BUILT FOR THE NEXT GENERATION

CAT TIER 4 INTERIM PRODUCTS

Cat Maintenance Agreements January 27, 2012

Andy Miller, LPSD Matthew Delzell, LPSD Eric Mathewson, CSS Mary Roethler, CSS
Note: This training provides detailed product support material and is for Cat Field Reps and Dealer personnel information purposes only. The intention of this material is to be used for training purposes only and is not to be included in any messaging presentations.
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Agenda

1. 2. 3. 4. 5.

NPI for 2011 NPI schedule for 2012 Pre-delivery checkpoints Maintenance changes for Tier 4 Interim Resources & Customer materials

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2011 Tier 4 New Product Introductions

Q1 Q2 Q3 Q4

TTT D6T TTT D7E TTT D8T HEX 336E HEX 349E MG 140M2 MG 160M2

FP 568 MWL 966K MWL 972K MWL 980K AT 735B AT 740B

WTS 621H WTS 623H WTS 627H HEX 329E HEX 324E FP 563 FP 573 Pav AP1000E Pav AP 1055E D11T* D11T CD*

MWL 950K MWL 962K HEX 323E HEX 320EL RR HEX 320E QCT 773G* QCT 775G* LWL 854K* LWL 992K*

*> 750 hp; Tier 4 Final

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CONFIDENTIAL YELLOW

Machine Engine Applications

175 - 750 hp > 750 hp

75 - 175 hp

C4.4
Articulated Trucks

C6.6

C7.1

C9.3
725

C13
730

C15
735/740

C18

C27

C32

C175

Forest Products

501/553/564/574 519/529/559

525/535/545/569/579 511/563/573/550 12/14/18/20MT

521/522/532/ 541/551/552

Hydraulic Excavators
311/312/314/318

320/321/323

324/325

336

345

365

385

Motor Graders 12/120 Off Highway Trucks 770 Paving Products AP4xx/5xx AP6xx AP10xx RM300 RM500 PM201 PM202 772 773/775 777
785/789/793/797

140/160

14/16

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Track Type Loaders

953 Track Type Tractors D3/4/5 Underground Mining R1700 AD30/R2900 AD45/R3200 AD55 D6K/N D6T/D7/572 D8/583/587 D9 D10 D11 963 973

Wheel Dozers/ Compactors

814/5/6 Wheel Loaders 908/914 Wheel Tractor Scrapers 924/930 938/950/962 966/972 980 988 990 992/993 994
4

824/5/6

834/6

844

854

For the latest version go to: http://catelectronics.corp.cat.com/organization/1200/Tier%5F4a/

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613

627/637 R. Eng

620 Tractor

657 Rear Eng

630/657 Tractor

Aftertreatment Configurations
C4.4 & C6.6 (75-175 hp)
DPF DOC
Backpressure Valve

Cat CEM C7.1 C18 (175 750 hp)

Optional Muffler Optional Air Filter DOC & DPF

Mounting Brackets

Cat CEM C27 C32 (>750 hp)

Integral Mounting Cradle

Cat Regeneration System

Integral Mounting Cradle

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Cat Regeneration System (CRS) Modes

Automatic Modes: The ECM will sense when conditions are optimal to regenerate and will initiate regen automatically with no operator intervention required. Two automatic modes: -Low Speed/High Speed: Regenerates during normal idle until DPF full to some trigger level- then high speed regeneration enabled. Default setting on all machines -Low Speed only: Machine will only regenerate during normal idle conditions Manual Mode: Will only regenerate when operator depresses regen button - Intended for operation in combustible environments Switching between modes: Requires a Cat ET.
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Key-off Regeneration

Key-off regen
Operator enabled push button, turn off key

Allows machine to regen, then cool down, and then turn off on its own
Disabled at the factory dealer can enable

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Engine Shutdown Timers

Auto shutdown
Simply turn off key Allows machine to cool down and then turn off on its own Once enabled, machine travel and implements are disabled for safety Disabled from factory dealer can enable

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Engine Shutdown Timers

Engine Idle Shutdown

Supports anti-idling legislation machine shuts down after programmed duration After machine shuts down, power is shut off so it doesnt drain batteries Operator can override idle shutdown timer with decel pedal Disabled at the factory dealer can enable

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Overview

Caterpillar Confidential: YELLOW

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Product / Vision Link and Operator Interface (dash lights):

