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Importance of S.O.SSM
Fluid Analysis
Planned Maintenance
Thorough Inspections
Transmission DOs & DONTs
Training, scheduling and
record-keeping
FAQs
Contents
Introduction.................................................................. 3
Thorough Inspections................................................... 6
Because of the wide variety of Caterpillar designs all parts, To increase productivity and
work they do, Caterpillar products including these gear groups, to prevent downtime, its vital to
use several types of transmissions, fall under three levels of wear. make sure that all drive train
including planetary powershift, By understanding that different components are constantly
countershaft powershift, direct components are intended to wear monitored. Look at their condition
drive and hydrostatic. Each is faster than others, you can inspect to ensure contamination isnt
designed to convert engine power for signs of wear and keep your entering their systems and to
into the exact combination of transmission running smoother check that correct operating
speed, direction and torque and longer. techniques are being used.
required for the particular This brochure focuses on how
For example, gears and shafts,
application. Transmissions do to identify problem indicators
if properly maintained, are
this by various means such as and how to maximize the
designed to last through
hydraulic clutches or a performance and life of your
multiple transmission rebuilds.
hydrostatic/hydraulic drive. transmission.
But components such as friction
Transmissions rely on the material, seals, gaskets and
engagement of gear groups to bearings are faster wearing.
provide the transfer of power Monitor them for abnormal
to your machine components. wear and replace when needed.
3
Importance of S.O.S
SM
In recent years it has become life of Caterpillar products. When The SOS Services testing is
apparent that the oil used to selecting lab instruments and tests quick and easy to do. Sample
achieve maximum engine life for the Scheduled Oil Sampling test analysis is done in your Cat
would not perform satisfactorily (SOS) Services, Caterpillar Dealer's laboratory by trained
in transmissions. Consequently, engineers begin by asking what technicians utilizing the most
Caterpillar developed specifica- information from used oil samples modern technology. These experts
tions for transmission oil just as would best identify the know what's happening inside the
the Company has done with the transmissions condition. transmission and how it relates to
engine oil for many decades. sample findings. They draw on a
Surveys constantly show major
large database of information and
Caterpillar designs the benefits for users who regularly
wear tables developed through
transmission oil to maximize the use SOS Oil Analysis. A 10:1
years of testing and evaluations.
performance and life of Caterpillar payback is a common payback
The following wear table outlines
products. Since only Caterpillar ratio when comparing the amount
transmission failures and their
engineers know exactly what saved on repair costs to the amount
common indicators using the
metallurgical specifications were invested in SOS Services. This
SOS Fluid Analysis.
designed into each part and figure is probably conservative
component, it was natural that they when you consider reduced
developed an oil analysis program downtime, greater productivity
to maximize the performance and and increased used-machine value.
4
Importance of S.O.S
What do these indicators mean? Component Wear RateWhat SOS Services test results are
components are wearing and at available within 24 hours after
If excessive amounts of silicate
what rate? receipt of the sample.
(Si) and aluminum (Al) are found
in the transmission fluid, it means Oil ContaminationWhat Evaluation is supplied in an
the oil is contaminated with dirt. contaminates are showing up easy-to-understand test report,
The SOS experts might in the oil? which calls for specific action
recommend you change your oil and/or makes carefully outlined
Oil ConditionIs the correct
right away and to change it more recommendations.
transmission oil being used?
frequently in the future. High
Has the oil been exposed to Reports can identify problem
levels of copper (Cu), iron (Fe) and
excessive heat? areas such as careless
lead (Pb) would indicate abnormal
maintenance or an operator
wear of the bronze friction discs Oil IdentificationIs there
who rides the brakes too much.
and steel separator plates. coolant or water leaking into the
Recommendations would include oil? Is the right oil being used? Using SOS Services saves time
stopping the machine and and money because potential
inspecting the transmission. Also, trouble spots can be identified
you would be advised to cut open What are the advantages of before they become major
and inspect the oil filter for large using SOS Services? problems.
particles.
Surveys constantly show major
benefits for regular users of
Consult your Cat Dealer for
SOS Services:
What tests are done by complete information and
SOS Services? Experts can provide analysis assistance on the SOS
and interpretation of trends and Oil Analysis program.
The SOS Oil Analysis consists
can forecast any wear problems.
of four standard analysis tests:
5
Preventive Maintenance
Regular preventive maintenance Use the Right Drive Train Oil Change Oil Properly
is the most cost-effective way to
Caterpillar Transmission/Drive Changing oil properly and at
keep your transmission operating
Train Oil (TDTO) is specially correct intervals is critical to
at peak performance. Preventive
formulated to increase the life and realizing maximum component
maintenance focuses on
performance of your Cat drive life. Actual oil life is determined
transmission and drive train oils,
train components. This oil reduces by many factors such as operating
filters, SOS and contamination
transmission slippage, controls conditions and applications or
control. Preventive maintenance:
brake chatter, provides greater contamination control. You can
Allows you to schedule machine rimpull and increases reduce contamination by:
downtime and plan for friction material life up to 45
Washing the transmission tank
maintenance and repair costs. percent. Cat TDTO surpasses the
and drain before removing cap.
TO-4 specification requirements
Helps prevent major failures,
and is specified as factory fill for Draining oil as quickly as
including failures of related
all Caterpillar machine possible and doing so when
parts.
compartments where TO-4 oils are it is agitated and warm.
Saves you money because you the primary recommendation.
Using a filtered transfer cart
can often repair before failure.
Caterpillar also offers a new to add new oil.
