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Caterpillar Confidential: GREEN
ACERTTM Technologyfor Off-Highway C27
Engines
ACERTTM Technologyfor Off-Highway C27
Engines
Caterpillar Confidential: GREEN
ACERT TechnologyACERT TechnologyWhat 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?
Caterpillar Confidential: GREEN
ACERT TechnologyACERT Technology
What does ACERT stand for?What does ACERT stand for?AdvancedCombustionEmissionsReductionTechnology
Caterpillar Confidential: GREEN
What is ACERT Technology?What is ACERT Technology?
Multiple technologiesVaries by engine familyVaries by engine application
– Medium duty – specs, changes, new design
– Heavy duty – specs, changes, new design
Multiple technologiesVaries by engine familyVaries by engine application
– Medium duty – specs, changes, new design
– Heavy duty – specs, changes, new design
Caterpillar Confidential: GREEN
How is the C27 Affected?How is the C27 Affected?
C27 ACERT is based off the 3412E platformDisplacement remains the same•Bore remains 137mm•Stroke remains 152mm
C27 ACERT is based off the 3412E platformDisplacement remains the same•Bore remains 137mm•Stroke remains 152mm
Caterpillar Confidential: GREEN
C27 ACERTC27 ACERT
Caterpillar Confidential: GREEN
Performance Ratings – HP*Performance Ratings – HP*
Machine Rating C27Horsepower
A 730
B 820
C 900
D 1000
E 1100
*Preliminary, subject to change
Caterpillar Confidential: GREEN
C27 / C32 PerformanceC27 / C32 Performance
2100 rpm provides•Widest operating range•Easiest match in changeover
1800 rpm provides•Best fuel economy•Best heat rejection •Less noise
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
POW
ER
ABCDE
1300 1500 1700 1900 2100
RPM
POW
ER
ABCDE
Full power from 1800 to 2100 rpm
Caterpillar Confidential: GREEN
Engine FeaturesEngine Features
C27 ACERTC27 ACERT
Caterpillar Confidential: GREEN
Design StrategyDesign Strategy
Leverage 3412E core V-12 structure structure and reduce percent of new content
Proven reliabilityThousands in operationDominates most high power
industrial segments
Leverage 3412E core V-12 structure structure and reduce percent of new content
Proven reliabilityThousands in operationDominates most high power
industrial segments
Caterpillar Confidential: GREEN
Design StrategyDesign 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
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
Caterpillar Confidential: GREEN
Design StrategyDesign Strategy
Current design from 3412E, C15 and C18
•Piston, rings, liners•Connecting rods•Intake manifolds•Modified 3412E block•MEUI injector•Valves, springs, seats•Cam lobes & bearings•Rod bearings
Current design from 3412E, C15 and C18
•Piston, rings, liners•Connecting rods•Intake manifolds•Modified 3412E block•MEUI injector•Valves, springs, seats•Cam lobes & bearings•Rod bearings
New designs •Cylinder head modified scaled from C15 / C18 •Rear gear train drive•Overhead cams•Front housing & gear train•ADEM 4TM ECM•Cross bolted main caps•Cam dampening system
New designs •Cylinder head modified scaled from C15 / C18 •Rear gear train drive•Overhead cams•Front housing & gear train•ADEM 4TM ECM•Cross bolted main caps•Cam dampening system
Caterpillar Confidential: GREEN
Design Strategy C27Design Strategy C27
Increased compression ratioComponent changes to increase peak
cylinder pressure capability• C27 - 18:1 compression ratio
Improves cold start characteristicsImproves white smoke clean up timeOptimizes ACERT performance
Increased compression ratioComponent changes to increase peak
cylinder pressure capability• C27 - 18:1 compression ratio
Improves cold start characteristicsImproves white smoke clean up timeOptimizes ACERT performance
Caterpillar Confidential: GREEN
Validation StrategyValidation Strategy
Rigorous endurance testingOver 40,000 hours per modelSpecialized tests include:
• Thermal abuse• Cold start qualification• Over speed qualification• Crankshaft structure• Head / block structure• Emissions certification
Rigorous endurance testingOver 40,000 hours per modelSpecialized tests include:
• Thermal abuse• Cold start qualification• Over speed qualification• Crankshaft structure• Head / block structure• Emissions certification
