Horton Fan Hub - National Highway Traffic Safety ... · Horton Fan Hub Status Update. Heat > 243º F. Grease Breakdown. Purge. Additional Heat Generated. Cage Failure. Bearing Ball
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Horton Fan HubHorton Fan Hub
Horton Fan Clutch Failures Horton Fan Clutch Failures
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Build Month
R10
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3 6 9 12 24
PreloadChange
BearingUpgrade
100% NewBearingSupplier
Partial Bearing Change & Preload& Grease Change
Redacted]
BeltMaterialChange
RingShroud
CATACERT
Seal toShield &Grease
60 Sec On Time& New Grease
Feb 2007 Bearing Upgrade
CONF BUS INFOConf Bus Info
Horton Fan Hub Failure ModesHorton Fan Hub Failure ModesHub failures have two similar causes• Oil separation due to excessive heat• Grease purge due to excessive heat
Both causes lead to Hub Bearing Failure
Old InstallationOld Installation
Horton Fan Hub Status UpdateHorton Fan Hub Status Update
Heat > 243º F
Grease Breakdown
Purge
Additional Heat Generated
Cage Failure
Bearing Ball Shift
Fan Clutch Failure
Seal Failure
Horton Fan Hub Failure ModesHorton Fan Hub Failure ModesFailure Modes:
• Oil Separation - leading to grease breakdown
• Grease Purge
Horton Fan Hub Horton Fan Hub –– Corrective ActionCorrective ActionGrease Purge:• Changed from GWP grease to GXK grease• GWP grease failure rates were ~0.5%• GXK grease failure rates are showing ~0.15%
Before (GWP grease) After (GXK grease)
Horton Fan Hub Horton Fan Hub –– ’’07 Design07 DesignSeal Improvements (grease purge): (February 07)• Change to Viton seal• Higher temp rating, improved grease retention
Before (NBR) After (Viton)
Horton Fan Hub Horton Fan Hub –– ’’07 Design07 DesignSteel Bearing Cage (bearing life): (February 07)• Change to Steel bearing cage from Plastic• Higher temp rating, improved bearing retention
Before (plastic) After (steel)
Horton Fan Hub Horton Fan Hub –– ’’07 Design07 DesignHardened Race (bearing life): (February 07)• Change to Heat stabilized steel• Consistent load at high temperature, improved
bearing life
Before (standard race) After (heat stabilized)
Corrective Action SummaryCorrective Action Summary
Key Product Improvements for 2007 conditions:• GXK grease: (May 2006)
– Reduced oil separation at high temperature– Capable of -40º F to 356º F
• Viton seal: (February 2007)– Reduced risk of seal degradation at high
temperature, resulting in less grease purge– Capable of -40º F to 392º F
Horton Fan Hub Horton Fan Hub –– Corrective ActionCorrective ActionGXK Grease – (grease breakdown):• Change to GXK grease (June 2006)• Hot Box testing confirms field test results
Before (GWP grease) After (GXK grease)
Upgraded BearingsUpgraded Bearings
The new bearing is expected to The new bearing is expected to positively affect the robustness of positively affect the robustness of the DriveMaster related to heat the DriveMaster related to heat induced failures in 2007 and beyondinduced failures in 2007 and beyond
Product PicturesProduct PicturesModel Year 2009
•• In anticipation of higher heat in 2010, In anticipation of higher heat in 2010, Horton proactively developed a new Horton proactively developed a new sheave bearing package capable of sheave bearing package capable of handling extreme high heat applications.handling extreme high heat applications.
•• Due to the overwhelming benefits, this Due to the overwhelming benefits, this technology has been pulled forward for technology has been pulled forward for immediate implementation.immediate implementation.
•• IntroducingIntroducing……
Historical Perspective 2008Historical Perspective 2008
CONFIDENTIAL
•• ImprovementsImprovements–– High Durability Double Row Angular Contact (DRAC) High Durability Double Row Angular Contact (DRAC)
bearing.bearing.
