2007 Acert

ACERT™ 2007
Systems Overview
GLOBAL MANPOWER DEVELOPMENT

Good Old Days
1969 427 Corvette 2006 427 CID LS7
Lowest emissions
Ease of service
435 hp 505 hp
Less service
460 ft-lb More Power 470 ft-lb
9-14 MPG More Torque 16-26 MPG

Best fuel economy
When were
1969 the good old days? Today

Regulated Diesel Emissions
• Particulate Matter (PM)
• Soot from incomplete combustion
• Soluble organic fractions from the fuel &
lubricating oil (SOF)
• Sulfates formed from the sulfur in the fuel
• Oxides of Nitrogen (NOX)
• Composed of nitric oxide (NO) and nitrogen
dioxide (NO2)
• Hydrocarbons (HC)
• Regulated either as total hydrocarbon
emissions (THC) or as non-methane
hydrocarbons (NMHC)
• Carbon Monoxide (CO)
• Smoke/Opacity

On-Highway Emissions 1988 to 2010
0.6 EPA ‘88
0.5
0.4
PM
0.3
EPA ‘91
0.2
0.1 EPA EPA EPA EPA
07/10 ‘04 ‘98 ‘94
0
0 1 2 3 4 5 6 7 8 9 10 11
NOx (g/bhp.hr)
New Engine Content
• Core engines remain essentially

the same
• Percent new content
• C7 / C9 = approx. 35%
• C13 = approx. 32%
• C15 = approx. 32%
• Predominantly external
components

2007 System Overview
Flow
Series Sensor
Turbochargers
Throttle
CGI
Cooler
CGI
ATAAC
Valve
C
T
Diesel
High Particulate
Intake Valve CCV Pressure Filter
Filter
Actuation Injection
System

ACERT™ 2007
Diesel Particulate Filter

Diesel Particulate Filter (DPF)

Dual DPF

Diesel Particulate Filter (DPF)
1. What is a DPF?
2. How does a DPF work?
3. What does a DPF look like?
4. Is special DPF maintenance

required?

Diesel Particulate Filter
•Single DPF •Dual DPF

•Vertical or Horizontal •600 Hp & Up
Mounting

What is a DPF
Cells Fill Up
Soot Collects
Along the Inlet
Walls
Particulate Matter
or Soot Clean
Exhaust Out

How does a DPF work
Substrate
HC Catalyst (Platinum) Washcoat

CO
NOx
PM (soot+SOF+sulfates)
O2
CO2
H2O
NOx
O2

Ash Distribution
• Low density ash plug near outlet of filter
• High density ash layer on wall – thickness
increasing from inlet to outlet

Core Materials
Cordierite
• Inexpensive raw material
(cordierite is basically sand)
• Low thermal expansion coefficient
• Good mechanical strength
Cordierite

What does a DPF look like?
Sensors on Center Section CGI Connection
DPF Outlet
DPF Inlet
Skin
Temperature
Protection
V-Band Clamps—Torque 100 inch/pounds

DPF Sensors
Particulate Trap # 1 Intake Particulate Trap #1 Outlet
Temperature Sensor Temperature Sensor
Particulate Trap #1 Particulate Trap # 1

Differential Pressure Differential Pressure
Sensor Tap Sensor Tap

Inlet Section

Inlet Section
Formed Marmon
Flange
Distributor
Tube
Condensate
Ring
Insulation
Formed Flange
Connections to
Lifting Center Section
Eye

Inlet - Description
Outer Shell
Inlet Diffuser
Tube
Condensation Ring
Outer End
Cap
Inner End
Cap Insulation
Lifting Eye Inner Shell

Center Section
Sensor Box Temperature
Probe
Pressure
Boss
Sensor Box
Strap
Filter does not
slide out of
center section

Center Section
1- time use gasket
Ceramic mat material –

review safety material in
Service Manuals

Center Section
Retaining ring is
welded in place

Irreversibility
Cone feature is longer on reverse side of filter and will
cause interference with tab if trying to install backwards

Center Section – Sensor Box
Rock Guards
75 in/lbs

Sensor Box

Insulation

Outlet Section

Outlet Description
Outer Shell
Irreversibility
Tabs
Outer End
Cap
Condensation Inner End

Ring Cap
Insulation
Inner Shell Lifting Eye

Outlet Section - Vertical
Rain Protection
System on
Verticals
Drain in this area

Typical DPF Installation
CGI Line
Air Flow
CGI Line

OEM DPF Harness Connection
Purge Pump
Power Connector
DPF 1 & 2 Connectors

Center Section Analysis
“Good” DPF – no signs of Soot collected on outlet side

soot on outlet of DPF -failed

Center Section Analysis
Soot collected on outlet side of DPF -failed

Failed DPF
Soot collected on outlet side of DPF

What do you think?

