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Caterpillar Tier 4 Final Customer Presentation11.17.pptx
1. The Next Generation of Value
CAT® TIER 4 FINAL TECHNOLOGIES
Caterpillar: Confidential Green
2. CATERPILLAR TIER 4* JOURNEY
Focused on what customers told us was important to them.
3. kW (hp) 2011 2012 2013 2014 2015
19-56
(25-75)
NOx + NMHC 4.7
g/kW-hr PM 0.03
g/kW-hr
Tier 4 Final
56-130
(75-175)
NOx 3.4 g/kW-hr
PM 0.02 g/kW-hr
NOx 0.40 g/kW-hr
PM 0.02 g/kW-hr
130-560
(175-750)
NOx 2.0 g/kW-hr
PM 0.02 g/kW-hr
NOx 0.40 g/kW-hr
PM 0.02 g/kW-hr
>560*
(>750)
NOx 3.5 g/kW-hr
PM 0.10 g/kW-hr
NOx 3.5 g/kW-hr
PM 0.04 g/kW-hr
EMISSIONS LIMITS AND TIMING
Four major power categories for non-road products.
Tier 4 Interim
Tier 4 Final
Tier 4 Interim
Tier 4 Interim
Tier 4 Interim
* Excludes Gensets, which in this power category have more stringent standards.
>560 kW is currently an EPA only regulation. These engines did not have a Tier 3
regulation requirement and will go straight from Tier 2 to Tier 4 Interim.
6. CATERPILLAR TIER 4 JOURNEY
Most successful launch ever; great product durability and reliability.
• 223,000+ Tier 4 products in the field
• 370M+ total machine & engine production hours
• Tier 4 Interim and Final machine reliability better
than target *Data as of August 2015
8. CATERPILLAR TIER 4 FINAL
Engine Product Line
C1.5 & C2.2 Aftertreatment
25-75 hp (19–56 kW)
EMISSION REDUCTION
TECHNOLOGIES
• Diesel Oxidation Catalyst (DOC) /
Diesel Particulate Filter (DPF)
• Passive regeneration under most
operating conditions
• Automatic active burner back-up regeneration
– Transparent to operator
MAINTENANCE
• 3,000 hour DPF ash service interval
9. C3.3B Aftertreatment
25-75 hp (19–56 kW)
EMISSION REDUCTION
TECHNOLOGIES
• Catalyzed DPF increases passive regeneration
• Traps soot and ash via wall flow filter
technology
• NOx reduction system
• In-cylinder dosing active regeneration
MAINTENANCE
• 3,000 hour DPF ash service interval
– No adapter needed for the portable cleaner
• Cat Reman DPF replacement option
CATERPILLAR TIER 4 FINAL
Engine Product Line
10. C3.4B Aftertreatment
25-75 hp (19-56 kW) / 75-175 hp (56-130 kW)
EMISSION REDUCTION
TECHNOLOGIES
• Flow through DPF – 60 / 67 / 74 hp (45 / 50 / 55 kW)
• Wall flow DPF – 74 hp (55 kW)
• No DPF with Selective Catalytic Reduction (SCR)
– Above 75 hp (56 kW)
• NOx reduction system
• In-cylinder dosing for active regeneration
• Transparent to operator
MAINTENANCE
• 3,000 hour DPF service interval for
wall flow DPF
CATERPILLAR TIER 4 FINAL
Engine Product Line
11. C4.4 ACERT Aftertreatment
75-175 hp (56-130 kW)
EMISSION REDUCTION
TECHNOLOGIES
• PM Aftertreatment (DOC/DPF)
– Passive only regeneration
– DPF on select products only
• NOx reduction (Exhaust Gas Recirculation)
• SCR NOx reduction
– Diesel Exhaust Fluid (DEF)
• Transparent to operator
MAINTENANCE
• Maintenance free DPF
– No ash service required until overhaul
CATERPILLAR TIER 4 FINAL
Engine Product Line
12. C7.1 ACERT Aftertreatment
75-175 hp (56-130 kW) / 175-750 hp (130-560 kW)
EMISSION REDUCTION
TECHNOLOGIES
• PM Aftertreatment (DOC/DPF)
– Passive only regeneration
• NOx reduction (Exhaust Gas Recirculation)
• SCR NOx reduction
– Diesel Exhaust Fluid (DEF)
• Transparent to operator
MAINTENANCE
• Maintenance free DPF
– No ash service required until overhaul
CATERPILLAR TIER 4 FINAL
Engine Product Line
13. C9.3-C18 ACERT Aftertreatment
175-750 hp (130-560 kW) EMISSION REDUCTION
TECHNOLOGIES
• PM Aftertreatment (DOC/DPF)
• Cat Regeneration System
• NOx reduction (Exhaust Gas Recirculation)
• SCR NOx reduction
– Diesel Exhaust Fluid (DEF)
• Transparent to operator
MAINTENANCE
• 5,000 hour DPF service interval
• Cat Reman DPF replacement option
CATERPILLAR TIER 4 FINAL
Engine Product Line
14. CATERPILLAR TIER 4 FINAL
Engine Product Line
C27 & C32 ACERT
Aftertreatment
>750 hp (>560 kW)
EMISSION REDUCTION
TECHNOLOGIES
• DOC / muffler only configuration
• No DPF required
• No SCR
• NOx reduction (Exhaust Gas Recirculation)
• MEUI-C Fuel System
• No lights or switches in the cab
MAINTENANCE
• No aftertreatment maintenance
15. TIER 4 FINAL MACHINE ENGINE TECHNOLOGY
Applied the technology solution that best meets customer needs in each
power range and application.
