Differential Maintenance

Management Guide
The differential plays a critical role within
a machine’s drive train by changing the
direction of the power coming from the
transmission 90 degrees to allow the
axles to be driven. They also allow speed
and torque differences between the
left and right axles. When a machine is
turning, the differential lets the outside
wheel move at a faster speed than the
inside wheel, allowing for easier turning
and less wear on tires or tracks. The
gears in the differential also provide
speed reduction and torque increases.

Establishing and following a preventive

maintenance program is a key factor in
guaranteeing fewer failures, more uptime,
and better machine resale value.

This guide discusses preventative

maintenance, repair management, and
highlights the components that wear and
fail in the differential. By understanding
these topics, you could minimize owning
and operating costs while maximizing
your productivity.
 Contents

Overview..................................................................................................................... 3

Preventive Maintenance.......................................................................................... 4

S•O•S SM Services....................................................................................................... 5

Contamination Control.............................................................................................. 6

Repair Management/Repair Indicators................................................................. 7

Differential Steering.................................................................................................. 8

Bearings/Gears.......................................................................................................... 9

Key Components/Component Durability.............................................................. 10

Repair Options/Scheduling and Record Keeping............................................... 11

Expect More from the Experts............................................................................... 12

This Differential Maintenance Management

Guide offers information, tips and
ideas but is not intended as a technical
manual or a substitute for the advice and
recommendations of our parts and service
experts. By using this manual to help you
understand Differentials and following the
recommendations in your Operations and
Maintenance manual, you can maximize the
productivity, service life and value of your
Cat® machines.
 Introduction

Overview of Differentials
The differential will decrease the speed and increase the torque as
needed for each wheel’s relative motion. When the machine is turning, the
differential will supply the needed adjustments to the wheels allowing the
outside wheel to move at a faster pace than the inside wheel. Caterpillar
designs and manufactures its differential components with these demands
in mind, using testing processes that replicate actual applications. In order
to get the productivity and life you demand, it is important to maximize the
life of these components by properly managing and maintaining them.

The key functions of a differential are:

• Transferring power coming from the transmission to the left and right
axle shafts
• Balancing the power according to the demand of each wheel
• To transmit the power to the wheels while allowing them to rotate at
different speeds
• Gears in the differential further reduce speed and increase torque to
drive the rear wheels

The key components of the differential are:

• Differential Assembly- Turns the spider and pinion gears that mesh
with the side gears, turning the axle shafts
• Pinion Gears- Transmits power from the spider to the side gears that
are attached to the axle shafts
• Side Gears- Splined to the axles and are driven by the pinion gears
• Spider- Serves as the mounting for the pinion gears, and rotates with
the differential assembly
• Bevel Pinion Gear- Driven by the drive shaft
• Bevel Ring Gear- Meshes with the bevel pinion gear, and is mounted to
the differential assembly
Bevel Ring
There are four types of Differentials: Side Gear Spider Gear

• Standard- As Shown
• Limited Slip Pinion Gears
• No Spin
• Locking
Bevel Pinion Gear