Good Filter
Weld marks
This is a new filter from the factory

What do you think?

Good Filter
Staining is Acceptable,
Black soot is not
This is a used filter from service

LC Lab DPF

LC Lab DPF

Nuked Trap

What’s Happening to the Iron?

Rules of Engagement
• Engines Purchased from Leasing Company

• Single Lease Customer Operation
• All 6 Units Operated on the same Route
• South East to West Coast
• 2 Phase Program (Phase 1=360K, Phase
2=475K)
• Outside Engine Industry Expert Conducts
• Teardown, Inspections & Written Reports

Products History
Cat C15 Cummins DDC S60

Line Haul Line Haul Line Haul
ACERT™ Cooled-EGR Cooled-EGR
1. 355,515 Miles 360,901 Miles 381,100 Miles
2. 480,973 Miles 455,319 Miles 480,717 Miles
Same Oil Change Intervals

Competitive Tear Down
Inlet Manifolds
Soot
Build Up

Detroit Intake
Phase 1 Phase 2
Soot Build Up

Cummins Intake
Soot Build Up

Cat Intake

Competitive Tear Down
Performance Deterioration
Cooled-EGR contaminates the

air system with soot, blocking
ports and acids attack valve
seats
Phase 1

Detroit Valves and Ports
Soot Build-Up Airflow Restricitons
Phase 2

Cummins Valves & Ports
Acid Attacking Soot Build-Up Reduced Air Flow

Valve Faces

Cat Valves & Intake Port
Phase 2
Airflow Unrestricted
Valves Free
of Deposits

Cummins EGR Cooler
Inlet Plugging Outlet 60% plugged
Phase 1 Phase 2

Detroit EGR Cooler
Soot Build Up
Phase 2

Engine Inspection Report
DETROIT
• Deep wear grooves – top ring reversal area
• Lack of honing marks throughout ring swept
area
• # 6 intake valves show unusually high levels of
deposits
• Oil rings show severe wear in expanders
• High soot levels, normal result from using EGR

CUMMINS
• Significant Wear Overall
• Significant Higher Top Ring Side Wear
• Cyl. Liners Worn Through Hone Pattern
• 60 MM Wide Below Top Ring Reversal Point
• High Soot Levels, Normal Result from Using
EGR

CATERPILLAR
• Excellent Top Ring Wear for 480K Miles
• Very Light Liner Step @ End of Ring Travel
• Lower Soot Levels = Lower Wear Levels

Anticipated Life In Miles
1,000,000
530,000 490,000
Cat Cummins DDC

Cooled EGR
• More Soot Into the Air Intake

• More Soot Build-Up in the Engine Oil
• More Wear of Critical Parts
• More Repair Costs over Time?
• Higher Overall Operating Costs?
• Overhaul before Trade Cycle?
• Resale ?

ACERT™ Technology
• More Cool Clean Air

• Cleaner Air = Cleaner Oil
• Better Durability/Reliability
• Lower Overall Operating Cost than EGR
• B50 = Million Miles to Overhaul
• Higher Resale Value

ACERT™ 2007
Special DPF Maintenance

DPF Ash Service

DPF Ash Cleaning Tool
• Requirements
• Shop Air (100 psi)
• 120 VAC
• Size
• 75”(l) x 40”(w) x 83”(h)
• 1.9m(l) x 1.01m(w) x 2.1m(h)
• Weight
• 1100 lbs
• 500 kg

DPF Ash Cleaning Tool
Computer HEPA
Controlled Filter
Valve
Control
Panel
Filters
Disposable
Bucket
(Behind Door)
Expansion
Tank
Accumulator Tank
Ash Cleaning Tool Features
• Extensive testing
• Patented “pulse” cleaning process
• Extended Cartridge filter life
• Self cleaning feature
• Pre-check burst to determine if DPF
is cleanable