Power
Range
75-175 hp
(56 – 130 kW )
175-750 hp
(130 – 560 kW)
750-1100 hp
(560 – 820 kW)
>1100 hp
(> 820 kW)
Machine
Examples SSL, BHL, SHEX LHEX, MTTT, MWL QCT, LTTT LMT
Engines C3.4 - C7.1 C7.1 - C18 C27 & C32 3500 & C175
NOx Reduction NRS + SCR NRS + SCR NRS SCR
Particulate
Matter
Aftertreatment
DOC/DPF
(C4.4 DPF and no
DPF applications)
DOC/DPF DOC N/A
Regen
Technology
Dosing, Passive Passive, Active burner N/A N/A
16. TIER 4 FINAL MACHINE INSTALLATION
Space claim planned at Tier 4 Interim.
17. WHAT ARE SCR AND DEF?
Work together to reduce NOx to meet Tier 4 Final emissions standards.
• Selective Catalytic Reduction (SCR)
– Selective: reductant reacts with NOx
– Catalytic: requires a catalyst
– Reduction: NOx is reduced to Nitrogen (N2 ) by a reductant
• Diesel Exhaust Fluid (DEF)
– De-Ionized Water (67.5 %) + Urea (32.5%) mixture
– Meets ISO 22241
– Source of ammonia reductant
18. CAT CLEAN EMISSIONS MODULE (CEM)
C9.3 – C18 ACERT Engines
Ammonia Oxidation
Catalyst (AMOX)
Prevents any trace amounts of ammonia not
converted from entering the atmosphere.
Selective Catalytic
Reduction (SCR)
Consists of a SCR catalyst, AMOX
and the Pump Electronics Tank Unit
(PETU). It uses a small amount of
DEF to convert NOx emissions in the
exhaust into nitrogen and water.
Diesel Particulate
Filter (DPF)
Traps particulate matter carried in
the exhaust stream.
Diesel Oxidation
Catalyst (DOC)
Uses a chemical process to
reduce hydrocarbons and carbon
monoxide in the exhaust stream.
Mixing Pipe
Mixes DEF and hot exhaust
gas to form ammonia.
1
2
5
Diesel Exhaust Fluid
(DEF) Injector
Injects DEF into mixing pipe.
4
6
3
19. DEF PUMP AND TANK
C9.3 – C18 ACERT Engines
Fill Adapter & Cap
Blue cap is the
industry standard for
easy identification.
Tank Heater
Thaws DEF when
needed so there’s
no lost time on
cold jobsites.
Drain Plug
Controller
Ensures the correct
amount of DEF is
supplied to the injector.
Pump Assembly
Supplies DEF to the injector
and purges line at shutdown.
Heated Lines
Warms up when necessary to
thaw any DEF left in lines and
to prevent freezing.
20. DEF STORAGE
Follow recommended storage requirements.
Any commercial DEF meeting ISO 22241
specifications can be used.
Optimal temperature for storage
is 15º F to 77º F.
• Rate of decay significantly accelerates when
stored in temperatures above 90º F
• Freezes at 12º F
Improper storage temperature and/or
exposure to sunlight decreases shelf life.
21. DEF STORAGE
Improper storage reduces DEF shelf life; increases risk of contamination.
DON’T Use Dirty
Containers or a
Container Not
Designed for DEF
DON’T Store the Fluid
in Direct Sunlight
22. DEF CONTAMINATION CONTROL
Dirty jobsite conditions a reality; must clean around cap at refill.
These “before” pictures
highlight just how dirty
the area surrounding the
blue DEF cap can become
during normal operation.
That’s why it is important
that you clean around the
cap with every refill to
avoid aftertreatment
system component
failures that result from
contamination.
23. DEF CONTAMINATION CONTROL
Avoid internal contamination; use proper tooling and fittings.
DEF is corrosive to most
materials. That’s why it’s
important to use proper
dispensing equipment and
procedures to avoid
contamination.
If even one of the fittings
is incorrect, it could
contaminate the entire
DEF supply, leading to
emission system faults
and engine shutdown.
Stainless steel bolt submerged in DEF for nine days.
Galvanized steel bolt submerged in DEF for nine days.
24. The DEF fill ratio is 1:1, meaning one
DEF tank refill to each fuel tank refill.
DEF consumption should be approximately
2 to 3% of fuel consumption.
DEF CONSUMPTION
Highlights the amount of DEF required for a fleet of equipment.
Shifts
Per Day
Daily DEF Usage
(US gal)
Weekly DEF Usage
(US gal)
Monthly DEF Usage
(US gal)
Scenario
16 Cat
Machines
1 62.1 310.7 1,242.6
2 124.3 621.3 2,485.2
25. DEF Level Gauge
OPERATOR INTERFACE
Enhancements help protect the aftertreatment and engine components.
Low DEF
Indicator Light
Delayed Engine
Shutdown
• DEF Level Gauge indicates the level of DEF in the tank
• Automatic systems to protect your investment
– DEF Purge: Purges DEF from the lines to prevent freezing
– Delayed Engine Shutdown: Engine idles briefly after key
off if cool down needed
– Wait to Disconnect Lamp: Illuminates until the product is
safe and ready for complete shutdown
– Regeneration: Warms up aftertreatment if needed
Transparent emissions systems your
operators won’t need to manage.
26. TIER 4 FUEL AND OIL REQUIREMENTS
Required to maintain operation and maximum life.
Ultra Low Sulfur Diesel (ULSD)
Fuel (15 ppm sulfur) for Tier 4 Interim
API CJ-4 (ECF-3) Low Ash Engine Oil
DEF must meet ISO 22241 specifications.
Biodiesel up to B20 can also be used when blended with ULSD.
1
2
27. * = no longer a service item on the majority of products. ++ = O&MM recommends 5,000 hours, but field results indicate a longer service level is often achieved.
TIER 4 FUEL AND MAINTENANCE REQUIREMENTS
C9.3 - C18 ACERT Engines
Max Fuel Sulfur Content
(in Parts per Million)
Diesel Exhaust Fluid (DEF)
Biodiesel
Fluid Consumption
Engine Oil
Drain/Filter Intervals
Valve Lash
DPF Ash Service
OCV Filter Replacement
CRS Spark Plug Interval
(Clean or Replace)
DEF Filter Replacement
Overhaul Life
Tier 3 Tier 4 Interim/Stage IIIB Tier 4 Final/Stage IV
500
Not Required
B20
Base
ECF-2 (CI-4)
500 hours
500 and 2,500 hours
N/A
N/A
N/A
N/A
Base
15/10
Not Required
B20
Up to 5% fuel
efficiency improvement
ECF-3 (CJ-4)
500 hours
2,500 hours
5,000 hours ++
2,000 hours*
5,000 hours
N/A
Same
15/10
Required (ISO 22241)
B20
Up to 5% net improvement over Tier
4 Interim (including DEF consumption)
ECF-3 (CJ-4)
500 hours
2,500 hours
5,000 hours ++
N/A
5,000 hours
5,000 hours
Same
28. • Proven technology
– Most tested & validated product in Caterpillar history
– Large field population using Tier 4 products
– Over 370 million operating hours accumulated
*Accumulated hour data as of August 2015
• Designed to meet customer needs
– Reliable & dependable for maximum uptime in the most
demanding applications on the planet
– Same long life to overhaul
– Improved fuel efficiency translates to lower operating cost
– Faster more productive machines
– Emissions technology without work interruption
– Supported by our world class dealer network
– Used equipment migration capability
CATERPILLAR TIER 4 JOURNEY
Providing customer value and meeting standards.
Editor's Notes
Note: This presentation provides Caterpillar customers with background information related to emissions regulations and a high-level overview of our Tier 4 Final solution.
At Caterpillar, we know you’re under constant pressure to do more work at a lower total cost with less environmental impact. Our Tier 4 Final solutions help you do just that.
Our new generation of engines meet your high expectations for reliability, performance, fuel efficiency and component life—all while producing significantly fewer emissions.
Focused on What Customers Told Us Was Important to Them
We know and understand what’s important to you, because we listen to our customers—each and every day. We also actively and constantly gather your input through both informal dialogue and field follow studies, focus groups, surveys and research studies. The point is: because we seek and listen to your input, we really do know what’s important to you. We know your primary focus is on whatever you need that will help you get the work done.
When it comes to equipment, we know product durability, reliability, parts availability and fuel efficiency are critical to you because they translate to power and performance—which help you achieve the lowest total cost of ownership.
At Caterpillar, we don’t think you should worry about emissions. That’s our job. We’re committed to making emissions as seamless and effortless for you as possible, with your Cat® dealer dedicated to delivering service value for the life of your machines.
Emissions Limits and Timing
The emissions limits and implementation timing are broken up into four major power categories for non-road products; 19-56 kW, 56-130 kW, 130-560 kW and greater than 560 kW (EPA only).
Each category range has different requirements and implementation timing for each regulatory standard (Tier 4 Interim to Tier 4 Final). Also, note that EU regulations may be slightly different than the U.S. EPA regulations.
This chart depicts the four power categories with the timeline for implementation.
Meeting Aggressive Emissions Standards
All manufacturers of diesel engines, including Caterpillar are required to deliver engines that meet government emissions standards that have been phased-in throughout the United States, Canada, Japan and the European Union. With our Cat Tier 4 Final engines, we meet stringent emissions standards and deliver the performance and efficiency that successful businesses demand.
The emissions standards have required significant Oxides of Nitrogen (NOx) and Particulate Matter (PM) reductions since the implementation of US EPA Tier 1 / EU Stage 1. Viewing the reductions in a graphical format makes it easier to visualize the magnitude of change.
This chart shows the stepped emission standards for the 130-560 kW power category, which has the most stringent requirements as compared to the other power categories. Comparing US EPA Tier 1 / EU Stage 1 to Tier 4 Final, the NOx levels reduced from 9.2 to .4 g / kW-hr, and PM reduced from .54 to .02 g / kW-hr, both equating to a 96% reduction.
Designed with the End in Mind
Caterpillar designed Tier 4 Interim products with Tier 4 Final standards in mind. By planning ahead, we were able to minimize design changes and deliver the reliability and performance you demand. For example, while designing for Tier 4 Interim, we went a step further and implemented the space claim required to meet Tier 4 Final.*
By adding technologies like this in advance of the final solution, and applying these common emissions technologies across multiple engine platforms, we have been able to expedite product development and enhance our product validation for Tier 4 Final.
Every Tier 4 Final engine is equipped with a combination of proven electronic, fuel, air and aftertreatment components. All are based on engine size, application and the geographic location in which it will work.
Applying proven technologies systematically and strategically, we’re able to meet your high expectations for productivity, fuel efficiency, reliability and service life. In most cases, we are simply adding one additional technology to the aftertreatment system to meet Tier 4 Final emissions requirements: Selective Catalytic Reduction (SCR).
Caterpillar is the largest vertically integrated manufacturer in our business, and our leading position gives us the power to build premium-quality products. We integrate manufacturing advancements into product designs and use common production processes across the manufacturing base. As a result, we can deliver exceptional quality right from the start.
* Because the space claim required for Tier 4 Final was made at Tier 4 Interim, customers owning Tier 4 Interim products should not be concerned when they notice the empty space in their engine compartment. Tier 4 Interim products are not updated to Tier 4 Final specifications simply because the space is there.
How are we doing so far?
Caterpillar has over 223,000 Tier 4 products (machine and commercial engines) in the field with over 370 million hours of reported production time. (The small yellow dots on the maps above represent the location of Tier 4 units with our VisionLink™ telematics system activated.)
Not only is this the largest product launch in Caterpillar’s history, it is also the most successful. Reliability and quality metrics have been excellent. And so has customer feedback.
(Note: Even though Australia is currently a Non-Regulated Country (NRC), the continent does have the proper oils and fuels needed to operate Tier 4 products. Subsequently, customers in that region are purchasing Tier 4 products due to their performance and fuel economy improvements.)