Tier 4 Interim Diesel Particulate Filter Notification Strategy
At 90% DPF soot load, light comes on in the cab. Operator warning begins:

At 100% DPF soot load, engine derates 50% and a level 2 event is logged on the ECM. This event is transmitted via Product Link/Vision Link at the next scheduled transmission and customer/user is notified per their preferences setup in Equipment Manager/VisionLink (EM/VL). Operator warning escalates to:
At 116% DPF soot load, the engine idles down. The operator has only 10 minutes to initiate a manual regen before regen is disabled. At 120% DPF soot load, engine derates 100% and a level 3 event is logged on the ECM. This event is transmitted via EM/VL immediately. Regen is disabled. Service mode regen only. + Horn Operator warning escalates to: At 140% DPF soot load, now have 30 second limp mode until key cycled back on and then another 30 seconds, etc. The DPF must be replaced. It can no longer be cleaned or reused at this point. GENERATIONS AHEAD Caterpillar Confidential: YELLOW

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Over 6,600 Production Deliveries to U.S. & Canada

Daily review of Product Link data & DSN Emerging issues are aggressively resolved No major issues to date Excellent Quality Results

Caterpillar Confidential: YELLOW

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Operator Training
Instructor Led Operator Training materials
12 languages Dealer.cat.com

Regen Quick Reference Cards

Laminated, Hole-punched Ship with machine and dealer literature orders
Spanish/English French/English German/English Japanese/English

Mobi tag Video on Cat.com (23 minutes) Video (YouTube) 6 minutes

http://youtu.be/gb20fcPewTI http://www.cat.com/technology/tier-4
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Smart phones, laptops, DVD, etc. Focuses on Regen

Pre-delivery Checklist Additions

Ensure Product Link is activated Double check the settings for Regen Mode Key off Regen Delayed Engine Shutdown Idle Timing Shutdown Operator Training for machines with Cat Regeneration System C7.1-C18 engine Regen Quick Reference Card 6 minute video

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Fuel, Oil, & Maintenance

CAT TIER 4 INTERIM

2010 EAME Train-the-Trainer

Stage IIIB
Caterpillar Confidential: YELLOW

Tier 4 Product Fuel and Oil Requirements

ULSD required for Tier 4 Interim product

15 ppm (mg/kg) sulfur content (currently up to 500 ppm (mg/kg)) Enables engine and aftertreatment performance/durability Violates EPA regulations if not used ULSD generally not available in LRC regions

ECF-3 API CJ-4 oil required:

Reduced sulfated ash, phosphorous, and sulfur To maintain DPF performance and cleaning cycles
EPA (required) Fuel inlet label

Biodiesel up to B20, when blended with ULSD Fuel additives:

May not exceed 15 ppm (mg/kg) sulfur, OR May not exceed 1% by volume of the resulting fuel/additive mixture

All Cat engine models can use ULSD fuel and CJ-4 low ash oil (backwards compatible)

Oil inlet cap label

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What is different about Tier 4 Interim/Stage IIIB?

Fuel
All nonroad U.S. EPA Tier 4, European Union (EU) Stage IIIB and IV, and Japan (MLIT) Step IV certified diesel engines are required to use only Ultra Low Sulfur Diesel (ULSD) and Sulfur-Free fuels that are 15 ppm (mg/kg) sulfur or less

Misfueling with diesel fuels greater than 15 ppm (mg/kg) sulfur can have the following negative effects:
Increased engine wear, corrosion, and deposits Increased regeneration frequency, reducing fuel efficiency Reduced aftertreatment performance, increasing the frequency of ash service Cause repairs not covered by warranty

Caterpillar Confidential: YELLOW

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CJ-4 Oil
Low Ash Oil Cat DEO-ULS or oils that meet the Cat ECF-3, API CJ-4, and ACEA E9 specification are required. Use of oil with greater ash and chemical levels can have the following negative effects: Aftertreatment will accumulate more ash sooner Cause aftertreatment damage Increase the frequency of ash service Reduce performance

