Transcript
GENERATIONS AHEAD 1
Cat Maintenance Agreements January 27, 2012
Andy Miller, LPSDMatthew Delzell, LPSDEric Mathewson, CSSMary Roethler, CSS
BUILT FOR THE NEXT GENERATION
CAT TIER 4 INTERIM PRODUCTS
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.
GENERATIONS AHEAD 2
Agenda
1. NPI for 2011
2. NPI schedule for 2012
3. Pre-delivery checkpoints
4. Maintenance changes for Tier 4 Interim
5. Resources & Customer materials
GENERATIONS AHEAD 3
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
GENERATIONS AHEAD 4
Machine Engine Applications
C4.4 C6.6 C7.1 C9.3 C13 C15 C18 C27 C32 C175
CONFIDENTIAL YELLOW
730 735/740725
ArticulatedTrucks
R1700 AD30/R2900 AD45/R3200 AD55
UndergroundMining
AP6xx AP10xx RM300 RM500 PM201 PM202
PavingProducts
324/325 336 345320/321/323 385365311/312/314/318
HydraulicExcavators
D6T/D7/572 D8/583/587 D9 D11D10D6K/ND3/4/5
Track TypeTractors
953 963 973
Track TypeLoaders
770 773/775 777772 785/789/793/797
Off HighwayTrucks
12/120 140/160 2414/16
Motor Graders
613 627/637 R. Eng 657 Rear Eng 630/657 Tractor620 Tractor
Wheel TractorScrapers
521/522/532/541/551/552
525/535/545/569/579511/563/573/55012/14/18/20MT
501/553/564/574519/529/559
ForestProducts
814/5/6 824/5/6 834/6 844 854
Wheel Dozers/Compactors
966/972 980 988938/950/962 990 992/993924/930 994908/914
WheelLoaders
For the latest version go to:http://catelectronics.corp.cat.com/organization/1200/Tier%5F4a/
AP4xx/5xx
75 - 175 hp 175 - 750 hp > 750 hp
GENERATIONS AHEAD 5
Aftertreatment Configurations
DPF
DOC
Mounting Brackets
Backpressure Valve
Cat Regeneration
System
DOC & DPF
Optional Muffler
Integral Mounting Cradle
C4.4 & C6.6 (75-175 hp) Cat CEM C7.1 – C18 (175 – 750 hp)
Cat CEM C27 – C32 (>750 hp)
Integral Mounting Cradle
Optional Air Filter
GENERATIONS AHEAD 6
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.
GENERATIONS AHEAD 7
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
GENERATIONS AHEAD 8
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
GENERATIONS AHEAD 9
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 doesn’t drain batteries
– Operator can override idle shutdown timer with decel pedal
– Disabled at the factory – dealer can enable
GENERATIONS AHEAD 11
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. 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.
+ Horn
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 12
• Daily review of Product Link data & DSN
• Emerging issues are aggressively resolved
• No major issues to date
• Excellent Quality Results
Over 6,600 Production Deliveries to U.S. & Canada
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 13
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
– Smart phones, laptops, DVD, etc.– Focuses on Regen– http://youtu.be/gb20fcPewTI– http://www.cat.com/technology/tier-4
GENERATIONS AHEAD 14
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
2010 EAME Train-the-Trainer Stage IIIBStage IIIBCaterpillar Confidential: YELLOW
Fuel, Oil, & Maintenance
CAT TIER 4 INTERIM
GENERATIONS AHEAD 16
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
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)
EPA (required) Fuel inlet label
Oil inlet cap label
GENERATIONS AHEAD 17
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
GENERATIONS AHEAD 18
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
GENERATIONS AHEAD 19
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.
GENERATIONS AHEAD 20
• 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)
Oil and filter change intervals C9.3 - C18
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 21
Lube Sump Capacity
0
5
10
15
20
25
30
35
40
45
336 966/972 627 D6T 140/160 980 627 349 740 D8T
Machine Model
Eng
ine
Oiil
Ref
ill C
apac
ity (l
iters
)
T4 refill capacities
T3 refill capacities
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 22
CJ4 Oil Part Numbers
OIL PART NUMBERS Jan-09 Aug-06 1 GAL
NAME VISC 1L 5L 20L 208L NAME VISC 1E SPEC Bulk L 1 GAL 4 Qty. 5 GAL 55 GAL BULK-GAL BULK-RAIL CAR
Cat® DEO-ULS™ 15W-40 300-7914 300-7915 301-2233 Cat® DEO-ULS™ 15W-40 1E1867E 291-3866 291-3868 291-3869 300-7913 335-2491
10w-30 341-0729 308-1476 317-3085 10w-30 1E1867E 317-3081 317-3083 317-3084 319-2260
Cat® DEO-ULS SYN™ 5W-40 335-9836 335-9837 335-9838 5W-40 1E1867E 335-9842 335-9840 335-9841 335-9842
1 - Engine Oils
Jan-09
OIL PART NUMBERS Aug-06 1 GAL
NAME VISC 1L 5L 20L 208L NAME VISC 1E SPEC Bulk L 1 GAL 4 Qty. 5 GAL 55 GAL BULK-GAL BULK-RAIL CAR
Cat® DEO-ULS™ 15W-40 300-7914 300-7915 301-2233 Cat® DEO-ULS™ 15W-40 1E1867E 291-3866 291-3868 291-3869 300-7913 335-2491
10w-30 341-0729 308-1476 317-3085 10w-30 1E1867E 317-3081 317-3083 317-3084 319-2260
5W-40 335-9836 335-9837 335-9838
Cat® DEO-ULS SYN™ 5W-40 1E1867E 335-9842 335-9840 335-9841 335-9842
1 - Engine Oils
GENERATIONS AHEAD 23
Ash in The Diesel Particulate Filter (DPF)
• Formed from lube oil additives that don’t 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
GENERATIONS AHEAD 24
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
GENERATIONS AHEAD 25
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• Serviceable Parts
– 364-6044 - Kit-Ring & Seal (large)– 371-3749 - Kit-Ring & Seal (med)– 367-8959 - Kit-Ring & Seal (small)– 366-6780 - Kit-Ash Disposal– 366-6781 - Kit-HEPA Filter
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 26
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 hours1. 1 hour for in-chassis Ash Service Regen2. 1-2 hours to cool3. 1-2 hours for Remove & Install4. 1 hour to clean DPF– Reman option eliminates steps 1, 2 & 4
D7E (C9.3)10 X 12" DPF 349 (C13) 12 X 13.5" DPF
Total Repair Cost to Clean & Reapply $700-800 $700-800Elapsed Time (ET) out of service 5-6 hrs 5-6 hrs
Total Repair Cost to Replace with Reman $744 - $844 $1600-1800ET out of Service 2 hrs 2 hrs
Anticipate Competition fromTEPS Dealers, Cummins Dealers
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 28
DPF Pricing
Serviced Level
Filter Kit Part # New *kit includes clamps
358-3659 $ 980.81 $ 1,334.44 20R0696 $ 539.45 $ 733.95 358-3662 $ 1,809.22 $ 2,461.52 20R0697 $ 756.01 $ 1,028.59 358-3664 $ 1,943.80 $ 2,644.63 20R0698 $ 971.90 $ 1,322.31
$ 1,668.97
Reman D/N $
$ 1,850.90
20R0699
20R0700 358-3669 $ 1,360.41 $ 3,701.80 $ 2,720.82
Suggested C/L New
D/N New
358-3667 $ 1,226.69 $ 3,337.93 $ 2,453.39
Suggested Reman C/L
Reman Filter Kit Part #
Diameter Length Weight
(in) (in) (lbs)
345-1858 $ 57.91 $ 78.79 $400-$600 C7.1, C9.3 (D7 only) 11 14 25.79345-1849 $ 63.96 $ 87.02 $400-$600 C7.1, C9.3 13 14 38.14345-1849 $ 63.96 $ 87.02 $400-$600 C9.3 (MWL only) 13 14 38.14
C15 (D8 only) C9.3 (Industrial only)
C13, C15, C9.3 (Industrial only)
D/N New
14 16
$400-$600 $ 94.53
Suggested C/L New
$ 94.53
$ 69.48 345-1839
345-1839 $ 69.48
DPF Cleaning Machine
*est 4-6 hrs
$400-$600 48.83
14 18 54.76
ApplicationTorca Clamps *needed for
cleaning
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 29
Open Crankcase Ventilation (OCV) Filter Breather - Transfers
blow by gas containing oil mist, PM and fumes
Atmosphere - Filtered gas and
condensate Block - Coalesced oil
drains back to crankcase
• 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)
GENERATIONS AHEAD 30
Air Filters
Engine Platform
Primary Element
Secondary Element
C4.4, C6.6, C7.1
346-6687 346-6693
346-6688 346-6694
C6.6, C7.1 349-6262 337-0790
C7.1, C9.3 349-6263 331-8108
C13, C15 349-6264 331-8111
C18 349-6265 333-1189
C27, C32 existing existing
Primary Secondary
Primary
Secondary
GENERATIONS AHEAD 31
New Maintenance Requirements for Tier 4 InterimC9.3 ACERT – C18 ACERT
Part Tooling Interval Labor Cost (parts only)
3rd Fuel Filter
Primary: 326-1643
Secondary: (2) 1R-0749
N/A 500 hrs ~ 30 min. 326-1643 ~ $30 D/N
1R-0749 (2) ~ $13 D/N each
Electric Priming Pump
Repair Kit: pump, CRS filter, seals (4)
Service tool to press in seals
5,000 hrs ~ 30-60 min. ~ $350 D/N
CRS Spark Plug
Spark Plug:
Spark Plug bore brush (305-2389)
5000 hrs ~ 15 min. ~ $12 D/N
Engine Valve Lash (C9.3-C18)
Reusable Valve Cover seal
(Inspect and replace as needed)
Engine Turning Tool, Timing Pin,
Feeler Gauge
2,500 hrs ~ 2-8 hrs.
