course-drive-train-works-wears-heavy-equipment-caterpillar.pdf

Drive Train Works & Wears

Drive Train Agenda ! ! ! !

Major components works & wears Anti-friction bearing & gear parts quality Electronics REMAN product offerings

Torque Converter/Divider

Torque Torque Converter

Converter

Torque Divider Torque

Divider

Transmissions

Typical Wheel Loader Transmission With ECPC

Transmission Types ! ! ! ! !

Planetary Countershaft Hybrid Planetary/Countershaft Hydrostatic Direct Drive

Planetary Transmissions

Planetary Transmissions ! ! ! ! ! ! ! ! ! !

Track Type Tractors D3C thru D11R Wheel Skidders Pipelayers Wheel Tractor Scrapers Construction and Mining Trucks & Tractors Articulated Trucks Wheel Tractors Compactors Wheel Loaders /IT 950 thru 994 Telescopic Handlers

Planetary Transmissions

Planetary Transmissions Torque Converter

Planetary Transmission

Transfer Gear Case

Large Truck Drive Train

793C Mechanical Drive Train

Transmission Hydraulic System

Transmission Hydraulic System

Transmission Solenoid Control Valve

Transmission Solenoid Control Valve

Countershaft Transmissions

Hybrid Planetary-Countershaft

! !

Challengers Motor Graders

Hybrid Planetary-Countershaft ! !

! !

!

Proven product Best of two worlds (countershaft & planetary) Gearing matched to engine power curve Independent clutch modulation for smooth, strong, efficient shifts Capable of up to 425 hp

Hydrostatic Transmissions 914G/IT14G Variable Displacement Pump

Cat Axles

Variable Displacement Motors Lubed-for-Life Universal Joints

Hydrostatic Transmissions !

Variable displacement pumps and motors " Track

Type Tractors D3C thru D5C, Optional " Wheel Loaders 902 thru 914G " All Track Type Loaders 933C thru 973

Piston Pumps

Direct Drive Transmissions ! ! !

Track Type Tractors D5E thru D7G Backhoe Loaders 416C thru 436C Challenger Tractors

Differentials Differential Case Assembly

Side Gears

Spider

Pinion Gears

Differentials !

797 Differential

Locking Differentials - 3 Types NoSPIN

Limited Slip

Differential Lock

Track-Type Machine Steering

Steering Clutch

Differential Steer

Steering Clutch

Track-Type Machine Steering Steering Clutch System

Differential Steer System

Differential Steer System !

!

!

Patented Cat design " Same concept as TTT & Challengers " Not “brake steer” Two inputs to steering differential " Transmission " Steering motor Power distribution is equal to both sides Transmission Input

Bevel Gear Steering Motor Input

Three Planetary Sets

Differential Steer System Benefit Summary: ! ! ! ! ! !

Powered turns Highly efficient Robust and durable Cat design Economical (Cost Effective) Superior performance Reduced operator fatigue, increased performance

Wheel Loader Four Piece Axle ! !

IT12B - IT62G Tool Carriers - 13 Models 910E - 970F Wheel Loaders - 18 Models

Wheel Loader Four Piece Axle !

Inboard brakes " Less braking force required to stop the machine " Oil cooled for extended brake life " Improved brake serviceability

Brakes

Disc Brakes

Shoe Brakes

Wet Disc Brakes

Expander Tube Brakes

Final Drives

Final Drives Bull Gear Single Reduction

Bull Gear Double Reduction

Planetary Single Reduction

Planetary Double Reduction

Drive Train Parts ! Gears ! Anti-friction bearings ! Friction materials ! Shafts, carriers ! Seals

Anti-Friction Bearings

Anti-Friction Bearings ! What is a ball bearing?

-A ball bearing has balls which move freely between the inner and outer races. A thin layer of oil separates the components with only a small area of the ball in contact to the race resulting in low friction. ! Applications: High Speed

Outer Race

-Torque converters -Powershift transmissions -Engine components

Contact Points

Balls Inner Race

Cage

Anti-Friction Bearings ! What is a straight roller bearing?

-It is similar to a ball bearing but has rollers instead of balls. The rollers move freely between the inner and outer races. The roller has a straight line of contact. A roller bearing can withstand greater radial loads than a ball bearing of the same size.

Rollers

! Applications:

-Powershift transmissions -Final drives

Inner Race

Outer Race

Cage

Anti-Friction Bearings ! What is a tapered roller bearing?

-It is similar to a straight roller bearing but its rollers are tapered to withstand thrust loads. Usually, tapered roller bearings are used in pairs Contact Lines on either end of a shaft. Outer Race ! Applications: Cage -Final drives Inner Race -Differentials -Transmission transfer case Rollers

Anti-Friction Bearings ! What is a needle bearing? "It is a special type of straight roller bearing. It has

smaller, longer rollers. The smaller diameters of the needle bearings allow them to be used in a smaller radial space for higher speed and moderate radial load conditions. ! Applications:

-Pumps drives -Planet shafts

Caterpillar Anti-Friction Bearings Are Different

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

IRM: DT99-1 PELM0916

Anti-Friction Bearings Technology ! World class bearing suppliers ! Periodic technology meetings ! Caterpillar research/technology commitment " Joint Caterpillar/Supplier development program

Anti-Friction Bearings Design !

Vast historical and experience base ! Constant field evaluation feedback loop " Continuous design updates " Product improvements ! Experience base for future designs

Anti-Friction Bearings Application Cat Standards

vs

Industry Standards

♦ Special material technology

♦ Industry materials

♦ Purpose built to Cat design

♦ Generic industry design

♦ ♦ ♦ ♦

specifications Special heat treatment - Case hardened Optimized roller crown profile Smoother surface finishes on bearing races Precise tolerances

♦ ♦ ♦ ♦

focus Standard heat treatment - through hardened Standard crown profile Standard surface finish on bearing races Standard tolerances

Anti-Friction Bearings Application

! Cat Special Bearings " Roller crown distributes loads

Anti-Friction Bearings Bearing failure is associated with inadequate roller crown.

Anti-Friction Bearings Wear Life ! Bearing enhancements ! Justified by application requirements " Example: truck wheel bearings

2x life improvement from industry standard bearings to Cat optimized bearings

Anti-Friction Bearings Wear Life !

Balanced component wear life " Use of non-genuine parts may compromise balanced component wear resulting in wasted life ! Special surface textures " Proper surface finishes are critical

Anti-Friction Bearings Reliability ! Application driven " Correct bearing for the application

! Bearings position other components " Alignment and tolerances critical

Anti-Friction Bearings Durability ! Case carbonized material " Required by Caterpillar " Extended roller element life

! Proper bearing settings = maximum life

Anti-Friction Bearings Added Value ! Special Cat requirements vs. industry standards ! Trade marking " Cat branded " Represents superior quality

! Cat part number " Ensures correct bearing for the application

! Dealer organization " Availability " Distribution

Drive Train Gears ! Function

-Reduce engine speed and increase torque ! Types -Spurs gears -Bevel gears -Helical gears

Drive Train Gears ! Transmission gears

-Long-term durability in a high-speed operation ! Final drive gears -Withstand extreme shock loads -Withstand continuous high loads over long periods

Drive Train Gears ! Characteristics " Design " Metallurgy " Manufacturing " Application customization

Drive Train Gears Design - Fillet Geometry

! Round root ! Large stress relieving area

Drive Train Gears Design - Tooth Profile

! Crowned ! Distributes stress under deflection ! Protects teeth tips

Drive Train Gears Design - Crown

Competition

Caterpillar

! Crowned ! Distributes stress under deflection ! Protects teeth tips

Drive Train Gears Metallurgy - Heat Treat

Caterpillar

! Deep hardened teeth ! Longer life

Competition

Drive Train Gears Caterpillar Commitment ! Research and development "Continuous improvements in, design, materials, metallurgy,

!

! ! !

manufacturing, heat treatment, & quality control Parts built to be reused "Published reusability guidelines "Lower life-cycle costs Parts continuously updated to provide service life improvements Parts built to Cat specs for Cat machines Superior parts availability

Friction Material Types Paper Bronze Metallic Elastomeric Graphitic

Brakes X X

Transmission

Steering Clutch

X X

797 Brake Pack

Brake Friction Material !

