Download - ISO Numero Control Contaminacion
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TC Training – 2005
Repair Process Repair Process EngineeringEngineering
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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
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TC Training – 2005
Pump and Motor Bench Test Procedures
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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)
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TC Training – 2005
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TC Training – 2005
Transmission Bench Test Procedures
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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)
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TC Training – 2005
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TC Training – 2005
Reuse and SalvageGuidelines
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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)
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TC Training – 2005
Arc Spraying a OHT Rear Spindle Bearing Journals
Use Again
Do Not Use Again
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TC Training – 2005
Undercarriage Reconditioning Bulletins
https://sis.cat.com/sisweb/servlet/cat.cis.sis.PController.CSSISMainServlet
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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)
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TC Training – 2005
Contamination Control Guidelines
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TC Training – 2005
Where Available
• SIS Web– Contamination Control Guidelines
• Example (992G, S/N: ADZ)
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TC Training – 2005
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TC Training – 2005
Training ClassesTraining ClassesAvailable from DSOAvailable from DSO
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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.
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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
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TC Training – 2005
Additional Additional ServicesServices
Available from Available from DSODSO
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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
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TC Training – 2005
Facility Planning and Development
• Facility Layouts and Design Contacts– Mike Rabe
https://dealer.cat.com/cda/layout?m=422598&x=7
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TC Training – 2005Section 804/08 (1)
Facility Planning and Development
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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
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TC Training – 2005
Any Questions?Any Questions?
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TC Training – 2005
Contamination Contamination ControlControl
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TC Training – 2005
• Anything in a fluid that doesn’t belong
• The #1 enemy of fluid systems
What is Contamination?
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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
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TC Training – 2005
Under 40 MicronsUnder 40 Microns40 Microns & Larger40 Microns & Larger
Two Types of Contamination
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TC Training – 2005
• Design
• Manufacturing & Assembly
• New Fluids
• Machine Operation
• Maintenance and Service
Sources of Contamination
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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
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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
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TC Training – 2005
ISO Cleanliness Code
•Explained in ISO Standard 4406
•Expressed Amount of Contamination in one mL of Fluid
2μm / 5μm / 15μm
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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
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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
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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
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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
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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
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TC Training – 2005
Dirt Samples
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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
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TC Training – 2005
Batu Hijau Newmont
Indonesia
18,000hrs4000hr Oil Chg
13,000hrs1200hr Oil Chg
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TC Training – 2005
Thank You
Any Questions?