ACERT 2007

Systems Overview

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

Good Old Days

1969 427 Corvette

435 hp
460 ft-lb
9-14 MPG

Lowest emissions
Ease of service
Less service

2006 427 CID LS7

505 hp

More Power

470 ft-lb

More Torque

16-26 MPG

Best fuel economy

1969

When were
the good old days?

Today

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

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

GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

On-Highway Emissions 1988 to 2010

0.6

EPA 88

0.5

PM

0.4
0.3
EPA 91

0.2
0.1

EPA
07/10

EPA
04

EPA
94

EPA
98

0
0

10

11

NOx (g/bhp.hr)
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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 and
will run and be tested along with the 2007 fleet engine soon.

2007ACERT_01.ppt

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

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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.

2007ACERT_01.ppt

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

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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 onhighway engines.
--You can find preliminary troubleshooting guides and preliminary Operation
and Maintenance Manuals on SIS Web using the engine serial prefix
numbers provided above.
-

2007ACERT_01.ppt

2007 System Overview

Series
Turbochargers

Flow
Sensor
Throttle

CGI
Cooler

Intake Valve
Actuation

CCV
Filter

ATAAC

CGI
Valve

High
Pressure
Injection
System

Diesel
Particulate
Filter

GLOBAL MANPOWER DEVELOPMENT

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 to
meet 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.
.

2007ACERT_01.ppt

2007 System Overview

Series
Turbochargers

Flow
Sensor
Throttle

CGI
Cooler

Intake Valve
Actuation

CCV
Filter

ATAAC

CGI
Valve

High
Pressure
Injection
System

Diesel
Particulate
Filter

GLOBAL MANPOWER DEVELOPMENT

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 of
the 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.

2007ACERT_01.ppt

ACERT 2007
System Components

GLOBAL MANPOWER DEVELOPMENT

System Components

2007ACERT_01.ppt

Component Identification

GLOBAL MANPOWER DEVELOPMENT

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. This
lesson will deal with component identification in the classroom and in the lab.

2007ACERT_01.ppt

10

Diesel Particulate Filter (DPF)

GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

11

Dual DPF

GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

12

DPF Connection

GLOBAL MANPOWER DEVELOPMENT

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

2007ACERT_01.ppt

13

CGI Line

CGI Line

CGI Line
GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

14

CGI Venturi & Cooler

GLOBAL MANPOWER DEVELOPMENT

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 is
different 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.

2007ACERT_01.ppt

15

CGI Line to the Mixing Valve

GLOBAL MANPOWER DEVELOPMENT

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).

2007ACERT_01.ppt

16

CGI Actuator

Mixing Valve Door

GLOBAL MANPOWER DEVELOPMENT

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.
*Instructor Nice to Know
*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.

2007ACERT_01.ppt

17

Clean Gas Induction System

C15

C7

GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

18

Aftertreatment Regeneration
Device

GLOBAL MANPOWER DEVELOPMENT

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 the
configuration of the C15.
*The spark plug boot is changing

2007ACERT_01.ppt

19

Cat Regeneration System

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

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

20

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

From Engine or ARD

Trapped in the DPF

In engine exhaust

Out tail pipe

GLOBAL MANPOWER DEVELOPMENT

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.
*Instructor Nice to Know
*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 the
DPF 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.

2007ACERT_01.ppt

21

Cat Common Rail Fuel System

GLOBAL MANPOWER DEVELOPMENT

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.

2007ACERT_01.ppt

22

A4E4

2
GLOBAL MANPOWER DEVELOPMENT

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 J1939
Datalink 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.

2007ACERT_01.ppt

23

Variable Nozzle Turbocharger

AVNT

DAVNT

GLOBAL MANPOWER DEVELOPMENT

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

2007ACERT_01.ppt

24

C7 Up-Ratability
Adv HP
300
275

Adv HP
250
250

Adv HP
230
230
230

Adv HP
210
210
190

Peak Torque
620
520
520

Peak Torque
660
620
560

Buy

Peak Torque
800
660

Buy

Adv HP
350
330

Peak Torque
860
800

Buy

Peak Torque
860
860

Buy

DPF, Turbo, &

Injectors

DPF

Injectors & Turbo

DPF & Pistons

Subject to Change 9/1/2006

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

25

C9 Up-Ratability

Adv HP
425
425
400

Adv HP
365
350
335

Adv HP
285

Peak Torque
890

Peak Torque
1250
1250
1150

Buy

Peak Torque
1350
1250
1250

Buy

DPF, Injectors

DPF, Injectors

Subject to Change 9/1/2006

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

26

C13 Up-Ratability
Adv HP
485
470
470
470
430
430
430
410
410
410
410
380

Adv HP
370
370
350
350
350
335
305

Peak Torque
1450
1350
1550
1450
1350
1250
1150

Peak Torque
1650
1550/1750
1650
1550
1550/1750
1650
1550
1450/1650
1450/1550
1550
1450
1450

Buy

DPF, Injectors, Turbo,

and Pre-cooler

Subject to Change 9/1/2006

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

27

C15 Up-Ratability
Adv HP
625
600
600

Adv HP
550
500
500
475
475
475
475
435
435
435
435
435/500

Peak Torque
1850
1850
1650
1650/1850
1650/1750
1850
1650
1550/1750
1550/1650
1650
1550
1550/1650

Peak Torque
2050
2050
1850

Buy

Pistons and DPF

Subject to Change 9/1/2006

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

28

GLOBAL MANPOWER DEVELOPMENT

2007ACERT_01.ppt

29