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Caterpillar Used Equipment Migration Position Statement Tier 4/Stage IIIB/MLIT Step 4 engines are intended for sale in Highly Regulated Countries (HRC) North America, Europe and Japan. Tier 4/Stage IIIB/MLIT Step 4 engines require Ultra Low Sulfur Diesel (ULSD) fuel that contains no more than 15 ppm sulfur in the U.S. and 10 ppm in the European Union. ULSD is not widely available outside of HRC countries. If Tier 4/Stage IIIB/MLIT Step 4 products with EGR and Diesel Particulate Filters (DPF) are operated on fuel other than ULSD, significant engine and aftertreatment damage will occur. Caterpillar warranties do not cover any failures caused by or related to mis-fueling Tier 4/Stage IIIB/MLIT Step 4 products. Used equipment has traditionally flowed from HRC to Less Regulated Countries (LRC) Countries other than North America, Europe and Japan. Tier 4/Stage IIIB/MLIT Step 4 products should not be exported to LRC countries for many reasons. Tampering with emissions systems in HRC areas is problematic and illegal in some countries. Caterpillar strongly advises against any engine emissions system modifications.

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Oil and filter change intervals C9.3 - C18

Engine Oil and Filter Change
Interval: 500 hrs under normal conditions; 250 hrs for severe duty
Parts Needed: Oil Filter 1R-1808 (qty 1) (~$20 D/N cost) CAT DEO-ULS Engine Oil 15W-40

291-3866 (1 gal container) (~$13 D/N cost)

291-3868 (5 gal container) (~$60 D/N cost) 291-3869 (55 gal container)

Service tool needed: Filter removal tool (185-3630 strap wrench)

Caterpillar Confidential: YELLOW

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Lube Sump Capacity

45 40
Engine Oiil Refill Capacity (liters)

35 30 25 20 15 10 5 0 336 966/972 627 D6T 140/160 980 627 349 740 D8T Machine Model T4 refill capacities T3 refill capacities

Caterpillar Confidential: YELLOW

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CJ4 Oil Part Numbers

OIL PART NUMBERS NAME 1 - Engine Oils Cat DEO-ULS 15W-40 10w-30 Cat DEO-ULS SYN 300-7914 341-0729 300-7915 308-1476 301-2233 317-3085 Cat DEO-ULS SYN Jan-09 VISC 1L 5L 20L 208L OIL PART NUMBERS NAME 1 - Engine Oils Cat DEO-ULS 15W-40 10w-30 Aug-06 VISC

1E SPE

1E1867

1E1867

5W-40

335-9836

335-9837

335-9838

5W-40

1E1867E

OIL PART NUMBERS NAME 1 - Engine Oils

Aug-06 VISC 1E SPEC Bulk L 1 GAL

1 GAL 4 Qty. 5 GAL 55 GAL BULK-GAL BULK-RAIL CAR

Cat DEO-ULS 15W-40 10w-30 Cat DEO-ULS SYN

1E1867E 1E1867E

291-3866 317-3081

291-3868 317-3083

291-3869 317-3084

300-7913 319-2260

335-2491

5W-40

1E1867E

335-9842

335-9840

335-9841

335-9842

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Ash in The Diesel Particulate Filter (DPF)

Formed from lube oil additives that dont combust Removal requires cleaning process
C7.1 ACERT C18 ACERT applications Dispose per applicable regulations 5000 smh

Multiple cleaning methods available

Stationary (on-highway) tool Additional adapters available Mobile tool

Caterpillar Reman Exchange

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319-2189 Diesel Particulate Filter (DPF) Ash Cleaning Tool

Offers a patented pulse cleaning process

Cleans all Caterpillar DPF sizes

Utilizes custom Cat software and adapters Accepts SD memory cards to install other OEM DPF cleaning software Adapters for Tier 4 will be available June 2011 373-3145 Adapter Kit Approximate Cost: $500.00 319-2189 DPF Cleaning Tool - $16,083.77 Dealer Net USD Availability: Currently Available
Caterpillar Confidential: YELLOW
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364-5971 Compact DPF Cleaner

The new Compact DPF Cleaner has the best available technology and is small enough to transport to all servicing locations Cleans DPF in approximately one hour Is quiet, less than 72.8 dB Requires no expensive consumables Requires no specialized adapters Is CE Compliant Pricing: DN $10,250.00 USD Availability: June 2011
364-6044 371-3749 367-8959 366-6780 366-6781 Kit-Ring & Seal (large) Kit-Ring & Seal (med) Kit-Ring & Seal (small) Kit-Ash Disposal Kit-HEPA Filter

