C15 Machine Acert 1q161c

ACERT Technology for Off-Highway C15 Engines TM

Caterpillar Confidential: GREEN

ACERT Technology ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ

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? ƒ Multiple technologies ƒ Varies by engine family ƒ 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 B C D E

440 475 540 580 595

*Preliminary, subject to change


C15 Power Band Performance 2100 rpm provides

1800 rpm provides Best fuel economy Best heat rejection Less noise

A B C D E

POWER

Widest operating range Easiest match in changeover

1300

1500

1700

1900

2100

RPM

Full Power from 1800 to 2100 rpm Caterpillar Confidential: GREEN

C15 / C18 Heat Rejection EPA Tier 3 Tier 3 Tier 2

Engine C18 C18 C-16

Hp 630 630 630

RPM 1800 2100 2100

Jacket Water JW* % Change 0.36 0.0% 0.38 5.6% 0.36

Tier 3 Tier 3 Tier 2

C15 C15 C-15

540 540 525

1800 2100 2100

0.36 0.38 0.39

-7.7% -2.6%

Air Air % Change 0.22 10.0% 0.24 20.0% 0.2 0.21 0.23 0.18

16.7% 27.8%

• 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 Tier 2

Engine C18 C18 C-16

Hp 630 630 630

RPM 1800 2100 2100

BSFC 219 228 209

% Change 4.8% 9.1%

Tier 3 Tier 3 Tier 2

C15 C15 C-15

540 540 525

1800 2100 2100

217 223 208.6

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 s 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

•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 s 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


•Retighten



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


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


Cat Brake Installation 6

4

2

1

3

7

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 •Rotate •Set

locknuts to 15 +/- 3 Nm

crankshaft 360 deg in direction of rotation

lash on cylinders 2, 4 and 6 to specification

•Tighten

locknuts to 15 +/- 3 Nm

•Recheck

lash setting Caterpillar Confidential: GREEN

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 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 ¾Reduces blow by ¾Improves oil control and consumption

Smooth Surface

Deep Cuts


Leak Free Design Improved ts 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.)


560

1900

540

1800

520

1700

HP

500

1600

480

1500

460

Power Torque

1400

440 420

1300

400

1200

1200

LB-FT

C15 Power Curve

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


C15 vs. C-15


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

C-15 525 HP 2100 14.6 L 137 mm 165 mm 59 x 36 x 50 in 2959 lb 5.64 lb / hp


Power Curves 560 540 520 500

C15 ACERT

480

BHP

C-15

460 440 420 400 00 22

00 21

00 20

00 19

00 18

00 17

00 16

00 15

00 14

00 13

00 12

RPM

* All C15 / C18 ACERT ratings are preliminary


Torque Curves 1900 1800

LB-FT

1700

C15 ACERT C-15

1600 1500 1400 1300 1200 00 22 00 21 00 20 00 19 00 18 00 17 00 16 00 15 00 14 00 13 00 12

RPM

* All C15 / C18 ACERT ratings are preliminary


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