399, G353, G379,

G398, G399

613, 613B, 621, 621B627/B, 631B/C/D


Released over 2500 part numbers!

Undercarriage Link assemblies, track shoes & hardware Pin & bushing groups Rollers, idlers, sprocket segment groups Guards & recoil mechanism parts

Drive Train Bevel gear / pinions Steering clutch parts & kits Final drive gears / shafts Sprocket hubs / shafts

Transmissions & Torque Converters

Gears & shafts Housings, pistons, carriers Impellers, TC Kits

Motor Grader Components Tandem Drive Axle / Steering Center Shift

Scraper Hitch Pins & Brgs

3300 PC/DI Engine Cylinder Heads Valve Kits Pre-combustion Chambers Crankshafts Fuel Transfer Pumps Fuel Lines Connecting Rods Manifolds Mufflers And many more…

HEX Components Final drive parts Pump drive parts Swing gears

TTL/WL/HEX Linkage Pins

TTT Equalizer Bars

Hydraulic Gear Pumps


Experience the Savings…

D6D -- 1978 Model YearTotal Hours: 44,800 hoursMarket Value: $24,000 - Fair Undercarriage (40%) - Operational ConditionCurrent Annual Use: 300 hours

Problem: Failed Transmission!

$ 8000 USD in Cat Original Parts vs. $ 3800 in Classic ™ Parts


Where’s the Difference?

• Material• Proprietary versus industry standard steels

• Heat Treatment• Market-leading heat treat technology versus standard, lower-cost treatment practices


Power Train

Component Management– Lowest cost per hour or cost per ton

Life Cycle Management– Based on needs of application

Performance Matched Parts – For your application

Differentiated for Longer Life


Power Train

DT; Equip Mgmt; CCR (1)

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