Ash Cleaning Tool Features
• Computer controlled
• Fully Automated
• Cleans all Caterpillar DPF sizes
• Full containment of Ash for easy
disposal
• HEPA filter system

Ash Cleaning Process

• Regen DPF on the Truck

• Cat ET attached
• Ash Service Test
• Let Cool and Remove Filter
• Place Filter in Tool

Adapter
Seal
DPF
•Various adaptors for

the different DPF’s
Seal
•1 adaptor can be
used for multiple sizes

Bed
Hand Pump Raise

the bed
Seals Unit in Tool
Hydraulic Cylinders
• Start Process
• Air Flow
• 30 Puffs
• 45 Minutes
• Totally
Automated

Ash
Collection
Area

• Remove Filter from Tool

• Re-install on Truck
• Replace Seals
• Hook-up Cat ET
• Reset Ash Model
• Interim Process - Call DSN
• Send the truck on its way!

• Cost
• Total time ≈ 3 hours labor
• Consumable Costs
• Tool Cost
• Customer Cost
• $400 to $600 USD

Part Numbers & Costs

Tool Part Numbers
• 319-2189 Cleaner Gp
• Includes:
• 319-2187 Cleaner – DPF
• 319-2190 Adaptor group
• 319-1834 Cone – 11 inch
• 319-1835 Cone – 13 inch
• 319-1836 Cone – 15 inch
• 319-1838 Adaptor-lower – large
• 319-1839 Adaptor-lower – small

Consumables
• Five Items
• HEPA Filter
• Cartridge Filters (2)
• Disposal Bucket
• Air Dryer Desiccant
• Coalescing Filter

Consumables
• HEPA Filter
• 319-2193
• Life
• 500 - 1000 DPF
Cleanings
• Cost
• $840.76 USD D/N

Consumables
• Cartridge filter
• 319-2194
• 14 dia, 30 long
• 2 filters/pack
• Life
• 15 to 100 DPF Cleanings
• Cost
• $ 349.45 USD D/N

Consumables
• Cartridge filter
Soot in DPF dramatically
• 319-2194
shortens Cartridge Filter
• 14 dia, 30 long
• 2 filters/pack life!
• Life
• 15 to 100 DPF Cleanings
Regen before
• Cost Cleaning DPF
• $ 349.45 USD D/N

Consumables
• Filter Bucket
• 319-1833
• Life
• 3 or 4 per clean out
• Clean out every 15 -
100 DPF Cleanings
• Cost
• $113.97 USD D/N

Consumables
• Air Dryer Desiccant

• 320-2679
• Life
• 25 DPF Cleanings
• Can be oven dried and re-used
• Cost
• $XX.XX USD D/N

Consumables
• Coalescing Filter
• 320-2680
• Life
• 500+ DPF Cleanings
• Cost
• $XX.XX USD D/N

Additional Adapters
Mass Transit Bus
• Use 319-2192 Adaptor-MTB*

• Use with 319-1835 cone
• Cost
• $739.74 USD D/N
*This is NOT part of the standard 319-2190 Adaptor

Group, it is ordered separately!

Cleaner Costs*
Dealer Net
319-2189 Cleaner Gp $16,169.47
Individual Pricing
319-2187 Cleaner – DPF $14,787.77
319-2190 Adaptor group $2,024.87
319-1834 Cone – 11 inch - $245.12
319-1835 Cone – 13 inch - $249.66
319-1836 Cone – 15 inch - $256.90
319-1838 Adaptor-lower – large - $747.64
319-1839 Adaptor-lower – small - $750.54
*Dealer Net prices as of 14 Sep 07

Shop Tips
This image is the result of

NOT using Anti-Seize on
the DPF Inlet
thermocouple sensor spin
nut or DPF mounting
boss during initial
installation in Tech Center
Building L (DPF Upgrade).