What Customers are Saying about Caterpillar’s Tier 4 Solution
The most important measure of our Tier 4 program success is what our customers say about it. Customer reaction has varied between “pleasantly surprised” to “delighted” with the new Tier 4 products they now own and operate.
C1.5 & C2.2 Aftertreatment
For Caterpillar to meet Tier 4 Final emission standards for C1.5 and C2.2 engines (19-56kW power category), a Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) were added. This is very similar technology to that used for at Tier 4 Interim for other products.
These engines use passive regeneration for most operating conditions. If active regeneration is required, a backup burner is activated. Both regeneration methods are transparent to the operator when using the automatic mode.
The DPF ash service interval is 3,000 hours*.
*A minimum of 3,000 operating hours is the regulatory minimum for DPF ash servicing. Hours before ash service may vary, but will not be less than 3,000 hours.
C3.3B Aftertreatment
For Caterpillar to meet Tier 4 Final emission standards for the C3.3B engine (19-56 kW power category), a Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) were added. This is very similar technology to that used at Tier 4 Interim for the C3.8 engine. These engines use passive regeneration for most operating conditions. In-cylinder dosing is used for active regeneration.
The DPF ash service interval is 3,000 hours*. There is no adapter needed for the portable cleaner. If you need to replace your Diesel Particulate Filter, Cat Reman offers a cost effective option.
*A minimum of 3,000 operating hours is the regulatory minimum for DPF ash servicing. Hours before ash service may vary, but will not be less than 3,000 hours.
C3.4B Aftertreatment
For Caterpillar to meet Tier 4 Final emission standards for the C3.4B engine (19-56kW power category), a Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) were added.
The C3.4B engines with a rating of 45, 50 or 55 kW will have a flow through DPF, whereas the 55 kW engines could have the flow through or the wall flow design DPF. These products use passive regeneration for most operating conditions. In-cylinder dosing is used for active regeneration. Both regeneration methods are transparent to the operator when using the automatic mode. The DPF ash service interval is 3,000 hours*.
For the C3.4B engine (56-130 kW power category), a Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) were added, but no DPF is required.
*A minimum of 3,000 operating hours is the regulatory minimum for DPF ash servicing. Hours before ash service may vary, but will not be less than 3,000 hours.
C4.4 ACERT Aftertreatment
Moving Cat products from Tier 4 Interim to Tier 4 Final emission standards required very few changes. For products with the C4.4 ACERT engine platform, we added Selective Catalytic Reduction (SCR) to the aftertreatment system. The Cat Clean Emissions Module (CEM) includes a new canister next to the DOC/DPF canister and a DEF tank.
For the C4.4 ACERT engine, not all applications will utilize a DPF; some will only feature a DOC/SCR system. All of the emission controls are completely transparent to the operator.
The C4.4 ACERT engines with the DPF aftertreatment design are maintenance free, so there is no DPF ash service required until overhaul.
Engine Product Line
Moving Cat products from Tier 4 Interim to Tier 4 Final emission standards required very few changes. For Cat products with the C7.1 ACERT engine platform, we added Selective Catalytic Reduction (SCR) to the aftertreatment system. The Cat Clean Emissions Module (CEM) includes a new canister next to the DOC/DPF canister and a DEF tank.
With these engine platforms, additional configurations apply.
For the C7.1 ACERT engine, we will release two versions: a single turbo design and twin turbo design. Typically, the single turbo design will be used in the 56-130 kW power category products, and the twin turbo design will be used in the 130-560 kW power category products.
The C7.1 ACERT engine also changed from a passive/active regeneration system (utilizing CRS) with Tier 4 Interim to a passive only system for Tier 4 Final.
The emission controls are completely transparent to the operator. Also, the C7.1 ACERT DPF is maintenance free, so there is no DPF ash service required until overhaul.
C9.3 - C18 ACERT Engines
For these Cat products to move from Tier 4 Interim to Tier 4 Final emission standards, very few changes were needed. The major change is the addition of Selective Catalytic Reduction (SCR), which was added to the Tier 4 Final aftertreatment system. The Clean Emissions Module (CEM) also includes a new canister next to the DOC/DPF canister and a DEF tank.
*A minimum of 4,500 operating hours is the regulatory minimum for DPF ash servicing. Hours before ash service may vary, but will not be less than 5,000 hours for Cat products with these engines.
C27 & C32 ACERT Engines
For these Cat products to move from Tier 4 Interim to Tier 4 Final emission standards, no changes were needed. These engine platforms utilize a DOC and muffler configuration to meet the emission standards. Using a DOC/muffler only design means there is no need for any aftertreatment lights of switches in the cab, or any aftertreatment maintenance intervals.
Caterpillar Tier 4 Final Machine Engine Technology
This chart gives you a broad and high level view of our Tier 4 Final machine engine technology plans. It shows that we have applied the technology solution that best meets customer needs in each of these power ranges and applications.
In the 75-175 hp (56-130 kW) range, we are implementing technology solutions that are compact, cost efficient systems, which means:
Engine systems in this range will have both EGR and SCR NOx reduction systems.
We will primarily use DPFs on all engines in this range except for a version of our C4.4 in some of our Business Construction Products (BCP) applications.
Regen technologies include both dosing and passive systems.
In the 175-750 hp (130 to 560 kW) range:
Engines systems will all have EGR and SCR NOx reduction systems.
All engines in this range will have Diesel Particulate Filters (DPFs).
Regen technologies will include a passive system on the C7.1 and the active CRS burner system on the C9.3 to C18 models.
You might ask why we equipped so many of these systems with DPFs in ranges below 560 kW. Caterpillar took this approach because at Tier 4 Final emissions levels, in most cases the lowest operating cost/best fuel efficiency technology includes a DPF.
In the 560 to 820 kW range:
We launched Tier 4 Final technology in 2011 on our C27 and C32 engines. So at the 2015 regulation date, those engines won’t change. They’ll simply get a new emissions label.
Finally, on our larger engines used in our global mining products:
We will be using an SCR system to provide the lowest operating cost/best fuel consumption system for our mining customers.
Tier 4 Final Machine Installation
Here is a view of a Wheel Loader with the Tier 4 Final engine and aftertreatment system installed. As mentioned earlier, Caterpillar engineers designed the next generation products with the “designed with the end in mind.” In doing so, the space claim for Tier 4 Final was integrated at Tier 4 Interim.
What is SCR and DEF?
Selective Catalytic Reduction (SCR) was first developed and used for reducing NOx emissions from stationary electric power plants. Starting in 2010, on-highway truck and European passenger car applications adopted the technology. Caterpillar began using SCR systems to meet Tier 4 Interim emission standards in some Locomotive and Generator Set applications.
For Cat products to achieve the NOx reduction levels as defined in the emissions regulatory standards for non-road applications, we integrated the SCR system. SCR is selective as it addresses NOx only by using a catalyst and a reductant to convert the NOx into nitrogen and water vapor.
The reductant is ammonia. Ammonia is delivered to the SCR system in the form of Diesel Exhaust Fluid (DEF). DEF is comprised of 67.5% de-ionized water and 32.5% urea. Urea is a white compound that contains nitrogen, which is solid at room temperature. When heated, the urea in the DEF releases ammonia (NH3). This mixture must meet ISO Standard 22241.
What’s New in the Cat Clean Emissions Module (CEM)?
The Cat Clean Emissions Module (CEM) protects interior components, minimizes the aftertreatment footprint and simplifies maintenance. With the addition of SCR with Tier 4 Final, new components have been added, including the Diesel Exhaust Fluid (DEF) injector, the mixing pipe, the SCR catalyst and the Ammonia Oxidation Catalyst (AMOX).
The exhaust is introduced into the CEM just before the Diesel Oxidation Catalyst (DOC). The exhaust flows through the DOC and then through the Diesel Particulate Filter (DPF), which is the same flow as with Tier 4 Interim products.
After the exhaust exits the DPF, it then moves to the mixing pipe where the DEF injector infuses DEF into the hot exhaust stream. The mixing pipe blends the DEF and the exhaust, where the heat from the exhaust evaporates the water and converts the urea to ammonia.
The blended exhaust and ammonia then flows through the SCR catalyst where a chemical reaction occurs to convert the NOx into nitrogen and water vapor. After the exhaust exits the SCR catalyst, it then flows to the AMOX, which cleans up any unused ammonia (sometimes referred to as “ammonia slip”) and converts it into nitrogen.
DEF Pump and Tank (Pump Electronics Tank Unit (PETU))
The Pump Electronic Tank Unit (PETU) stores, controls and supplies the appropriate quantity of Diesel Exhaust Fluid (DEF) from the DEF tank to the DEF injector. It has many parts that make DEF injection possible. In some applications, the DEF pump and electronic controls are located separately form the DEF tank. The major parts to the DEF tank are:
DEF controller that controls all DEF injection functionality.
DEF pump assembly, which supplies DEF to the injector and also purges the DEF lines at shutdown.
