THE CAT D7E WITH ELECTRIC DRIVE

Frequently Asked Questions

AEXQ0462 2009 Caterpillar All Rights Reserved Printed in the USA CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, 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.

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

We Listened to Our Customers

When Caterpillar set out to develop a highly advanced, first-of-its-kind electric drive track-type tractor, we knew there would be questions. Customers and dealers would want information that would help them understand the new technology, how it might affect their businesses and what inherent benefits it could offer to their day-to-day operations. To find out what specific things customers would need to know to understand the technologyand ultimately be driven to purchase the new machinewe engaged customer and dealer groups throughout the development process. We met with separate advisory groups made up of Caterpillar customers and dealers in various locations throughout North America and Europe. First, each group received background information on the development of the machine, how the technologies work, what they mean for businesses and how they might affect the future evolution of track-type tractor design. We then followed up with the same groups to identify concerns critical to machine acceptance.

What Makes the D7E Innovative from the Inside Out?

Modular 10% to 30% less
fuel consumed per hour electric air conditioning system that eliminates long coolant lines and delivers the best performance in a track-type tractor

Exclusive
center-post cab with unprecedented all-around visibility, more overall room, lower noise levels and a tilt feature that provides access to drive system components

35% more visibility Easy to operate

with low-effort controls and no shifting

10% to 30%
reduction in greenhouse gas (CO2) emissions

50% lower noise levels Larger cab

with ergonomic controls

50% better
steering performance

Simplified 60% fewer

moving parts in the electric drive train hydraulics, including a D9-sized single lift cylinder

Grouped service points

for fast, convenient service access

Grade Control Ready

from the factory

10% lower
lifetime operating costs

Electric drive train Dedicated steering pump Up to 50%

longer life for the electric drive train

Less fluids used 10% more

material moved per hour

Hydraulic demand fan Cat C9.3 engine

with ACERT Technology

Up to 70% lower The following document provides answers to the questions these dealers and customers identified as most important when considering whether to purchase the D7E WITH ELECTRIC DRIVE.
undercarriage owning & operating costs with optional SystemOne undercarriage

Electro-hydraulics 25% more

material moved per gallon/liter of fuel

Less down time

with no engine belts to replace or adjust

D7E FREQUENTLY ASKED QUESTIONS

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

Overview
What separates the D7E from competitive machines of similar size and power? The D7E offers many features that are not available on any other machine in its class. The most obvious is the electric drive system, which provides unprecedented productivity, efficiency and maneuverability. A dedicated pump for the differential steering system, combined with continuously variable speed control, provides highly efficient, high-performance steering. Differential steering performs at an entirely new level on this machine. The continuously variable electric drive train enables a locked-track turn, and the use of a dedicated steering pump helps it deliver full steering speed and power under a wide variety of operating conditions. Why did Caterpillar develop the D7E? The Cat D7E was designed to meet a growing demand for powerful yet highly maneuverable track-type tractors. More and more, dozers in the D7 class are called upon for site development work, especially in residential applications. These jobs demand a mix of straight-ahead dozing power and tight-quarters maneuverability. Until now, it has been difficult to find the right balance between these two capabilities in a single machine. But by adapting electric drive technology to the unique requirements of dozer applications, Caterpillar has developed an all-new class of tractor that delivers the best possible balance of heavy-dozing and fine-grading performance. It moves more material per gallon/liter of fuel while costing less to maintain and service, and meeting emissions requirements. What makes the D7E different from previous D7 models? The D7E was completely reengineered from the ground up to take advantage of an all-new electric drive system. The D7Es electric drive is the most advanced electric drive system for a track-type tractor. The entire machine was designed around this new drive system, with the goal of eliminating many of the mechanical components that contribute significantly to operating and maintenance costs. The electric drive system also helps to make the D7E the most fuel-efficient and productive track-type tractor of its size, with the lowest-ever overall operating costs in its class. Machine balance with and without attachments has been optimized as well. Adding or removing rear attachments will have less effect on the machines center of gravity and overall balance, giving better performance in all implement configurations. Ground clearance has been maintained from previous D7 models, and a smoother ride helps maximize operator productivity. How do the operating costs of the D7E compare with those of conventional tractors in its class? Depending on application and other factors, the D7E can reduce lifetime operating costs by up to 10 percent. The savings are realized through a combination of factors, including: A reduction by as much as 25 percent in fuel usage per cubic yard/meter of material moved. Longer component operating life, particularly for the electric drive system and SystemOne undercarriage. Beltless designAccessory systems are electrically powered, so engine belts, which require frequent adjustment and replacement, and alternators are not needed. Extended maintenance intervalsFor example, the electric drive train oil change period is up to four times longer, depending on application and SOSSM sampling results, than that recommended for a power shift drive train, in part because the mechanical torque converter has been eliminated. Dramatic reductions in the number of gears, bearings and clutches also extend filter life. How does maintenance access on the D7E compare with previous models? Easy service access to the drive train system is accomplished by tilting the cab. The modular component design makes swap-outs and repairs easy. The D7E also features convenient left-handside grouped service points, plus extended service intervals, especially for drive train components. Are there environmental benefits? With 10 percent to 30 percent lower fuel usage per hour of operation than the D7R Series 2, the D7E will dramatically reduce carbon dioxide production. Lower power train oil volume and longer power train oil life help reduce oil disposal issues. Overall, the new D7E is designed to consume fewer resources (parts, fluids and fuel) over its working life than any other track-type tractor in its class. The electric drive system delivers longer service life than conventional drives. The D7E also features a proven Cat C9.3 engine with ACERT Technology. It meets all U.S. EPA Tier 3, EU Stage IIIA and Japan MLIT Step 3 regulations while delivering reliable performance and long service life.

