Caterpillar Defence Products Delivering Mission Solutions

in Defence Caterpillar Inc, with its headquarters in Peoria, Illinois, USA, is the world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. Caterpillar serves the Defence market with a comprehensive range of products for military applications in both Land and Marine domains. Customers are able to select from Commercial Off The Shelf Industrial products (COTS), already developed and available Military Off The Shelf products (MOTS) or engage with the design teams to develop new product configurations or arrangements to provide application specific performance and long term value.

Delivering mission critical solutions, Caterpillar is a leading supplier of diesel engines, transmissions and powerpacks for military ground vehicle applications. Customers and end users benefit from the strength of the Caterpillar enterprise through delivery of well supported, cost effective defence drive train solutions. Military users are able to select from an increasing and enhanced product range to suit the application specific needs, with the additional benefit of the worldwide logistical support of Caterpillar’s global dealer network. The range of high power density engines, up to 1500bhp (1120kW), is suitable for applications from light protected wheeled vehicles to main battle tanks, giving end users cross fleet supportability benefits and a reduced training burden. Original Equipment Manufacturers are able to utilise the space and weight budget more effectively to reduce vehicle weight or improve protection. Offset, Industrial Participation and localisation efforts are important elements of Defence contracts. With its global supply chain and manufacturing footprint, Caterpillar is able to assist customers in fulfilling their obligations with support from its dedicated offset team. Caterpillar military customers demand through life support to be provided for products expected to be in service for 30 years or more. Supporting the inherent reliability and durability of the original products, an important part of Caterpillar’s long term value proposition is the capability to remanufacture products to at least original performance specification, ensuring the long term performance and availability of the products.

Easy to do business with, Caterpillar has a long history and a deep understanding of the Requirements of Defence customers, to suit arduous military specifications and applications. Caterpillar understands the detailed US, UK and other Export Controls regulations for product going into Defence applications, smoothing the regulatory processes. Customers demanding a cost effective engineered solution with installation and through life support can rely on Caterpillar to deliver. With a highly developed product line of engines, transmissions, powerpacks and final drives with the application knowledge to design from a Systems approach, customers are able to select the appropriate package to suit their needs. Caterpillar’s strong brand reputation in the Defence sector is founded on strong technical capabilities including complex systems engineering, military grade electronic integration and ground vehicle application knowledge, coupled with a willingness and ability to undertake application specific tailoring in order to provide customers with the most cost effective, application specific solution. Cat® products are successfully performing in service in combat and logistic vehicles with more than 50 armies worldwide. As examples, the British Army uses Cat engines in its Challenger 2 main battle tanks and Warrior infantry fighting vehicles. Cat engines power the world renowned Stryker family of vehicles chosen by the US Army for its Brigade Combat Team requirements.

Contents Page Designed for Success 4 Performance Engines 6 Durable Transmissions 8 Enduring Powerpack Solutions 10 Global Through Life Support 12 Adjacent Defence Products and Services 14

Designed for Success Bringing the latest concepts and technologies into military markets, Caterpillar utilises the broad engineering and design expertise from within the total Caterpillar enterprise. Technologies may come from well proven experiences in the construction and off-highway market places or from the development of emerging technologies where application benefits are apparent for Defence applications. Customers concerns over fuel consumption, emissions, smoke, noise, current or emerging legislation are addressed by the engineering teams to produce cost effective legislative compliant solutions. The Defence design teams have extensive knowledge of the key design constraints such as the limited space available, the requirement for ease of maintenance, operation in extreme climatic conditions, operation on NATO fuels, oil monitoring regimes and specific vehicle operating characteristics such as slope and gradient. Products are designed with consideration for the complete life-cycle for performance, ease of manufacture, supportability and remanufacture. The design teams work with all stakeholders and vehicle OEMs to achieve the best design solution and packaging to meet the vehicle requirements.

Military vehicles in-service life may extend for many years after original production has ceased. The design teams at Caterpillar not only design for today, but design for supportability and maintainability through that extended life. The design process is applied to all vehicle family variants such as Repair and Recovery vehicles, to give as much logistic commonality as possible and to deliver long term value. OEMs can rely on Caterpillar to understand and assist with vehicle integration issues. A Systems approach is applied to ensure that the overall vehicle performance is met whether this is designing the engine, the transmission or the complete powerpack including any auxiliary or integrated systems such as air filtration and cooling.

