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TM
ACERT Technology for Off-Highway C15 Engines
ACERT Technology
What does ACERT stand for?
What is ACERT Technology?
What engines are affected?
How is ACERT Technology Different?
What does ACERT Technology look like?
How does ACERT Technology work?
What are the advantages of ACERT Technology?
Is extra maintenance required?
ACERT Technology
What does ACERT stand for?
What is ACERT Technology?
What engines are affected?
How is ACERT Technology Different?
What does ACERT Technology look like?
How does ACERT Technology work?
What are the advantages of ACERT Technology?
Is extra maintenance required?
ACERT Technology What does ACERT stand for? Advanced Combustion Emissions Reduction Technology
What is ACERT Technology?
Multiple technologies
Varies by engine family
Varies by engine application – Me Medi dium um dut duty y – sp spec ecs, s, changes, new design – Hea Heavy vy dut duty y – spe specs, cs, cha change nges, s, new design
How is the C15 Affected? • C15 ACERT is based off the C-15 platform • Displacement changes from 14.6 to 15.2 ltr. •Bore remains 137mm •Stroke increases to 171mm from 165mm
C15 ACERT
Performance Ratings- HP* Machine Rating
C15 1800-2100 RPM
A
440
B
475
C
540
D
580
E
595
*Preliminary, subject to change
C15 Power Band Performance 2100 rpm provides Widest operating range Easiest match in changeover
1800 rpm provides Best fuel economy Best heat rejection Less noise
A B
R E W O P
1300
C D E
1500
1700 RPM
Full Power from 1800 to 2100 rpm
1900
2100
C15 / C18 Heat Rejection EPA Tier 3 Tier 3
Engine C18 C18
Hp 630 630
RPM 1800 2100
Jacket Water JW* % Change 0.36 0.0% 0.38 5.6%
Tier 2
C-16
630
2100
0.36
Tier 3 Tier 3
C15 C15
540 540
1800 2100
0.36 0.38
Tier 2
C-15
525
2100
0.39
-7.7% -2.6%
Air Air % Change 0.22 10.0% 0.24 20.0% 0.2
0.21 0.23
16.7% 27.8%
0.18
• Changing from 2100 rpm’s to 1800 DECREASES heat rejection in the C15 and maintains same heat rejection in the C18 C15 / C18 ACERT
* kW of heat rejection per kW of engine power—jacket water
C15 / C18 Fuel Efficiency EPA Tier 3 Tier 3
Engine C18 C18
Hp 630 630
RPM 1800 2100
BSFC 219 228
Tier 2
C-16
630
2100
209
Tier 3 Tier 3
C15 C15
540 540
1800 2100
217 223
Tier 2
C-15
525
2100
208.6
% Change 4.8% 9.1%
4.0% 6.9%
• Changing from 2100 rpm’s to 1800 fuel economy is maximized in the C18 and C15 C15 / C18 ACERT
Engine Features C15 ACERT
Design Strategy ACERT technology Few external changes from Tier 2 / Stage II Proven heavy duty workhorse Easy changeover from Tier 2 / Stage II Excellent power density
Design Strategy ACERT technology Externally similar to C-15 One installation for wide power range Best in class power density
Design Strategy Increased displacement C15 increase from 14.6 to 15.2 liters Supports higher ratings C15 provides wide power range from a single installation Increased power density allows higher power without increasing machine weight More production from same size package
Design Strategy • Increased compression ratio • C15 - 18:1 compression ratio • Component changes to increase peak cylinder pressure capability • Improves cold start characteristics • Improves white smoke clean up time • Optimizes ACERT performance
Validation Strategy Rigorous endurance testing Over 40,000 hours per model Specialized tests include: Thermal abuse Cold start qualification Over speed qualification Crankshaft structure Head / block structure Emissions certification
ACERT Multiple Injection Capability TM
MEUI and ADEM 4 • Variable injection timing • Controls quantity of fuel • Optimizes fuel pressure • Transient control for both speeds and loads
Camshaft Changes
•Extra
“bump” on the injector lobe
•Difficult
to see but it can be felt
•Facilitates •Injector
pilot injection capability
lobe profile varies depending on HP rating
Fuel System Mechanical Electronic Unit Injector Proven design Proven high reliability
Enhancements Multiple injection Rate shaping
ADEM 4 Electronic Engine Control Generations of Experience
1987 8-bit PEEC II
1991
1993
Advanced 8-bit PEEC III
Two 8-bit ADEM II
1998 32-bit ADEM III
2004 32-bit ADEM 4
Proven Reliability
ADEM 4 Testing In Extremes Extreme temperature test Vibration test Salt spray test Electrostatic test
ADEM 4 Processing speeds and memory increased New 120 Pin engine connector Retains 70 Pin OEM connector More fuel maps to optimize ACERT Technology Better performance Better efficiency
ADEM 4 No change in OEM / machine interface Worldwide service network Using Cat ET Common electronics from C6.6 – C32
Allows greater protection and prognostics Full machine integration (Canbus, J1939, etc.)