Caterpillar Confidential: GREEN
ACERT Multiple Injection Capability
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
MEUI and ADEM 4 • Variable Injection timing• Controls quantity of fuel• Optimises fuel pressure• Transient control for both
speeds and loads
Caterpillar Confidential: GREEN
Fuel SystemFuel 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
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
Caterpillar Confidential: GREEN
A4 Engine Control ModuleA4 Engine Control Module
Generations of Experience
19878-bit
PEEC II
1991Advanced
8-bitPEEC III
1993Two 8-bitADEM II
1998 32-bitADEM III
2004 32-bit
ADEM 4
Proven Reliability
Caterpillar Confidential: GREEN
A4 TestingA4 Testing
Extreme temperaturesVibration Salt spray
Electrostatic
Extreme temperaturesVibration Salt spray
Electrostatic
Caterpillar Confidential: GREEN
A4 SpecificsA4 Specifics
Processing speeds and memory increasedNew 120 Pin engine connector Retains 70 Pin OEM connectorMore fuel maps to optimize ACERT Technology
Better performanceBetter efficiency
Processing speeds and memory increasedNew 120 Pin engine connector Retains 70 Pin OEM connectorMore fuel maps to optimize ACERT Technology
Better performanceBetter efficiency
Caterpillar Confidential: GREEN
A4 SpecificsA4 SpecificsNo change in OEM / machine interfaceWorldwide service network
Using Cat ETCommon electronics from
C6.6 – C32Allows greater protection and prognosticsFull machine integration (Canbus, J1939, etc.)
No change in OEM / machine interfaceWorldwide service network
Using Cat ETCommon electronics from
C6.6 – C32Allows greater protection and prognosticsFull machine integration (Canbus, J1939, etc.)
Caterpillar Confidential: GREEN
New A4 FeaturesNew A4 Features
Throttle input strategy• Multi-throttle capability• Configures throttle input
priorityEngine 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
priorityEngine control system options
• Full range governor• Min max governor
Speed droop control•Simulates mechanical fuel system performance•Adjustable from 0-10% droop
Caterpillar Confidential: GREEN
A4 CAN J1939 Data LinkA4 CAN J1939 Data Link
High speed 2-way communicationsStandard SAE link for all C-series enginesBroadcasts engine performance, status and diagnostic informationSupports messages for powertrain integrationInterface with Cat Messenger and analog gauges
High speed 2-way communicationsStandard SAE link for all C-series enginesBroadcasts engine performance, status and diagnostic informationSupports messages for powertrain integrationInterface with Cat Messenger and analog gauges
Caterpillar Confidential: GREEN
TurbochargerTurbocharger
Single wastegate turbocharger
Provides higher boost over wide range
Improves engine response
Outstanding low end performance
Improved peak torque
Single wastegate turbocharger
Provides higher boost over wide range
Improves engine response
Outstanding low end performance
Improved peak torque
Caterpillar Confidential: GREEN
Turbocharger Wastegate Function
BoostElevated BMEP
Improved Response
RPM
Caterpillar Confidential: GREEN
Turbocharger Wastegate Function
Wastegate Boost
Boost
Wastegate Active – Reduced BMEP
RPM
Caterpillar Confidential: GREEN
Cylinder HeadCylinder 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
High cam position• Power to drive injectors• Short accurate valve /
injector actuation• Optimize timing and
injection• Provides over speed
safety• Enhances performance
and economy
Caterpillar Confidential: GREEN
Cylinder HeadCylinder Head
Crossflow design• Improved breathing• Reduce pumping loss• Better combustion• Improved performance• Improved power density• Improved efficiency
Crossflow design• Improved breathing• Reduce pumping loss• Better combustion• Improved performance• Improved power density• Improved efficiency
Caterpillar Confidential: GREEN
Cylinder HeadCylinder 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
Caterpillar Confidential: GREEN
Cylinder BlockCylinder Block
Cross bolted mains and new material• Allows higher PCP • Increased strength• Maintains critical alignment• Minimal weight impact• Optimizes ACERT
performance
