TC Training – 2005

Repair Process Repair Process EngineeringEngineering

TC Training – 2005

Providing World-ClassProviding World-Class

Dealer Dealer SupportSupport

• Undercarriage Service Training• Service Tooling Training• Tooling & Process Development• Undercarriage Shop Reviews• Service Information• Technical Consultation• Train Dealers to identify salvageable parts using “scrap-barrel” analysis

UndercarriaUndercarriagege

Hydraulics & CHS, Hydraulics & CHS, Contamination Contamination CleaningCleaning• Custom Hydraulic Service Program• Hydraulic Components Repair Training• Dealer Shop/Operations Reviews• Parts Reuse and Salvage• Contamination Control Guidelines• Pump and Motor Testing• Hose & Coupling Assembly Training• Train Dealers to identify salvageable parts using “scrap-barrel” analysis

Applied Failure Applied Failure AnalysisAnalysis• Teaches a Logical, Fact-Based Method of Analyzing Product Failures• Determines the Problem’s Root Cause• Reduces Repetitive Failures• Reduces Repair Costs• Increases Customer Satisfaction• Consulting Services

Repair ProcessRepair ProcessRepair ProcessRepair ProcessEngineeriEngineeri

ngngEngineeriEngineeri

ngng

Drive Train & Metal Drive Train & Metal RestorationRestoration • Drive Train Support• Transmission Test Procedures• Thermal Spray Technology• High Velocity Oxygen Fuel (HVOF) Technology • Arc Spray Technology• Abrasion Resistant Material• Train Dealers to identify salvageable parts using “scrap-barrel” analysis

Engine Engine RebuildRebuild

Facility Planning & Facility Planning & DevelopmentDevelopment

• Engine Component Reuse & Salvage Guidelines• Provide Dealer Training on Engine Repair Processes• Train Dealers to identify salvageable parts using “scrap-barrel” analysis

• Site Concepting• Cost Estimates• Sizing Studies• Location Management Implementation• Bar Coding / RF Technology Implementation

• Detailed Facility Design• Specialized Repair Areas• Bin Sizing Analysis• Warehouse Layouts• Customer Equipment Maintenance Facility

TC Training – 2005

Pump and Motor Bench Test Procedures

TC Training – 2005

Where Available

• SEBF8810 – New Pump, Motor and Cylinder Testing Manual

– Available by subscription only.

• SIS Web– Bench Test Procedures

• Example (992G, S/N: ADZ)

TC Training – 2005

TC Training – 2005

Transmission Bench Test Procedures

TC Training – 2005

Where Available

• SEBF8760 – Transmission, Torque Converter & Relief Valve Test Bench Procedures

– Available by subscription only

• SIS Web– Bench Test Procedures

• Example (992G, S/N: ADZ)

TC Training – 2005

TC Training – 2005

Reuse and SalvageGuidelines

TC Training – 2005

Where Available

• SEBF8000 – Guideline for Reusable Parts Library

– SEBF8029 – Index of Reusability & Salvage Publications

– SEBF8052 Automatic Subscription List

• SIS Web– Example (D11R, S/N: AAF)

TC Training – 2005

Arc Spraying a OHT Rear Spindle Bearing Journals

Use Again

Do Not Use Again

TC Training – 2005

Undercarriage Reconditioning Bulletins

https://sis.cat.com/sisweb/servlet/cat.cis.sis.PController.CSSISMainServlet

TC Training – 2005

Where Available

• SEBF8599 – Undercarriage Reconditioning Guide

– Available by subscription only

• SERF8890 – Undercarriage Service CD

– Available by subscription only

• SIS Web– Undercarriage Reconditioning

Guide

• Example (D11R, S/N: AAF)

TC Training – 2005

Contamination Control Guidelines

TC Training – 2005

Where Available

• SIS Web– Contamination Control Guidelines

• Example (992G, S/N: ADZ)