New ADEM 4 Features Throttle input strategy Multi-throttle capability Configures throttle input priority Engine control system options Full range governor Min max governor Speed droop control Simulates mechanical fuel system performance Adjustable from 0-10% droop
New ADEM 4 CAN J1939 Data Link High speed 2-way communications Standard SAE link for all C-series engines Broadcasts engine performance, status and diagnostic information Supports messages for powertrain integration Interface with Cat Messenger and analog gauges
Head bolt torque sequence
Head Bolt Torque Procedure •Tighten
bolts 1-26 in sequence to 270 +/- 15 Nm
•Tighten
bolts 1-26 in sequence to 450 +/- 15 Nm
•Retighten
bolts 1-26 in sequence to 450 +/- 15 Nm
Turbocharger • Wastegated turbocharger • Provides higher boost over wide range
• Single turbo • Improves engine response • Outstanding low end performance • Improved peak torque
Turbocharger Wastegate Function Boost
Improved Response
RPM
Elevated BMEP
Turbocharger Wastegate Function Wastegate Active – Reduced BMEP
Wastegate Boost Boost
RPM
Cat Compression Brake Some models equipped with Cat Brake Developed and manufactured by Caterpillar Functionally similar to previous compression brakes
lash adjusting screw locknut torqued to 30 +/- 7 Nm
•Injector
Height Gauge 9U-7227
•Injector
height adjusting screw locknut torqued to 100 +/-
10 Nm
Injector and Valve Lash Setting Procedure •Set
Number 1 piston at TDC compression
•Set
intake valves on cylinders 1, 2 and 4
•Set
exhaust valves on cylinders 1, 3 and 5
•Set
unit injector on cylinders 3, 5 and 6
•Turn
crankshaft 360 degrees (direction of engine rotation)
•Set
intake valves on cylinders 3, 5 and 6
•Set
exhaust valves on cylinders 2, 4 and 6
•Set
unit injector on cylinders 1, 2 and 4
Piston Monotherm piston Forged steel design High strength Light weight Better tolerance control Rings conform to liner better Better oil control Reduced blow-by Less liner wear
Piston Ring Installation •Install
top and intermediate rings with “up” marking towards top of piston
•Orient
piston ring gaps 120 degrees apart
C15 Piston Assembly
Piston is a one piece design.
Connecting Rod
Increase rod diameter Drilled rod for lubrication 4 bolts improve clamping Designed for durability Compliments ACERT
C15 Connecting Rod Assembly Connecting rod cap uses four bolts
Rod Bolt Torque Sequence
Connecting Rod Bolt Torque Lubricate bolts with engine oil before assembly Torque bolts 1 and 3 to 70 +/- 4 Nm Torque bolts 2 and 4 to 70 +/- 4 Nm Turn bolts 2 and 4 an additional 60 +/- 5 degrees Retighten bolts 1 and 3 to 70 +/- 4 Nm Turn bolts 1 and 3 an additional 60 +/- 5 degrees
Hardened Plateau Honed Liner Two step honing process: - Cuts deep grooves for oil retention - Smoothes the tops off to reduce wear and better contact Reduces blow by Improves oil control and consumption
Smooth Surface
Deep Cuts
Leak Free Design Improved joints through out the engine Oil pan seal Timing cover Block to flywheel housing
All fluid connections sealed with standard thread “O” ring design
Specifications
C15 ACERT
Specifications Model
C15
Rated RPM
1800-2100
Displacement
15.2 Ltr. (927 cu. in.)
Bore
137 mm (5.4 in.)
Stroke
171 mm (6.7 in.)
Specifications Model
C15
Length
1651 mm (65 in.)
Width
889 mm (35 in.)
Height
1346 mm (53 in.)
Weight
1335 Kg. (2937 lb.)
C15 Power Curve 560
1900
540
1800
520
1700
500 P H
480 460
1600 T F
Power
1500
Torque
1400
440 420
1300
400
1200
1200
B L
1400
1600
1800
RPM
2000
2200 * All C15 / C18 ACERT ratings are preliminary
Maintenance Information 500 hr. oil change interval with CAT DEO (or oil meeting CAT ECF-1 spec) below 6000 ft. altitude. 250 hr. change interval above 6000 ft. High load factors and high fuel sulfur content will affect oil change intervals. Equipped with Cat’s new high efficiency oil filter S.O.S. sampling
High Efficiency Oil Filters Revolutionary filter design Increased contamination control Double the efficiency without increasing the changing interval Reduces wear on all oil lubricated surfaces