Cross bolted mains and new material• Allows higher PCP • Increased strength• Maintains critical alignment• Minimal weight impact• Optimizes ACERT
performance
Cross tie bolts
Caterpillar Confidential: GREEN
Piston / Rod / LinerPiston / Rod / Liner
Leverage C15 / C18 iron into C27
Piston, liner, rod, cooling jet and piston pin
Validated componentsProven reliable componentsHigh volume componentsHigh parts commonality
Leverage C15 / C18 iron into C27
Piston, liner, rod, cooling jet and piston pin
Validated componentsProven reliable componentsHigh volume componentsHigh parts commonality
Caterpillar Confidential: GREEN
C27 Connecting Rod Assembly
C27 Connecting Rod Assembly
Connecting rod cap uses four bolts
Caterpillar Confidential: GREEN
PistonPistonMonosteel 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
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
Caterpillar Confidential: GREEN
Hardened Plateau Honed LinerHardened Plateau Honed Liner
Smooth SurfaceTwo 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
Deep Cuts
Caterpillar Confidential: GREEN
Intake ManifoldIntake 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
Caterpillar Confidential: GREEN
Rear Gear TrainRear Gear Train
•Provides drive for twin overhead cams•Provides auxiliary drive capability•Lowers noise vs. front gear train designs•Only minimal increased length compared with 3412E
•Provides drive for twin overhead cams•Provides auxiliary drive capability•Lowers noise vs. front gear train designs•Only minimal increased length compared with 3412E
Caterpillar Confidential: GREEN
Front Gear TrainFront Gear Train
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
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
Pendulum
Caterpillar Confidential: GREEN
Leak Free DesignLeak Free Design
Advanced lower weight block designImproved joints through out the engine
• Oil pan seal• Timing cover• Block to flywheel housing
All fluid connections sealed with standard thread “O” ring design
Advanced lower weight block designImproved joints through out the engine
• Oil pan seal• Timing cover• Block to flywheel housing
All fluid connections sealed with standard thread “O” ring design
Caterpillar Confidential: GREEN
SpecificationsSpecifications
C27 ACERTC27 ACERT
Caterpillar Confidential: GREEN
SpecificationsSpecifications
Model C27
Rated RPM 2100
Displacement 27 L (1647 cu. In.)
Bore 137.2mm (5.402 in.)
Stroke 152.4mm (6.000 in.)
Caterpillar Confidential: GREEN
SpecificationsSpecifications
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.)
Caterpillar Confidential: GREEN
Maintenance InformationMaintenance 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
filterS.O.S. sampling
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
filterS.O.S. sampling
Caterpillar Confidential: GREEN
High Efficiency Oil FiltersHigh Efficiency Oil Filters
Revolutionary filter design• Increased contamination
control• Double the efficiency without
increasing the changing interval
• Reduces wear on all oil lubricated surfaces
Revolutionary filter design• Increased contamination
control• Double the efficiency without
increasing the changing interval
• Reduces wear on all oil lubricated surfaces
Caterpillar Confidential: GREEN
ComparisonsComparisons
C27 vs. 3412EC27 vs. 3412E
Caterpillar Confidential: GREEN
C27 ACERT vs. 3412E Tier 2C27 ACERT vs. 3412E Tier 2Model C27 ACERT 3412E
Rated Power 671 kw (900 hp) 671 kw (900 hp)
Weight 2367 kg (5207 lbs) 2140 kg (4708 lbs)
Power Density 3.5 kg/kw(5.8lb/hp)
3.2 kg/kw(5.2lb/hp)
Max RPM 2100 2100Displacement 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
Caterpillar Confidential: GREEN
Advantages of C27 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
• 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
Caterpillar Confidential: GREEN
Advantages of C27 Advantages of C27
• Extended ratings up to 1100 hp
• Starts with leadership of the 3412E and improves it with higher technology
• High commonality with the popular C15 / C18 engines
• Extended ratings up to 1100 hp
• Starts with leadership of the 3412E and improves it with higher technology
• High commonality with the popular C15 / C18 engines