Products are introduced to the market using Caterpillars robust New Product Introduction (NPI) process to ensure appropriate verification and validation. Modifications to COTS products for defence applications give the volume and cost benefits associated with the original product, coupled with tailoring to the application requirement to provide the best packaged compliant solution.

Emerging technologies such as electric and hybrid drive, already available in Cat construction machinery, can be adapted for use in military environments.

Performance Engines High power density allows the OEM to design a more efficient package solution and adapt the overall weight budget more effectively for mission critical elements. In addition to its comprehensive range of standard engines for Industrial applications, Caterpillar offers a range of high power density diesel engines suitable for the arduous duty cycles of both wheeled and tracked Armoured Fighting Vehicles. In-line or V-engines may be selected to suit the vehicle installation.

The engine range offered by Caterpillar for Defence applications is based on the Commercial Off The Shelf range of engines used worldwide in Caterpillar’s global range of products. Customers gain the benefit from the reduced costs associated with volume manufacturing together with the global support available. The products are specifically designed for military applications, though customers may select Commercial/Industrial products if space or the application is not a restriction. For wheeled vehicles the range extends to 950bhp (708kW) and for tracked vehicles up to 1500bhp (1120kW).

High Power Density 17.4l V8 The high power density V-configuration engine with a displacement of 17.4l, provides up to 1000bhp (746kW) unregulated and 800bhp (592kW) Euro III, ideally suited to lnfantry Fighting Vehicle applications. The earlier V8 engine rated at 550bhp (410kW) is fitted to the British Army Warrior vehicle.

Cat C4.4 The C4.4 is a compact 4.4 litre, 4 cylinder diesel engine with an industrial rating of 173.5bhp (129.5kW) Tier 4 Interim, Stage IIIB. Ideally suited for a high mobility light armoured vehicle.

Cat C6.6 The C6.6 is a compact 6.6 litre, 6 cylinder diesel engine with industrial ratings up to 275bhp (205kW) Tier 3, Stage IIIA.

Cat C7 With ratings up to 370bhp (276kW), the C7 has been fitted to a wide range of vehicles in service including the UK Mastiff fleet and the US FMTV. A significant population of these engines are in service and supported by Caterpillar throughout the world.

Cat C9 The C9 engine, in-service in a variety of wheeled vehicles at 400bhp (298kW) can provide up to 600bhp (447kW) for light armoured vehicles, typically 8x8.

Cat C13 The C13 engine is available with ratings up to 710bhp (530kW) unregulated and 520bhp (387kW) Euro III. The engine is in service today in the US Army’s Buffalo Route Clearance Vehicle.

Cat C18 The powerful C18 engine, rated at 700bhp (520kW), was selected by BAE Systems for the new Terrier combat engineer vehicle for the British Army. It has also been chosen by Oshkosh for its Heavy Equipment Transporter. With a rating of 950bhp (708kW) the C18-950 has been installed in an Airfield Crash Tender application. A horizontal version of the C18 at 700bhp (520kW) has been developed for use in a Rail application and could suit armoured fighting vehicles with particular low height space constraints.

Durable Transmissions For rugged and demanding off-highway and defence applications select from Caterpillar’s proven range of automatic transmissions. A range of products is suitable for wheeled vehicles of installed power up to 700bhp (520kW). The cross-drive transmission aimed at Infantry Fighting Vehicles is rated up to 800bhp (600kW). Transfer cases, drop boxes and axles are all available from the Caterpillar range of Industrial and Defence products. In addition Caterpillar has designed a bespoke final drive fitted to the UK Ministry of Defence Terrier vehicle. This engineering and manufacturing capability is available to all customers. Caterpillar works closely with other engine and transmission suppliers to ensure satisfactory integration of the transmission with the engine, associated driveline and final integration into the vehicle to suit the application.

