The Dirt from Cashman

Contamination Control: Clean Fluids

Previously, we talked about the four parts of a good contamination control program – clean fluids, clean components, clean facilities, and clean shop repair processes. Today, we want to share some best practices for clean fluids.

Clean Fluids
- Keep oil barrels indoors where they won’t get rusty or dirty and protect them with a cover so rain and dust cannot enter the drum when the cap is removed.
- Always wipe off fluid container lids (jugs, cans, etc.) with a clean shop towel before opening.

- Filter all fluids before they go into your machines, as the oils may have picked up contaminants during transport.

- Never pre-fill lube oil or fuel system filters, which can introduce potentially dirty fluid directly into the system because it misses the final filtering process.

Contamination Control

Keeping machine fluids free from outside contaminants saves money, reduces downtime, and helps maintain productivity.

What Can You Do?

Make sure you use Cat’s four-part contamination control program. It includes:

1. Clean Fluids – Proper fluids handling and clean, tightly sealed containers help prevent potential contamination.
2. Clean Components – Carefully clean out hoses, protecting them with end plugs and caps.
3. Clean Facilities – Shops with high-pressure wash bays, closed bay doors, and non-dirt drives help minimize contaminants.
4. Clean Shop Repair Processes – Our technicians take extra care during service to eliminate contaminants.

Following these steps will help you be prepared to control contamination and keep your Cat equipment performing at its best. For more information, contact our Fluids Analysis Lab or your Product Support Rep!

The increasing costs of fuel can be crippling to your business. At Caterpillar, millions of dollars have been spent on research, design, and development for improved fuel efficiency throughout the product line of over 300 machines. Reducing owning and operating costs is a top priority.

Cat machines, Cashman Equipment, and you are the keys to finding ways to reduce fuel costs in every way possible. Every dollar saved can make an incredible difference over the life of your machine. The fuel saving tips below will help you get started.

Fuel-Saving Tips

• MINIMIZE IDLING Depending on the application, idling can amount to 15-20% of total fuel used!
• AVOID QUICK STARTS Operator machine handling plays a big factor in fuel economy. Make sure all operators are properly trained on each machine.
• KEEP MACHINE IN TOP CONDITION Diligent maintenance not only saves fuel, but reduces repairs, improves reliability, and minimizes exhaust emissions. Replace air filter, oil filters, and change oil (using recommended oils) per manufacturer’s recommendations. Blocked air filters can increase fuel consumption by 20%. One stuck valve lifter can increase fuel usage by 10 -15%. Improperly working thermostats have been noted to increase fuel consumption by 25%. Throttle linkage needs to be kept properly adjusted. Other culprits affecting fuel economy include: valve and ring wear, engine liming, water in fuel, and external leakage.
• FAULTY FUEL CAPS Damaged or loose fuel caps cause fuel evaporation.
• MAINTAIN PROPER TIRE INFLATION Under-inflation by just 6 psi consumes 3% more fuel.
• TIRE SLIPPAGE Insufficient ballast creates excessive slippage and increases fuel consumption, along with premature engine wear. Remove ballast for light loads. Match the weight to the job for the proper rolling resistance.
• SIZE MACHINE FOR JOB Too much or too little horsepower can drastically affect fuel efficiency. Our job at Cashman Equipment is to help you match the right machine to the job you’re doing.
• GEAR UP - THROTTLE DOWN Select the gear that provides the desired ground speed at a reduced engine rpm without overloading. Studies have shown 5 -15% fuel efficiency at 75% power and 15 – 30% efficiency at 50% power.
• JOB LAYOUT Effectively plan your job site travel patterns to reduce idling and minimize turns.
• RECOMMENDED FUEL GRADE Be sure to use the recommended fuel grade depending on weather conditions.
• FUEL STORAGE Minimize evaporation. If possible, keep storage tanks well-shaded. Less evaporation occurs with white or aluminum painted storage tanks versus red.
• UPGRADE TO NEWER FUEL-EFFICIENT MODELS Visit Cashman Equipment to learn more about the latest features, benefits, and savings to protect your bottom line.

Cashman’s technicians are amazing… and have been for years. In 2004, they completed the first rebuild of a gigantic 994 Wheel Loader – one typically used in mining. It took approximately four months to replace every part, including all hoses and electrical harnesses.