CGI Line
CGI Line
CGI Line

CGI Venturi & Cooler

CGI Line to the Mixing Valve

CGI Actuator
Mixing Valve Door

Aftertreatment Regeneration
Device

Cat Regeneration System
Consists of:
• ARD (Aftertreatment Regeneration
Device)
• DPF (Diesel Particulate Filter)
• Electronic Controls

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 From Engine or ARD
In engine exhaust Out tail pipe

Soot and Ash
Definition of Soot Soot Cleaning
Soot is a byproduct of • DPF Collects the soot
incomplete combustion
• Elevated exhaust
temperatures convert the
soot to vapor
Definition of Ash Ash Cleaning

Ash is Noncombustible • DPF Collects the ash
residue of a lubricating
• Ash is removed using a
oil or fuel
special service tool

Regeneration Types
Active Regeneration
No
Regeneration Passive Regeneration
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Passive Regeneration
• Occurs when the engine is under high

load
• Exhaust temperatures alone are
enough to regenerate small amounts
of soot Passive Regeneration
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Active Regeneration
• Mobile Active (No Interaction) (Moving)

• Enhanced Passive (No Interaction)
(Stationary)
• Manual (Requires Interaction)
Active Regeneration
(Stationary)
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Mobile Active Regeneration
• Occurs when a regeneration is needed

and vehicle is over 20 MPH
• No operator notification
Active Regeneration
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Enhanced Passive Regeneration
• Occurs at 0 MPH
• Maintain soot during extensive idle
periods
• Lower exhaust temp
• 700 RPM, Fan On
Enhanced Passive
• 400° C for 20 minutes every 2 hours
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Manual Regeneration
• Occurs at 0 MPH
• DPF lamp must be illuminated
• Must initiate with force switch
• ET commanded manual regen does not
require DPF lamp to be illuminated
Active Regeneration
0°C 200°C 400°C 600°C 700°C

32°F 392°F 752°F 1112°F 1292°F

Manual Regen Requirements
• Level 1 regeneration warning
reached
• DPF Light “On”
• Coolant Temp greater than 20°C
(68°F)
• ARD out Temp greater than 30°C
(86°F)
• Aftertreatment Disable Switch Off
or Not Programmed
• Clutch Pedal Position Switch Off
(open)
Manual Regen Requirements
• Transmission neutral switch engaged

• Service brake switch #2 engaged
• In park (if automatic transmission)
• PTO On/Off Switch in the “Off” position
(if programmed)
• Regeneration in PTO set to enabled (if
programmed)
• Vehicle must be stationary

Manual Regen
• Hold manual regen switch for 4 seconds

• ECM tests the air valve and fuel valve
• DPF lamp will go out and engine speed
will ramp to 1400 rpm
• Engine fan turns on (for parasitic
loading)
• HEST lamp will come on when exhaust
temp exceeds 450° C

ARD Lights for 5 Reasons
• Automatic – DPF regeneration

• Enhanced passive – maintenance of the
DPF
• Manual – DPF regeneration
• Mid-Range warm-up – emissions
strategies and white smoke elimination
• HC cleanup (MR/HD) – emissions
strategies and white smoke elimination

Emissions Strategies
Mid-Range Warm-Up
• Emissions compliance sooner
• Runs if dpf out is less than 250° C and
vehicle speed is 0 MPH
• Engine RPM remains at low idle due to VNT
usage
• Runs until dpf inlet is greater than 450° C (1
second) or dpf outlet is greater than 325° C
for 2 minutes

Emissions Strategies
HC Clean-up (on MR and HD)
• Eliminate HC slip (raw fuel in the DPF)
• Engine RPM will elevate to 700 RPM
• Runs every one hour based on a timer
• Timer will be 0 if:
• Vehicle speed is above 0 mph
• Soot is greater than 115% (enhanced passive starts at 120%)
• Dpf inlet is greater than 400° C or outlet is greater than 150° C
•Runs until dpf inlet is above 400° C or outlet is greater than 325° C
for 2 minutes

What Triggers a Regen?
• ECM soot calculation
• ECM calculates the amount of soot the
engine is putting out under all operating
conditions
• Time
• HD - 12 hours (6 hours with sensor fault)
• MR - 5 hours
• DPF differential pressure

• Used as a fail safe since there is no direct
correlation between soot loading and
differential pressure
perrylb:
perrylb:
Trigger Graph illustrator
illustrator
Soot
Time
Pressure
Soot %
Pressure
12 Hrs (5 MR)
Time (hours)

Partial Soot Loading Model Inputs
• Coolant Temperature
• Ambient Air Temperature
• Altitude
• Fuel Flow
• DPF Inlet & Outlet Temperature
• Shot Mode
• Engine Speed
• Exhaust Gas Temperature #1 (Turbo Out)
• Exhaust Gas Temperature #3 (Flame Length)
• CGI Flow
• Timing
• Total Exhaust Flow

CRS Indicators and Switches
Force Regen Switch

DPF Lamp
HEST Lamp
Manual Disable Switch

Operator Interface Review
Permanent System Lockout

Stop Engine Lamp
Engine derate
Check engine lamp
DPF Lamp - blink
DPF Lamp - solid
0 100
INCREASING SOOT LOAD

ARD Combustion System
• ARD Head
• Spark Plug
• Ignition Coil/cable
• Combustion Air
Line and sensor
• Fuel
Lines/valves/sens
ors
• ARD Housing

Combustion Zones
Primary
Secondary
Zone
Zone
Max length 12”

ARD Housings

ARD Head
Nozzle
Swirler Plate

ARD Combustion
Combustion Air Holes
Pilot & Main

Exit here

ARD Combustion System
Combustion Air Vents
The spark for ignition jumps

directly to the swirler plate

ARD Housing Assembly
ARD Head Combustion Containment ARD Housing

Canister

ARD Housing Assembly
ARD Head Combustion Containment ARD Housing

Canister

ARD Fuel Supply
• Fuel Filter base

• Fuel Enable Valve
• Pilot and Main
Fuel PWM valves
• Pilot and Main
Fuel Pressure
Sensors

ARD Fuel Supply
Fuel Enable Valve

ARD Fuel Supply
Pilot Main Fuel

Fuel Line
Line
Pilot Main Fuel

Main Pilot Fuel Pressure
Solenoid Pressure Sensor
Solenoid Sensor

ARD Fuel Supply
Pilot Coolant In Main Coolant Out
Pilot
Main

New Fuel Manifold Location

ARD Air Supply
Venturi Differential Pressure Sensor
CRS Combustion Air Valve

CRS Temp Sensors
Flame Detect
Flame Length
DPF DPF
Outlet Inlet
Turbo Out

Temp Control & Monitoring
• Exhaust gas
temperature #1
• Exhaust gas
temperature #2
• Exhaust gas
temperature #3
• Particulate trap inlet
and outlet temperature
sensors
Exhaust Gas Temperature #2 Sensor
Exhaust Gas Temperature

#3 Sensor

Particulate trap # 1 outlet and inlet temperature sensors

To Disable Regeneration
• Set the disable regeneration switch

on the dash (If Installed)
OR
• Go to ET configuration screen and
use the ARD Data Link Disable
parameter to manually disable the
regen.
Both actions will manually disable the CRS (air,fuel,and

spark).

Cat Common Rail Fuel System

Variable Nozzle Turbocharger
AVNT DAVNT


2007 Acert

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ACERT™ 2007

GLOBAL MANPOWER DEVELOPMENT

9-14 MPG More Torque 16-26 MPG

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

• Core engines remain essentially

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

2. How does a DPF work?

3. What does a DPF look like?

4. Is special DPF maintenance

GLOBAL MANPOWER DEVELOPMENT

•Single DPF •Dual DPF

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

HC Catalyst (Platinum) Washcoat

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

V-Band Clamps—Torque 100 inch/pounds

GLOBAL MANPOWER DEVELOPMENT

Particulate Trap #1 Particulate Trap # 1

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Lifting Eye Inner Shell

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

1- time use gasket

Ceramic mat material –

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Condensation Inner End

Inner Shell Lifting Eye

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

DPF 1 & 2 Connectors

GLOBAL MANPOWER DEVELOPMENT

“Good” DPF – no signs of Soot collected on outlet side

GLOBAL MANPOWER DEVELOPMENT

Soot collected on outlet side of DPF -failed

GLOBAL MANPOWER DEVELOPMENT

Soot collected on outlet side of DPF

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

This is a new filter from the factory

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

This is a used filter from service

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT