dt; equip mgmt; ccr (1)
TRANSCRIPT
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Preventive Maintenance
Power Train
Marcial Jr. R. MilitantePS Marketing
Internal Sales Specialist
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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
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Whayne Supply January, 2009
Same Look. Same Build. Same Performance?
All Filters Look Alike
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Whayne Supply January, 2009
Filter Cleanliness
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Whayne Supply January, 2009
Acrylic Beads
Prevents BunchingMaximizes Media Surface
Area Utilization
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Whayne Supply January, 2009
Spiral Roving
Reduces Pleat Flex and FatigueMaximizes Media Surface UtilizationIncreases Contamination Retention
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Whayne Supply January, 2009
Molded End Caps
One-piece DesignMedia Molded into Urethane
Eliminates Possible Leak Paths
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Whayne Supply January, 2009
Non Metallic Center Tube
Stronger than MetalMaximum Cleanliness
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Whayne Supply January, 2009
• Provides Structural Strength• Eliminates Potential Leak Paths• Aluminum Top Plate - No Metallic Contamination
One-Piece Canister & Top Plate
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Whayne Supply January, 2009
Lube Filter Efficiency Options
• Standard 30 to 40 Microns
• Advanced 10 to 30 Microns
• Ultra High 6 to 10 Microns
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Whayne Supply January, 2009
• 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
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Whayne Supply January, 2009
0% WornLevel III
100% Worn
Level II
Level I
Time
Life Cycles of Power Train Parts
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Whayne Supply January, 2009
Life Cycles of Power Train Parts
0% WornLevel III
100% Worn
Level II
Level I
Time
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Level III Parts - Engine
Longest life– Blocks/Housings– Covers/Oil Pan– Manifolds– Crankshafts
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Whayne Supply January, 2009
Level III Parts - Drive Train Life of Machine
– Transmission cases, shafts, carriers, and gears
– Final drive cases, hubs, and shafts
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Whayne Supply January, 2009
2 Types of Repair Indicators
– Planned
– Problem
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Whayne Supply January, 2009
Problem Indicators
Smoke Low power Unusual Noise Vibration Overheating Oil Consumption Leaks Slippage Debris in Filter Brake chatter
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Planned Indicators
S·O·S fluid analysis Machine service meter hours Service history Experience Fuel Consumption VIMS/ET Inspections Site Operation and Maintenance
Advisor
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Whayne Supply January, 2009
Are Caterpillar parts different from the rest?
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Whayne Supply January, 2009
Engine Parts
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
– 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
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Whayne Supply January, 2009
2 Types of Repair Indicators
– Planned
– Problem
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Whayne Supply January, 2009
Water openings oversized, without screw thread, omitted
Competitors Appropriate machining
Caterpillar
Cylinder Heads
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Whayne Supply January, 2009
Blocked conduitsCompetitors
Rigorous cleaning processCaterpillar
Cylinder Heads
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Cylinder Jackets
Competitors Random crisscross
pattern
Caterpillar Uniform crisscross pattern
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Whayne Supply January, 2009
Brakes – Friction Material
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
Cat Extended Life Friction Material
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Whayne Supply January, 2009
Cat Extended Life Friction Material
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).
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Gears
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Whayne Supply January, 2009
CaterpillarRounded rootLarge area for tension relief
Competitors Flat root Small area for tension relief Concentrations of tension
Gear design – Angle geometry
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Gear Metallurgy - Heat Treat
The right process means longer life
Induction (Through) Hardened
Case Carburizing Hardened
Nitride Hardened
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Whayne Supply January, 2009
Through Hardening- Heat Treat
High bending strength
No need for high pitting resistance
Increased core strength
Heat Treat Furnace
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Whayne Supply January, 2009
Nitriding Improved wear
characteristics
High hardness
Very low heat treat distortion.
Nitiriding Furnace
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Whayne Supply January, 2009
Standard Case Carburizing
High bending strength
Pitting and scoring resistance
Gears being carburized
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Whayne Supply January, 2009
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.
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Example of material and heat treatment… Cemented gear Cat Original Competition
Hardness of the surface Rc 64 – 59 Rc 63 – 58
Hardness at 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
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Whayne Supply January, 2009
Example of material and heat treatment… Cemented gear Cat Original Competition
Hardness of the surface Rc 64 – 59 Rc 63 – 58
Hardness at 1.8 mm Rc 48 – 45 Rc 47 – 35
Hardness at 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
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Whayne Supply January, 2009
Example of material and heat treatment… Cemented gear Cat Original Competition
Hardness of the surface Rc 64 – 59 Rc 63 – 58
Hardness at 1.8 mm Rc 48 – 45 Rc 47 – 35
Hardness at 2.8 mm Rc 39 – 34 Rc 38 – 28
Hardness of the core Rc 44 – 35 Rc 31 – 19
Bainita B0 – B1 B7
Ferrita F1 – F2 F4
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Whayne Supply January, 2009
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)
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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!
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Anti-Friction Bearings Cage Design
Stamped Industry Standard Snap In
BrassRigidNon Metallic
…application driven designs!
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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)
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Whayne Supply January, 2009
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.”
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Whayne Supply January, 2009
How Bearings Work
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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.
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Caterpillar Parts for the
Performance You Require!
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Cat Remanufacturing Services
Is the component rebuilt or remanufactured?
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Whayne Supply January, 2009
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.
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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.
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
20 - 25,000 Hours
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Whayne Supply January, 2009
Like New
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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.”
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Whayne Supply January, 2009
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.
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
• 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…
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
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Whayne Supply January, 2009
Where’s the Difference?
• Material• Proprietary versus industry standard steels
• Heat Treatment• Market-leading heat treat technology versus standard, lower-cost treatment practices
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Whayne Supply January, 2009
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
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Whayne Supply January, 2009
Power Train