2007 acert

GLOBAL MANPOWER DEVELOPMENT

ACERT™ 2007

Systems Overview


2006 427 CID LS71969 427 CorvetteLowest emissions

Ease of service

Less service

More Power

More Torque

Best fuel economy

When were the good old days?1969 Today

Good Old Days

435 hp 505 hp

460 ft-lb 470 ft-lb

9-14 MPG 16-26 MPG


• 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/OpacitySmoke/Opacity

Regulated Diesel Emissions


On-Highway Emissions 1988 to 2010

0

0.1

0.2

0.3

0.4

0.5

0.6

0 1 2 3 4 5 6 7 8 9 10 11

NOx (g/bhp.hr)

PMEPA ‘88

EPA ‘91

EPA‘94

EPA‘98

EPA‘04

EPA 07/10


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

TC

TC

CCVFilter

SeriesTurbochargers Throttle

TC

CGIValve

CGICooler

FlowSensor

Diesel Particulate

Filter

TC

ATAA

C

Intake Valve Actuation

High Pressure Injection System


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

Soot CollectsAlong the Inlet

Walls

Cells Fill Up

Particulate Matter or Soot Clean

Exhaust Out


How does a DPF work

HCCONOxPM (soot+SOF+sulfates)

O2

Substrate

WashcoatCatalyst (Platinum)

CO2H2ONOxO2


Ash Distribution• Low density ash plug near outlet of filter

• High density ash layer on wall – thickness increasing from inlet to outlet


Cordierite• Inexpensive raw material

(cordierite is basically sand)• Low thermal expansion coefficient• Good mechanical strength

Cordierite

Core Materials


V-Band Clamps—Torque 100 inch/pounds

DPF Inlet

Sensors on Center Section

Skin Temperature Protection

What does a DPF look like?CGI Connection

DPF Outlet


DPF Sensors

Particulate Trap #1 Differential Pressure

Sensor Tap

Particulate Trap # 1 Intake Temperature Sensor

Particulate Trap # 1 Differential Pressure

Sensor Tap

Particulate Trap #1 Outlet Temperature Sensor


Inlet Section


Inlet SectionFormed Marmon Flange

Formed Flange Connections to Center SectionLifting

Eye

Insulation

Condensate Ring

Distributor Tube


Insulation

Inlet - DescriptionInlet Diffuser Tube

Outer End Cap

Inner End Cap

Lifting Eye

Condensation Ring

Outer Shell

Inner Shell


Center Section

Sensor Box Temperature Probe

Pressure Boss

Sensor Box Strap

Filter does not slide out of center section


Center Section

Ceramic mat material –review safety material in Service Manuals

1- time use gasket


Center SectionRetaining 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

75 in/lbs

Rock Guards


Sensor Box


Insulation


Outlet Section


Inner End Cap

Lifting Eye

Condensation Ring

Irreversibility Tabs

Outlet Description

Outer End Cap

Outer Shell

Inner Shell

Insulation


Outlet Section - Vertical

Rain Protection System on Verticals

Drain in this area


Typical DPF InstallationCGI Line

CGI Line

Air Flow


OEM DPF Harness Connection

DPF 1 & 2 Connectors

Purge PumpPower Connector


“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

Center Section Analysis


Soot collected on outlet side of DPF

Failed DPF


What do you think?


Good FilterWeld 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


Nuked Trap


What’s 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


Same Oil Change Intervals

Cat C15Line Haul ACERT™

355,515 Miles480,973 Miles

CumminsLine Haul

Cooled-EGR360,901 Miles455,319 Miles

DDC S60Line Haul

Cooled-EGR381,100 Miles480,717 Miles

1.2.

Products History


SootBuild Up

Inlet ManifoldsCompetitive Tear Down


Detroit Intake

Soot Build Up

Phase 1 Phase 2


Cummins Intake

Soot Build Up


Cat Intake


Cooled-EGR contaminates the air system with soot, blocking ports and acids attack valve seats

Performance Deterioration

Phase 1

Competitive Tear Down


Detroit Valves and Ports

Soot Build-Up Airflow Restricitons

Phase 2


Cummins Valves & Ports

Soot Build-UpAcid AttackingValve Faces

Reduced Air Flow


Cat Valves & Intake Port

Valves Free of Deposits

Airflow Unrestricted

Phase 2


Cummins EGR Cooler

Outlet 60% pluggedInlet Plugging

Phase 2Phase 1


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

Cat Cummins DDC

1,000,000

530,000 490,000


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

HEPA Filter

Accumulator Tank

Control Panel

Disposable Bucket(Behind Door)

Filters

Expansion Tank

Computer Controlled Valve


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

Seal

DPF


•Various adaptors for the different DPF’s

•1 adaptor can be used for multiple sizes


Hand Pump Raise the bed

Seals Unit in Tool


Bed

Hydraulic Cylinders



• Start Process• Air Flow

• 30 Puffs• 45 Minutes• Totally

Automated



AshCollectionArea



• 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• 14 dia, 30 long• 2 filters/pack

• Life• 15 to 100 DPF Cleanings

• Cost• $ 349.45 USD D/N

Soot in DPF dramatically shortens Cartridge Filter

life!