TC Training – 2005

TC Training – 2005

Training ClassesTraining ClassesAvailable from DSOAvailable from DSO

The training covers hydraulics from basics to testing. Both web based & instructor led curriculums are offered. Training includes: • • Basic hydraulics • • Hydraulic information systems • • D&A procedures • • Parts reuse & failure analysis • • Work processes • • Contamination Control • • Component testing

Hose & Coupling training improves dealer technician assembly skills, efficiency, quality, and opens market focus through part identification and application. The training includes classroom & lab instruction and provides: • • Hose & Coupling identification • • CAT-approved hose assembly procedures • • Reference material availability • • New products & tooling review • • Machine operator safety

Hydraulic Technician Training

Hose & Coupling Hose & Coupling Training Training

Test Bench Training Test Bench Training

Bench Testing ensures correct assembly and operation of the component. This allows the dealer to ensure that the component will operate properly in the machine. The training includes on-site test bench instruction and provides: • • Efficient Test Bench Development • • Up-to-Date Test Methods • • Field/Lab Validated Test Procedures

Engine Repair Process Training

Engine Repair Process Training provides dealers with up-to-date information on the processes and procedures used for the reuse and salvage of used engines and their components. The training helps the technician to identify salvageable parts using “scrap-barrel” analysis.

Undercarriage Service Undercarriage Service Training Training Undercarriage Service Training provides a four-day

course that covers servicing rollers, idlers, and track, as well as roller and idler welding. This training class offers the following: • • Classroom instruction on recommended processes and procedures • • Hands-on application of instruction • • Production facility tours to verify methods and processes

Reuse & Salvage Reuse & Salvage Training Training Reuse & Salvage Training covers all

components of CAT equipment. It enables the technician to determine whether or not the parts are reusable during repair/rebuild procedures. The training offers the following: • • Modules that are created from a global perspective • • Discusses the different failure modes

Applied Failure Analysis Training AFA teaches a logical, fact based method of

analyzing product failures to determine the root cause of the problem. • This training reduces repetitive failures, reduces repair costs, and increases product availability.

TC Training – 2005

Additional Training ClassesSchedule through the Global Manpower Development (DLMS) Web Site:https://dlms.logicbay.com/dlms/login/landing.jsp 

• Hose and Coupling Assembler Training• Pump and Motor D&A and Parts Reuse I (Rexroth A2, A4, A8, A11 Models)• Pump and Motor D&A and Parts Reuse II (Caterpillar Proprietary and Sauer Danfoss Series 46 & 90)• Test Bench Training (Schematics & Pump Operation/Testing)• Undercarriage Service Training • Applied Failure Analysis Training

For the following training contact Dave Haney, in Repair Process Engineering, at 309-636-5941. There is no set curriculum and the training is tailored for the individual dealer needs. 

• Engine Repair Process Training• Reuse & Salvage Training

TC Training – 2005

Additional Additional ServicesServices

Available from Available from DSODSO

TC Training – 2005

Shop Reviews

• Hydraulic Shop Reviews

– Rob Aldrich

• Dealer Service Shop Reviews

– Dave Haney

• Machine Shop Reviews

-Dave Haney

• Undercarriage Shop Reviews

– Doug Thacker

TC Training – 2005

Facility Planning and Development

• Facility Layouts and Design Contacts– Mike Rabe

https://dealer.cat.com/cda/layout?m=422598&x=7

TC Training – 2005Section 804/08 (1)

Facility Planning and Development

TC Training – 2005

Sources For Help – Sources For Help – Self-Help SourcesSelf-Help Sources

8-2

● Cat Facility Planning Web Site

● Facility Planning Questionnaires– Available from Facility Planning Web Site

● Cat Facility Planning Guide– Available upon request

● Web-Based E-Learning Module

● Dealer’s local & regional Caterpillar offices

TC Training – 2005

Any Questions?Any Questions?

TC Training – 2005

Contamination Contamination ControlControl

TC Training – 2005

• Anything in a fluid that doesn’t belong

• The #1 enemy of fluid systems

What is Contamination?

TC Training – 2005

Effects of Contamination

Hydraulic System experts attribute

75 to 85%

of all component failures to particle contamination in the fluid and not a weakness in the system components.