> Tilt-cab service access

D7E FREQUENTLY ASKED QUESTIONS

D7E FREQUENTLY ASKED QUESTIONS

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

Electric Drive System

What is electric drive? The D7Es electric drive system uses electrical components (generator, power inverter and the electric propulsion module) in place of some traditional mechanical power train components (torque converter and transmission). These electrical components are designed and built to handle the demands of track-type tractor operation. They are fully sealed off from the environment and connected by purpose-built, heavy-duty electrical cabling. The D7Es electric drive system simply converts engine power into electricity and then uses that electricity to power the drive motors and various machine systems. It does not store power in a battery. How does the electric drive system work? The D7Es electric drive power train starts with a proven Cat C9.3 engine with ACERT Technology. The engine drives a powerful electric generator, which efficiently turns engine power into AC electricity. The electric current flows through a power inverter and into the propulsion module (electric drive motors). The generator, inverter and propulsion module together form the electric drive train, taking the place of the torque converter and mechanical transmission of a power shift drive train. The power inverter converts AC current from the generator into DC current. The DC current is used for machine control and to provide power to accessory systems such as heating, air conditioning, ventilation, water pumps and more. The power inverter then converts the current back to variablefrequency AC and routes it to the propulsion module, which delivers smooth, well-modulated power to the final drives.
Electric Cables

Is the D7E a hybrid machine? The D7E has an advanced Electric Drive power train that is designed specifically to meet demanding dozer applications, while enabling significant improvements in productivity, efficiency and sustainability. It can be considered a hybrid in that it combines a diesel engine with an electric generator to provide propulsion. However, unlike automotive hybrids, it does not use a battery or capacitor to collect, store or release energy during operation. The D7E does capture mechanical energy in the flywheel that is generated during braking, providing more efficient directional shifts and contributing to the overall efficiency of the machine. This technology is often referred to as a diesel-electric hybrid power train. Is electric drive safe? Yes. Electrical safety was a very important design requirement during the development of the D7E. Cabling, connectors and all electrical components had to be engineered to safely withstand the rigors of track-type tractor applications before Cat engineers could consider using them in a production machine. Electrical components have been safely used in many types of heavy equipment for decades (even under water, in the case of equipment ranging from submersible pumps to submarines). With similar precautions used with, say, high-pressure hydraulic systems, you can be confident in your peoples ability to work safely with the electric drive system. Consult the machines Operation and Maintenance Manual for complete safety information and procedures.

