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 Steering Clutch

Differential Steer
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
Shoe Brakes
Brakes

Wet Disc Expander

Brakes 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.
Contact Points
Outer
Race
! Applications: High Speed
-Torque converters
-Powershift transmissions
-Engine components 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 Rollers
bearing of the same size.

! 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
on either end of a shaft. Contact Lines
Outer Race
! Applications:
-Final drives Cage

-Differentials Inner Race

-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. Cats 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 focus
Special heat treatment - Case Standard heat treatment - through
hardened hardened
Optimized roller crown profile Standard crown profile
Smoother surface finishes on Standard surface finish on
bearing races bearing races
Precise tolerances 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 Competition

! Deep hardened teeth

! Longer life
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
Brakes Transmission Steering Clutch
Paper X
Bronze Metallic X
Elastomeric X
Graphitic 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
! 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
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
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

! Benefits
" Precise electronic retarding
" Higher productivity
" Reduced risk of overspeed
ARC Advantages
Engine Speed (RPM)

* 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

992G
Basic Control Group With Traditional Controls
1 Engine
Chip
2 Implement
4 Power Train
Software Group 28 Monitoring
Control Assembly Application Specific
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

! 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

! 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 5130 & 5230

Pump Drive Swing Drive
Groups Groups

5130 & 5230

Final Drive Groups

! 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: ! Brake Band Coverage:

" MG - 12E-14D " TTT - D3-D9H
" WL & WD " TTL - 941H-983
814-816B ! Pricing:
966-980B " 30% of new
" Scrapers - 615-657E
" OHT - 776, 777
! Pricing:
" 40% of new
REMAN Clutch Plates

! 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

! Process:
" Laser cladding
! Coverage:
" WL - 994
" OHT - 776 - 793
! Pricing:
" 50% of new
REMAN Final Drive Hubs

! 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

! 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 ECMs

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 Customer/Dealer Discussion
transmission wear and potential failure.

Overhaul Management Guide OMG indicates estimated life to overhaul and indicates how Customer/Dealer Discussion
you can extend that time by changing operation and
maintenance factors.

Hesitation Worn plates and discs Technical Analysis Inspection

Wrong oil used Repair Determination Inspection
Linkage out of adjustment Customer/Dealer Discussion
Incorrect pressure settings
Low fluid level

Slippage Worn plates and discs Technical Analysis Inspection

Linkage out of adjustment Repair Determination Inspection
Low fluid level SOS Fluid Analysis
Incorrect pressure settings
Wrong oil used

Unusual noises Worn gears/bearings Technical Analysis Inspection

Dirt entry Repair Determination Inspection
Aeration/cavitation Customer/Dealer Discussion
Low fluid level

Vibration Bent drive shaft Technical Analysis Inspection

Gear failure Repair Determination Inspection
Bearing failure SOS Fluid Analysis
Customer/Dealer Discussion
Drive Train Repair Indicators

Indicators Possible Cause Options

Overheating Wrong oil used Technical Analysis Inspection
Plugged radiator Repair Determination Inspection
Worn pump SOS Fluid Analysis
Worn pressure relief valve Customer/Dealer Discussion
Worn or damaged seals
Worn/dirty control valve

Debris in filter/on magnetic screen Dirty entry SOS Fluid Analysis

Wrong oil used Customer/Dealer Discussion
Extended oil change period
Worn gears or bearings
Disc disintegration

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 SOS Fluid Analysis
as a repair indicator. Customer/Dealer Discussion

Operator discussion Talking with your machine's operator can reveal many Repair Determination Inspection
potential transmission problems.