Heated lines that are electronically controlled to heat up when necessary to thaw any DEF left in the lines and to prevent DEF from freezing in the lines during operation.
Fill adapter and cap where the DEF is filled. (The cap is blue, which is an industry standard.)
DEF tank heater used to thaw DEF when the ambient temperature is below 12º F and the DEF is frozen.
Drain plug used to drain the tank.
Diesel Exhaust Fluid (DEF) Storage
It’s important to remember that Cat products require Diesel Exhaust Fluid (DEF) that meets ISO 22241. DEF has some characteristics that users need to be familiar with, including:
DEF has a finite storage life. In optimal storage conditions, meaning sheltered and maintained in temperatures of 15 to 77º F, it can last 36 months.
As temperature increases, the shelf life of DEF decreases. Storing DEF above 95º F for longer than one month decreases the life to less than six months. Under those conditions, be sure to test the DEF prior to use.
DEF shelf life is also decreased by direct exposure to sunlight.
DEF can also freeze when stored at 12º F or less. Unlike extreme heat, freezing does not harm the chemical composition of DEF.
DEF can be corrosive to various materials. Proper containers and tooling should be used to transport, store and dispense DEF.
If DEF is spilled, it should be cleaned up immediately to prevent rusting or material damage.
As DEF dries, it will leave small white crystals on the surface.
Diesel Exhaust Fluid (DEF) Storage
This picture shows Diesel Exhaust Fluid (DEF) being stored in a dirty environment and in direct sunlight. Direct sunlight will reduce the shelf life of the DEF. And the dirty environment would likely introduce contamination in the DEF tank.
Diesel Exhaust Fluid (DEF) Contamination Control
Contamination of Diesel Exhaust Fluid (DEF) is an issue that needs to be addressed and prevented. Jobsites are inherently dirty, with many opportunities for contaminants to enter the DEF supply.
Diesel Exhaust Fluid (DEF) Contamination Control
In addition to the external contamination factors (primarily jobsite dirt and dust) summarized on the previous slide, you must also consider the impact of internal contamination, as well.
Because DEF is corrosive to most materials, it is important to use the proper dispensing equipment and procedures. Failure to use DEF-specific tooling and fittings will result in corrosion and contamination. In fact, if even one of the fittings is incorrect, it could contaminate the entire DEF supply, and lead to emission system faults and engine shutdown.
If DEF is spilled, clean up should begin immediately. Simply rinse the area with water and wipe clean to prevent the contacted surface from corroding.
Diesel Exhaust Fluid (DEF) Consumption Example
On Cat products equipped with SCR systems, DEF consumption is approximately 2 to 3% of fuel consumption depending on the product and application. The DEF tank has a 1:1 fill rate with the fuel tank. If fuel is added, DEF needs to be added.
To help put in perspective the amount of DEF needed, the chart example shows a fleet of 16 machines with an approximate usage of DEF on a daily, weekly and monthly basis. The top horizontal line of the chart represents a single shift operation’s DEF consumption, while the line below it shows how a two shift operation impacts DEF consumption.
Operator Interface
Enhancements were made to the operator interface to coincide with the introduction of Tier 4 Final technologies, including:
DEF Level Gauge: The DEF Level Gauge is new to the display. The gauge indicates the DEF level in the DEF tank. An indicator lamp at the bottom of the gauge alerts the operator if the DEF level is low. When the DEF tank if filled each time the machine is filled with fuel, the lamp should not illuminate.
DEF Purge: The operator does not have an interface to the DEF Purge function, but it’s important to understand how it works and why it’s necessary. At every shutdown, the DEF pump will purge the DEF from the lines to prevent freezing and other potential SCR system failures. The purge takes approximately 70 seconds to complete.
Delayed Engine Shutdown (DES): The Delayed Engine Shutdown function keeps the engine running for a period of time if an operator “keys off” and the engine component temperatures are above a predetermined level. (The exact criteria varies from product to product.) The function can be overridden in emergency situations and fault codes are logged in the event of an emergency override.
Wait to Disconnect Lamp: A Wait to Disconnect Lamp was added next to the master disconnect switch. The lamp will remain illuminated until the product is safe and ready for complete shutdown. The DEF Purge cycle and the DES function are the primary factors that cause the lamp to illuminate. Fault codes are logged if the disconnect switch is turned off prior to the lamp turning off.
Purpose of Regeneration: The purpose of regeneration has also changed with the introduction of Tier 4 Final. With Tier 4 Interim products, the primary function of the regeneration process was to clean out soot from the DPF. With Tier 4 Final products, the primary function of the regeneration process is to warm up the aftertreatment components and to remove any urea deposits.