–– 40% longer life on air cartridge40% longer life on air cartridge•• Redesigned with longer wear lengthRedesigned with longer wear length•• Decreased maintenance intervalsDecreased maintenance intervals
–– Upgraded friction liners for high torque applicationsUpgraded friction liners for high torque applications•• Innovative dualInnovative dual--lipped backing plate stiffens assemblylipped backing plate stiffens assembly•• Improved durability and lining protection helps prevent Improved durability and lining protection helps prevent
““chunkingchunking””•• Backing plate doubles as a visual wear indicatorBacking plate doubles as a visual wear indicator
–– Available in on/off, Remanufactured, and 2Available in on/off, Remanufactured, and 2--speedspeedCONFIDENTIAL
•• DoubleDouble--Row Angular Contact (DRAC) sheave bearing.Row Angular Contact (DRAC) sheave bearing.–– More than a threeMore than a three--fold improvement in predicted reliability over fold improvement in predicted reliability over
the successful 2007 design.the successful 2007 design.–– Field testing of DRAC brg over the past three years in over 340 Field testing of DRAC brg over the past three years in over 340
trucks and 71 million miles.trucks and 71 million miles.
CONFIDENTIAL
Bearing Style ComparisonBearing Style ComparisonDM Advantage DriveMaster
Other On/Off Mfg. (rear bearing) Other On/Off Mfg. (front bearing)
• DRAC bearing• 14 Rolling elements/row• Rolling elements fill nearly the
entire bearing diameter• Highest load capacity• High contact angle – able to
withstand more thrust load• Dual lip Viton seals• Highest temp grease available• Size:45x85x39mm
• 6209 Deep Groove bearing 2 needed
• 10 Rolling elements/row• Preloaded to increase
stiffness• Dual lip Viton seals• Size:45x85x19mm
• 6209 Deep Groove bearing • 9 Rolling elements/row• Low load capacity• Not preloaded• Size:45x85x19mm
• 6207 Deep Groove bearing• 9 Rolling elements/row• Not preloaded• Lowest load capacity• Small size:35x72x17mm
CONFIDENTIAL
CrossCross--section Comparisonsection Comparison
•• DriveMaster kits with bearings can NOT be used DriveMaster kits with bearings can NOT be used interchangeably with DM Advantageinterchangeably with DM Advantage
DriveMaster with (2x) DriveMaster with (2x) 6209 bearings and spacer6209 bearings and spacer
DM Advantage with (1x) DM Advantage with (1x) DRAC bearingDRAC bearing
CONFIDENTIAL
•• Confidence in productConfidence in product
–– Backed with a 2 year / 200,000 mile nationwide Backed with a 2 year / 200,000 mile nationwide warranty on OEM installationswarranty on OEM installations
•• 100,000 miles over base vehicle coverage100,000 miles over base vehicle coverage
–– 1 year / 100,000 mile warranty support on over the 1 year / 100,000 mile warranty support on over the counter salescounter sales
CONFIDENTIAL
Component ComparisonComponent Comparison
•• Testing in hot box to confirm seal and grease lifeTesting in hot box to confirm seal and grease life•• DM advantage bearing ran 10 times longer than the DM advantage bearing ran 10 times longer than the
bearing used in the will fitters clutch and master kit.bearing used in the will fitters clutch and master kit.
Hours to Failure in Hot Box Test
3767
3860
500
1000
1500
2000
2500
3000
3500
4000
DM Advantage Bearing Will Fitter's clutch and MasterKit
Hou
rs
Test Conditions: Bearings run at 2400 rpm and 300°F for 22 hours and rapidly cooled at 0 rpm for 2 hours to 80°F daily
CONFIDENTIAL
Component ComparisonComponent ComparisonEngagement Time at 2600 rpm Input speed
0
500
1000
1500
2000
2500
3000
0 0.5 1 1.5 2 2.5Time (sec)
Spee
d (r
pm)
Will Fitter input Will Fitter fan DM Advantage input DM Advantage fan
The smooth engagement of the DM Advantage prevents damage
to belts and tensioners
CONFIDENTIAL
SummarySummary
•• Horton is again setting the benchmark Horton is again setting the benchmark for fan clutch durabilityfor fan clutch durability
–– The DM Advantage has proven to have a superior The DM Advantage has proven to have a superior sheave bearing design when compared to all other sheave bearing design when compared to all other clutches and repair kits.clutches and repair kits.