Serviceable Parts

Caterpillar Confidential: YELLOW

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DPF Cleaning
ECM logs a code stating Ash Service Due @ 5000 hours

Can only be cleared by Electronic Technician (ET)

Dealer or Customer must complete 1 hour in-chassis Ash Service Regeneration

Initiated by ET

The only Caterpillar supported ash service options are

Replace with New Replace with Cat Reman (50 55% of new) Dealer clean & re-install on same machine

Estimated dealer cost/labor hours

1. 2. 3. 4. 1 hour for in-chassis Ash Service Regen 1-2 hours to cool 1-2 hours for Remove & Install 1 hour to clean DPF Reman option eliminates steps 1, 2 & 4

Anticipate Competition from TEPS Dealers, Cummins Dealers

Caterpillar Confidential: YELLOW

D7E (C9.3)10 X 12" DPF 349 (C13) 12 X 13.5" DPF Total Repair Cost to Clean & Reapply Elapsed Time (ET) out of service Total Repair Cost to Replace with Reman ET out of Service $700-800 5-6 hrs $744 - $844 2 hrs $700-800 5-6 hrs $1600-1800 2 hrs

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DPF Application Coverage

Caterpillar Confidential: YELLOW

DPF Pricing

Serviced Level Filter Kit Part # New *kit includes clamps 358-3659 358-3662 358-3664 358-3667 358-3669
Torca Clamps *needed for cleaning 345-1858 345-1849 345-1849 345-1839 345-1839

D/N New

Suggested C/L New $ $ $ $ $ 1,334.44 2,461.52 2,644.63 3,337.93 3,701.80

Reman Filter Reman D/N $ Suggested Kit Part # Reman C/L 20R0696 20R0697 20R0698 20R0699 20R0700
Application

$ 980.81 $ 1,809.22 $ 1,943.80 $ 2,453.39 $ 2,720.82

$ $ $ $ $

539.45 756.01 971.90 1,226.69 1,360.41

$ 733.95 $ 1,028.59 $ 1,322.31 $ 1,668.97 $ 1,850.90

D/N New Suggested DPF Cleaning C/L New Machine *est 4-6 hrs $ $ $ $ 57.91 63.96 63.96 69.48 $ $ $ $ $ 78.79 87.02 87.02 94.53 94.53 $400-$600 $400-$600 $400-$600 $400-$600 $400-$600

Diameter Length Weight (in) (in) 14 14 14 16 18 (lbs) 25.79 38.14 38.14 48.83 54.76

C7.1, C9.3 (D7 only) C7.1, C9.3 C9.3 (MWL only) C15 (D8 only) C9.3 (Industrial only) C13, C15, C9.3 (Industrial only)

11 13 13 14 14

$ 69.48

Caterpillar Confidential: YELLOW

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Open Crankcase Ventilation (OCV) Filter

Crankcase emissions to atmosphere now regulated (EPA) Open circuit using new high-efficiency filter Coalescing cartridge style filter Cleaner engine compartment 2,000 hr service (C9.3 - C18) 1,500 hr service (C4.4 - C7.1)
Block - Coalesced oil drains back to crankcase
Atmosphere Filtered gas and condensate Breather - Transfers blow by gas containing oil mist, PM and fumes

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Air Filters
Engine Platform C4.4, C6.6, C7.1 C6.6, C7.1 C7.1, C9.3 C13, C15 C18 C27, C32 Primary Element 346-6687 346-6693 349-6262 349-6263 349-6264 349-6265 existing Secondary Element 346-6688 346-6694 337-0790 331-8108 331-8111 333-1189 existing

Primary

Secondary

Primary

Secondary

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New Maintenance Requirements for Tier 4 Interim C9.3 ACERT C18 ACERT
Part 3rd Fuel Filter Primary: 326-1643 Secondary: (2) 1R-0749 Electric Priming Pump Repair Kit: pump, CRS filter, seals (4) CRS Spark Plug Spark Plug: Engine Valve Lash (C9.3-C18) Reusable Valve Cover seal (Inspect and replace as needed) OCV filter Filter: 326-4689 DPF Ash Service Torca Clamps (p/n varies by application) Reman Filter Tooling N/A Interval 500 hrs Labor ~ 30 min. Cost (parts only) 326-1643 ~ $30 D/N 1R-0749 (2) ~ $13 D/N each ~ $350 D/N

Service tool to press in seals

5,000 hrs

~ 30-60 min.