Differential
Assembly

3
Preventive Maintenance

Optimize Equipment Life

The key components in differential Cat TDTO (Transmission Drive Train that previously specified TO-4 lubricants
preventive maintenance include quality Oil) is specially formulated to increase and do not contain friction material.
oils and filters, regular S•O•S Oil Analysis the life and performance of your Cat drive
and contamination control. train components. Cat FDAO has the following qualities:
• Compatible with Cat Transmission
This oil: Drive Train Oil (TDTO)
Preventive Maintenance: • Reduces transmission slippage • Excellent protection against rust
• Controls brake chatter and copper corrosion
• Allows you to schedule downtime • Provides greater machine rimpull • Minimizes foaming for increased
and plan for maintenance and • Increases friction material life up to lubrication
repair costs 45 percent • Low oxidation rate for improved
• Helps prevent major failures, oil life
including failure of related parts Cat TDTO surpasses the TO-4 • Maintains desired viscosity and film
• Saves you money because you can specification requirement and is specified strength
often repair before failure as factory fill for all Caterpillar machine • Provides reduced wear from debris
• Reduces total downtime compartments where TO-4 is the primary particles suspended in the oil
• Maximizes parts reusability recommendation.
• Optimizes equipment life to keep
your machine productive and on Cat TDTO-TMS (Transmission Multi-
the job Season) is a multi-season formulation
• Increases machine resale value of TDTO. This Caterpillar exclusive is a
partially synthetic lubricant that eliminates
the need to change oil at seasonal
intervals. As a result you use the oil for its
Proper Oil Use full life, so there’s less used oil disposal
The three main functions of oil are to and less downtime for maintenance.
provide cleaning, cooling and lubrication. Cat TDTO (TMS) has shown improved
Modern Cat drive train systems feature transmission performance in cold weather
new metals, elastomers and paper disc for machines with electronic controls.
materials which may have advanced Cat Gear Oil offers maximum protection
lubrication needs, requiring you to change Cat recommends TDTO for transmissions, against the following damage: scoring of
oil regularly, properly, and use the right final drives or differentials, torque the gear teeth, pitting of the gear teeth,
drive train oil to achieve top performance. converters, and brakes where TO-4 and pitting of the parts in roller bearings.
specification oils are recommended for
Use the Right Drive Train Oil use; and recommends TDTO -TMS to avoid Cat Gear Oil provides:
Cat differentials experience high gear unnecessary oil changes in climates with • Excellent stability under high
and bearing loads and temperatures. In widely ranging ambient temperatures. temperature conditions
these conditions, it is important gears and • Superior low temperature
bearings are protected. Cat FDAO (Final Drive Axle Oil) was performance.
developed specifically to protect gears • Protection against rust and
It is essential that components be and bearings in bevel gears, differentials, corrosion
run in the correct oil. Always consult final drives and axles that do not contain Some applications require additives for
your Operations and Maintenance friction materials. the extreme pressures that can occur at
Manual for the specific oil needed.
the edges of the components. For these
The publication SEBU6250, Caterpillar Cat FDAO is the preferred lubricant for applications, Cat Gear Oil provides the
Machine Fluids Recommendations, can Cat Off-highway truck front wheels, extra protection. Cat Gear Oil should not be
be used for additional verification on oil differentials and final drives. It is used in compartments that specify TO-4 or
recommendations. compatible with Cat final drives and axles TO-4M oil.
4
 S•O•SSM Services

Importance of S•O•S Oil Analysis

Scheduled Oil Sampling is a crucial part
of machine management. Oil sampling
at scheduled intervals validates your
maintenance procedures, tracks what
is going on inside of the equipment
and forecasts wear-related problems.
Our S•O•S Oil Analysis program is well
recognized for its ability to detect
potential failures before they occur. Each
S•O•S Services test is designed to reveal
specific information about the condition of
Caterpillar® products.

The four types of analysis are below:

• Wear Metal—monitors and tracks
metal wear particles, contaminants
and oil additive package elements
• Oil Condition—compares used oil • Easy-to-understand test report, reports, determine what additional tests
to new oil to see if it is providing which calls for specific action need to be performed, and recommend the
adequate lubrication and protection and/or makes carefully outlined proper corrective action better than other
• Oil Cleanliness—determines if recommendations oil analysis programs.
abrasive contaminants are causing • Saves time and money by identifying
accelerated wear trouble spots before they become Particle Count
• Oil Contamination —detects water, major failures Particle count is another way of assuring
glycol, or fuel in oil oil cleanliness. When used in conjunction
S•O•S Services help you avoid complete with fluid analysis, particle counting can
Advantages of using S O S Services
• • failures. Often an adjustment or be a valuable tool in reducing failures in
Surveys have shown that there are many replacement of a single part, based on differential systems. The particle count
benefits to using our S•O•S Oil Analysis S•O•S Services findings, can prevent a instrument counts the number of particles
program: small problem from growing into a major in several different size ranges, from as
• Experts can provide analysis  and repair. S•O•S Oil Analysis is different from small as two microns to over 100 microns.
interpretation of trends and can other oil analysis programs because it It measures both metallic and non-
forecast any excessive wear focuses on component condition, not just metallic particles and provides an early
concerns oil condition. Since only Caterpillar knows warning of abnormal component wear and
• Test results are available within 24 the exact design of your Cat drive train contaminant ingestion.
hours after receipt of the sample system, we can help you analyze S•O•S

