Course Caterpillar Acert Technology Engine Systems Maintenance Components Parts Filters Sensors Combustion Fuel PDF

ACERT 2007
Systems Overview
GLOBAL MANPOWER DEVELOPMENT
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
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
PM
0.4
0.3
EPA 91
0.2
0.1
EPA
07/10
EPA
04
EPA
94
EPA
98
0
0
NOx (g/bhp.hr)
10
11
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

Series
Turbochargers
Flow
Sensor
Throttle
CGI
Cooler
Intake Valve
Actuation
CCV
Filter
ATAAC
CGI
Valve
High
Pressure
Injection
System
Diesel
Particulate
Filter
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
Vertical or Horizontal
Mounting
Dual DPF
600 Hp & Up
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)
CO
NOx
PM (soot+SOF+sulfates)
O2
Washcoat
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 ClampsTorque 100 inch/pounds
DPF Sensors
Particulate Trap # 1 Intake
Temperature Sensor
Particulate Trap #1 Outlet

Temperature Sensor
Particulate Trap #1
Differential Pressure
Sensor Tap
Particulate Trap # 1
Differential Pressure
Sensor Tap
Inlet Section
Inlet Section
Distributor
Tube
Formed Marmon
Flange
Condensate
Ring
Insulation
Lifting
Eye
Formed Flange
Connections to
Center Section
Inlet - Description
Inlet Diffuser
Tube
Outer Shell
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
Ring
Inner End
Cap
Insulation
Inner Shell
Lifting Eye
Outlet Section - Vertical
Drain in this area
Rain Protection
System on
Verticals
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 on outlet
Soot collected on outlet side

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
Whats 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
Line Haul
ACERT
1. 355,515 Miles
2. 480,973 Miles
Cummins
Line Haul
Cooled-EGR
360,901 Miles
455,319 Miles
DDC S60
Line Haul
Cooled-EGR
381,100 Miles
480,717 Miles
Same Oil Change Intervals

Competitive Tear Down

Inlet Manifolds
Soot
Build Up
Detroit Intake
Phase 2
Phase 1
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
Phase 2
Airflow Restricitons
Cummins Valves & Ports
Acid Attacking
Valve Faces
Soot Build-Up
Reduced Air Flow
Cat Valves & Intake Port

Phase 2
Airflow Unrestricted
Valves Free
of Deposits
Cummins EGR Cooler

Inlet Plugging
Phase 1
Outlet 60% plugged
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
Cat
Cummins
490,000
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
Controlled
Valve
HEPA
Filter
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 DPFs
1 adaptor can be
used for multiple sizes
Seal
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
319-2194
Soot in DPF dramatically
14 dia, 30 long
shortens Cartridge Filter
2 filters/pack life!
Life
15 to 100 DPF Cleanings
before
Regen
Cleaning
DPF
Cost
$ 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
319-2190 Adaptor group
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
$14,787.77
$2,024.87
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
incomplete combustion
DPF Collects the soot
Definition of Ash
Ash Cleaning
Ash is Noncombustible
residue of a lubricating
oil or fuel
DPF Collects the ash
Elevated exhaust
temperatures convert the
soot to vapor
Ash is removed using a

special service tool
Regeneration Types
Active Regeneration
No
Regeneration
0C
32F
200C
392F
Passive Regeneration
400C
752F
600C
1112F
700C
1292F
Occurs when the engine is under high
load
Exhaust temperatures alone are
enough to regenerate small amounts
of soot
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
Active Regeneration
Mobile Active (No Interaction) (Moving)
Enhanced Passive (No Interaction)
(Stationary)
Manual (Requires Interaction)
Active Regeneration
(Stationary)
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
Mobile Active Regeneration

Occurs when a regeneration is needed
and vehicle is over 20 MPH
No operator notification
Active Regeneration
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
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
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
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
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
Manual Regen Requirements

Level 1 regeneration warning
reached
DPF Light On
Coolant Temp greater than 20C

(68F)
ARD out Temp greater than 30C
(86F)
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
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:
illustrator
illustrator
Trigger Graph
Soot
Pressure
12 Hrs (5 MR)
Time (hours)
Pressure
Soot %
Time
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
Stop Engine Lamp

Engine derate
Check engine lamp
DPF Lamp - blink
DPF Lamp - solid
0
INCREASING SOOT LOAD
Permanent System Lockout
Operator Interface Review
100
ARD Combustion System
ARD Head
Spark Plug
Ignition Coil/cable
Combustion Air
Line and sensor
Fuel
Lines/valves/sens
ors
ARD Housing
Combustion Zones
Secondary
Zone
Max length 12
Primary
Zone
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
Canister
ARD Housing
ARD Housing Assembly
ARD Head
Combustion Containment
Canister
ARD Housing
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
Main Fuel
Line
Pilot
Fuel
Line
Pilot
Solenoid
Main
Solenoid
Pilot Fuel Pressure

Sensor
Main Fuel
Pressure Sensor
ARD Fuel Supply

Pilot
Coolant In Main
Pilot
Main
Coolant Out
New Fuel Manifold Location
ARD Air Supply

Venturi
Differential Pressure Sensor
CRS Combustion Air Valve
CRS Temp Sensors

Flame Detect
Flame Length
DPF
Outlet
DPF
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

Course Caterpillar Acert Technology Engine Systems Maintenance Components Parts Filters Sensors Combustion Fuel PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Course Caterpillar Acert Technology Engine Systems Maintenance Components Parts Filters Sensors Combustion Fuel PDF

Uploaded by

Copyright:

Available Formats

ACERT 2007

GLOBAL MANPOWER DEVELOPMENT

Good Old Days

2006 427 CID LS7

Best fuel economy

Regulated Diesel Emissions

GLOBAL MANPOWER DEVELOPMENT

On-Highway Emissions 1988 to 2010

New Engine Content

GLOBAL MANPOWER DEVELOPMENT

2007 System Overview

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter (DPF)

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter (DPF)

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

How does a DPF work

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

What does a DPF look like?

Particulate Trap #1 Outlet

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Filter does not

Ceramic mat material

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Center Section Sensor Box

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Outlet Section - Vertical

Drain in this area

GLOBAL MANPOWER DEVELOPMENT

Typical DPF Installation

GLOBAL MANPOWER DEVELOPMENT

OEM DPF Harness Connection

DPF 1 & 2 Connectors

GLOBAL MANPOWER DEVELOPMENT

Center Section Analysis

Good DPF no signs of

GLOBAL MANPOWER DEVELOPMENT

Soot collected on outlet side

Center Section Analysis

Soot collected on outlet side of DPF -failed

GLOBAL MANPOWER DEVELOPMENT

Soot collected on outlet side of DPF

GLOBAL MANPOWER DEVELOPMENT

What do you think?

GLOBAL MANPOWER DEVELOPMENT

This is a new filter from the factory

What do you think?

GLOBAL MANPOWER DEVELOPMENT