Caterpillar

Fuel Burn to Overhaul Model*

10000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Model Equipment ID Idle Time Hours Operating Hours Total Fuel Used (Gallons) Engine Displacement (Liters) Fuel to Overhaul (Gallons) % Idle Time Gallons / Hour Target Change-out (Hours) Optimized Change-out (Hours) Optimized Change-out w/ 10% Buffer (Hours) Hours to Overhaul Target Change-out Hour to Overhaul Optimized Change-out Hour to Overhaul Optimized Change-out w/ 10% Buffer Equipment Fleet Model 1 Model 2 Model 3 Model 4 Model 5 Model 6 Fleet Number Fleet Number Fleet Number Fleet Number Fleet Number Fleet Number
1,503 7,251 124,693 18.1 181,000 21% 17.2 10525 12707 12489 3274 3953 3885 351 1,288 18,083 18.1 181,000 27% 14.0 12892 16405 16054 11604 14766 14450 179 1,221 18,881 18.1 181,000 15% 15.5 11705 13421 13249 10484 12021 11867 341 2,591 22,283 8.8 88,000 13% 8.6 10232 11579 11444 7641 8647 8546 2,413 7,945 166,845 27.0 270,000 30% 21.0 12857 16762 16372 4912 6404 6255 1,047 3,159 109,313 15.2 152,000 33% 34.6 4393 5848 5703 1234 1642 1602

*Key Assumptions Drive Model Logic:

- 1 liter of engine displacement equals 10,000 gallons of fuel burned to overhaul - Based on Caterpillar's engine product group's analysis of fuel consumption vs load factors in captive engines - % of idle time can cause a deviation in the target change-out hours - Logic works for 3300, 3400, 3500, & C series engines (except for C175)

Key Results of Model Logic Include:

This model can help provide alignment of the planned engine change-outs with the customer's machine ownership assumptions. It can also be used to help the customer budget for engine overhauls. NOTE: Consult additional condition monitoring elements prior to engine change out or repair.

Model Help:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Enter machine model number. Enter customer's machine or equipment ID. Record idle time hours from Product Status Report available in Cat ET or VisionLink. Record operating hours from Product Status Report available in Cat ET or VisionLink. Record total fuel used from Product Status Report available in Cat ET or VisionLink. Enter the engine displacement in liters for each machine in the fleet. Fuel to overhaul is a calculated field by taking engine displacement (liters) * 10,000 gallons. % idle time is a calculated field by taking idle time hours divided by operating hours. Gallons per hour is a calculated field by taking total fuel used divided by operating hours. Target change out hours is a calculated field by taking fuel to overhaul divided by gallons/hour. Optimized change-out is a calculated field by taking target change-out * (1 + idle time percentage). Optimized Change-out with a 10% buffer is a calculated field by taking target change-out * (1 + (Optimized change-out * 0.9)). You can adjust the buffer to what ever % you prefer. Hours to overhaul target change-out is a calculated field by taking (fuel to overhaul - total fuel used) divided by gallons per hour. Hours to overhaul optimized change-out is a calculated field by taking hours to overhaul target change-out * (1 + % idle time). Hours to overhaul optimized change-out with a 10% buffer is a calculated field by taking hours to overhaul target change-out * (1 + (% idle time * 0.9))

you prefer.

Fuel Burn to Overhaul Thoughts

Fuel efficiency is measured in tons of material moved per gallon of fuel burned. Most customer's can't me track fuel burn rate (gallons/hour). Engine speed (RPM) is directly proportional to fuel burn rate (gallons/hour). Many factors can impact the amount of fuel a machine burns. Here are 4 key factors that impact the fuel 1. Machine application or what type of work the machine is doing. In a difficult load & carry application may burn 60 to 100% more than the same machine in a truck loading application in an aggregate yard.

2. Operator technique such as an aggressive truck loading cycle (20 seconds) can burn 60 to 80% more moderated cycle (30 seconds).

3. Idle time pertains to the percentage of time a machine is idling which has a large impact on the fuel bu loaders can burn less than 1 gallon/hour idling. A 980K working steady (no idle time) in a difficult sand & per hour. A typical 980K burns 6 gallons/hour or less. The higher the percentage idle time, the more it re Idle times in the 30% to 40% range for medium wheel loaders is common in North America.

4. Machine configuration features can impact fuel burn but to a far smaller degree than application, ope these features can include electronic fuel systems, engine idle management & shutdown systems, loading *Source: Understanding Fuel Efficiency and Fuel Burn Rate (AEXQ0649) Other thoughts impacting fuel burn include:

Application determines engine load factors and fuel consumption. Engine load factors refer to the instanta relative to its maximum capability. An engine continuously producing full rate horsepower is operating at a machines may reach a 100% load factor intermittently, but seldom operate at this level for extended perio dozer and pusher travel in reverse, haul units traveling empty, close maneuvering at part throttle and oper conditions which reduce load factors. Engine load factors are to be used as a general guide and will vary

Keep in mind that many variables can affect fuel consumption. Two operators of different temperament o machines side by side in the same material can have as much as a 10 to 12% difference in their fuel cons

The general thoughts that comes with the idea of fuel burn or fuel consumption is the actual fuel cost for a thought, however, there are other important factors within an operation that affect the fuel burn efficiency. can tell whether the operator is loading the machine too heavy, too light, or excessive idling. The amount

the surrounding conditions such as altitude and temperature. For instance, generally a machine working at higher a closer to sea level due to the thinner air. Temperature which could be in terms of the surrounding air, fuel, and oil c

Customers are always tasked with ensuring that the overall operation including maintenance is managed as efficien overhaul model can be used for a machine or fleet. When measuring fuel burn to overhaul, consideration should b time. This factor can have a major influence on the planned component change (PCR) hours and as such should b

The fuel burn to overhaul model provides an example of how to create the benchmark component life based on ma and the percent of idle time.

customer's can't measure fuel efficiency and simply

hat impact the fuel burn rate (gallons/hour):

& carry application like a sand and gravel pit, a loader n aggregate yard. urn 60 to 80% more fuel than the same machine in a

mpact on the fuel burn rate (gallons/hour). Medium wheel in a difficult sand & gravel pit may burn over 12 gallons time, the more it reduces the overall fuel burn average.

han application, operator technique and idle time. Some of wn systems, loading sensing hydraulics, & torque converters.

refer to the instantaneous loading of the engine wer is operating at a load factor of 100%. Earthmoving l for extended periods of time. Periods spent at idle, art throttle and operating downhill are examples of guide and will vary by model and application.

rent temperament or attitude operating identical nce in their fuel consumption rates.

actual fuel cost for a piece of equipment. This is a valid fuel burn efficiency. Such factors include load factor, which idling. The amount of fuel burn can also be affected by

ne working at higher altitude burns more fuel than if it were ding air, fuel, and oil can all impact the amount of fuel burn.

s managed as efficiently as possible. The fuel burn to onsideration should be given to the percent of idle and as such should be included in the calculation.

nent life based on machine average fuel burn rates