(depending on application)
~ $100-$150 (seal)
OCV filter
Filter: 326-4689
N/A 2,000 hrs ~ 15 min. ~ $25 D/N
DPF Ash Service
Torca Clamps (p/n varies by application)
Reman Filter
Stationary Tool
Mobile Tool
5,000 hrs ~ 2-8 hrs. (depending on service performed)
Clamps: ~ $300 D/N
Reman Filter:
~ $600 - $1,800
New service items for CSA’s
Caterpillar Confidential: YELLOW
GENERATIONS AHEAD 32
New Maintenance Requirements for Tier 4 InterimC9.3 ACERT – C18 ACERT
Part Tooling Interval Labor
3rd Fuel Filter
Primary: 326-1643
Secondary: (2) 1R-0749
N/A 500 hrs ~ 30 min.
OCV filter
Filter: 326-4689
N/A 2,000 hrs ~ 15 min.
Engine Valve Lash (C9.3-C18)
Reusable Valve Cover seal
(Inspect and replace as needed)
Engine Turning Tool, Timing Pin,
Feeler Gauge
2,500 hrs ~ 2-8 hrs.
(depending on application)
Electric Priming Pump
Repair Kit: pump, CRS filter, seals (4)
Service tool to press in seals
5,000 hrs ~ 30-60 min.
CRS Spark Plug
Spark Plug
Spark Plug bore brush (305-2389)
5,000 hrs ~ 15 min.
DPF Ash Service
Torca Clamps (p/n varies by application)
Reman Filter
Stationary Tool
Mobile Tool5,000 hrs ~ 2-8 hrs. (depending
on service option performed)
Caterpillar Confidential: YELLOW
See the Operations & Maintenance Manual for specific part numbers and instructions
GENERATIONS AHEAD 33
C9.3 - C18 ACERT Engine Maintenance Interval
• C9.3 = 356-9897• C13 = 356-9898• C15 = 362-0328• C18 = 356-9900
Example of 356-9897
GENERATIONS AHEAD 34
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
GENERATIONS AHEAD 35
Komatsu http://www.forconstructionpros.com/online/Construction-Equipment-News/First-Construction-Equipment-Maker-to-Offer-Complementary-Maintenance-is-Komatsu/38FCP21185
GENERATIONS AHEAD 36
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
GENERATIONS AHEAD 39
NPI Materials by Model – example MWL 966Khttps://dealer.cat.com/cda/layout?m=331735&x=7
2
3
4
5
GENERATIONS AHEAD 40
For more information on Tier 4 Machines
http://ed1cd7186edd44b6a187e849cecc832d.cloudapp.net/Landing.aspx?PID=2Features new Tier 4 Interim Core Industries Product
See video clips and customer
feedback
GENERATIONS AHEAD 42
Tier 4 Tools & Resources dealer.cat.com /emissionstechnology
Cat.com/operator-training, Dealer.cat.com, DVD and Powerpoint
GENERATIONS AHEAD 45
Caterpillar Regen Video on YouTube http://youtu.be/gb20fcPewTIOr type in Caterpillar Tier 4
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