All of the features are used to protect the aftertreatment and engine components. In addition to these features, new inducements have been introduced. The inducements are common across all manufacturers and are part of the emissions regulations. The inducements are triggered by low fluids, faulty components and tampering. Once an inducement has been triggered, a lamp will illuminate on the operator display. If a second-level inducement is triggered, the previously illuminated lamp will continue and a flashing action lamp will appear. Upon a third-level inducement, the previously illuminated lamp and the flashing action lamp will be illuminated along with a horn. Once the horn is sounded, a derate of the product will occur.
Tier 4 Fuel and Oil Requirements
Our Tier 4 Interim and Final engines are designed to provide maximum life, and to ensure that:
These engines require the use of Ultra Low Sulfur Diesel fuel—15 parts per million (mg/kg) fuel sulfur or less. The same fuel that can be used in all Cat engines.
The Tier 4 Interim and Final engines require a new type of low ash oil, CJ-4 (ACEA E9). Using this oil will help reduce ash accumulation in the Diesel Particulate Filter (DPF), which keeps the DPF operating at top performance throughout its useful life. This oil can also be used in previous-generation engines.
These engines can also operate on biodiesel fuel that meets ECF-3 specs of up to B20. Keep in mind, many of the Tier 4 Final products require the use of Diesel Exhaust Fluid (DEF), which must meet the ISO 22241 specification for all Caterpillar products that require the use of DEF. (You can approximate 2 to 3% of DEF consumption to fuel consumption.)
Tier 4 Final 9L-18L Products Fuel and Maintenance Requirements
In addition to the fuel and oil requirements, this page offers you more details on how to properly maintain your Tier 4 Final products. Let’s focus on a few key points:
First, it’s important to note that many Tier 4 Final products will see up to 8% fuel economy improvements over Tier 4 Interim. With the addition of Diesel Exhaust Fluid (DEF), up to a 5% net improvement of fluid consumption (DEF and fuel) will be gained.
The drain/filter intervals, valve lash, the Diesel Particulate Filter (DPF) ash service (regulation) and the overhaul life have not changed from Tier 4 Interim to Tier 4 Final.
The emissions regulation for DPF ash service is set to a minimum of 4,500 hours, and Caterpillar specifies a DPF ash service of 5,000 hours in our Operation & Maintenance Manual (OMM). However, by tracking many field follow units and our monitoring of Product Link™ data, Caterpillar has found that the 5,000 hours ash service interval has not been necessary on many products. In fact, we’re finding many Tier 4 products don’t require an ash service until they reach 8,000 to10,000+ hours. It is recommended that ash service be completed when the message center displays the DPF Ash Level High service code of “E997-2,” which will be logged and visible via Product Link.
The Open Crankcase Ventilation (OCV) Filter is no longer a service item on the majority of our products. And the CRS spark plug remains a “clean or replace” item at 5,000 hours.
Caterpillar Tier 4 Journey Recap: Providing Value and Meeting Standards
When Caterpillar looked at the technology needed to meet Tier 4 regulation standards for the entire product line, it was clear that a “one size fits all” solution was not the proper approach. Cat products are used in a variety of demanding applications and environments, which meant our Tier 4 solution needed to be as individualized as the products themselves. And it is. Our new generation of engines meet your high expectations for reliability, performance, fuel efficiency and component life—all while producing significantly fewer emissions.
Designed to meet customer needs. Caterpillar customers need products that perform as designed in all applications, including high altitude or extreme cold ambient temperatures. That’s why Caterpillar performed extensive testing on Tier 4 products in the most extreme conditions. Overall, more than one million hours of validation were amassed prior to the Tier 4 product launch. Now, with more than 223,000 Tier 4 products in the field and over 370 million hours of logged run time, Caterpillar has the largest validation of technology in the industry.
By having a large population of products operating in a variety of applications, we are able to prove the reliability of our products. The benefits to you include lower fuel costs, reduced exhaust emissions and a smaller carbon footprint—all without any compromise in production, reliability, durability or operability in all applications.
Also, with Tier 4 Final products, as it is with Tier 4 Interim products, the emissions management is transparent. That means aftertreatment is automatic and requires minimal or no operator intervention. It’s transparent because, as a customer, you want more than just a product that meets emissions standards. You want a product that makes your business better.
Thank you. Contact your local Cat dealer for more information.