–– The DM Advantage is available The DM Advantage is available NOWNOW at all truck at all truck OEMsOEMs
–– A full line of DM Advantage Reman fan drives are A full line of DM Advantage Reman fan drives are available for upgrade and retrofits at no additional available for upgrade and retrofits at no additional charge or core penaltycharge or core penalty
CONFIDENTIAL
Typical Installations of
Model Year 2007 & 2008 PACCAR Vehicles
Caterpillar C15 Installation-Driver Side
• (A) = 6 inch space
• (B) = Metal Ring
• (C) = Molded Shroud
FWD
(A)
(C)(B)
Caterpillar C15 Installation-Pass. Side
FWD
(A)
(B)
(C)
Cummins ISX Installation-Driver Side
FWD
(A)(B)
(C)
• (A) = 6 inch space
• (B) = Metal Ring
• (C) = Molded Shroud
Cummins ISX Installation-Pass. Side
FWD
(A)
(B)
(C)
• (A) = 6 inch space
• (B) = Metal Ring
• (C) = Molded Shroud
Standard Warning Label
• Label affixed to both sides of cooling module all on PACCAR products
HortonHortonDriveMaster statusDriveMaster status
2
Horton understands the need to bring a Horton understands the need to bring a swift and effective solution to the current swift and effective solution to the current
situation situation
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Failures Since January 2005Failures Since January 2005
• Failures have two similar causes• Oil separation due to excessive heat • Grease purge due to excessive heat
• If the rough bearing is not identified in time the following may occur• More heat - loss of oil / grease - more heat, etc.
until a seal failure and/or cage failure.
• If the cage fails, the bearing balls can lose their alignment, allowing the raceways to separate.
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ResultResult
• There have been incremental improvements with the bearing revisions for DriveMaster.
• Peterbilt warranty remained higher than other OEM’s.• Extensive use of CAT C15 ACERT engine and
• Under hood temperature?• Addition of ring shrouds?• Belt material and changes?• Different heat exchanger package?
• The change to the new grease is expected to significantly reduce the bearing failure rates for Horton products built since May, 2006.
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Improvement from GWP to GXKImprovement from GWP to GXK
• Although the Peterbilt warranty data for ’06 build is somewhat immature, it does indicate a significant improvement.
• GWP grease failure rates were ~0.5% at 6 months• GXK grease failure rates are showing ~0.15% at 6
months
• Breaking out the higher failure rates indicates 3 key Peterbilt Part Numbers to target.
Key Part NumbersKey Part NumbersFailure by Part for Different Bearings
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
PB 989313 PB 989334 PB 989809 KW 989361 KW 989437 KW 989801
NSK - >23 mo.All SKF, GWP - >7 mo.
SKF, GXK - <7 mo.
Kenworth and Peterbilt Bearing Failure Percentages6 and 12 Months of Service
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN
2005 2006
In-Service Year & Month
Fail
%
KW 12 Month Fail %
KW 6 Month Fail %
PB 12 Month Fail %
PB 6 MonthFail %
What this graph shows: Comparison of claims by In-Service Year & Month after 6 & 12 months of Service.
PACCAR Bearing FailuresPACCAR Bearing Failures
SKF GWPSKF GWP
Proposed Upgrade ProgramProposed Upgrade Program• Peterbilt trucks put into service in 2005 and 2006 with
Horton part numbers 989313, 989334, or 989809 and pre-SKF GXK.• In service in 2005:
• 995048 Kit at No Charge or • 995051 Special Super Kit at a 50% discount
• In service date in 2006 and pre-SKF GXK:• 995048 Kit at No Charge or • 995051 Special Super Kit at a 50% discount
- and• 2.5 hours of labor @ $80/hr.
• If customer selects Special Super Kit they will have warranty extended by 1 year 100K miles from repair date
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Proposed Upgrade ProgramProposed Upgrade Program
• Exclude trucks that have received a repair since 7/1/06. They have received the SKF with GXK grease.
• Upgrades to be performed by September 1st 2007• Horton will be able to support up to a total of 2000
Kits/Week • Horton would like PACCAR’s assistance in identifying
the VINs of eligible trucks.• VIN range possible.• VIN of trucks that have been repaired since 7/1/06.
10
What do the upgrades get you?What do the upgrades get you?
• GXK grease (no change from current production)• Reduced oil separation at high temperature over original.
• Viton seal• Reduced risk of seal degradation at high temperature which will
result in less grease purge.
• Steel cage• Higher temperature rating able to withstand the higher operating
temperatures expected in 2007 without degradation.• Failure is less likely to result in the separation of the bearing races.