Spark Plug bore brush (305-2389) Engine Turning Tool, Timing Pin, Feeler Gauge N/A Stationary Tool Mobile Tool

5000 hrs 2,500 hrs

~ 15 min. ~ 2-8 hrs. (depending on application) ~ 15 min. ~ 2-8 hrs. (depending on service performed)

~ $12 D/N ~ $100-$150 (seal)

2,000 hrs 5,000 hrs

~ $25 D/N Clamps: ~ $300 D/N Reman Filter: ~ $600 - $1,800

New service items for CSAs

Caterpillar Confidential: YELLOW
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New Maintenance Requirements for Tier 4 Interim C9.3 ACERT C18 ACERT
Part 3rd Fuel Filter Primary: 326-1643 Secondary: (2) 1R-0749 OCV filter Filter: 326-4689 Engine Valve Lash (C9.3-C18) Reusable Valve Cover seal (Inspect and replace as needed) Electric Priming Pump Repair Kit: pump, CRS filter, seals (4) CRS Spark Plug Spark Plug DPF Ash Service Torca Clamps (p/n varies by application) Reman Filter Tooling N/A Interval Labor ~ 30 min.

500 hrs

N/A Engine Turning Tool, Timing Pin, Feeler Gauge Service tool to press in seals

2,000 hrs 2,500 hrs

~ 15 min. ~ 2-8 hrs. (depending on application) ~ 30-60 min.

5,000 hrs

Spark Plug bore brush (305-2389) Stationary Tool Mobile Tool

5,000 hrs 5,000 hrs

~ 15 min. ~ 2-8 hrs. (depending on service option performed)

See the Operations & Maintenance Manual for specific part numbers and instructions
Caterpillar Confidential: YELLOW
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C9.3 - C18 ACERT Engine Maintenance Interval

C9.3 = 356-9897 C13 = 356-9898 C15 = 362-0328 C18 = 356-9900 Example of 356-9897

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950 MWL Maintenance Costs

950H Cost per hour up to 2000hrs = $4.18 950K Cost per hour up to 2000hrs = minimal change
OCV filter & 3rd fuel filter

5000 hrs service interval New DPF

Cost estimate ~ $2460 (DPF + ~2 hours labor)

Caterpillar Exchange (Reman)

Cost estimate ~ $1050 (DPF exchange + ~2 hours labor)

Dealer Clean & Reapply

Cost estimate ~ $750 (DPF + ~2 hours labor)

Additional costs -- $1,000 / 5,000hr = $.20 per hour

*Estimated costs as of today

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Komatsu
http://www.forconstructionpros.com/online/Construction-Equipment-News/First-Construction-Equipment-Maker-to-OfferComplementary-Maintenance-is-Komatsu/38FCP21185

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Maintenance Points by Horse Power

C4.4 & C6.6 (75-175 hp)

No mandatory DPF cleaning No DOC maintenance No active regeneration

C7.1-C18 (175-750 hp)

Mandatory DPF cleaning at 5000 hrs Mandatory OCV filter at 2000 hrs No DOC maintenance Regen spark plug at 5000 hrs Regen head at overhaul

C27 & C32 (>750 hp)

No DPF cleaning No DOC maintenance No active regeneration

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Resources and Customer Materials

CAT TIER 4 INTERIM

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NPI Materials by Model https://dealer.cat.com/cda/layout?m=331735&x=7

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NPI Materials by Model example MWL 966K https://dealer.cat.com/cda/layout?m=331735&x=7

3 4

5
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For more information on Tier 4 Machines

http://ed1cd7186edd44b6a187e849cecc832d.cloudapp.net/Landing.aspx?PID=2 Features new Tier 4 Interim Core Industries Product

See video clips and customer feedback

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Tier 4 Tools & Resources

dealer.cat.com /emissionstechnology

Cat.com/operator-training, Dealer.cat.com, GENERATIONS AHEAD 42 DVD and Powerpoint

Cat.com

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Tier 4 Interim Operator Training 23 minute video on Cat.com/operator-training

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Caterpillar Regen Video on YouTube

http://youtu.be/gb20fcPewTI Or type in Caterpillar Tier 4

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Thank you!! Questions?

CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and the Power Edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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