acert 2007 cat

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GLOBAL MANPOWER DEVELOPMENT

ACERT 2007

Systems Overview

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2006 427 CID LS7969 427 Corvette

Lowest emissions

Ease of service

Less service

More Power

More Torque

Best fuel economy

When were

the good old days?

1969 Today

Good Old Days

435 hp 505 hp

460 ft lb 470 ft lb

9 14 MPG 16 26 MPG

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Particulate Matter (PM)

Soot from incomplete combustion

Soluble organic fractions from the fuel &lubricating oi l (SOF)

Sulfates formed from the sulfur in the fuel

Oxides of Nitrogen (NOX) Composed of nit ric ox ide (NO) and nitrogen

dioxide (NO2)

Hydrocarbons (HC)

Regulated either as total hydrocarbonemissions (THC) or as non-methane

hydrocarbons (NMHC)

Carbon Monoxide (CO)

Smoke/OpacitySmoke/Opacity

Regulated Diesel Emissions

Regulated Diesel Emissions

Regulated diesel emissions consist of;

unburned hydrocarbons (HC),

carbon monoxide (CO)

NOx (oxides of nitrogen) and

particulate matter.

Of these emissions, NOx and particulate matter are two of the more difficult

hurdles to overcome. Visible smoke must also be minimized.

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On-Highway Emissions 1988 to 2010

0

0.1

0.2

0.3

0.4

0.5

0.6

0 1 2 3 4 5 6 7 8 9 10 11NOx (g/bhp.hr)

PM

EPA 88

EPA 91

EPA

94EPA

98

EPA

04EPA

07/10

On-Highway Emissions

--On Highway emissions regulations have tightened dramatically in the last

15 years.

--Particulate matter has decreased substantially to a level of 0.01 g/bhp-hr.

--Particulate matter levels this low are only possible with particulate filters.

--It addition, the Nox + HC emissions levels are down to 1.2 g/bhp-hr.

--Crankcase emissions have become measured as part of the total

emissions output of the engine and closed crankcase breathers will be seen

as well. Cat ACERT technology has formed the building blocks that allow

Caterpillar to achieve 2007 on-highway emissions.

*Instructor Nice to know

*The path for 2010 is being developed right now, prototype engines are

being built right now and a Cat fleet truck will have a 2010 engine in it andwill run and be tested along with the 2007 fleet engine soon.

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New Engine Content

Core engines remain essentiallythe same

Percent new content C7 / C9 = approx. 35%

C13 = approx. 32%

C15 = approx. 32%

Predominantly externalcomponents

New Engine Content

--As stated before, there are new components on the outside of the

ACERT 2007 engines, however the core engines remained the same.

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2007 On Highway Engine

S/N Prefixes C15 TRUCK ENGINE

Prefix: SDP

C13 TRUCK ENGINE

Prefix: LEE

C9 TRUCK ENGINE

Prefix: C9S

C7 TRUCK ENGINE

Prefix: C7S

Serial Number Prefixes

--Current On-highway engine serial number prefixes for the C7 through C15

are shown here.

--SIS is currently being populated with service information for these on-highway engines.

--You can find preliminary troubleshooting guides and preliminary Operation

and Maintenance Manuals on SIS Web using the engine serial prefix

numbers provided above.

-

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2007 System Overview

T

C

T

C

CCV

Filter

Series

TurbochargersThrottle

T

C

CGI

Valve

CGI

Cooler

FlowSensor

Diesel

Particulate

Filter

T

C

ATAAC

Intake Valve

Actuation

High

Pressure

Injection

System

System Overview

--This 2007 overview shows how a systems approach was used to achieve

the required emissions levels.

--No one component or part is responsible for the ability of the engines tomeet emission.

--All components function together as a team to get the job done.

--IVA reduced NOX some, but the CGI cooler reduced Nox more.

What is a DPF?--A DPF is a trap which collects soot generated by the

combustion process. How does it work?

The DPF contains a filter-like substrate material through which the exhaust

gas is forced to pass. While the gaseous portion of the exhaust passes

through easily, the particulate matter does not pass through and is held

within the DPF.

.

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2007 System Overview

T

C

T

C

CCV

Filter

Series

TurbochargersThrottle

T

C

CGI

Valve

CGI

Cooler

FlowSensor

Diesel

Particulate

Filter

T

C

ATAAC

Intake Valve

Actuation

High

Pressure

Injection

System

System Overview (continue):

The cleaner exhaust gas then flows to the Clean Gas Induction cooler. A

CGI Cooler is a standard tube bundleengine mounted cooler that cools the

cleaner Exhaust gas that exited from the DPF. How does CGI work?CGI draws a measured amount of clean inert, non combustible gas, from

the clean or outlet side of the DPF. This clean inert gas is then directed

through the CGI cooler and introduced into the intake air. When the intake

air is mixed with the clean inert gas, the end result is a reduction in flame

front temperature in the combustion chamber. Lower combustion chamber

temperatures result in less NOx formation. The amount of clean inert gas

that is directed to the intake is monitored by a mass flow sensor located in

the CGI system plumbing.

