Drive Train Parts Quality

Drive Train Parts
Quality
Drive Train Components
TORQUE TRANSMISSION OUTPUT TRANSFER

CONVERTER GEAR CASE
REAR REAR PARKING FRONT FRONT

FINAL DRIVE DRIVE SHAFT BRAKE DRIVE SHAFT FINAL DRIVE
Drive Train Parts
Gears
Anti-friction bearings
Friction materials
Shafts, carriers
Seals
Drive Train Gears
Function
Reduce engine
speed and
increase torque
Spur
Types
Spurs gears
Helical Bevel gears
Helical gears
Bevel
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 of time
Drive Train Gears -- Characteristics
Design
Metallurgy
Manufacturing
Application customization
Gears Total System Design
Product knowledge and experience

Tooth thickness customization
Tooth profile optimization
Latest engineering changes
Design
Fillet geometry
Tooth profile
Crown geometry
Surface finish
Gear Design - Fillet Geometry
Caterpillar Competition
Round root Flat root
Large stress relieving area Small stress relieving area
Stress concentrations
Drive Train Gears Characteristics
Design - Tooth Profile
Competition Caterpillar
No crown Crowned
Stress on tooth ends Distributes stress under deflection
Leads to breakage Protects teeth tips
Design - Crown
Crowned
No crown
Distributes stress under deflection
Stress on tooth ends Protects teeth tips
Leads to breakage
The Difference in Caterpillar Gears
Design
Metallurgy
Manufacturing
Metallurgy
Material chemistry
Heat treat selection
Proprietary heat treat

methods
Gears Metallurgy - Heat Treat
Inadequate hardness Deep hardened teeth
Insufficient hardness depth
Reduced life
Case Induction
Carburizing Nitride
(Through)
Hardened Hardened
Hardened
The right process means longer life

Competitor Standard Caterpillar Carbide

Carburized Structure Process Structure
Soft Constituents
500X Mag..
500X Mag. Caterpillar Standard

500X Mag.
Carburized Structure
Not all Carburizing Processes are Equal!

Manufacturing
Industry Heat
Hobb Shave Treat
Std.
Caterpillar Near Net CBN Heat

Process Forge Grind Treat
Quality controlled throughout
Special tooling
Hobbing
Shaping
Grinding
CBN grinding
Drive Train Gears - Field Test
D8K Final Drive
Cat on one side and "will fit" on the other
"Will fit" failed at 2191 hours
No failures on Cat side
Had 1000's of hours left
D8K Final Drive
"Will fit" failure due to

Lack of crown
Improper heat treat
D8K Final Drive
"Will fit" failure due to

Dimensional inaccuracies
Improper mesh
Oversize OD
No crown
Material
Insufficient hardness
Insufficient hardness depth
Drive Train Gears - Summary
Caterpillar Commitment Competitors Commitment

Research and development Try to copy Cat Dimensions
Continuous improvements in,
and appearance
Design, Materials, Metallurgy,
Lower parts reusability
Manufacturing, Heat treatment,
Quality Control Avoid the subject
Parts built to be reused No reusability guidelines
Published reusability guidelines
Increased life cycle costs
Lower life-cycle costs
Outdated technology
Parts continuously updated to provide service
life improvements Parts built with no knowledge
Parts built to Cat specs for Cat machines of Cat system specs or the
Superior parts availability machine operating
requirements
Incomplete product line
Anti-Friction Bearings
An Elephant, An Ant & Bearings
Permit smooth movement between surfaces

Reduce rolling friction between two parts while under tremendous loads
Decrease: friction, heat, and wear
Types
Ball
Roller (tapered and straight)
Needle
Ball Needle
Bearing Bearing
Cylindrical Tapered
Roller Roller
Bearing Bearing
What is a ball bearing?

A ball bearing has balls which move freely Contact Points
between the inner and outer races. A thin Outer
layer of oil separates the components with Race
only a small area of the ball in contact to
the race resulting in low friction.
Applications: High Speed

Torque converters Balls
Power shift transmissions
Engine components Inner
Race
Cage
Rollers
What is a cylindrical 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. Inner
Race
Applications:
Powershift transmissions
Final drives
Outer
Race
Cage
What is a tapered roller bearing? Contact Lines

It is similar to a straight roller bearing Outer Race
but its rollers are tapered to withstand
thrust loads. Usually, tapered roller Cage
bearings are used in pairs on either end
of a shaft. Inner Race
Applications:
Final drives
Differentials Rollers
Transmission transfer case
What is a needle bearing?

