ACERT C27

ACERT Technology for Off-Highway C27 Engines TM TM

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? work? What are the advantages of ACERT Technology? Is extra maintenance required?

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? work? What are the advantages of ACERT Technology? Is extra maintenance required?

ACERT Technology What does ACERT stand for? Advanced Combustion Emissions Reduction Technology

What is ACERT Technology?  

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Multiple technologies Varies by engine family Varies by engine application  – Me Medi dium um du duty ty – sp spec ecs, s, changes, new design  – He Heav avy y duty duty – sp spec ecs, s, cha chang nges es,, new design

How is the C27 Affected?  

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C27 ACERT is based off the 3412E platform Displacement remains the same •Bore remains 137mm •Stroke remains 152mm

C27 ACERT

Performance Ratings – HP* Machine Rating A B C D E *Preliminary, subject to change

C27 Horsepower 730 820 900 1000 1100

C27 / C32 Performance 2100 rpm provides •Widest operating range •Easiest match in changeover

A A B B

    R     R     E     E     W     W     O     O     P     P

C C D D E E

1800 rpm provides •Best fuel economy •Best heat rejection •Less noise

1300 1300

1500 1500

1700 1700

1900 1900

2100 2100

RPM RPM

Full power from 1800 to 2100 rpm

Engine Features

C27 ACERT

Design Strategy Leverage 3412E core V-12 structure structure and reduce percent of new content Proven reliability Thousands in operation Dominates most high power industrial segments

Design Strategy Leverage C15 / C18 technology • • • •

MEUI fuel system Valve train comp. Increased PCP designs ACERT technology

Benefits of new technology • • •

Emissions capability Fuel efficiency Power density

Design Strategy Current design from 3412E, C15 and C18 •Piston, rings, rings, liners liners •Connecting rods rods •Intake manifolds •Modified 3412E block •MEUI injector •Valves, springs, springs, seats seats •Cam lobes & bearings •Rod bearings

New designs •Cylinder •Cylinder head head modified modified scaled scaled from from C15 C15 // C18 C18 •Rear •Rear gear gear train train drive drive •Overhead •Overhead cams cams •Front •Front housing housing & & gear gear train train TM TM •ADEM •ADEM 44 ECM ECM •Cross •Cross bolted bolted main main caps caps •Cam •Cam dampening dampening system system

Design Strategy C27 Increased compression ratio Component changes to increase peak cylinder pressure capability • C27 - 18:1 compression ratio

Improves cold start characteristics Improves white smoke clean up time Optimizes ACERT performance

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

ACERT Multiple Injection Capability MEUI and ADEM 4 • • • •

Variable Injection timing Controls quantity of fuel Optimises fuel pressure Transient control for both speeds and loads

Fuel System Mechanical Electronic Unit Injector • Proven design • Proven high reliability

Enhanced design • • • • • •

Multiple injection Rate shaping 30,000 PSI peak injection pressure Outstanding atomization Improved combustion

A4 Engine Control Module Generations of Experience

1987 8-bit PEEC II

1991

1993

Advanced 8-bit PEEC III

Two 8-bit ADEM II

1998 32-bit ADEM III

2004 32-bit ADEM 4

Proven Reliability

A4 Testing Extreme temperatures Vibration Salt spray Electrostatic

A4 Specifics Processing speeds and memory increased New 120 Pin engine connector Retains 70 Pin OEM connector More fuel maps to optimize ACERT Technology Better Better performance performance Better Better efficiency

A4 Specifics No change in OEM / machine interface Worldwide service network Using Cat ET Common electronics from C6.6 C6.6 –– C32

Allows greater protection and prognostics Full machine integration (Canbus, J1939, etc.)

New A4 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

A4 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

Turbocharger Single wastegate turbocharger Provides higher boost over wide range Improves engine response Outstanding low end performance Improved peak torque

Turbocharger Wastegate Function Boost

Improved Response

RPM

Elevated BMEP

Turbocharger Wastegate Function Wastegate Active – Reduced BMEP

Wastegate Boost Boost

RPM

Cylinder Head High cam position • • • • •

Power to drive injectors Short accurate valve / injector actuation Optimize timing and injection Provides over speed safety Enhances performance and economy

Cylinder Head Crossflow design • • • • • •

Improved breathing Reduce pumping loss Better combustion Improved performance Improved power density Improved efficiency

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

Cylinder Block Cross bolted mains and new material • • • • •

Allows higher PCP Increased strength Maintains critical alignment Minimal weight impact Optimizes ACERT performance

Cross tie bolts

Piston / Rod / Liner Leverage C15 / C18 iron into C27 Piston, liner, rod, cooling jet and piston pin Validated components Proven reliable components High volume components High parts commonality

C27 Connecting Rod Assembly Connecting rod cap uses four bolts

Piston Monosteel 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

Hardened Plateau Honed Liner 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

Smooth Surface

Deep Cuts

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 • • •

Rear Gear Train •Provides drive for twin overhead cams •Provides auxiliary drive capability •Lowers noise vs. front gear gear train designs •Only minimal increased length compared with 3412E

Front Gear Train Pendulum

Pendulum damper •Proven design (used since ’94) •Used on non-driven end of cam •Reduces gear noise •Dampens cam flex to maintain optimal injection timing

Leak Free Design Advanced lower weight block 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

Specifications

C27 ACERT

Specifications Model

C27

Rated RPM

2100

Displacement

27 L (1647 cu. In.)

Bore

137.2mm (5.402 in.)

Stroke

152.4mm (6.000 in.)

Specifications Model

C27

Length

2120 mm (83.5 in.)

Width

1483 mm (58.4 in.)

Height

1496 mm (58.9 in.)

Weight

2372 kg (5219 lbs.)

Maintenance Information 500 hr. oil change interval with CAT 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 oil filter S.O.S. sampling

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

Comparisons

C27 vs. 3412E

C27 ACERT vs. 3412E Tier 2 Model

C27 ACERT

3412E

Rated Power

671 kw (900 hp)

671 kw (900 hp)

Max RPM

2100

2100

Displacement

27 L (1647 in cu)

27 L (1647 in cu)

Bore

137 mm (5.39 in)

137 mm (5.39 in)

Stroke

152 mm (5.98 in)

152 mm (5.98 in)

Size (LWH)

2083 x 1473 x 1499 mm

1996 x 1483 x 1496 mm

Weight Power Density

2367 kg (5207 lbs) 2140 kg (4708 lbs) 3.5 kg/kw (5.8lb/hp)

3.2 kg/kw (5.2lb/hp)

Advantages of C27 • 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