Contamination Control
Keeping machine fluids free from outside contaminants saves money, reduces downtime, and helps maintain productivity.

What Can You Do?
Make sure you use Caterpillar’s four-part contamination control program. It includes:

1. Clean Fluids – Proper fluids handling and clean, tightly sealed containers help prevent potential contamination.
2. Clean Components – Carefully clean out hoses, protecting them with end plugs and caps.
3. Clean Facilities – Shops with high-pressure wash bays, closed bay doors, and non-dirt drives help minimize contaminants.
4. Clean Shop Repair Processes – Our technicians take extra care during service to eliminate contaminants.

Following these steps will help you be prepared to control contamination and keep your Cat equipment performing at its best. Contact Cashman’s Product Support Sales Reps for more info.

Machine drivetrain major component rebuild costs account for over 60% of total machine maintenance and repairs costs excluding tires and fuel. An effective condition monitoring plan for your components will reduce machine operating costs through improving major component life. This directly impacts machine cost per hour and the bottom line.

Improving major component life also has the additional benefit of reducing the frequency of planned and unplanned machine stoppages, which increases machine overall availability and production.

Managing major component life involves two basic fundamentals:
- Eliminate or reduce unplanned component removals due to failures or premature wear. Since failures often shorten life by 50% or more, taking action to reduce the frequency of failures has a significant impact on average fleet component life.
- Set, monitor, evaluate, and adjust planned component replacement (PCR) targets for optimum life.

Process

Collect and analyze component life data and information.

Fleet component life hours achieved are tracked and summarized by machine model. Required data includes:

- Machine model
- Machine serial number
- Component name (such as engine, transmission, wheel group, differential, torque converter, suspension, etc.)
- Component serial number (or assigned ID number)
- Component removal date
- Hours on component when removed
- Removal planned or unplanned? (Failure or Planned Component Replacement)
- Root Cause of Failure (part / part group causing failure)
- Component source (component removed was new, reman, or rebuilt)
- Other helpful data as appropriate, such as “total engine fuel burn”

The component life data should be collected as a minimum for all component removals over the past three years. Over a three year period, close to 100% of the fleet components will have completed a life cycle. Component life data that is more than five years old should not be used in the analysis of “current” fleet component life performance.

Reducing Early Failures and Premature Wear Out

The management and reduction of early hour failures and premature wear out is a key success factor in increasing overall component life and machine reliability.

- Identify the root causes of failure impacting the machines.
- Determine and prioritize the top issues.
- Develop containment and solutions

Root Causes

It is important to the process to identify the “root cause” for any component removed prior to reaching the planned life target. A technical failure analysis is the best means to identify the root causes of failures.

A common mistake is to identify “what” failed rather than “why” it failed. Understanding true root causes enables preventative actions to be developed and implemented.

Failures usually originate from one or more of the following sources:

- Part defect (Caterpillar or Rebuilder Reuse and Salvage)
- Workmanship defect (Caterpillar or Rebuilder)
- Engineering Design (Caterpillar)
- Maintenance practices (Minesite)
- Operation practices (Minesite)
- Improper Removal and Installation – system contamination (Installer)

It is vital to establish a policy to perform technical failure analysis on all premature removals and a resource to provide the analysis. Most Caterpillar dealers have extensive Applied Failure Analysis (AFA) training, tooling and lab equipment required, as well as extensive knowledge of Caterpillar equipment, specifications, and technical product issues.

Define and Prioritize Issues

The accumulation of failure analysis information allows the top reasons for failures to be identified and prioritized by those issues which are most impacting component life and machine availability. Plans and actions can then be developed to contain known problems and find permanent solutions.

Action Plan – Containment and Solutions

Once key issues affecting component life performance and availability are identified and prioritized, action plans can be developed. Action plans consist of temporary containment measures and permanent corrective measures.