The CGI mixture air and fresh air then travel through the 2 compressors ofthe turbos and then into the Air To Air After Cooler (AATAC) and finally into

the intake manifold and to the injectors.

Note, the image represents a heavy duty arrangement and the C7 and C9

arrangements have a single turbocharger.

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ACERT 2007

System Components

System Components

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Component Identification

Component ID Lab

Lets look at the new engine components. As you can see by the different

color schemes there are several several groups of components that the

mechanic will need to identify before being able to work on this engine. Thislesson will deal with component identification in the classroom and in the lab.

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Diesel Particulate Filter (DPF)

Diesel Particulate Filter (DPF)

--Here is an example of a DPF on a truck.

--The DPF collects and holds soot which is a natural byproduct of incomplete

combustion and ash which is a natural byproduct of the oil.

--The DPF is a Cat Part, so if the DPF needs to be replaced for any reason

the part must be ordered from the Cat.

--The OEM provides the pipe from the CRS outlet to the inlet of the DPF and

the OEM provides the CGI line.

*Instructor Nice to Know

*Is currently no vertical DPF for medium duty

*DPFs will be matched to the engine based on the deterioration factor of the

engine. For example, if the engine has 200,000 miles on the engine, then

the Reman DPF will have approximately 200,000 miles on it as well.

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Dual DPF

Dual DPF

--There are also dual DPFs that you might see in your shop.

--The dual DPF will be used on 600 horsepower and up (realistically 551 HP

and up)

--The center sections are are limited in size on the duals and because of that

we must have two center sections.

--All dual DPFs are one unit.

--The harness running from the DPF to the harness is an OEM part.

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DPF Connection

DPF Connection

--In this image you can see just how the DPF connects to the engine.

--Take a look at the CGI Line (highlighted by the red arrow) exiting the clean

or outlet side of the DPF. This line is the line that carries the cleanedexhaust to the CGI cooler.

--The CGI line is also an OEM part and must be ordered from the OEM.

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CGI Line

CGI Line

CGI Line

CGI Line

--The CGI Line placement is fixed because there must be so much

temperature drop between the DPF inlet and outlet.

*Instructor nice to know

*The temperature drop between the outlet of the ARD and the inlet of the

DPF is important, you cant modify the length of the pipe.

*If the exhaust is modified without following the guidelines laid out in the

Application and Installation Guide, then a positive suction can be put on the

whole system and any damage accrued as a result will not be covered by

warranty. A modified exhaust pipe will impact emissions and the

performance of the engine.

*In 2007, there is a zero leak law and the body builders must follow the A&I

Guide exactly.

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CGI Venturi & Cooler

CGI Cooler

--The CGI is a standard tube bundle cooler and it is highlighted within the

green rectangle.

--The tube conducting the cleaned CGI exhaust gas into the CGI Cooler isdifferent because it contains a Venturi.

--A Venturi is simply a narrowing of the pipe that allows for the CGI mass

flow to be measured.

--The image on the left demonstrates the narrowing of the pipe.

--You might also notice the two pressure taps on the Venturi that along with

other values contribute to the measurement of Mass Air Flow.

--There isnt a single sensor for mass air flow.

*Instructor nice to know

*On the mid-range the venturi is after the CGI Cooler.

*The clamps on the CGI Venturi are one time use right now.

*There are no 2007 brakesaver ratings currently.

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CGI Line to the Mixing Valve

CGI Line to the Mixing Valve

--Some components were removed in this image (pre-cooler outlet duct) in

order to clearly show the CGI line leading to the Mixing Valve.

--The Mixing Valve is where the CGI gas and fresh air are mixed together.

--Some heavy dutys have a pre-cooler.

--There are 2 oil filters on the C13 due to packaging constraints(both are

main flow filters).

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CGI Actuator

Mixing Valve Door

CGI Actuator

--The CGI actuator shown here controls the movement of the CGI Mixing

Valve door.

--The mixing valve door is controlled by a hydraulic actuator.

--Engine oil pressure is used by the hydraulic actuator.

--Low oil pressure can negatively affect the CGI Actuator.

--The ECM sends a Pulse Width Modulation signal to the CGI solenoid,

which allows oil to flow through the hydraulic actuator, that turns the shaft,

that in turn opens or closes the CGI mixing valve door.

--The Mixing Valve Door as shown in the image on the right controls the

percentage of CGI gas and Fresh Air.

--In ACERT engines no more than 15% of CGI gases will be used.

--Amount of CGI will be controlled by the Ambient Air temperature sensor.


*The actuator does not rely on a spring to pull the CGI Mixing Valve door

shut if there is a failurewe rely on gravity for this.

*The spring return in the actuator is now gone.

*If the air filter is plugged up then, the Air Inlet Temperature will go up.

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Clean Gas Induction System

C15 C7

Clean Gas Induction System

Clean Gas Induction or CGI, is used to reintroduce clean, inert air back into

the engine. This enables a drastic reduction in Nox production. The system

consists of a few major components, all on the turbo side of the engine,some of which can be seen here. These include (click) a CGI cooler, (click) a

venturi, (click) CGI coolant lines for coolant in (click) and coolant out.