The X300 is currently in production for the BAE Systems Hägglunds CV90 Infantry Fighting Vehicle, selected by the Swedish, Norwegian, Finnish, Swiss, Dutch and Danish armies. Over 1200 of these vehicles have been produced since introduction of the vehicle in the early 1990’s.

Original Equipment Manufacturers, customers and end-users benefit from the availability of transmissions and driveline assemblies already in volume production for Caterpillar’s extensive range of products. Benefits include availability, durability, supportability and lower cost.

The X300 transmission, manufactured under licence from Allison Transmissions, features a 3-phase torque converter with lock-up clutch, infinitely variable hydrostatic steering, with pivotal turn in neutral and integral service and parking brakes with both mechanical and hydraulic apply. Rated up to 800bhp (600kW) for vehicle weights up to 36t, the X300 transmission is designed to fit both front or rear drive vehicles, and includes optional output rotation with a simple internal change. The British Army’s Warrior Infantry Fighting Vehicle is equipped with the X300-4B while the Kuwait Army’s Desert Warrior IFV is fitted with the X300-6. In both vehicles, the X300 is linked to a CV8 diesel engine rated at 550bhp (410kW) in a compact powerpack.

Enduring Powerpack Solutions Effective packaging and integration of a complete powerpack solution allows the Original Equipment Manufacturer to concentrate on other elements of the vehicle design, reducing costs and time to market for development of complete vehicle solutions. From small auxiliary power units to Main Battle Tank propulsion, Caterpillar has proven expertise in designing and delivering a drive train or powerpack to suit the most demanding of Land vehicle applications including the provision of bespoke final drives. Caterpillar’s engineers have knowledge and experience of the demanding challenges of packaging for performance within Armoured Fighting Vehicle space envelopes to operate in extreme climatic conditions. Air filtration and flow systems, cooling systems, electrical power and electronic control systems can all be tackled by the strength of the Caterpillar enterprise. The building blocks of the complete powerpack may benefit from standard COTS components from throughout the Cat range meaning lower cost, improved reliability, durability and supportability for the Customer.

Using a CV12 engine coupled to a David Brown TN54 cross-drive transmission, purpose designed air filtration and cooling systems, plus electrical interfaces, this powerpack is fitted to the UK Ministry of Defence Main Battle Tank which entered service in 1998. A later version of the CV12 engine is fitted in the Engineer vehicles Titan and Trojan. Caterpillar is working with the UK Ministry of Defence to upgrade the vehicle to CSP standard, improve performance where required and to enable supportability through to the declared out of service dates for the heavy armour fleet.

Using a modified Cat C18 engine coupled to an X300 cross-drive transmission, self-cleaning air filtration system, purpose designed cooling system and Caterpillar designed and manufactured final drives, this powerpack and complete driveline is fitted to the UK Ministry of Defence Terrier vehicle which entered service in April 2013. Using a CV8 engine coupled to an X300 cross-drive transmission, purpose designed air filtration and cooling systems, plus electrical interfaces this powerpack is fitted to the UK Ministry of Defence Warrior Infantry Fighting Vehicle which entered service in 1988. Caterpillar is working with Lockheed Martin and the UK Ministry of Defence to upgrade the vehicle to WCSP standard and to enable upgrading and support through to the declared life expectancy of 2040 and beyond.

A Cat C13 engine coupled with a Cat CX 35 transmission provides a compact and supportable drive train with proven reliability and durability.

Global Through Life Support Global product support is a major advantage offered to Customers utilising the worldwide Caterpillar distribution network. Customers are provided with a guaranteed level of support wherever the vehicle or equipment is manufactured, used or deployed. The full range of services offered by the Caterpillar dealer network are available to Defence customers including genuine parts supply, technical support, service call-out, repair and overhaul and Remanufacture through the Reman Exchange and Reman Non-exchange programmes. Typically, military vehicles remain in service for many years beyond the commercial life of the product, requiring careful management of support and obsolescence. The excellent supportability of the product, combined with Caterpillar’s dedication to and experience in the Defence market means customers can be assured of through life support for the products. Caterpillar are able to offer a comprehensive Integrated Logistic Support package for all its products including appropriate publications, parts codification, design and supply of special tools and test equipment and tailored training packages in addition to worldwide parts supply.