It is a special type of cylindrical 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
Anti-Friction Bearings -- Applications
Pump Drive
Converter
Bearing Speed
Tapered
Ball Bearing
Bearing
Transfer Case
Transmission
Needle Cylindrical
Bearing Bearing
Radial
Load Load
Transmission Final Drive
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.
Timken
Technology
Design
Application
Wear life
Reliability
Durability
Added value
Technology
World class bearing suppliers
Periodic technology meetings
Caterpillar research/technology commitment
Joint Caterpillar/Supplier development program
Bearing Technology Programs
Current
Full Film
Industry
Technology
Supplier A
Technology
Development Supplier B
Program Technology
Development
Program
Full Metallic Contact

Relative Load
Design
Vast historical and experience base

Constant field evaluation feedback loop
Continuous design updates
Product improvements
Experience base for future designs
Design
Non-Caterpillar bearings may be dimensionally

equivalent but fall short in:
-Material
-Surface finish
-Roller profile
-Lubrication
-Tolerances 40% - 60%
Life at risk
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
bearing races races
Precise tolerances Standard tolerances
Application
Designed for each specific function based on:

Loads
Operating speeds
Temperature range
Size
Past field performance
Desired design life
Application
Standard bearings may cause Cat special bearings
damage Roller crown distributes loads
Textured Anti-Friction Bearings
Developed as way to achieve better balance

among components
Used in slow-speed, high-load applications
(gear boxes, differentials & final drives)
2X life improvement for
bearings from better
maintaining the proper
oil film thickness
Proprietary technology,
Caterpillar exclusive applications
Application
Special materials
Tight dimensional tolerances
Special heat treatment
Case hardened
Optimized roller crown
L-Riding cage
Anti-Friction Bearings -- Roller Profile
No Crown Standard Industry Crown
CAT Special Crown

2-3x Life
Improvement
Over Industry
Standard
Bearing failure is associated with inadequate roller crown.

L- Riding cage
Wear Life
Bearing enhancements
Justified by application requirements
Example: truck wheel bearings
2x life improvement from industry
standard bearings to Cat optimized bearings
Wear Life
Life Research
(future)
Industry standard 1.0
Enhancements
Surface finish 1.25 - 1.31 X15
Optimized profile/
improved material 1.93 X7
(Cat today)
Truck wheel 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
Balanced Component Wear Life
Wear Life
Improper surface finish
Lubrication failure
Reliability
Application driven
Correct bearing for the application
Bearings position other components
Alignment and tolerances critical
Reliability
Incorrect alignment
Durability
Case carbonized material

Required by Caterpillar
Extended roller element life
Proper bearing settings = maximum life
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
Summary
Technology
Design
Application
Wear life
Reliability
Durability
Added value
How
Bearings
Work
Debris Resistant Anti-Friction Bearings
Lab Test Results (contaminated oil with debris)
122
Debris Res.
Caterpillar Std. 22.2
Industry Std. 13.6
0 20 40 60 80 100 120 140

L10 Life (hours)
Anti-Friction Bearing Kits
Transmission, final drive

and differential bearing kits
Caterpillar part number
Ensures correct bearing
for the application
Availability
Distribution
Savings over individual
parts purchase
Same Industry Number MU1308
Caterpillar
Industry Standard
Bearing
Pin cage design
X bar cage
Used in very slow
Strong design
speed applications
Used in high
Group roller design
speed/torque
Premature wear will applications
occur as a result of
roller contact
Same Industry Number 32210
Caterpillar Bearing
Industry Standard
Stronger cage
Weaker cage design design
Metric bearing so Fewer rollers
no control on
Specific bearing
bearing angle
angles
Longer rollers
Used in high speed
Used is slower applications
speed applications
Same Industry Number M1210
Caterpillar Bearing
5H1901
X cage design
Special hardness
Optimized roller crown
Special surface finish
Industry Standard
Industry Standard
Larger O.D.
Pin cage design
Pin lock retention not required
Roller groups
Increased loads on components
For slow speed
applications only
Estimated Cat Value Advantage
Technology 5% - 6%
Design 10% - 12%
Application 10% - 15%
Wear life 5% - 7%
Reliability 3% - 5%
Durability 6%
Added value 8%
Overall 47% - 59%

Drive Train Parts Quality
CATERPILLAR DRIVE TRAIN
PARTS
Genuinely
Better
Thank you, any questions?

Drive Train Parts Quality

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Drive Train Parts

TORQUE TRANSMISSION OUTPUT TRANSFER

REAR REAR PARKING FRONT FRONT

Final drive gears

Product knowledge and experience

Design - Tooth Profile

Heat treat selection

Proprietary heat treat

The right process means longer life

Competitor Standard Caterpillar Carbide

500X Mag. Caterpillar Standard

Not all Carburizing Processes are Equal!

Caterpillar Near Net CBN Heat

D8K Final Drive

"Will fit" failure due to

D8K Final Drive

"Will fit" failure due to

Caterpillar Commitment Competitors Commitment

Permit smooth movement between surfaces

What is a ball bearing?

Applications: High Speed

What is a tapered roller bearing? Contact Lines

What is a needle bearing?

Timken provides anti-friction bearings to

Full Metallic Contact

Vast historical and experience base

Non-Caterpillar bearings may be dimensionally

Special material technology Industry materials

Designed for each specific function based on:

Developed as way to achieve better balance

CAT Special Crown

Bearing failure is associated with inadequate roller crown.

Surface finish 1.25 - 1.31 X15

Balanced component wear life

Case carbonized material

Lab Test Results (contaminated oil with debris)

Caterpillar Std. 22.2

Industry Std. 13.6

0 20 40 60 80 100 120 140

Transmission, final drive

Overall 47% - 59%

Thank you, any questions?

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