Information Release Memo DT04-01 April 2004

Drive Train
ALTERNATIVE CAT® EXTENDED LIFE BRAKE DISCS

An improved line of brake discs has been certified and is available as a parts service option
in Caterpillar Off-Highway Trucks with oil-cooled wet brakes. The new discs use an
innovative carbon paper friction material that outperforms the standard paper cellulose brake
discs giving an opportunity for extended component life. Longer brake disc life, the result of
improved friction material wear and glazing resistance, isn’t the only benefit; it may also
reduce brake noise, which can be a problem in certain braking applications. The new discs
sell at a slightly higher price, but improved wear performance can mean lower costs over the
life of the brake.

Relative Life of Brake Friction Materials

Results May Vary Depending on Application & Severity

2x - 4x
3
Relative Life

Longer
Current Mat'l
New Mat'l
2

0
Glazing* Wear*
Failure Mode
*The Glazing and Wear Lives of Current Material are not Equal

PELJ0320 Printed in U.S.A. © 2004 Caterpillar

 Information Release Memo IRM/402190820.doc DT04-01 Page 2

Usage Recommendation

The new carbon paper friction material can last >2X the life of paper cellulose discs. These
results hold up in both moderate and severe operating conditions, including downhill braking
with full loads. In applications where friction material is wearing out prior to the wheel
station components, the new carbon paper discs can offer a better component life balance
with wheel station components. Longer service life means equipment is available and
productive more of the time. No matter what the application and wheel station overhaul
cycle, most customers should realize significant savings in lower parts consumption and
labor hours as illustrated in the chart below.

Friction Material Cost Comparison

Cat Extended Life Standard Cat Disk

TIME
Fewer
Wheel Wheel Wheel Labor
Friction Disk Friction Disk Friction
Application Station Station Station Hrs
Replacement Only Replacement Only Discs
Overhaul Overhaul Overhaul Savings *
Consumed*

Light 33% None

Normal 40% 64-102

Severe 57% 128-204

* Percentages reflect fewer friction discs consumed over three wheel station overhaul cycles using the Cat
Extended Life Discs over Standard Discs. Labor hour savings based on brake replacements performed
outside of normal wheel station overhaul cycle and may vary based on machine type (Models 777-789).
 Information Release Memo IRM/402190820.doc DT04-01 Page 3

Increased Customer Value

With the release of each new Cat Extended Life Brake Disc part number, we’ve lowered
prices for the equivalent standard disc by 20%. The new Cat Extended Life Brake Disc is
priced at a 30% premium above the new price for the standard (or 10% above current prices).

This strategy will accomplish two objectives. First, it improves the competitiveness of
standard discs in the marketplace. Second, it offers significant increased value for customers
buying the new Cat Extended Life Friction Disc. The new disc provides 200% to 400%
longer life for only a marginal 30% premium over standard discs. Savings in reduced interim
brake rebuilds (parts & labor), potential reduction in premature disposal of useable wheel
station components, and reduced machine down time makes Cat Extended Life Friction
Discs the best choice for value conscious customers.

With a competitively priced, two tier product offering that lowers Cat machine owning and
operation costs, dealers will be positioned regain lost brake parts business and penetrate new
markets for friction materials.

Usage Table:

Size – OHT Model (F=Front, R=Rear) Cat Extended Life Standard Brake
Brake Disc Disc
19” – 771(R), 769(R) 222-2333 9W-7018
21” – 777(F) 221-0775 8E-2183
28” – 773(R), 775(R), 777(R), 785(F), 789(F) 196-7866 9W-7017
34” – 785(R), 793(F) 190-3532 7T-2815
34” – 789(R), 793(R) 226-2826 198-1137
42” – 797(F & R) (Available Soon) 207-1265 145-5185
 Information Release Memo IRM/402190820.doc DT04-01 Page 4

FAQ:

Q: Are these friction discs available today?

A: Parts available are listed in the ‘Usage Table” above and are available today.

Q: Are there minimum or multipack requirements when ordering?

A: No. Dealers may order in any quantity.

Q: Is the new Cat Extended Life Brake Disc a direct replacement for the standard disc
or do the brakes need to be modified?
A: The new discs are a direct replacement and do not require any modifications.

Q: Has the new material passed current brake test performance standards and local
mining codes such as the Alberta and British Columbia codes?
A: Yes. All wet friction brake discs listed in the usage table meet or exceed the ISO 3450
braking test performance standard and as a result are capable of meeting the current Alberta
and British Columbia mining codes.

Q: Is the new friction disc branded?

A: The new discs are stamped with a Caterpillar® part number with no other references.

Q: Can this material be obtained for Caterpillar machines from aftermarket suppliers?
A: Caterpillar Extended Life Brake Discs can only be obtained through Caterpillar dealers.

Q: What is the warranty coverage?

A: The discs are covered by the standard 6-month Caterpillar parts warranty.

If you have any questions please contact:

Emil Ferenz
Parts Product Division – Power Train
LC2188 – (309) 675-5638

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