• Heat stabilized steel races• Reduces deformation of the races at high temperatures resulting in
more consistent preload throughout operation.
• In field and lab testing, the new bearing grease/package has greatly improved the reliability of the DriveMaster fan drive.
11
Bearing Upgrade KitBearing Upgrade Kit
• 995048 Contents:• All Seals and lubricant• Upgraded Bearings• Main Nut (for fresh lock patch)• Liner Screws (for fresh lock patch)
• Omissions that can be shipped as necessary:• Cage Nut (tool for disassembly)
• Torx 55 Plus Bit (tool for disassembly)
• Literature • teardown/rebuild instructions available on the website or via
mail, fax and e-mail
Special Super Kit Upgrade Special Super Kit Upgrade
• 995051 Special Super Kit Contents:• New FMFD• New Liner• New Clutch Pack• All Seals and lubricant• Upgraded Bearings• Main Nut (for fresh lock patch)• Liner Screws (for fresh lock patch)
• Omissions that can be shipped as necessary:• Cage Nut (tool for disassembly)
• Torx 55 Plus Bit (tool for disassembly)
• Literature • teardown/rebuild instructions available on the website or via
mail, fax and e-mail
13
Upgrade Program ImplementationUpgrade Program Implementation
• Horton would prefer PACCAR assistance in distributing the parts and tracking the progress of the program.• Bearing kits will be shipped at N/C and thus no mark up $’s• Special Super Kits will be shipped at 50% off of the regular
price of Super Kits with upgraded bearings• No parts credit necessary on repairs• Could be sold at standard mark up, or special lower mark
up to encourage higher take rate• Package price - parts and labor - on special super kit to
make it a more attractive option, particularly for 2005 vehicles?
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AppendixAppendix
15
Key ApplicationsKey Applications
• 989313 – Peterbilt 387 with C15: 1.2:1 ratio• 989334 – Peterbilt 379 with C15: 1.2:1 ratio• 989809 – Peterbilt 379 with C15: 1.3:1 ratio
• 989361 – Kenworth W900L with C15: 1.25:1 ratio• 989437 – Kenworth T600/800/C15: 1.25:1 ratio• 989801 – Kenworth T2000 with ISX: 1.3:1 ratio
Kenworth Failures by Part NumberKenworth Failures by Part Number
0
5000
10000
15000
20000
25000
30000
9894
37
9898
01
9893
61
9893
60
9893
62
9893
66
9891
54
9891
98
9893
39
9898
16
9894
36
9894
21
9894
05
9892
33
9894
44
Un
its
Sh
ipp
ed
0
100
200
300
400
500
600
Cla
ims
ClaimsUnits Shipped
Kenworth Part # 989347, 989361, 989801 Bearing Failure Percentages6 Months of Service
0%
2%
4%
6%
8%
10%
12%
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN
2005 2006
In-Service Year & Month
Fail
%
989437 - 6 Month Fail %
989361 - 6 Month Fail %
989801- 6 Month Fail %
What this graph shows: Comparison of Part # by In-Service Year
& Month after 6 months of Service.
Kenworth Bearing FailuresKenworth Bearing Failures
SKF GWPSKF GWP
Kenworth Part # 989361 Bearing Failure Percentages3, 6, 9, 12 Months of Service
0%
2%
4%
6%
8%
10%
12%
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP
2005 2006
In-Service Year & Month
Fa
il %
989361 - 3 Month Fail %
989361 - 6 Month Fail %
989361 - 9 Month Fail %
989361 - 12 Month Fail %
What this graph shows: Comparison of Part # by In-Service Year & Month after 6, 3, 9, 12 months of Service.
Kenworth Bearing FailuresKenworth Bearing Failures
SKF GWPSKF GWP
Thank YouThank You
We value our partnership with PACCAR.
We continue to seek ways to improve our mutual customer’s satisfaction.
2007-09-24 Fan Drive Improvements – Peterbilt
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
2007_Airflow_TG841_Design Review
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
DecisionAnalysis_2007_FanSystemSupplier
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
DFMEA_2007_PCP840-841
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
PACCAR Six Sigma_121207 rev 1
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
Reliability Predict 2007 Initial
Submitted to the Office of Chief Counsel
With a Request for Confidential Treatment
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