How does the electric drive system affect engine performance? The D7E electric drive system allows the engine to work in a narrow speed range. The continuously variable electric drive train can vary its power demand with minimal change to the engine speed. That allows other systemssuch as implement hydraulics and steering hydraulicsto provide consistent performance. That helps the engine work more efficiently, which contributes to lower fuel usage. It can also enhance overall engine life. Is the electric drive system easy to operate? Because it has no gears to shift, the D7Es electric drive system is easy to operate and easy to learn. New operators get up to speed quickly, and experienced operators adapt to it easily, especially if they have ever operated a machine with a hydrostatic transmission. The electric drive system delivers precise, smooth implement control, and it relieves operators of most engine management responsibilities. That makes operation easier and allows the operators to concentrate on the work being done at the blade or ripper. What are the key benefits of the D7Es electric drive system? Unmatched Efficiency & Versatility The electric drive system delivers engine power to the ground efficiently, and it provides infinitely variable speed control similar to that of a hydrostatic transmission. As a result, it delivers both excellent maneuverability and efficient production dozing performance. In fact, the D7E delivers a quantum leap in overall dozing efficiency, moving 25 percent more cubic yards/meters of material per gallon/liter of fuel than its class-

leading predecessor, the D7R Series 2. In utility and finish-grading applications, the D7E can deliver an even greater improvement. Fewer Moving Parts, Lower Service CostsThe D7Es electric drive is technically advanced but mechanically simple when compared with conventional drive systems. It has 60 percent fewer moving parts than a mechanical drive system, which means there are fewer components to wear out or potentially break down. These components have been designed to last up to 50 percent longer than a conventional drive system working in a similar application. For example, the electric drive system contains no friction clutches, which reduces service requirements. And because many accessory systems are electrically powered, the D7E is entirely beltless. There are no engine belts to break, wear or replace, which improves operational reliability and further lowers service costs. Improved Fuel ConsumptionThe D7E delivers a 10 percent to 30 percent improvement in fuel consumption (as measured in gallons/liters of fuel burned per hour of operation) compared with the previous model, while delivering a 10 percent increase in productivity (cubic yards/meters per hour) in most applications. Dramatically Improved Steering PerformanceThe combination of electric drive and Caterpillars proven differential steering system also delivers 50 percent more steering performance than the D7Es predecessor machine. The continuously variable electric drive train also means there are no gears to shift, so operators can concentrate on guiding the machine and controlling its implements.

> Improved steering performance

Power Inverter Accessory Power Converter

Generator

D7E Beltless Engine

Propulsion Module Final Drive

Engine
6 D7E FREQUENTLY ASKED QUESTIONS D7E FREQUENTLY ASKED QUESTIONS 7

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

Electric Drive System (continued)

Will the power train life of the new D7E be as good as the D7R Series 2? In most cases, it will be substantially better. The D7Es electric generator, power inverter and drive motors are expected to last up to 50 percent longer than todays power shift transmission (excluding bearings and seals) without requiring a rebuild. The fact that the electric drive train has 60 percent fewer moving parts translates directly into high reliability and long service life. The extended drive life changes the total lifetime ownership and operating cost equation. It pushes electric drive train rebuild costs to much later in the machines operating life, which in turn can have a powerful impact on the length of time D7E owners keep their machines in service. How strong is the machines torque? Does the torque come on smoothly? The new electric drive system delivers outstanding torque in either direction, with smooth torque modulation that makes operation easy and predictable. The D7Es torque is very strong, providing enough drawbar force to exceed tractive capability in almost all situations, but with precise control that allows operators to apply exactly the torque needed for the operating conditions. Will D7E operators be able to adjust top speeds and machine sensitivities? Yes. Operators have the ability to set their desired top travel speed for the specific application they are performing.
Electric Generator

This functional capability, combined with the electric drive system, enhances overall performance. The operator does not have to constantly change the desired top travel speed, because the electric drive train system optimally and automatically adjusts its speed to varying loads. How is the D7Es electric drive system different from those found on other types of heavy equipment, such as mining haul trucks? The D7Es electric drive system is engineered specifically for track-type tractor use. It features some crucial innovations that make it well suited to track-type tractor forward/reverse cycling operations. All the electrical components in the D7E drive train are completely sealed off from the environment and liquid-cooled. Robust sealing and jacket cooling enable the electric drive system to work easily and safely in thick dust, deep mud, heavy debris and even in water.