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Aftertreatment Regeneration

Device

Aftertreatment Regeneration Device

The ARD will be mounted on the turbo side of the engine. The picture on the

left shows where the sparkplug is located in the regeneration system. On the

right is a vertically mounted CRS on a C13 engine, similar to theconfiguration of the C15.

*The spark plug boot is changing

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Cat Regeneration System

Consists of: ARD (Aftertreatment Regeneration

Device)

DPF (Diesel Particulate Filter)

Electronic Controls

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CRS Cat Regeneration System

Goal: To increase exhaust gas temperature to accelerate

regeneration of the Diesel Particulate Filter (DPF)

C (s) + O2 + Energy (heat) = CO2 (g) + H2O

Trapped in the DPF

In engine exhaust

From Engine or ARD

Out tail pipe

Cat Regeneration System (CRS)

--Carbon in the form of soot is trapped in the DPF.

--ARD increases the exhaust gas temperature if needed to regenerate the

DPF so that the end result is Carbon Dioxide out the tailpipe.


*The ARD head wont light under 20 MPH, but will continue a regeneration

under 20 MPH.

*Cat is the only company to have a catalyst inside the DPF.

*The DPF is intended to last the life of the engine or 1 million miles.

*If a turbo seal is blown right now, then a brand new DPF is bought. There is

a chance that a regen can be done at a lower temperature to cook the ash

out, but isnt confirmed right now.

*If there are black dots of any kind on the outlet of the DPF filter, then theDPF has failed and must be replaced.

*The backpressure of the DPF to a useful life is 120 inches of water, a back

pressure of 140 inches of water indicates that the DPF is at the end of its

useful life and must be replaced.

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Cat Common Rail Fuel System

Cat Common Rail Fuel System

The rail, contains fuel at extremely high pressure. It travels from the tube to

each injector through a supply line shown to the left.

*The Cat Common Rail operates at 190 MPA or 27,500 psi.

*The High Pressure Pump is manufactured in Pontiac.

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A4E4

2

1

A4E4

The A4E4 is a new control package with both a 70 (item 1) and a 120-pin

(item 2) interface location.

Because of the nature of the ECM and diagnostic codes it uses, a J1939Datalink cable must be used.

--The suffix codes and part numbers for the C13/C15 and the C7/C9 A4E4

ECM are different.

--The suffix code for the C13/C15 is RA and the part number is 292-9610.

--The suffix code for the C7/C9 is RB and the part number is 292-9609.

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Variable Nozzle Turbocharger

AVNT DAVNT

Variable Geometry Turbocharger

With Variable Geometry Turbochargers the low boost pressure is

compensated for. The turbine fins are able to adjust their angle to produce

maximum efficiency--Variable Nozzle Turbochargers adjust the angle of their inlet fins to ensure

that there is adequate boost to off set the closed crankcase pressure on the

C7/C9.

--VNT provides compressed air for the engine and the CRS.

--VNT has an actuator that receives a PWM command from the ECM.

--The actuator uses pressurized engine oil to convert the PWM command

into movement of the moveable vanes inside the turbine housing.

--Movement of the vanes causes the boost pressure to change.

*The turbos for the the C7 and C9 are manufactured by Garrett.*The VNT moves more air which provides better response.

*The VNT controls turbo speed and controls the amount of air moving

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Injectors & Turbo

DPF

DPF, Turbo, &Injectors

DPF & Pistons

Adv HP Peak Torque

210 620

210 520190 520

Adv HP Peak Torque

230 660

230 620

230 560

Adv HP Peak Torque

300 860

275 800

Adv HP Peak Torque

350 860

330 860

Adv HP Peak Torque

250 800

250 660

Subject to Change 9/1/2006

C7 Up-Ratability

Buy

Buy

Buy

Buy

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DPF, Injectors

DPF, InjectorsAdv HP Peak Torque

285 890

Adv HP Peak Torque

365 1250

350 1250

335 1150

Adv HP Peak Torque

425 1350

425 1250

400 1250

Buy

Buy


C9 Up-Ratability

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DPF, Injectors, Turbo,

and Pre-cooler

Adv HP Peak Torque

370 1450

370 1350

350 1550

350 1450

350 1350

335 1250

305 1150

Adv HP Peak Torque

485 1650

470 1550/1750

470 1650

470 1550

430 1550/1750430 1650

430 1550

410 1450/1650

410 1450/1550

410 1550

410 1450

380 1450

Buy


C13 Up-Ratability

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Pistons and DPFAdv HP Peak Torque550 1850

500 1850

500 1650

475 1650/1850

475 1650/1750

475 1850

475 1650

435 1550/1750

435 1550/1650

435 1650

435 1550

435/500 1550/1650

Adv HP Peak Torque

625 2050

600 2050

600 1850

Buy


C15 Up-Ratability

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acert 2007 cat

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