797F Caterpillar update

1. 797F 4x4 LMR Program Update
Presentation to Chinalco – Toromocho
February 19, 2016

2. 797F Low Maintenance Ratio (LMR) High Altitude Engine
Bundling of key customer value features:
• 4x4 high altitude air system
• Self-cleaning oil filter + Centrifugal Oil Filter (COF)
• Hydraulic Valve Lash Adjusters (HLA)
with low lift cam
• Individual port thermocouples – telematics ready
• Extends oil change intervals
• Eliminates oil filter replacement
• Reduces contamination risk to engine during service
• Eliminates lash adjustment and reduces valvetrain loads
• Provides full life turbochargers and air system
• Reduces engine weight compared to current 4x2 HAA
configuration
• Lab Testing – full strain, vibration, and thermal assessment (complete)
• TPG Testing – Machine performance and vibration (in process)
• Field – 2 HAA machines for in use demonstration (begin early 3Q16)
Project
Description
Customer
Benefits
Validation
LMR Key Iron
T2 C175 Iron

3. 4X4 Air System Benefits
Future 4X4 vs Current 4X2
• Approximately 1000 kg weight reduction
• 550 mm reduction in overall package
height
• Reduces overall air system
vibration levels
• 100 fewer parts per engine
• Front and rear support structures are
independent of each other
• Eliminates potential for vibratory
interactions between the two
systems.
• Reduces effects of thermal growth
and distortion
• Predicted reduction in cycle fuel
consumption
4x4 HAA 4x2 HAA

4. 4x2 Lessons Learned Applied
Turbos
Exhaust
Intake
Structures
• C175-20 engine 2nd order and 5th order
block vibration factored into design
• Turbochargers completely supported
from front and rear housings for optimal
vertical support
• Minimized system height and lengths to
reduce overall package vibration levels
• Air system structure separated into two
halves
• Minimize system thermal growth
and distortion of support structures
• Eliminates vibratory interactions
between front and rear
turbochargers
• Inner-stage exhaust ducting between
HP and LP made as short as possible
to eliminate need for hot exhaust piping
supports
• Eliminated wastegate + left & right Air &
Exhaust mixing

5. HLA and Low Lift Cam Benefits
Valve Seating Velocity
Reduction
Rotator
Fatigue Life improvement
Spring Fatigue Factor
Improvement
Pushrod Force
Reduction
Lifter Shaft / Bolt
Fatigue life improvement
Wear Reduction
Rocker Shaft / Bolt
Fatigue Life (IN) improvement
Wear Reduction
Bridge
Fatigue Life improvement
Wear Reduction
Valve Seat
Fatigue Life improvement
Wear Reduction
Pushrod
Fatigue Life (IN)
improvement
Wear Reduction
Hyd Lash Adj (HLA)
Eliminates lash setting interval
Maintains targeted lash
Cylinder Head

6. HLA – How They Work
Body - Tip
Body -
Lower
Body -
Upper
Piston
Retaining
Ring
Seat -
Check
1. Check
Ball
Ball
Retainer
Feed
Spring
Intake Valve Closed
1. Check valve opens.
2. Oil refills chamber
3. Lash reset to zero
Intake Valve Open
4. Check valve closes
5. HLA is hydraulically
locked
6. Maintains zero lash
during valve lift event.

7. 797F LMR Engine – Lubrication System
Distributor Motor
Backflush
Oil To COF
SCF Functional Overview
Dirty oil filtered through fine mesh screens.
< 0.5% of the filtered oil flow powers the hydraulic motor which turns the distributor.
3% of the filtered oil is directed back through the screen elements to flush out the debris (self clean) and is carried to
a centrifugal filter.
~97% of clean oil goes to the engine main oil gallery
SCF filters oil to 40 micron absolute. (Today’s cartridge filter is 20 micron)
Centrifugal filter removes contaminants from the backflush oil.
No service required for SCF which means clean side of lube system always remains closed!
Supplier YouTube Video – Functional Overview (https://www.youtube.com/watch?v=5UQfLr_EZ2s)
Self Cleaning Filter & COF
IMG_0571 - Windows Photo Viewer
Aluminum body: 88 kg
No Filter bypass valve
Filter Out
Unfiltered oil press.
HPFP clean oil
port
Backflush To
COF
Filter In

8. 797F LMR Engine – Lubrication System
Centrifugal Oil Filter (COF)
Spindle
Cleaning
chamber
(high pressure)
Contaminant
buildup
Inlet
Drain
Cut-off valve
Nozzle
Drive chamber
(crankcase pressure)
• 4 liters of dirt holding capacity
• 25 lbs when full of contaminants
• 1 unit per engine (2nd unit
potentially required for HA sites.)
• CAT custom base design for
optimal packaging

9. 797F Low Maintenance Ratio (LMR) High Altitude Engine
• As reviewed, Ferreyros and Caterpillar are
committed to making the 797F 4x2 C175-20 a
successful engine for Toromocho.
• We are also committed to developing new
technologies and products to improve performance,
improve efficiency, and reduce maintenance costs
for Toromocho.
• Thank you for partnering with us!

10. Thank You!