Brushless motors have minimal electrical contacts between moving parts, which cuts out potential wear and failure points and reduces service and maintenance requirements. Brushless technology is so superior, in fact, that it is becoming the standard in all types of electric drive systems. Do the liquid-cooled drive components require a separate radiator? Yes and no. The generator and power inverter are jacket-cooled, which means liquid coolant circulates around them in a sealed jacket. The coolant then circulates through a separate radiator circuit built into the main engine radiator. Although the engine and drive train coolant remain isolated from each other, the radiator appears and acts as one integrated unit. All the radiator cores are in a single plane, so the entire radiator system is easy to clean and service. So, yes, the jacket cooling system has its own radiator, but no, it is not a completely separate unit.

Why does the D7E have a single lift cylinder? Is dozing performance affected? The single lift cylinder on the D7E delivers the same dozing performance, power and stability as a dual-cylinder system. The advantage is that it uses less than half the components. That helps reduce lifetime operating and service costs, especially when coupled with the fact that the single-cylinder systems components are larger, stronger and more resistant to wear or damage. For example, there are half as many seals as in a dual-cylinder system, and the seals are larger, thicker and better able to reject contamination. Also, the single-cylinder system does not require a quick-drop valve. Larger ports on the single cylinder and shorter hose length allow the blade to drop quickly by gravity alone. Although dual-cylinder systems look like they add stability, they are actually plumbed to act as a single unit. They offer no additional resistance to unequal pressures on either side of the blade. Only the tilt cylinder mounted to the push arm provides tilt resistance. Tilt forces on a two-cylinder lift system cause one cylinder to extend and the other to retract as the cylinders simply exchange fluid.

How will this tractor operate in water? The D7E delivers equivalent performance to the D7R Series 2 in water. All electric drive components are fully sealed to keep water out and allow for safe operation in damp, wet and submerged conditions. Of course, all tractors are limited to running in water that comes up no higher than the bottom of the engine fan, unless they are specially equipped for high-water fording. How is the stability on slopes? Operators report that the D7E works better on slopes than previous models, not only as the result of excellent balance and a low center of gravity, but also because the electric drive offers infinitely variable speed for maximum traction and control. The electric drive system also eliminates uncontrolled freewheeling caused when an operator inadvertently puts a power shift transmission into neutral on a slope. What kinds of technology enhancements or information systems does the D7E offer? The D7E comes from the factory gradecontrol ready, which makes installation of the AccuGrade system much faster, easier and less expensive. Product Link is also a standard feature. This system can provide a range of real-time transmittable and downloadable data that can facilitate more effective machine management.

> Single lift cylinder

Power Inverter

> Operation in water

Drive Motors

D7E FREQUENTLY ASKED QUESTIONS

D7E FREQUENTLY ASKED QUESTIONS

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

D7E TRACK-TYPE TRACTOR What Will Our Customers Ask?