S•O•S Oil Analysis Example:

Typical Differential Combinations:
Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Iron Chromium Gears, Anti-friction bearings Pre-load problem (if no water
or dirt is evident)

Aluminum, Chromium Iron Sleeve bushings Wearing out, or previous

contamination

5
Contamination Control

Control Contamination, Reduce Overall

Operating Costs
Dirt, sand, grit and even the finest dust
can cause problems when they find their
way into the differential. They cause parts
to wear faster, making them more prone to
premature failure.

There are four ways contamination can

get into machine systems:

1) Contaminants can be built

in during manufacturing and
assembly operations.
2) Contaminants can enter during
servicing and maintenance
procedures.
3) Contaminants can enter with
new fluid.
4) Contaminants can enter during
operation through pitted shafts,
broken breathers, worn seals and
other trouble spots.

Fortunately there are steps you can

take to prevent fluid contamination. An
effective contamination control program
is made up of many small steps that help
maintain fluid cleanliness and reduce By following these steps, you will be The use of fluid filters in differentials
opportunities for contaminants to get in better prepared to control contamination, varies by machine type. Filters can be
machine systems. Caterpillar recommends reduce overall operating costs and keep found on the 797 and 793 off-highway
a four-part contamination control program your Cat equipment performing at its best. trucks and machines using a common
consisting of: reservoir system such as backhoe
Filters loaders. For further information on
1) Clean fluids Control contamination inside your selecting the correct fluid filters,
2) Clean components differential through the use of Cat fluid consult your machine’s Operation and
3) Clean facilities filters. By changing filters regularly and Maintenance Manual.
4) Clean shop-repair processes properly, and by selecting the right filters,
you maintain system cleanliness, reduce
component wear and lower costs.

6
 Repair Management/Repair Indicators

Managing Repairs
Repair Management is only one factor Application concerns might involve: service history and SOMA software.
that influences your owning and operating • Ambient temperature Problem indicators are usually found
costs. You should also address operating • Design of haul roads and during inspection and include noises,
technique and application as well as repetitiveness of the work leaks, overheating, and poor performance.
preventative maintenance. Even with excellent maintenance,
Repair Indicators eventually repairs will be needed.
In the area of operating technique: There are two types of indicators: planned However, problems can be caught early
• Avoid high-speed direction changes and problem. Planned indicators are by performing daily inspections and
• Avoid backing over obstructions part of a good Differential Maintenance responding quickly to repair indicators.
• Avoid extreme braking Management Program that will give you
• Operators should adequately before-failure repair options to lower Differential Repair Indicators
warm-up the machine your operating costs. Planned indicators Below is a list of planned and problem
• Pay attention to warning lights are those that are performed or checked indicators for Cat differentials, along with
• Do daily walk around inspections routinely such as S•O•S Oil Analysis, possible causes and repair options.
Technical Analysis, service meter hours,

