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
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Challengers Motor Graders
Hybrid Planetary-Countershaft ! !
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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 !
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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
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specifications Special heat treatment - Case hardened Optimized roller crown profile Smoother surface finishes on bearing races Precise tolerances
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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,
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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 !
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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 !
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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 ! !
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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 !
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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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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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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
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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 !
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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 !
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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 !
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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 !
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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
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Process: " Epoxy & rivets (bake to remove) " Salvage shoes & bands
REMAN Brake Bands and Shoes !
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Brake Shoe Coverage: " MG - 12E-14D " WL & WD • 814-816B • 966-980B " Scrapers - 615-657E " OHT - 776, 777 Pricing: " 40% of new
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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 !
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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 !
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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 !
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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
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Converter Drive / Max.Torque " " "
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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
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Shift points matched to engine torque
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Larger discs/plates, addl. discs. in 2 & 3 gears, larger pistons, 4th planetary gear
Controlled Throttle Shift
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Reduce torque spikes, increase transmission life
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Possible only through ECM integration
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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
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Traction Control System (TCS) " Improve productivity " Increase operator confidence " Utilizes service brakes
Manufacturing / Quality Control ! !
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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
