TRENDS HD TRANSMISSION OILS KEY DRIVERS, CONSEQUENCES, FIELD EXPERIENCES

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1 TRENDS HD TRANSMISSION OILS KEY DRIVERS, CONSEQUENCES, FIELD EXPERIENCES Frank Machatschek Product Application Specialist Shell Lubricants 1

2 Key Drivers For Transmission Oil Development Total Cost of Ownership Measures to improve TCO also affecting transmission oil Transmission oil needs to be robust against mechanical and thermal load over extended oil drain intervals and compatible with new materials 2

3 New Developments Longer drain intervals Today: 400k-500k km Mid-term: 750k km, Long-term: 1 Mio km... Fill-for-Life Increased power density High demand on cooling and wear protection capability at high load Higher operating temperatures Higher power density Smaller oil volumes Reduction by 30-50% for lower churning losses 3

4 New Developments Improved Fuel Economy 0,5 1,5% higher efficiency through less friction losses Eg Gear box: 75W-90 75W-80, Axle: 80W-90 75W-85 Improved, durable and constant shifting quality Special oils for special applications (operation, climate) Mining, off-raod, hot climate: Volvo SAE 75W-90 Protection Long haul: lower viscosities Efficiency New materials Plastic material compatibility Carbon synchronizer 4

5 Carbon Synchronizer Many EU OEMs moved to carbon in recent years Benefits compared to Molybdenum: Longer service life, higher loads higher temperatures More shift cycles, improved shift comfort Less vulnerable against faulty shifting Carbon can be used to replace Mo synchro at repair/maintenance refer to manuel instructions New oil spec to prevent synchro failure due to oil carbon: ZF TE-ML 01 Shell Spirax S6 GXME 75W-80 approved against ZF TE-ML 01L 5

6 New Developments Require Advanced Lubricant Solutions Base oil Improved thermal stability and oxidation/deposit control More high quality synthetic base oils Gr III or Gr IV OEMs: global availability and supply security Additives Higher shear stabililty advanced VI-Improver Advanced EP/AW to compensate for lower viscosity Anti-Foam: higher durability Finished formulation DRAIN INTERVAL Improved compatibility ela/synchro OEM tailored formulations EFFICIENCY & DURABILITY OIL VOLUME 6

7 Various OEM Requirements Cannot Be Met By One Product OEM AXLE TRANSMISSION ArvinMeritor O76 O81 (SAE J2360, MIL-PRF-2105E) DANA/Eaton SHAES 254 PS-164 Rev 7 SHAES 256 Rev C ZF TE-ML 05, 12 TE-ML 02 Volvo Iveco SAE J 2360 (MIL-PRF-2105E) TE-ML 02 DAF (GL-5) TE-ML 02 MAN Typ 342/3343 Typ 341/3343 Scania STO 1:0 STO 2:0A STO 1:0 STO 2:0G Mercedes-Benz 235.0, , 235.9, , ,

8 THERMAL STABILITY Various OEM Requirements: Scania Transmission Oil Additive Chemistry (EP/AW) GL-4 STO MTF API GL-4 SAE 75W-80 GL-5 STO 2:0G API GL-5 SAE 75W-90 STO 2:0G API GL-5 SAE 75W-80 75W-90 75W-80 FUEL ECONOMY SAE viscosity grade commercially available under development 8

9 Various OEM Requirements: Mercedes-Benz Axle Oil FUEL ECONOMY SPIRAX MB 90 SPIRAX S3 AD Transmission MB SPIRAX S5 ADE 85W-90 80W-90 75W-90 75W-85 9

10 Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80 5x Eaton gear box RTSO Test duration: 500k km Fe [ppm] Cu [ppm] Oil Milage [km] 10

11 Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80 Some more examples: DAF, MAN, Volvo 11

12 Axle Oil Drain Intervals In EU Approach Fill-For-Life????? Shell Lubricants 12

13 Oil Drain Interval Axle: Spirax S6 AXME 75W-90 6 x MAN hypoid axle HY-1350 Test duration: 6 years No oil drain!! No top up!! Shell Lubricants 13

14 Oil Drain Interval Axle: Spirax S6 AXME 75W-90 2 axles inspected after 680k km 2 axles inspected after after 1,0 Mio km 4 axles inspected after 1,2 Mio km All oil parameters excellent Normal wear pattern No oil sludge No oil leakages Shell Lubricants No failures 14

15 Fuel Economy: Shell Driveline Test Rig Evaluation Unique test facility at Shell R&D lab Germany Each lubricant combination Engine-Gearbox-Axle can be tested Each single FE contribution (engine-gearbox-axle oil) can be measured Gear Box Power Brake Generator Pmax:470kw Mmax:50.000Nm Diff Ratio 1:1 / 1:4 / 1:8 /1:16

16 Fuel Economy: Shell Driveline Test Rig Evaluation Driveline test with Mercedes-Benz G gearbox and HL-7 axle FE improvement 1,5-1,7% Oil temperatures are reduced for longer equipment endurance Reference Shell FE Fluids Axle MTF Axle MTF SAE 90 80W 75W-90 75W-80 API GL-5 GL-4 GL-5 GL-4 KV KV100 VI 16,9 97 9, , ,1 143 Decrease in fuel consumption per hour at 65 km/h at 75 km/h at 85 km/h average 1,5... 1,7% Shell Lubricants 16

17 Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Question: What was the maximum oil drain interval in the MAN field trial with Shell Spirax S6 AXME in the rear axle?