The UK Ministry of Defence fleet of heavy armoured vehicles is supported by remanufacture of the CV12 engines. The guaranteed performance to OEM specifications assures no compromise in vehicle performance through to Out of Service Date. Mid-life upgrades and performance enhancements are incorporated at each remanufacturing opportunity meaning the product is at least as good as new.

Caterpillar offers unique processes and salvage techniques to return an end-of-life, broken or blemished product to “same-as-new” condition in a manufacturing environment. This provides the customer with significant through life cost benefits.

The techniques involved mean that an assembly such as an engine may have multiple lives, which is essential in long service life applications found in Defence, particularly in Armoured Fighting Vehicles which may suffer from damage as well as wear. The Caterpillar remanufacturing process involves complete strip, cleaning, inspection, remanufacture and salvage where possible, injection of new parts required, build and full performance test prior to return to the customer with an original warranty.

Adjacent Defence Products and Services Caterpillar offers global customers the benefits of its worldwide organisation where the capability provided is able to offer superior long term value. Defence customers may benefit from complementary products and services offered by the Caterpillar enterprise.

Standard and specialised machines for War fighting, Caterpillar serves the Armed Forces with state-of-the-art equipment and support as well as sophisticated testing services and a research and development programme that is committed to providing the technology and hardware needed for tomorrow’s military environment. Our mission is straight-forward: ‘Apply Caterpillar’s advanced technology, manufacturing capabilities, global support network and the expertise of our skilled men and women to provide Armed Forces with the most productive, mobile and cost-effective products possible.’

Industrial Participation Many Defence procurement contracts require Offset as an integral part of the overall solution. A significant advantage offered by Caterpillar to Prime Contractors is extensive expertise and experience in providing and trading Offset. Caterpillar has a global manufacturing footprint and associated supply chain together with a dedicated resource supporting Industrial Participation activity. Caterpillar has a proud record of discharging 100% of its Offset Obligations.

Sub-Systems The UK Ministry of Defence Trojan vehicle is fitted with a modified Caterpillar excavator arm normally fitted to a CAT 315C excavator. Standard assemblies are available as COTS or modified for military purposes.

Marine Caterpillar is well renowned for providing high power density power solutions for marine applications for pleasure craft or Naval applications. Main propulsion or hotel load can be satisfied by a range of dedicated marine or marinised COTS engines and generator sets from within the Cat family.

Standby Power Cat diesel and natural gas fuelled generators provide emergency standby power and temporary prime power supplies for remote military applications; diesel generator sets from 5ekW to more than 13,600ekW and natural gas generator sets from 8ekW to 3,500ekW as well as generating power for applications for use in marine power supplies.

Caterpillar is able to adapt and modify standard Cat machines into special purpose machines to carry out demanding roles in unique applications. Customers gain the cost advantage of volume production with bespoke design and tailoring for the application providing a cost effective solution with the long term support of the Caterpillar global distribution network. In addition Caterpillar is able to provide vehicle OEMs with standard components or sub-assemblies such as engines, transmissions and axles to ensure performance with reduced procurement cost by utilising COTS product from Caterpillar manufacturing facilities around the world.

From a broad range of products, customers may select the most appropriate Commercial off the Shelf, Military off the Shelf or bespoke product to suit the application, performance criteria and available budget. Leveraging the strength of Caterpillar, customers receive innovative, durable and high performance drive train solutions supported by a world class global dealer network. Discharging 100% of its offset obligations Caterpillar assists OEMs with their needs. Through effective remanufacture and obsolescence management users can be assured of through life support. From Requirements definition through to mission success, working with Caterpillar provides customers a through life experience, designing, selecting, integrating and supporting for performance with long term superior value. Contact us at: Caterpillar Defence Products Lancaster Road Shrewsbury Shropshire SY1 3NX United Kingdom Tel: +44 (0) 1743 212000 Fax: +44 (0) 1743 212701 Email: Cat_Defence_Products@cat.com Or visit our website at: www.catdfp.com 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. © 2013 All Rights Reserved

Caterpillar Defence Products are available from Barloworld PowerTel: 0860 898 000E-mail: engines@barloworldpower.comwww.barloworldpower.com