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TC Training 2005

TC Training 2005
Providing World-Class
Dealer Support
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
Undercarriage
Hydraulics & CHS,
Contamination Cleaning
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 Analysis
Teaches a Logical, Fact-Based
Method of Analyzing Product
Failures
Determines the Problems Root
Cause
Reduces Repetitive Failures
Reduces Repair Costs
Increases Customer Satisfaction
Consulting Services
Repair Process
Engineering
Drive Train & Metal Restoration
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 Rebuild
Facility Planning & Development
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 Salvage
Guidelines
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.CSSISMainS
ervlet

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

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 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 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 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 Classes
Schedule 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

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 2005
Section 8
04/08 (1)
Facility Planning and Development
TC Training 2005
Sources For Help Self-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
Dealers local & regional Caterpillar offices
TC Training 2005
TC Training 2005

TC Training 2005
Anything in a fluid that doesnt 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 Microns
40 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 Hydraulic
System Clearances
MICRONS
(m)
5
30

40
80
Smallest
Visible
to the Eye
Human Hair
Particles You Cant See Are Harmful!
Pamas
2: 18032
5: 2036
10: 754
15: 155
20: 92
25: 36
50: 2
100: 1
TC Training 2005
ISO Cleanliness Code
Explained in ISO Standard 4406

Expressed Amount of Contamination in one mL of Fluid
2m / 5m / 15m
TC Training 2005
X
Y
First number represents number of particles
equal 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 particles
that cause "silting" or clogging of oil flow
>15 micron particles indicate the presence of
wear and potential early failure

Metrics
TC Training 2005
ISO Code

23
22
21
20
19
18
17
16
15
14
13
12
11

ISO Code Chart
Pamas
ID: Hydro Oil

3/16/02 21/18/14

2: 18032
5: 2036
10: 754
15: 155
20: 92
25: 36
50: 2
100: 1
Number of Particles / mL

40,000 - 80,000
20,000 - 40,000
10,000 - 20,000
5000 - 10,000
2500 - 5000
1300 - 2500
640 - 1300
320 - 640
160 - 320
80 - 160
40 - 80
20 - 40
10 - 20

Dirty



Clean



Cleaner
TC Training 2005

Non-Pressurized, Non-Filtered Compartments
Target To Be Established
Recommended Cleanliness Targets
Fill Oil .... ISO16/13

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


Transmission Systems
Electronic ..ISO18/15
Mechanical Transmissions.. ISO21/17

Component Rebuild
Engines (Roll-off) ....Pending.. ISO18/15
Transmission, 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 from
ISO 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/min
x 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
C
o
n
t
a
m
i
n
a
t
i
o
n
ISO
22/19
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
18,000hrs
4000hr Oil
Chg

13,000hrs
1200hr Oil
Chg
TC Training 2005
Thank You

Any Questions?