Planned Indicators Description Options

S O S oil Analysis
• • S O S Services provide the best insight into the internal differential wear and
• • Customer/Dealer Discussion
potential failure
Service Meter Hours When visiting the customer, be sure to keep track of machine’s service meter S•O•S Services
Customer Dealer Discussion
Experience Talking with your machine’s operator can reveal many potential differential problems Repair Determination Discussion
-Observation and discussion
Service History Service history indicates how frequently routine maintenance is performed Customer/Dealer Discussion
Fuel Consumption Indicates when a piece of equipment is operating at less than optimum efficiency Customer/Dealer Discussion
Site Operations Maintenance Advisor (SOMA) SOMA is a software that assesses customers operating and maintenance practices
and provides component life estimates
Problem Indicators Possible Causes Options
Bent or Damaged Lines External damage Technical Analysis Inspection
Repair Determination Discussion
Unusual Noises Worn gears/bearings Technical Analysis Inspection
(When Traveling Straight) Ring & pinion Require Adjustment Repair Determination Discussion
Dirt entry Customer/Dealer Discussion
Low fluid level
Unusual Noises Worn differential case assembly Technical Analysis Inspection
(When Turning) Worn spiders Repair Determination Discussion
Worn spider gears Customer/Dealer Discussion
Vibration Gear failure Technical Analysis Inspection
Spider failure Repair Determination Inspection
Differential failure Customer/Dealer Discussion
Bearing failure S-O-S Services
Debris on Magnetic Plug Contamination entry (dirt/debris) S-O-S Services
Extended oil change period Customer/Dealer Discussion
Wrong oil used
Worn gears/bearings
Leaks Worn/damaged seals (pinion/differential) Repair Determination Discussion
Worn bearings Customer/Dealer Discussion
Overheating Wrong oil used Technical Analysis Inspection
Low fluid level Repair Determination Discussion
Worn or damaged seals S-O-S Services
Customer/Dealer Discussion

Keep in mind determining the cause is usually easier said than done. A visual exam may identify the type of damage, but it may not aid in recognizing what is causing
the problem. Remember, if you merely replace the failed component without finding and fixing the root cause, the replacement component will most likely endure the
same wear and damage as the original.
7
Differential Steering

Understanding Differential Steering

Differential steering uses 3 planetary gear sets and a

hydraulic motor to change the speed of each track.

This system delivers uninterrupted power The results are turns of any degree,
to both tracks during turns. Power from from slight to sharp, without interruption
the transmission is delivered through the in power. The operator turns, reverses
bevel gears to three planetary gear sets, direction and changes speed ranges using
then to the final drives and tracks. By one hand on a single tiller.
adding power to one of the planetary gear
sets, the motor adds (or redistributes) This Caterpillar-patented steering system
power to the steering differential, and by is available in the Caterpillar D6R through
its direction of rotation, speeds up one D9R, and Challenger Tractors.
track and slows down the other to make
turns. By rotating one direction, it makes
a right turn, and by rotating the other
direction, it makes a left turn. Thus the
hydraulic motor determines the direction
and degree of the turn.

8
 Bearings and Gears

How Bearings and Gears Work

Bearings are used in the differentials to It is critical that the surface of the
maintain position and alignment of gears contact areas retains an adequate oil
Causes of Premature Bearing Failure
and shafts, and to minimize friction, heat film thickness to prevent metal-to-metal
In order to maximize bearing life, it is
and wear. They also carry the weight of contact with the mating part.
important to eliminate the four primary
the vehicle and payload, subjecting them
causes of premature failure:
to very high loads and temperatures. Cat Caterpillar bearing design is application
bearings have precision surfaces that are driven, which means we offer the correct • Improper installation— Bearings are
separated by a film of lube oil. bearing for the application. not properly installed with the correct
pre-load
• Improper tolerances—Width
tolerances are incorrect for the
application
• Overload (fatigue)—Resulting from
machine overloading or long hours of
use
• Contaminated lube oil— Causes
accelerated surface pitting and
premature failure

The basic function of gears in the differential is to Causes of Premature Gear Failure
transfer power from the drive shaft to the axle shafts. There are five primary causes of premature
gear failure:
Loads are transferred through gears by to avoid metal-to-metal contact. The
gear teeth pushing against each other. heat treatment, material and machining • Pitting from surface fatigue— Normal
Gears used in the differentials are put processes used on gears are based upon end-of-life failure mode; however,
through a carburizing and hardening the specific application. consistent overloading accelerates this
process. This creates a durable outside • Contaminated lube oil— Causes
surface enabling them to carry very high accelerated surface pitting and
loads for thousands of hours. The gears cracking
are machined and precision ground to • Gear tooth bending fatigue— Result of
exact tolerances, making it crucial for severe gear overloading
the lubricating oil to be at its proper level • Improper alignment—Creates
unbalanced loading and contact
on gears
• Improper lube oil—Increases
surface wear

9
Key Components/Component Durability

A Look at the Key Components

Understanding how differentials work and wear is key to
maximizing component life. Differential repair parts can be
broken up into three groupings. They are:

Level I—fastest wearing parts, not reusable

• Anti-friction bearings
• Seals and gaskets
• Duo-cone seals

Level II—slower wearing parts, possibly reusable

• Plates
• Discs
• Gears

Level III—longest life, designed not to be replaced

• Housings and axles.