Maximizes parts reusability. multi-season formulation of
Installing and removing
TDTO called TDTO (TMS). This
Optimizes equipment life to filters carefully.
Caterpillar exclusive is a partially
keep your machine on the job.
synthetic lubricant that eliminates Keeping filters in package
Increases machine resale value. the need to change oil at seasonal until ready for use.
intervals. As a result you use the
By following a preventive Cutting open and inspecting
oil for its full life, so theres less
maintenance plan, we have seen used filters before installing
used oil disposal and less
an increase in transmission life new ones.
downtime for maintenance.
from 9,000 hours to 15,000 hours!
Cat TDTO (TMS) has shown
improved transmission
performance in cold weather for
Proper Oil Use
machines with electronic controls.
Oil helps to perform three main TDTO (TMS) is recommended in
functions: cleaning, cooling and climates with widely ranging
lubricating the transmission. ambient temperatures to avoid
Todays transmissions feature new unnecessary oil changes.
metals, elastomers and paper disc
materials that require advanced
lubrication. You must use the right
oil and change it regularly and
properly to achieve top
performance.
6
Preventive Maintenance
Filters
7
Preventive Maintenance
8
Thorough Inspection
A good inspection program combines your daily inspections with Your daily visual inspection routine should
our periodic in-depth analysis. By combining both, you can: include a complete visual and operational check
Locate potential problems before they become major repairs. of your transmission. The following chart
summarizes planned and problem indicators
Schedule transmission maintenance and service. that are associated with the transmission.
Plan and control your operating costs and downtime.
S.O.S Services S.O.S Services provide Hesitation/Slippage Worn plates and disks Technical Analysis Inspection
the best insight into Linkage out of adjustment Repair Determination Inspection
internal transmission wear Low fluid level S.O.S Services
and potential failure. Linkage not free Customer/Dealer Discussion
Incorrect pressure settings
Service Meter Hours Our dealers use service Wrong oil used
meter hours as a repair
indicator. Unusual Noises Worn gears/bearings Technical Analysis Inspection
Dirt entry Repair Determination Inspection
Operator Discussion Talking with your machine Aeration/cavitation S.O.S Services
operator can reveal many Low fluid levels Customer/Dealer Discussion
potential transmission
problems. Vibration Bent shaft drive Technical Analysis Inspection
Gear failure Repair Determination Inspection
Bearing failure S.O.S Services
Customer/Dealer Discussion
9
Training, Scheduling and Record-keeping
10
Frequently Asked Questions
What are some of the subtle signs that you may have What have been the major technological changes to
transmission problems? transmission design in recent years and how have
Overheating, slippage or jerky shifting can signify these affected the maintenance and upkeep of
a problem with a transmission component. If this transmissions?
occurs, take your machine into your local dealer As the expectations of life and durability of machines
to have a thorough inspection and SOS sampling increase, Caterpillar engineers have responded by
done on the machine. making many mechanical and electrical changes that
What are some of the primary causes of transmission allow increased productivity and longer life of your
failure and/or reduced power output or performance? product. However, these changes require smaller
tolerances and increases in pressure in your machine
Low oil pressure can cause clutch slippage.
that make maintenance and the upkeep of your
Check your transmission filter and oil levels
transmission essential. Because these mechanical and
in the transmission. They may need replaced.
electrical changes are advanced, they often require
Incorrect pressure may cause transmission failure or unique testing and repair that only your local
reduced power output or performance. Transmissions Caterpillar Dealer can provide accurately.
are designed to run at around 200 lbs of pressure.
When a company with a diverse fleet uses just one
Check all pressures to ensure correct levels.
or two lubricating oils, what is the effect?
Contamination from other failing parts can cause
Using the incorrect lubricating oil can cause incorrect
plugged filters. Check all parts for contamination.
pressure, faster wear or slippage.
Are construction company shops equipped to handle
Are shared oil reserves with implement cylinders
most transmission problems? Or, as with automobiles,
(vane or gear pumps) a problem?
are these maintenance and repair chores better left to
dealers or specialists? Shared oil reserves can cause cross contamination.
Newer machines are being designed without them.
Most construction company shops are not equipped
to handle transmission maintenance or repairs. Our Do different types of equipment wear out
service shops have technicians who are well trained transmissions at different times? For example,
with many years of experience in identifying and how does a transmission wear in load-and-carry
fixing a transmission failure. We also provide operations vs. stay-at-home operations?
technicians with many resources such as reusability Transmissions do wear out at different intervals due
guidelines and continuous, up-to-date training that to the applications they are in. If you are constantly
construction company shops do not have access to. shifting from gear to gear or from forward to reverse,
For example, to determine the reusability of a bearing, your clutches and gears may wear out faster.
our technicians can use reusability guidelines as well Can cutting open a filter help you diagnose
as accurate tools to help them distinguish between a problem?
damaged bearings and good bearings. Construction
Yes. Cutting open a filter is very important to
shops may guess on the quality of the bearing because
determine the root cause of a problem. By finding
they may not have access to tools that help them
pieces of metal in the filter, you can determine
identify possible damage. Finally, these construction
what is failing. Refer to the filter section of
shops do not have the cleanliness standards Cat
planned maintenance.
requires in all dealer service locations. Because
contamination is a common cause for component What happens to the transmission when fluid
failure, a clean environment for maintenance or repairs becomes too hot?
is a must. The transmission oil additives deteriorate and lose
Are oil additives usually recommended? their ability to control wear. Oil samples results will
show high oxidation and an increase in viscosity.
Cat doesnt recommend any additives; they are already
in the lubricant.
11
Expect More from the Experts
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