Undercarriage
How does the new configuration compare to the high-drive system on previous models? Any high-drive configuration offers three key benefits: 1) easy service access to the transmission, 2) the ability to use suspended undercarriage and 3) the mitigation of final drive shock loads. Lets look at how the D7Es design addresses each of these. Service AccessThe D7Es design handles drive system serviceability in a different way, but it provides much of the same level of accessibility as a high-drive configuration. For starters, there is no transmission to service. All the electric drive system components are modular, and all are accessed under the tilt cab. The drive components also need less total maintenance and service than the mechanical systems found in previous models. So the D7E not only provides easy service access, it also needs less lifetime service and thus delivers lower total drive system operating costs than previous D7 models. Suspended UndercarriageThe primary purposes for a suspended undercarriage are to improve track-to-ground contact in rocky and uneven applications and to improve operator ride. Cat D7-class tractors have always delivered long, dependable service life in their intended applications without a suspended undercarriage. Note, however, that Caterpillar plans to keep high drive and suspended undercarriage on D8 and larger tractors. Shock LoadsTo make sure the new low-drive system could handle the impact loads of a typical D7 application, Cat engineers used D10Tcapacity sprocket bearings on the D7E. They also designed the undercarriage system to direct shock loads through the roller frame, instead of directly through the final drives. With these enhancements and other advances in materials and engineering, it was possible to extend a low-drive configuration (already used on many smaller Cat track-type tractors) into the larger D7 size. Add the enhanced visibility of the D7Es low-drive system (especially to the sides), and it becomes clear that this is the best design for the new modelone that will deliver the lowest possible operating costs and maximum operating efficiency in a much wider range of applications than ever before possible with a D7-class machine. Will SystemOne be available on the D7E? A heavy-duty undercarriage configuration will be standard on the D7E, and SystemOne will be available as an attachment option. SystemOne undercarriage has been proven to reduce total undercarriage costs by 35 percent to 70 percent. These cost savings come from specialized components that reduce wear, offer longer life and dramatically cut total lifetime maintenance needs. Lifetime sealed and lubricated cartridge eliminates bushing turns. Sprockets require no replacement during the life of the chain. A rotating bushing design allows the center tread idlers and sprocket segments to last through at least two sets of track. An open and smooth roller frame design reduces mud buildup and enables easy clean-out. In addition, all SystemOne undercarriage components are designed to work and wear as a system. They deliver long, balanced wear life and require very little service between undercarriage overhauls. Lower Noise LevelsThe self-contained HVAC (Heating, Ventilation, Air Conditioning) system is mounted outside and to the rear of the cab. In combination with other improvements, this configuration helps reduce noise levels inside the cab by 50 percent. The D7E is quieter on the outside, too. The electric drive motors are essentially silent, and electric drive enables the engine to operate in a tighter power band, so high revving is dramatically reduced. As a result, outside noise levels are dramatically reduced compared with the D7R Series 2.
> Cab visibility

> D7E undercarriage

Why does Caterpillar use a low-drive undercarriage configuration on the new D7E? Since Caterpillar was redeveloping the centerline of the new machine for the electric drive system, there was an opportunity to design a completely new track system that could deliver more versatility with even lower operating cost. That opportunity led to the development of an all-new low-drive (or oval track) configuration. Before Caterpillar engineers chose a low-drive undercarriage design for the D7E, they very carefully weighed its advantages for the D7Es intended applications. The mix of applications for which customers use D7-size machines has changed since the introduction of the original Cat D7H. Customers todayespecially those working in site preparation applicationsdemand much more maneuverability from this size of machine than they did twenty-some years ago when the first Cat D7H models were produced. As they developed the D7E, Cat engineers wanted to retain the advantages of high drive, but also gain some additional benefits. Their goal was to make the D7E as productive and cost-efficient as possible in its intended applications.

Operating the D7E

What are the operator benefits of the new cab design? Increased VisibilityThe new center-post cab is larger overall, with larger windows and improved viewing angles. That works with the overall design of the machine to provide much better visibility all around, especially to the critical areas around the blade. The effect of this unprecedented visibility is immediately apparent when an operator steps into the cab. Operators experience a 35 percent increase in forward visibility because the precleaner, exhaust and single lift cylinder all line up with the center post cab. Rear views are also improved, in addition to views to the sides and blade corners. Added ComfortOperator comfort was a top design priority on the D7E. The ergonomically designed steering, speed and implement controls and the air ride seat are all fully adjustable for maximum comfort and operating efficiency. As a result, operators experience less fatigue and remain more productive throughout their shifts.

Cat Track-type Tractor Product Line

Whats happening to the D7R Series 2? The D7R Series 2 will remain available along with the D7E until mid 2010, before the former is eventually phased out in regulated markets. Why did Caterpillar start with the D7 for electric drive? Whats next in the machine line? The D7 size class offered a just-right sized platform for the new electric drive system, which helped to facilitate the E Family development process. As more product development occurs, electric drive may expand into other class sizes.

> HVAC system

For more information on the D7E, visit www.cat.com/D7E

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D7E FREQUENTLY ASKED QUESTIONS

D7E FREQUENTLY ASKED QUESTIONS

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