Tài liệu đào tạo của Caterpila về kiểu động cơ C15 ,C18,C27,C32

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ACERTTM Technology

for Off-Highway C15, C18,

C27 and C32 Engines

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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?

 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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ACERT Technology

What does ACERT stand for?

Advanced Combustion Emissions Reduction Technology

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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

 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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C15, C18 ACERT

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How are the C15 and C18

•Bore increases from 137mm to 145mm

•Stroke increases from 171mm to 183mm

• C15 and C18 ACERT are based off the C-15

•Bore increases from 137mm to 145mm

•Stroke increases from 171mm to 183mm

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Best fuel economy

Best heat rejection

Best fuel economy

Best heat rejection

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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• Changing from 2100 rpm’s to 1800 fuel economy is

maximized in the C18 and C15

C15 / C18 ACERT

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Engine Features C15, C18 ACERT

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Design Strategy

ACERT technology

Few external changes

from Tier 2 / Stage II

Proven heavy duty

Few external changes

from Tier 2 / Stage II

Proven heavy duty

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Design Strategy

• Increased compression ratio

• C15 - 18:1 compression ratio

• C18 – 16.3:1 or 18:1 based on HP rating

• Component changes to increase peak

cylinder pressure capability

• Improves cold start characteristics

• Improves white smoke clean up time

• Increased compression ratio

• C18 – 16.3:1 or 18:1 based on HP rating

• Component changes to increase peak

• Improves cold start characteristics

• Improves white smoke clean up time

• Optimizes ACERT performance

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ACERT Multiple Injection

Capability

MEUI and ADEMTM 4

• Variable injection timing

• Controls quantity of fuel

• Optimizes fuel pressure

• Transient control for

both speeds and loads

MEUI and ADEMTM 4

• Variable injection timing

• 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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ADEM 4 Electronic Engine

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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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

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

New ADEM 4 CAN J1939

Data LinkHigh 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

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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C15, C18 Head bolt torque

sequence

C15, C18 Head bolt torque

sequence

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C15, C18 Head Bolt Torque

Procedure

C15, C18 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 Wastegate Function

Boost

Elevated BMEP

Improved Response

RPM

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Turbocharger Wastegate Function

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Water Cooled Center Section

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C15, C18 Cat Compression

Brake

C15, C18 Cat Compression

BrakeSome models equipped with Cat Brake

Developed and manufactured by Caterpillar

Functionally similar to previous compression brakes

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C15, C18 Compression Brake Oil Flow Schematic

Engine supply oil

Oil Sump Actuator valve

Cylinder 2

Cylinder 1

Check valves Drain line

Slave piston Master piston

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C15, C18 Cat Brake Oil Feed Path

3/4 in Hex Heads on 1/2

in Threaded Fasteners

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C15, C18 Cat Brake Oil Feed Path

Oil Feed Bolt OIL

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C15, C18 Brake and

Non-brake Rockers

C15, C18 Brake and

Non-brake Rockers

Common CAT Brake

& Non- Brake

Injector Rocker:

Cat Brake master

Cat Brake slave piston contacts here

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C15, C18 Cat Brake Installation

6

Tightening Sequence

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C15, C18 Valve Cover Base

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C15, C18 Cat Brake Lash

Setting

C15, C18 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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C15, C18 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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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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Better tolerance control

Rings conform to liner better

Better oil control

Better tolerance control

Rings conform to liner better

Better oil control

Reduced blow-by

Less liner wear

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C15, C18 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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C15, C18 Piston Assembly

Piston is a one piece design.

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C15, C18 Connecting Rod

Increase rod diameter

Drilled rod for lubrication

4 bolts improve clamping

Designed for durability

Compliments ACERT

Increase rod diameter

Drilled rod for lubrication

4 bolts improve clamping

Designed for durability

Compliments ACERT

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C15, C18 Rod Bolt Torque

Sequence

C15, C18 Rod Bolt Torque

Sequence

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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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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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C15, C18 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

Oil pan seal

Timing cover

Block to flywheel housing

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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

500 hr oil change interval with CAT DEO (or oil meeting CAT ECF-1 spec) below 6000 ft altitude.

S.O.S sampling

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High Efficiency Oil Filters

Revolutionary filter design

Increased contamination

control

Double the efficiency

without increasing the

Double the efficiency

without increasing the

changing interval

Reduces wear on all oil

lubricated surfaces

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Affected?

• C27 ACERT is based off the 3412E platform

• Displacement remains the same

• C27 ACERT is based off the 3412E platform

• Displacement remains the same

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C27, C32 ACERT

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•Best fuel economy

•Best heat rejection

•Best fuel economy

•Best heat rejection

Full power from 1800 to 2100 rpm

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Engine Features

C27, C32 ACERT

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C27, C32 Design Strategy

Leverage 3412E core V-12

structure structure and

reduce percent of new

Leverage 3412E core V-12

structure structure and

reduce percent of new

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C27, C32 Design Strategy

Leverage C15 / C18 technology

• MEUI fuel system

• Valve train comp.

• MEUI fuel system

• Valve train comp.

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•Valves, springs, seats

•Cam lobes & bearings

•Valves, springs, seats

•Cam lobes & bearings

•Cross bolted main caps

•Cam dampening system

•Cross bolted main caps

•Cam dampening system

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Design Strategy C27, C32

Increased compression ratio

Component changes to increase peak

• C32 - 16.5:1 compression ratio

Improves cold start characteristics

Improves white smoke clean up time

Optimizes ACERT performance

Increased compression ratio

Component changes to increase peak

• C32 - 16.5:1 compression ratio

Improves cold start characteristics

Improves white smoke clean up time

Optimizes ACERT performance

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Mechanical Electronic Unit Injector

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Capability

MEUI and ADEM 4

• Variable Injection timing

• Optimises fuel pressure

• Transient control for both

speeds and loads

MEUI and ADEM 4

• Variable Injection timing

• Optimises fuel pressure

• Transient control for both

speeds and loads

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A4 Engine Control Module

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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Single wastegate

turbocharger

Provides higher boost

over wide range

Provides higher boost

over wide range

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C27, C32 Cylinder Head

High cam position

• Power to drive injectors

• Short accurate valve /

High cam position

• Power to drive injectors

• Short accurate valve /

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C27, C32 Cylinder Head

Single piece design

• Rigid head becomes part of

the engine structure

• Allows high cam position

• Provides best power

density with lighter block

• Reduces leaks

Single piece design

• Rigid head becomes part of

the engine structure

• Allows high cam position

• Provides best power

density with lighter block

• Reduces leaks

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• Maintains critical alignment

• Minimal weight impact

• Maintains critical alignment

• Minimal weight impact

• Optimizes ACERT

performance

Cross tie bolts

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C27, C32 Piston/Rod/Liner

Leverage C15 / C18 iron

into C27 and C32

Piston, liner, rod, cooling

jet and piston pin

Validated components

Proven reliable components

High volume components

High parts commonality

Leverage C15 / C18 iron

into C27 and C32

Piston, liner, rod, cooling

jet and piston pin

Validated components

Proven reliable components

High volume components

High parts commonality

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• Better tolerance control

• Rings conform to liner

• Better tolerance control

• Rings conform to liner

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Two step honing process:

•Deep grooves for oil retention

•Tops smoothed off to reduce

wear and better contact

•Reduces blow by

•Improves oil control and

consumption

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C27, C32 Intake Manifold

Smooth direct airflow

• Reduced air resistance

• Reduce pumping loss

• Enhanced turbulence in

cylinder

• Eliminates after cooler

leak issues with ATAAC

• Improved performance

and efficiency

Smooth direct airflow

• Reduced air resistance

• Reduce pumping loss

• Enhanced turbulence in

cylinder

• Eliminates after cooler

leak issues with ATAAC

• Improved performance

and efficiency

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C27, C32 Rear Gear Train

•Provides drive for twin

•Only minimal increased length

compared with 3412E

•Provides drive for twin

•Only minimal increased length

compared with 3412E

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C27, C32 Front Gear Train

•Reduces gear noise

•Dampens cam flex to

maintain optimal injection

•Reduces gear noise

•Dampens cam flex to

maintain optimal injection

timing

Pendulum

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C27, C32 Leak Free Design

Advanced lower weight block design

• Oil pan seal

• Timing cover

• Block to flywheel housing

Advanced lower weight block design

• Oil pan seal

• Timing cover

• Block to flywheel housing

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Maintenance Information

S.O.S sampling

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C27 ACERT vs 3412E Tier 2

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C32 ACERT vs 3508B Tier 2

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Advantages of C27, C32

with the high technology inline 6

which has proven reliability

the C15 / C18 engines

• Combines the best of 3412E core engine with the high technology inline 6

• Leverages the 3412E core structure

which has proven reliability

• Leverages the new technology used in

the C15 / C18 engines

• Meets current and future emissions

• Maintains fuel efficiency

• Improved power density

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