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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?
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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
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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
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C15 Power Band
Performance
2100 rpm provides
Widest operating
range
Easiest match in
changeover
1800 rpm provides
Best fuel economy
Best heat rejection
Less noise 1300 1500 1700 1900 2100
RPM
POWER
A
B
C
D
E
Full Power from 1800 to 2100 rpm
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C15 / C18 Heat Rejection
• 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
of engine power—jacket water
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
Air
Jacket Water
C15 / C18 ACERT
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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
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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
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Design Strategy
ACERT technology
Externally similar to C-15
One installation for wide
power range
Best in class power
density
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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
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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
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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
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ACERT Multiple Injection
Capability
MEUI and ADEM
TM
4
• Variable injection timing
• Controls quantity of fuel
• Optimizes fuel pressure
• Transient control for
both speeds and loads
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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
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Areas of higher roller contact
Secondary roller markings
(new with Tier III)
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
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Fuel System
Mechanical Electronic
Unit Injector
Proven design
Proven high reliability
Enhancements
Multiple injection
Rate shaping
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ADEM 4 Electronic Engine
Control
1987
8-bit
PEEC II
1991
Advanced
8-bit
PEEC III
1993
Two 8-bit
ADEM II
1998 32-bit
ADEM III
2004 32-bit
ADEM 4
Generations of Experience
Proven Reliability
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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
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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.)
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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
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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
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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
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Turbocharger
• Wastegated turbocharger
• Provides higher boost over
wide range
• Single turbo
• Improves engine
response
• Outstanding low end
performance
• Improved peak torque
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Water Cooled Center Section
Water cooled
return to
radiator line
Water cooled
turbo supply
line
Water cooled
turbo supply
from water pump
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Cat Compression Brake
Some models equipped with Cat Brake
Developed and manufactured by Caterpillar
Functionally similar to previous compression
brakes
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C15 Cat Brake – Oil Feed Path
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
OIL
FEED
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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
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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
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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
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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
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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
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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
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Hardened Plateau Honed
Liner
Smooth Surface
Deep Cuts
Two step honing process:
- Cuts deep grooves for oil
retention
- Smoothes the tops off to
reduce wear and better contact
Reduces blow by
Improves oil control and
consumption
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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
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C15 Power Curve
400
420
440
460
480
500
520
540
560
1200 1400 1600 1800 2000 2200
RPM
HP
1200
1300
1400
1500
1600
1700
1800
1900
LB-FT
Power
Torque
* All C15 / C18 ACERT
ratings are preliminary
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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
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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
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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
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Power Curves
400
420
440
460
480
500
520
540
560
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
RPM
BHP
C15 ACERT
C-15
* All C15 / C18 ACERT
ratings are preliminary