Acert Technology For Off-Highway C15 Engines: Caterpillar Confidential

ACERT Technology
TM
for Off-Highway C15

Engines
Caterpillar Confidential: GREEN

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
– Medium duty – specs,
changes, new design
– Heavy duty – specs, changes,
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
A
range B
POW ER
Easiest match in C
changeover D
E
1800 rpm provides
Best fuel economy
Best heat rejection
Less noise 1300 1500 1700 1900 2100
RPM
Full Power from 1800 to 2100 rpm

C15 / C18 Heat Rejection
Jacket Water Air
EPA Engine Hp RPM JW* % Change Air % Change
Tier 3 C18 630 1800 0.36 0.0% 0.22 10.0%
Tier 3 C18 630 2100 0.38 5.6% 0.24 20.0%
Tier 2 C-16 630 2100 0.36 0.2
Tier 3 C15 540 1800 0.36 -7.7% 0.21 16.7%

Tier 3 C15 540 2100 0.38 -2.6% 0.23 27.8%
Tier 2 C-15 525 2100 0.39 0.18
• Changing from 2100 rpm’s to 1800 DECREASES heat rejection
in the C15 and maintains same heat rejection in the C18
* kW of heat rejection per kW

C15 / C18 ACERT
of engine power—jacket water

C15 / C18 Fuel Efficiency
EPA Engine Hp RPM BSFC % Change
Tier 3 C18 630 1800 219 4.8%
Tier 3 C18 630 2100 228 9.1%
Tier 2 C-16 630 2100 209
Tier 3 C15 540 1800 217 4.0%

Tier 3 C15 540 2100 223 6.9%
Tier 2 C-15 525 2100 208.6
• 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
MEUI and ADEM 4 TM
• Variable injection timing

• Controls quantity of fuel
• Optimizes fuel pressure
• Transient control for
both speeds and loads

Camshaft Changes
•Revised profile on the injector lobe

•Difficult to see but it can be felt
•Facilitates pilot injection capability
•Injector lobe profile varies depending on HP rating

Areas of higher roller contact
Primary area of roller markings

(similar to Tier II)
Tier 2 – one main area of heavy

roller contact
Tier III – two main areas of
contact
Secondary roller markings

(new with Tier III)

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 1991 1993 1998 32-bit 2004 32-bit

8-bit Advanced Two 8-bit ADEM III
8-bit ADEM II ADEM 4
PEEC II
PEEC III
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
Elevated BMEP
Improved Response
RPM

Turbocharger Wastegate Function
Wastegate Active – Reduced BMEP
Wastegate
Boost
Boost
RPM

Wastegated Turbo
Actuator
Hose
Wastegate
Actuator

Water Cooled Center Section
Water cooled
return to
radiator line
Water cooled
turbo supply
line
Water cooled
turbo supply
from water pump

Cat Compression Brake
Some models equipped with Cat Brake
Developed and manufactured by Caterpillar
Functionally similar to previous compression

brakes

C15 Compression Brake
Oil Flow Schematic
Cylinder 1
Check valves Drain line

Cylinder 2
Actuator valve Slave piston Master piston

Oil Sump
Engine supply oil

C15 Cat Brake – Oil Feed Path
OIL
FEED
3/4 in. Hex Heads on 1/2

in. Threaded Fasteners
5 Places
9/16 in. Hex Heads

on 3/8 in. Threaded
Fasteners 2 Places

C15 Cat Brake – Oil Feed Path
Oil Feed Bolt
OIL
FEED
“Studded” Bolt, 4
locations, used
w/Cat Brake only

Brake and Non-brake Rockers
Injector Rocker:
Cat Brake master Exhaust Rocker:
piston fits in here
Cat Brake slave
piston contacts here
Common CAT Brake

& Non- Brake

Cat Brake Installation
6 7
2
4 1 3 5
Tightening Sequence

Valve Cover Base Installation
Tighten to 18 +/- 3 Nm in numerical sequence

Cat Brake Lash Setting
•Set Cyl. 1 to TDC compression
•Set lash on cylinders 1, 3, and 5 to specification
•Tighten locknuts to 15 +/- 3 Nm
•Rotate crankshaft 360 deg in direction of rotation
•Set lash on cylinders 2, 4 and 6 to specification
•Tighten locknuts to 15 +/- 3 Nm
•Recheck lash setting

Injector and Valve Lash
Setting Notes
•Valve lash set with engine cold and stopped
•Valve 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 Notes
Intermediate ring is keystone design
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
Smooth Surface
Two step honing process:
- Cuts deep grooves for oil
retention
- Smoothes the tops off to
reduce wear and better contact
Reduces blow by Deep Cuts
Improves oil control and
consumption

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
LB-FT
1600 Power
HP
480
1500 Torque
460
440 1400
420 1300
400 1200
1200 1400 1600 1800 2000 2200
* All C15 / C18 ACERT
RPM
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

C15 vs. C-15

C15 ACERT vs. C-15 Tier 2
Model C15 ACERT C-15
Rated Power 540 HP 525 HP
Max RPM 2100 2100
Displacement 15.2 L 14.6 L
Bore 137 mm 137 mm
Stroke 171 mm 165 mm
Size (LWH) 65 x 36 x 53 in 59 x 36 x 50 in
Weight 2937 lb 2959 lb
Power Density 5.44 lb / hp 5.64 lb / hp

Power Curves
560
540
520
500
C15 ACERT
480 C-15
BHP
460
440
420
400
RPM * All C15 / C18 ACERT


Torque Curves
1900
1800
1700
C15 ACERT
LB-FT
1600
C-15
1500
1400
1300
1200
* All C15 / C18 ACERT

RPM

Acert Technology For Off-Highway C15 Engines: Caterpillar Confidential

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ACERT Technology

for Off-Highway C15

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

What does ACERT stand for?

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

• C15 ACERT is based off the C-15 platform

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

*Preliminary, subject to change

Caterpillar Confidential: GREEN

Full Power from 1800 to 2100 rpm

Caterpillar Confidential: GREEN

Tier 3 C15 540 1800 0.36 -7.7% 0.21 16.7%

* kW of heat rejection per kW

Caterpillar Confidential: GREEN

Tier 3 C15 540 1800 217 4.0%

C15 / C18 ACERT

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

MEUI and ADEM 4 TM

• Variable injection timing

Caterpillar Confidential: GREEN

•Revised profile on the injector lobe

Caterpillar Confidential: GREEN

Primary area of roller markings

Tier 2 – one main area of heavy

Secondary roller markings

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

1987 1991 1993 1998 32-bit 2004 32-bit

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

•Tighten bolts 1-26 in sequence to 270 +/- 15 Nm

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Wastegate Active – Reduced BMEP

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Some models equipped with Cat Brake

Developed and manufactured by Caterpillar

Functionally similar to previous compression

Caterpillar Confidential: GREEN

Check valves Drain line

Actuator valve Slave piston Master piston

Caterpillar Confidential: GREEN

3/4 in. Hex Heads on 1/2

9/16 in. Hex Heads

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN