Tier 4 PM Agreements Jan 2012

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 10

Overview

Caterpillar Confidential: YELLOW


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



• 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



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

http://youtu.be/gb20fcPewTI




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


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


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



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


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.


• 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



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



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


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


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



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



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


DPF Application Coverage



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



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)


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


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



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)


See the Operations & Maintenance Manual for specific part numbers and instructions


C9.3 - C18 ACERT Engine Maintenance Interval

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

Example of 356-9897


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


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


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


Resources and Customer Materials

CAT TIER 4 INTERIM


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

1

2


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

2

3

4

5


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



Tier 4 Tools & Resources dealer.cat.com /emissionstechnology

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


Cat.com


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


Caterpillar Regen Video on YouTube http://youtu.be/gb20fcPewTIOr type in Caterpillar Tier 4


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.

Thank you!!Questions?

Tier 4 PM Agreements Jan 2012

Documents

integral mounting

engine shutdown

engine turning

reman filter

mandatory

cat regeneration

dealer clean

crs filter