In order to correctly identify failure modes for differentials, it is

necessary to understand how the component works, the causes
of its premature wear or failure, and the maintenance steps that
can be taken to minimize the causes of wear and failure.

Key steps to improving

component durability

Clean Lube Oil Avoid Overload and Fatigue

By far, the most common and preventable Two factors that dramatically accelerate
cause of component failure is due subsurface fatigue and component life are
to contaminated lube oil. To ensure excessive loads and rolling resistance.
components run in clean lube oil, it
should be built clean, installed clean and Replace Parts Before Failure
operated clean. Differential piece parts do not have an
infinite life. After being run for thousands
Correct Lube Oil of hours at high loads and temperatures,
It is essential to the component’s life to the material will eventually fatigue.
be run in high-quality lube oil. Using the Thoroughly inspecting the components
correct lube oil will improve component results in detecting defects and
wear life up to 40% in some applications. deterioration before they fail completely
and damage other vital components.
Proper Installation and Assembly
Components are built with specific
tolerances and preloads. Proper
installation and assembly practices are
absolutely essential to component life.

10
 Repair Options / Scheduling and Record-Keeping

Selecting the Right Repair Option

Selecting the right repair option is a way • Rebearing and reseal—signaled After-failure overhaul is recommended
to lower owning and operating costs. by excessive leaks, elevated S.O.S when large pieces of metal are discovered
results or target hours during magnetic plug inspections, when
Before-Failure Repairs • Before-failure overhaul—involves failure occurs or when broken parts
Repairing before failure gets your machine rebuilding the entire differential are discovered during before-failure
back to work sooner and costs two to procedures. It includes removal and
three times less than after-failure repairs. After-Failure Repairs replacement of the entire differential
Our before failure repair options: Repairing before failure is the best way and axle group.
to reduce your downtime and costs.
• Help prevent major failures and However, if your differential system does
failure of related parts fail, we are in the best position to help
• Maximize parts reusability you control costs and save time. Part
designed into many differential parts replacement costs are kept to a minimum,
• Allow you to schedule downtime using Cat Parts Reusability Guidelines
and plan costs and replacing only damaged components.
• Maximize equipment life and Possible options include using Exchange
productivity or Cat Reman components. Cat Reman
components are available from inventory,
Differential repair options: offer same-as-new performance,
• Reseal—required when oil leaks and carry the same warranty as new
are discovered during inspections components at a lower cost.

Scheduling and
record-keeping
Good scheduling means maintenance,
inspections and planned repairs are done
on time to prevent differential failures
caused by overlooked maintenance. You
can also view S•O•S Oil Analysis results
on-line.

Record-keeping
By developing an accurate machine
record-keeping system, you can identify
high-cost or problem areas, track work
flow, control costs, and increase machine
resale value. An accurate record-
keeping system documents drive train
history by detailing component life and
cost information. We can help you set
up manual record-keeping and work
order systems, or we can help you install
computer software programs to perform
scheduling, checklists and other record-
keeping functions.

11
 Expect More From
the Experts
Maximize the Life of Your Differentials
For any machine to be safe, reliable and productive, regular preventive maintenance
is vital. It is the most cost effective way to keep your differential operating at peak
performance. If you take care of your differential, then gears and shafts can last through
multiple rebuilds and the overall differential life increases. Take a proactive approach by
planning for scheduled downtime, maintenance and repair costs. When you plan, you
save money and time—and who couldn’t use more of each?

Cat ® D ealers defi ne

world- class product
support.
We offer you the right parts and service

solutions, when and where you need them.

The Cat Dealer network of highly trained

experts can help you maximize your equipment

investment.

PEGJ0049
www.cat.com

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