Temporary containment options may include:

- Identify which machines that may be affected by an issue
- Inspect machines for a defect
- Monitor machines for signs of a developing problem. VIMS data, oil analysis, particle count, magnetic plug and filter inspections, testing, etc.
- Perform a mid- life replacement of part or subcomponent known to be causing issues.
- Temporary machine systems modification

Permanent solutions may include:

- Updated part or design from Caterpillar/manufacturer
- Change in workmanship procedure
- Change in maintenance procedure
- Change in operation procedure

Manage and Adjust Planned Component Replacement Intervals

Determine Component Life Targets

- Cat / Dealer Recommendation
- Experience and History
- Experience in similar applications
- Load Factors – Fuel Burn Rate

Track Component PCR Life

- Average PCR Life
- Percentage of Components Reaching PCR

Adjusting PCR Targets

- Evaluate component condition during rebuild – life remaining?
- Rebuild based on condition rather than by hours alone
- Monitor oil consumption, smoke, oil analysis, particle count, VIMS, etc
- Evaluate parts reusability/rebuild costs at PCR

Implementation Steps

The fundamentals of this component life improvement process are:

- Collect and Analyze Component Life Data
- Manage Early Hour Failures and Premature Wear Out
- Manage and Adjust Planned Component Rebuild (PCR) Intervals

To implement, the requirements are:

- Company commitment to create an availability / component life management process
- Process owner: Assign a Reliability Manager / Engineer
- Administrative system and database to track component life
- Maintenance and Repair records database
- Policy on performing failure analysis and a database for reports and history tracking
- Develop desired management reports
- Use data to identify opportunities
- Explore opportunities for causes and solutions
- Implement containment and solutions

Benefits

- Improved fleet availability and production
- Increased average fleet component life lowers cost per hour
- Reduced unplanned machine stoppages – improved scheduling and planning
- Lower parts consumption due to reduced failure rates

Cashman Equipment’s Product Support Sales and/or Technical Services Representatives can assist you with implementing this process for your job or mine site.

Sort of scary to see your machine mid-rebuild, right? Don’t worry. Cashman’s Service department has done hundreds of Cat Certified Rebuilds, as well as Cashman Certified Rebuilds. Our Component Rebuild Center and Main Shop technicians know where everything goes, will fix any and all problems, put it back together, test it thoroughly, paint it Cat yellow, and get it back to you in perfect working order (with a new serial number if it’s a Cat Certified Rebuild!). Need more information on rebuilds? Learn more here.

Good maintenance is critical to increasing machine availability and decreasing overall operating costs. Whether you operate one machine or a fleet, comprehensive lube services are an integral part of a cost-saving preventive maintenance plan.
First, incorporate thorough lube services on a regularly scheduled basis. Look for a shop that:
1. Guarantees scheduled and unscheduled services will be completed within a 2- to 24-hour time-frame.
2. Has technicians who follow the Original Equipment Manufacturer (OEM) guidelines, using high-quality parts and lubricants.
3. Oil samples every designated compartment so you can be alerted to potential problems with the engine, drivetrain, or hydraulic systems.

Some shops, like Cashman’s, have factory-trained Mobile Lube Technicians who can provide the same level of skilled service at your convenience, right on the job site. Finding the right lube service shop means one with dedicated support staff who will provide behind-the-scenes assistance by scheduling needed repairs, dispatching the mobile lube service, sending maintenance status updates, and providing written follow-up reports.

These things will help maximize your productivity through proper maintenance. To accurately monitor equipment operation, regular analysis of oils, coolants, and filters provides excellent indicators of potential issues. Normal component wear is expected and predictable; abnormal wear may be the result of improper maintenance or operating techniques, and it can adversely affect your productivity and your owning/operating costs. However, good lube service technicians (like the ones at Cashman) are prepared to help you execute an effective preventive maintenance plan. Three of the biggest savings areas are listed below.

1. OILS
Engine oil performs three main functions: cleaning, cooling, and lubricating engine parts. High-quality oils provide maximum protection in a number of ways:

• Engine oil cleans parts by carrying away damaging metal particles and deposits.
• Engine oil cools parts by absorbing and carrying away heat.
• Engine oil lubricates parts by forming a thin film to support and separate them.

To ensure your engine oil correctly performs these functions, it is important to change the oil regularly, in the proper manner, using high-quality Cat oil.

Engine wear and failure causes
Problems in the engine lubrication system can cause accelerated abrasive wear or catastrophic failure of core components. A few of the common causes of engine wear and failure are:

• Excessive soot in the oil.
• Poor quality/low performance engine oil.
• Extended oil change intervals.
• Poor maintenance practices.
• Fuel dilution.

2. COOLANT
The cooling system of your machine maintains correct engine temperatures by taking away unwanted heat generated by combustion and friction. To help keep this system functioning properly you should:

• Maintain the cooling system properly, paying attention to high or low temperature gauge readings.
• Follow proper start-up procedures, including cleaning debris from the radiator and fan, checking the radiator cap seal, and watching for dripping coolant or oil.
• Use Cat Extended Life Coolant (ELC) to extend coolant life from 6,000 hours to 12,000.
• Over 40% of engine failures are caused or aggravated by cooling system problems, so be sure to maintain your coolant system for maximum productivity.

Cooling system wear and failure causes
Problems in the cooling system can cause accelerated erosion or catastrophic damage to the core engine components. The single most common problem is poor coolant quality, which causes accelerated cavitation, erosion of cylinder liners, corrosion, and failure of waste pump seals. Poor coolant quality is due to:

• Not maintaining adequate levels of coolant additives.
• Using coolant that does not meet manufacturer’s minimum recommendations.
• Not keeping the cooling system topped off.
• Using coolant past its useful life.

3. FILTERS
Air, oil, and fuel filters are designed to control contamination inside your engine. Effective filter changes and accurate filter selection will help maintain engine cleanliness and reduce component wear.

Select the right filters

• Air filters – Inadequate filtration can reduce horsepower, rob performance, and ultimately damage your engine. Most Caterpillar air filters feature a radial seal design preventing dirt, soot, sand, and other contaminants from entering your engine. Plus, the quick change characteristic enables you to change your filter and get your machine back to work fast. Cat Ultra High Efficiency Filters are designed for environments containing fine dust, soot, or both and can last two to four times longer than standard filters in these conditions.
• Oil filters – Quality oil filters work in unison with fluids to provide the highest levels of filtration cleanliness, performance, and protection. Cat oil filters are manufactured to meet the most demanding specifications, providing increased performance and lower costs.
• Fuel filters – Fuel filters prevent fuel system wear caused by dirt. Cat High Efficiency Fuel Filters feature special media that trap particles as small as two microns (the average period at the end of a sentence is 400 microns.) High-quality filters are essential to maximizing fuel injector and fuel pump life and prevent hard starting caused by premature injector wear

An effective and efficient preventive maintenance plan, with proper oil, coolant, and filter services, will keep your equipment and your business running at optimal performance. If you haven’t found the right partner to help you do this, contact Cashman Equipment at 1.800.937.2326 or at Cashman@cashmanequipment.com.

Why should you invest in condition monitoring practices like regular fluids analysis and remote machine monitoring? Put simply – it helps your machines live longer! Well, actually, it lets you effectively monitor the condition of your equipment so that you can schedule maintenance as well as prevent costly catastrophic failures.

How does it do that? Fluids analysis tells you what is going on inside your machine before it causes a breakdown on the job. It:

• Enables you to better manage budgets by predicting repairs, downtime, and equipment life.
• Monitors positives as well as negatives, so you won’t have to pay for repair of components that are not worn out.
• Verifies that routine practices like oil changes are being completed.
• Provides accurate equipment history for evaluating performance, planning replacement purchases, and often brings a higher trade-in price.

Another important tool for condition monitoring is Product Link, a remote monitoring solution that enables efficient and effective fleet management. Through the simple VisionLink interface, you can:

• Optimize your fuel usage.
• Track equipment locations.
• View a variety of customized health and utilization reports.

Plus, the information can be transmitted by cell and satellite… which means you are always in touch. Whether you have five machines or 50, Product Link can monitor the condition of both Cat and non-Cat equipment.

For more information on condition monitoring options like fluids analysis and Product Link, please contact your Cashman Equipment Product Support representative!

Cashman Equipment currently has an opening for a Product Support Sales Representative in Reno, Nevada prepared to perform the following functions:

• Sell parts and service to specified customers within a specified territory.
• Maintain contact with customers as outlined in the Quarterly Call Report.  Follow up with completed call report form via computer software.
• Keep customers informed of new parts and services available.
• Inspect undercarriage and ground engaging tools to determine wear at customer site or shop – make recommendations and produce quotes for service needed.
• Conduct customer sales/training meetings as well as making sales presentations.
• Negotiate successful settlement of customer product support disputes.

Ideal candidate must demonstrate leadership, integrity, teamwork, and provide great customer service.  Cashman Equipment also offers great benefits – 401(k), medical, dental, paid holidays, paid personal leave, and more! Visit our Career Search for more details on this position and many others.