18 Performance Requirements MTF vs ATF Wet Clutch Friction Stability Low Temperature Properties Oxidation Stability Synchroniser Performance Scuffing Protection ATF MTF Wear Protection Pitting Protection 18

19 Technology Leader In Automatic Transmission Oils Long history of cooperation with OEMs Range of fully-synthetic ATFs First Fill business eg ZF, Voith Longest ODIs Spirax S6 ATF ZM: km Spirax S6 ATF VM Plus: km Multiple long drain Spirax S4 HDX: Voith, ZF, Allison Shell Lubricants 19

20 Shell ATF Products Are Approved For Longest Oil Drains Allison Voith ZF Spirax S6 ATF 295 Spirax S6 ATF VM Plus Spirax S6 ATF ZM mls km km 20

21 New Developments Capable for long drain intervals Today: increase from km up to km over last 3 decades Mid-term: Fill-for-life ( km) Cope with increased mechanical and thermal load Provide constant friction behaviour over entire oil drain period Extremely high shear stability Provide corrosion protection 21

22 oil sump temperature [ C] Increasing Oil Sump And Peak Temperatures Drove Development 120 Euro VI 110 Euro III & IV 100 Euro II & articulated bus 90 Euro I Euro II 80 Oil sump peak: 120 C time Torque converter: C 22

23 Oxidation Stability Mineral vs Synthetic ATF Oxidation 170 C and 384 h Spirax S6 ATF ZM mineral ATF change of 100 C + 0,8 mm 2 /s + 16,1 mm 2 /s sludge No Yes Superior oxidation stability enables both longest ODI and high durability of ATs 23

24 Spirax S6 ATF ZM ZF First Fill Oil Approved for highest specifications: TE-ML 14E for Ecomat up to km ODI TE-ML 20 F for Ecolife up to km ODI MAN 339 Z13 Ecolife TE-ML 04D (marine) and 16N (rail) Benefits compared to other ATFs: Joint development with ZF Designed to meet requirements of ZF transmissions Esp high temperature and long ODI Ecomat Excellent low temperature performance Better viscosity control through high shear stability Shell Lubricants 24

25 Spirax S6 ATF ZM: Excellent Viscosity Control 12,0 kin. viscosity [mm 2 /s] Donax TZ 10,0 8,0 6,0 4, Shell Lubricants Oil Milage [km] 25

26 Spirax S6 ATF VM Plus Voith First Fill Oil Approved for highest spec: Voith H Section 3 Underwent severe field trials in coop with Voith with continuous oil analysis and hardware inspections, up to km ODI Only Voith approved oil for max ODI of km w/o restrictions H Section 2: km with restictions (eg GVW) H Section 1: km w/o restrictions Benefits compared to other ATFs: Joint development with Voith Designed to meet requirements of Voith transmissions Excellent low temperature performance Improved oxidation stability Shell Lubricants Better viscosity control through high shear stability 26

27 Spirax S6 ATF 295 Approved for highest spec: TES 295 HD trucks and buses as well as MD and LD vehicles Significantly extended ODI compared to TES 389 up to ml ( km) or hrs Benefits compared to TES 389 fluids: Synthetic: better than previous spec (eg Allison C-4) Improved low temperature performance Improved oxidation stability Better viscosity control through high shear stability Meets GM Dexron-III for steering/hydraulics Shell Lubricants Meets specs based on Allison TES 389/295 eg Cat AT-1 Synthetic ATF 27

28 TRANSMISSION OILS FOR MINING APPLICATIONS Carlos Torres Indirect Lubricant Technical Coach Shell Lubricants 28

29 Applications Power Train Hydraulic Systems Wet Breaks Shell Lubricants 29

30 Mining Sector Trends Extended Component Life Extended Service Intervals Energy Efficiency High Loads Fine Filtration Low Environmental Impact Shell Lubricants 30

31 Off Road Haul Truck Mechanical Brake & Hoist System Torque Converter & Transmission Steering System Differential & Final Drives Shell Lubricants 31

32 Off Road Haul Truck Electric Drive Omala S4 Wheel Traction Motor Planetary Gears Shell Lubricants 32

33 Shovels Omala S3 GP Omala S4 GX Omala S4 Wheel Shell Lubricants 33

34 Fuel Economy Transmission Fluids Trends Load Capacity Viscosity Oxidation Resistance Friction Coefficient Shear Stability Viscosity Index Heat Dissipation Shell Lubricants 34

35 Shell Spirax Portfolio for Mining FZG Low Speed Wear Test Spirax S5 CFD S5 CFD M 50/60 M 10 S4 CX 50 Wear [mg] CAT FD-1 < Shell Lubricants 35

36 Success Case 01 Albian Sands Energy Shell Spirax S5 CFD M Final Drives of CAT 797F 1 CHALLENGE 2 SOLUTION 3 OUTCOME Albian Sands Energy in Fort McMurray Canada operates 75 haul trucks Caterpillar 797F. In 2008, Albian introduced a new fleet of haul trucks and started to experience failures in less than 5000 hrs of operation whereas the expected life was of hrs. Shell, through Shell LubeExpert, made a detailed analysis of the application and proposed the use of a high-performance lubricant for final drives (Shell Spirax S5 CFD M 50). Together with the change of lubricant, a systematic monitoring of the final drives, a process of contamination control and training of all staff involved was implemented. All these actions delivered a life extension of the lubricant and increased the life of the final drives. 4 VALUE Savings of over USD 160,000.00/year with productivity increasing and life extension of the lubricant Life extension of the lubricant from 2000 hours to 4000 hours Increased the life of the final drives from 5,000 hours to 20,000 hours (expressive values not accounted in this case) Increased the life and reliability of the final drives The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices. 36

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