Drive Train

Management
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
Maintenance Cost Comparison
Cat 980 Final Drives

Customer A
After Failure Repair

Overhaul: 17,000 hours

Cost of repair: $27,800
Cost/hour $1.64
Days out of production: ???
Maintenance Cost Comparison
Cat 980 Final Drives

Customer A Customer B
After Failure Repair Before Failure Repair

Overhaul: 17,000 hours 15,000 hours

Cost of repair: $27,800 $12,800
Cost/hour $1.64 $0.85
Days 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 Power Train

Transmission Engine + Drive Train
Torque converter
Driveshaft
Differential
Final drive
Brakes
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

1980s Current

Transmission /
Drive Train Oil
(TO-4, TO-4M)
UNIVERSAL OIL
(CD/TO-2)
Engine Oil
(CI-4, CH-4, CG-4,
CF-4/CFSL)
Transmission/Drive Train Oil

Importance of TDTO over non TO-4 Oil

Insufficient lube caused adhesive wear

Be sure to use the correct oil
(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
SOS 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
Oil Analysis Cost Comparison
D7H Transmission

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 Comparison
D7H Transmission

Customer A Customer B
Before Failure Repair After Failure Repair

Overhaul: 7,200 hours 12,175 hours

Cost of repair: $3,400 $13,725
Cost/hour: $0.37 $1.12
Days out of production: ??? ???

4,975 extra hours cost Customer B $2.22/hour!

How do you rate your oil analysis program?

No Provide
Report on oil Trend Forecast
sampling recommendations
condition analysis wear
program on maintenance
only related
problems 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 SOS oil analysis

Focuses on component condition, maintenance, and operating practices
And on oil condition
Cat SOS 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 SOS 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?

1/2teaspoon.Thatsit!
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

its a necessity!
What is Contamination?

Dirt Sealing materials

Metals Grease
Products from oil oxidation Weld spatter
Heat Air
Paint flakes 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

Planned Indicators

SOS Oil Analysis

Technical Analysis
Service Meter Hours
Service History
Experience
Site Operations and Maintenance Advisor (SOMA)
Planned Indicators

SOS Oil Analysis

Technical Analysis
Service Meter Hours
Service History
Experience
Site Operations and Maintenance Advisor (SOMA)
Technical Analysis

Complete, in-depth inspections

1000 and 2000 hour intervals
2 levels
Recommends maintenance & repairs
Controls costs and downtime
Planned Indicators

SOS Oil Analysis

Technical Analysis
Service Meter Hours
Service History
Experience
Site Operations and Maintenance Advisor (SOMA)
Preventive Maintenance Schedules
Service Meter Hours

Low sprocket tractors & power shift track loaders

10-hour or daily
Walk-around inspection 1000-hour or six-month
250-hour or monthly Change oil on both sides
Check final drive oil level Check magnetic plug
500-hour or quarterly 2000-hour or annually
Change fluid filters
SOS fluid samples
Adjust sprocket hub bearing and
valves
Change final drive oil
Preventive Maintenance Schedules
Service Meter Hours

Wheel Loaders & Integrated Tool carriers

10-hour or daily
Walk-around inspection
Check lube levels for leaks
2000-hour or annually
Change differential and final drive oils
250-hour or monthly Clean all differential and final drive drain plugs
Check final drive oil level
500-hour or quarterly
Change fluid filters
Inspect magnetic plug for particles
SOS fluid samples
Preventive Maintenance Schedules
Service Meter Hours

Elevated Sprocket Tractors & Pipe layers

10-hour or daily
Walk-around inspection
250-hour or monthly
Check final drive oil level
Inspect magnetic plug
500-hour or quarterly
SOS fluid samples
Change fluid filters
2000-hour or annually
Change final drive oils

Check your Operation & Maintenance Manual for specific recommendations.

Maintenance Tips

Axle oil cooler

Axle temperature indicators
G-Series wheel loaders
Brake clearance measurement

Use your experience as an indicator!

Planned Indicators

SOS Oil Analysis

Technical Analysis
Service Meter Hours
Service History
Experience
Site Operations and Maintenance Advisor (SOMA)
Site Operations and Maintenance Advisor (SOMA)

Identify operator or maintenance factors that

can improve component life

Determines best time to perform before-failure

overhaul based on:
Machines 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 Indicators
Summary of Repair Indicators
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
Ringgears
Finaldrivegears
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
0%

Level III
% Worn

Level II

Level I

100%
Time
Life Cycle of Drive Train Parts
0%

Level III
% Worn

Level II

Level I

100%
Time
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
Unknown quality
Uncertain specs
Possible contamination

Caterpillar parts are engineered to

work and wear together
Maintenance Made Easy

Daily Inspections
Preventive Maintenance
Oils and filters
Grease
SOS Fluids Analysis
Contamination Control

Simplify with a customized

Customer Support Agreement!
Customer Support Agreement

No unexpected maintenance & repair costs

Optimizes drive train life If 20% or more of
Maximizes availability
your drive train
repairs are after
failure, you can
benefit from a
CSA.

Helps you understand and manage the

owning & operating costs of your equipment.
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 theyre 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!
 Drive Train Parts Quality
CATERPILLAR DRIVE TRAIN
PARTS
Genuinely
Better

Thank you, any questions?