-- Hydraulics & Pneumatics, June 2005

-- Equipment Today, August 1997

TC Training – 2005

Under 40 MicronsUnder 40 Microns40 Microns & Larger40 Microns & Larger

Two Types of Contamination

TC Training – 2005

• Design

• Manufacturing & Assembly

• New Fluids

• Machine Operation

• Maintenance and Service

Sources of Contamination

TC Training – 2005

What is a Micron?

1 Millionth of a Meter

100 microns (m) - grain of table salt

80 microns (m) - diameter of a human hair

TC Training – 2005

Cat HydraulicSystem

Clearances

MICRONS(m)

530 40

80

SmallestVisible

to the EyeHuman Hair

Particles You Can’t See Are Harmful!

Pamas2: 180325: 203610: 75415: 15520: 9225: 3650: 2100: 1

TC Training – 2005

ISO Cleanliness Code

•Explained in ISO Standard 4406

•Expressed Amount of Contamination in one mL of Fluid

2μm / 5μm / 15μm

TC Training – 2005

X Y

First number represents number of particlesequal to or greater than 5 microns

Second number represents number of particles equal to or greater than 15 microns

Why were these sizes selected?>5 micron particles indicate wear particlesthat cause "silting" or clogging of oil flow>15 micron particles indicate the presence ofwear and potential early failure

Metrics

TC Training – 2005

ISO CodeISO Code

23222120191817161514131211

ISO Code Chart

PamasID: Hydro Oil

3/16/02 21/18/14

2: 180325: 203610: 75415: 15520: 9225: 3650: 2100: 1

Number of Particles / mLNumber of Particles / mL

40,000 - 80,00020,000 - 40,00010,000 - 20,0005000 - 10,0002500 - 50001300 - 2500640 - 1300320 - 640160 - 32080 - 16040 - 8020 - 4010 - 20

Dirty

Clean

Cleaner

TC Training – 2005

Non-Pressurized, Non-Filtered Compartments…Target To Be Established

Recommended Cleanliness TargetsFill Oil …………………………………………….…………………..……. ISO16/13

Hydraulic Systems (Implement & Steering)....………………………. ISO18/15Hydraulic Oil Extension IRM # FLU01-02…………………………... PELE0824

Transmission SystemsElectronic ……………………….……………………….……

ISO18/15Mechanical Transmissions……………………………….. ISO21/17

Component RebuildEngines (Roll-off) ...………………….…Pending……….. ISO18/15Transmission, Pumps, Governors Etc ………..…..…… ISO16/13

Fuel …………………………………………………………???……… ISO18/16/13 Injector Testing Equipment Calibration Fluid……..………………… ISO15/13

TC Training – 2005

How Much of a Difference Will Cleaning Your Oil fromISO 21/17 to ISO 16/13 Really Make?

32 GPM Pump Working 8 Hours / day for 200 Days

Example:

?

Contamination Control

TC Training – 2005

(.52 or 2.08 or 16.64)mg/L x 3.785 L/gal x 32 GPM = 93.3 mg/minx 60 min/hr x 8 hr/day for 200 days/year =

193,481,933 mg/year divided 1000 mg/gal divided 454 gal/lb = Amount of “Dirt” Flowing

Amount of “Dirt” in Oil Through Pump in One Year

ISO 21/17

ISO 18/15

ISO 16/13

426.2 lb/yr

53.2 lb/yr

Contamination Control

13.3 lb/yr

TC Training – 2005

Dirt Samples

TC Training – 2005

Pump Manufacturer

Component Life Over Time

Contamination

ISO22/19

21/17

20/15

19/16

18/15

17/14

16/13

15/12

14/11

13/10

12/09

----

------------

-----

Clean New Oil

Component Life

10,000

2,500

25,000

TC Training – 2005

Batu Hijau Newmont

Indonesia

18,000hrs4000hr Oil Chg

13,000hrs1200hr Oil Chg

TC Training – 2005

Thank You

Any Questions?