!

Size of vehicle or component determines use " Used on loaders, hauling units & TTT Bronze metallic withstands more heat " Used on D9, D10, & D11

Transmission Friction Material !

!

Elastomeric used on transmission clutch discs " Provides higher energy capabilities in short periods F37 elastomeric material is proprietary " Developed by Chem Products " Available for 20 years " Manufactured in Boonville, MO facility

Steering Clutch Friction Material ! !

Graphitic material used on large TTT & Challengers Graphitic meets demands of longer slipping times than transmission clutches

Drive Train Electronics

Electronic Programmable Transmission Control ! !

!

EPTC II is an off-highway transmission control module Engine communicates with EPTC II through the EPTC II harness, Cat Data Link, and the EPTC II harness connector ports

EPTC II will log four different events " Transmission abuse " Coasting in neutral " Engine overspeed " Machine overspeed

EPTC II !

Benefits " Smoother

shifts " Less transmission wear " Overspeed control in neutral " Faster troubleshooting

Electronic & Hydraulic Control Systems

Electronic Clutch Pressure Controls !

!

ECPC provides smooth, yet firm engagement of the selected gear Provides high clutch flows required for the large volume clutches and individual clutch pressure control that can be tailored for each gear.

Transmission Electronic Control System

Transmission Electronic Control System 950G/960G Example !

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!

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Engine Speed Sensor - measures engine speed in the range of 250 to 3000 rpm Oil Temperature Sensor - measures transmission oil temperatures Input Speed Sensor - measures transmission input speed or torque converter output speed in the range of 25 to 3000 rpm Intermediate Speed Sensor No. 1 - measures transmission intermediate speed in the range of 25 to 3000 rpm Intermediate Speed Sensor No. 2 - identifies the direction of travel in the range of 25 to 3000 rpm

Transmission Electronic Control System !

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!

!

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950G/960G Example Output Speed Sensor No. 1 - measures transmission output speed in the range of 250 to 3000 rpm Output Speed Sensor No. 2 - identifies output direction of travel in the range of 25 to 3000 rpm Transmission Proportional Valves - controls oil flow and pressure to the clutches Air Inlet Heater Relay - turns on the engine air inlet heater Ride Control Solenoid (optional) - opens the ride control solenoid valve

Transmission Electronic Control System !

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!

!

950G/960G Example Back-up Alarm - sounds when transmission is in REVERSE Engine Start Solenoid - controls current to the starter relay (located between the key start switch and the starter relay) Secondary Steer Relay (optional) - turns on the secondary steer motor Dual Horsepower Solenoid (962G only) - increases engine horsepower

Control Throttle Shifting !

Regulates engine rpm during a shift to reduce driveline stress for smoother shifts and extended component life

CTS

Automatic Retarder Control ! ! ! ! !

ARC automatically controls retarding on grade Allows operator to concentrate on steering and shifting Automatically controls braking on off-highway trucks ARC will log one event - engine overspeed Components include: " Wiring harness for input/output devices " Engine speed sensor " Air solenoid valves which turns on or off the air flow used for automatic retarding. The air control solenoid modulates air pressure to the brakes during automatic retarding

Automatic Retarder Control !

Engine Speed (RPM)

ARC Advantages

*

Benefits " Precise electronic retarding " Higher productivity " Reduced risk of overspeed

Automatic Retarder Control (Maintains Engine RPM) Manual Retarder Control (Wide Variation in Engine RPM) *Optimum Engine RPM

Time (Seconds)

Integrated Braking Control !

IBC electronically combines ARC & TCS into one, integrated control system ARC

TCS 1. Service Brake Sensor 2. Engine Sensor 3. ARC 4. ARC Switch 5. Brakes 6. Service Brakes 7. Axle Speed Sensor 8. TCS

Flash Software Controls !

! !

Allows electronic information transfer without removing or adding any hardware Single electronic control may be used on multiple machines Engine, power train, implement & monitoring

Traditional Controls Morton Supplied “Stuffed Box”

Supplier

Basic Control Group

Chip

Control Assembly

Software Group Application Specific

992G With Traditional Controls 1 Engine 2 Implement 4 Power Train 28 Monitoring 35 Total Controls

Flash Software Servicing

Morton Flash Software Ordering Preloaded ECM

Dealer Mailboxes Public Access Area

SIS Diskette

SIS CD or DVD-ROM

SIS WEB

SIS Flash Software Servicing

SIS Flash Software Objective !

!

Provide a user friendly system that will allow dealer technicians to retrieve the most current flash software for Caterpillar vehicles and engines Phase II development delivered through SIS in October 2000

REMAN Transmissions !

Process: " Engineering updates " REMAN valves " Testing • REMAN valves • Transmission test bench " Cleanliness standards • ISO 16 - 13

REMAN Transmissions !

!

Coverage: " TTT - D8L - D11R " WL - 980C - 994D " Wheeled Tractor - 824C - 836 " Scrapers - 621E - 657E " OHT - 768C - 793C " MG - 16G - 24H Pricing: " 25% of new

REMAN Torque Converters !

!

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Process: " Engineering updates " Hydraulic test bench " Cleanliness (ISO 16/13) Coverage: " Includes valves and pumps " Not same configuration as new (no seeding) " TTT - D8L - D11R, WL - 988B - 994D, MG - 24H " OHT - 768C - 793C, Wheeled Tractor - 834B - 836 Pricing: " 25-30% of new

REMAN Steering Clutch & Brake Group !

!

!

Process: " Clutches are cycled on test bench " Cleanliness (ISO 16-13) Coverage: " TTT - D8L - D11R " Includes D9R differential steer Pricing: " 50 - 60% of new

REMAN Final Drive Wheel Groups !

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Process: " Cladded axles " Engineering updates " Wheel assembly Coverage: " OHT - 777 - 793C " TTT - D7H - D11R " WL - 980C - 994D " WD & Compactor - 824C - 836 Pricing: " 30 - 45% of new

REMAN Shovel Drive Groups

5130 & 5230 Pump Drive Groups

5130 & 5230 Swing Drive Groups

5130 & 5230 Final Drive Groups

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!

Process: " Product updates Pricing: " 60% of new

REMAN Brake Bands and Shoes

!

Process: " Epoxy & rivets (bake to remove) " Salvage shoes & bands

REMAN Brake Bands and Shoes !

!

Brake Shoe Coverage: " MG - 12E-14D " WL & WD • 814-816B • 966-980B " Scrapers - 615-657E " OHT - 776, 777 Pricing: " 40% of new

!

!

Brake Band Coverage: " TTT - D3-D9H " TTL - 941H-983 Pricing: " 30% of new

REMAN Clutch Plates !

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Process: " Check for flatness & regrind " Circumferencial (internal) " Radial - check surface finish Coverage: " Scrapers - 621E - 657F " OHT - 772B - 773B " WL - 950 - 992 " TTT - D6D - D9H, 583 - 593 " WD & Skidders - 814 - 836, 518 - 530E Pricing: " 30% of new

REMAN Final Drive Wheel Assemblies !

!

!

Process: " “Re-wrappering” of wheel assembly " Restore bearing bores " Ultrasonic check of welds Coverage: " 785 & 789 only " Plan to introduce other models in 2000 Pricing: " 50% of new

REMAN Final Drive Axle Housing Spindle !

!

!

Process: " Laser cladding of bearing surfaces and splines " Bonal harmonics stress relieving Coverage: " OHT - 769 - 793C " WL - 994 Pricing: " 50% of new

REMAN Final Drive Reaction Hubs !

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!

Process: " Laser cladding Coverage: " WL - 994 " OHT - 776 - 793 Pricing: " 50% of new

REMAN Final Drive Hubs !

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Process: " Submerged arc welding of bearing surfaces and splines Coverage: " TTT - D4H - D11R " WL - 930 - 992G " Scrapers - 621 - 639 Pricing: " 50% of new

REMAN Product Expansions !

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!

Existing Product lines " 797 Components " OHT Fabricated Wheel Assemblies " 994D Components Piece Parts " Transmission Yokes " Final drive carriers Products to be evaluated " Transmission pumps (non-current) " Transmission clutch plates

REMAN Drive Train Summary !

!

REMAN business is changing " Dealers will do more rebuilds " REMAN will do rebuilds of older cores " REMAN will provide more piece parts " Pricing will change to reflect this REMAN offers a number of value priced products

Drive Train Works & Wears

Power Train Integration

E-Series Final Drives ! !

Single reduction bull gear & pinion Robust and durable " Cat leader in gear technology

Planetary Transmissions

Planetaries

Radial & Thrust Loads Radial

Thrust

797 Drive Train Components

Differential

Rear Wheel Station

Differential ! ! !

Pressurized, filtered lube VIMS monitored Fiberglass shroud

Lock-up Torque Converter

!

Converter Drive / Max.Torque " " "

!

Start-up First gear (< 5 MPH) Shifts

Direct Drive / Max. Efficiency " "

First gear (> 5 MPH) All other gears

Linked to Engine/Trans./Brake ECM’s

Planetary Power Shift Shift Transmission !

Transmission / Chassis Control (TCC) " " " "

Body hoist Auto lube Neutral start Rear axle filtration

!

Shift points matched to engine torque

!

Larger discs/plates, addl. discs. in 2 & 3 gears, larger pistons, 4th planetary gear

Controlled Throttle Shift

!

Reduce torque spikes, increase transmission life

!

Possible only through ECM integration

!

Smoother ride, less spillage

Wheel Station ! ! ! !

Laser hardened spindle One-piece cast wheel Next larger bearing Rear axle filtration

Brakes ! ! ! ! !

Forced oil cooling Redundant systems Spring applied, hydraulically released Four corner braking / retarding Integrated Brake Control system (IBC)

Integrated Brake Control !

Automatic Retarder Control (ARC) " Reduce operator effort " Improve productivity " Overspeed protection " Reduce component stress

!

Traction Control System (TCS) " Improve productivity " Increase operator confidence " Utilizes service brakes

Manufacturing / Quality Control ! !

! !

ISO 9001 certified Ultrasonic weld inspection " 100 % of frames Coordinate measuring Contamination control

Drive Train Repair Indicators Indicators

Possible Cause

Options

SOS results

SOS Fluid Analysis provides the best insight into internal transmission wear and potential failure.

Customer/Dealer Discussion

Overhaul Management Guide

OMG indicates estimated life to overhaul and indicates how you can extend that time by changing operation and maintenance factors.

Customer/Dealer Discussion

Hesitation

Worn plates and discs Wrong oil used Linkage out of adjustment Incorrect pressure settings Low fluid level

Technical Analysis Inspection Repair Determination Inspection Customer/Dealer Discussion

Slippage

Worn plates and discs Linkage out of adjustment Low fluid level Incorrect pressure settings Wrong oil used

Technical Analysis Inspection Repair Determination Inspection SOS Fluid Analysis

Unusual noises

Worn gears/bearings Dirt entry Aeration/cavitation Low fluid level

Technical Analysis Inspection Repair Determination Inspection Customer/Dealer Discussion

Vibration

Bent drive shaft Gear failure Bearing failure

Technical Analysis Inspection Repair Determination Inspection SOS Fluid Analysis Customer/Dealer Discussion

Drive Train Repair Indicators Indicators

Possible Cause

Options

Overheating

Wrong oil used Plugged radiator Worn pump Worn pressure relief valve Worn or damaged seals Worn/dirty control valve

Technical Analysis Inspection Repair Determination Inspection SOS Fluid Analysis Customer/Dealer Discussion

Debris in filter/on magnetic screen

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

SOS Fluid Analysis Customer/Dealer Discussion

Leaks

Worn, hard, or cracked seals

Repair Determination Inspection Customer/Dealer Discussion

Bent or damaged lines

External damage

Technical Analysis Inspection Repair Determination Inspection

Transmission service meter hours

Our PSSRs are trained to use service meter hours as a repair indicator.

SOS Fluid Analysis Customer/Dealer Discussion

Operator discussion

Talking with your machine's operator can reveal many potential transmission problems.

Repair Determination Inspection