Regen beforebefore Cleaning DPF


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


*This is NOT part of the standard 319-2190 Adaptor Group, it is ordered separately!

Additional AdaptersMass Transit Bus

• Use 319-2192 Adaptor-MTB*• Use with 319-1835 cone• Cost

• $739.74 USD D/N


Cleaner Costs*Dealer Net319-2189 Cleaner Gp $16,169.47

Individual Pricing319-2187 Cleaner – DPF $14,787.77319-2190 Adaptor group $2,024.87

319-1834 Cone – 11 inch - $245.12319-1835 Cone – 13 inch - $249.66319-1836 Cone – 15 inch - $256.90319-1838 Adaptor-lower – large - $747.64319-1839 Adaptor-lower – small - $750.54

*Dealer Net prices as of 14 Sep 07


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 SystemGoal: To increase exhaust gas temperature to accelerate regeneration of the Diesel Particulate Filter (DPF)

C (s) + O2 + Energy (heat) = CO2 (g) + H2OTrapped in the DPF

In engine exhaust

From Engine or ARD

Out tail pipe


Soot and AshDefinition of Soot

Soot is a byproduct of incomplete combustion

Definition of Ash

Ash is Noncombustible residue of a lubricating oil or fuel

Soot Cleaning

• DPF Collects the soot

• Elevated exhaust temperatures convert the soot to vapor

Ash Cleaning

• DPF Collects the ash

• Ash is removed using a special service tool


0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

NoRegeneration Passive Regeneration

Regeneration Types

Active Regeneration


Passive Regeneration

• Occurs when the engine is under high load

• Exhaust temperatures alone are enough to regenerate small amounts of soot

0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

Passive Regeneration


Active Regeneration

• Mobile Active (No Interaction) (Moving)• Enhanced Passive (No Interaction)

(Stationary)• Manual (Requires Interaction)

(Stationary)

0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

Active Regeneration


Mobile Active Regeneration

• Occurs when a regeneration is needed and vehicle is over 20 MPH

• No operator notification

0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

Active Regeneration


Enhanced Passive Regeneration

• Occurs at 0 MPH• Maintain soot during extensive idle

periods• Lower exhaust temp• 700 RPM, Fan On• 400° C for 20 minutes every 2 hours

0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

Enhanced Passive


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

0°C32°F

200°C392°F

400°C752°F

600°C1112°F

700°C1292°F

Active Regeneration


Manual Regen Requirements• Level 1 regeneration warning

reached• DPF Light “On”

• Coolant Temp greater than 20°C (68°F)

• ARD out Temp greater than 30°C (86°F)

• 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 andvehicle 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 StrategiesHC 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° Cfor 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


Time (hours)12 Hrs (5 MR)

SootTime

Pressure

Soot

%Pressure

Trigger Graphperrylb:

illustrator

perrylb:

illustrator


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

DPF Lamp

HEST Lamp

Force Regen Switch

Manual Disable Switch


0 100

DPF Lamp - blink

Engine derate

Check engine lamp

Stop Engine Lamp

DPF Lamp - solid

Perm

anen

t Sys

tem

Loc

kout

Operator Interface Review

INCREASING SOOT LOAD


ARD Combustion System

• ARD Head• Spark Plug• Ignition Coil/cable• Combustion Air

Line and sensor• Fuel

Lines/valves/sensors

• ARD Housing


Combustion Zones

PrimaryZoneSecondary

Zone

Max length 12”


ARD Housings


Nozzle

Swirler Plate

ARD Head


ARD Combustion

Pilot & Main Exit here

Combustion Air Holes


ARD Combustion System

The spark for ignition jumps directly to the swirler plate

Combustion Air Vents


ARD HousingCombustion Containment Canister

ARD Head

ARD Housing Assembly


ARD Fuel Supply

• Fuel Filter base• Fuel Enable Valve• Pilot and Main

Fuel PWM valves• Pilot and Main

Fuel Pressure Sensors


Fuel Enable Valve

ARD Fuel Supply


Pilot Solenoid

Main Solenoid

Pilot Fuel Pressure Sensor

Main Fuel Pressure Sensor

Pilot Fuel Line

Main Fuel Line

ARD Fuel Supply


ARD Fuel Supply

Pilot

Main

Pilot Coolant In Main Coolant Out


New Fuel Manifold Location


Differential Pressure SensorVenturi

CRS Combustion Air Valve

ARD Air Supply


CRS Temp Sensors

Turbo Out

Flame Detect

DPFInlet

Flame Length

DPFOutlet


• Exhaust gas

temperature #1

• Exhaust gas

temperature #2

• Exhaust gas

temperature #3

• Particulate trap inlet

and outlet temperature

sensors

Temp Control & Monitoring


Exhaust Gas Temperature #3 Sensor

Exhaust Gas Temperature #2 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

2007 acert

Documents