教程卡特彼勒1

1、ACERTTM Technologyfor Off-Highway C7, C9 and C11, C13 EnginesACERT Technology What does ACERT stand for? What is ACERT Technology? 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 maintenanc

2、e required?ACERT NomenclatureLack of a hyphen in the model number indicates an ACERT technology engine:C-7, C-9 are NOT ACERT enginesC7, C9 ARE ACERT enginesACERT TechnologyWhat does ACERT stand for?AdvancedCombustionEmissionsReductionTechnologyWhat is ACERT Technology?“ACERT technology is a series

3、of evolutionary, incremental improvements that provide a breakthrough engine technology built on systems and components that have been developed by Cat with proven reliability.”John Campbell, director of on-highway engine products, Caterpillar Power Systems DivisionWhat is ACERT Technology? Multiple

4、 technologies Varies by engine family Varies by engine application Medium duty specs, changes, new design Heavy duty specs, changes, new designC7 ACERTC7 Engine SpecsDisp. = 7.2 litersBore = 110 mmStroke = 127 mmATAACUp to 330 hp*Subject to changeC7 Design StrategyLeverage 3126B core structure Thous

5、ands in serviceProven reliabilityFully electronic engineHEUITM fuel systemC7 Design StrategyEnhancements over 3126B ACERT technologyImproved injector and pumpIncreased peak cylinder pressureNoise reductionsC7 DevelopmentCurrent 3126BPiston & ringsConnecting rodsIntake manifoldsModified 3126B blo

6、ckHEUI injectorValves, springs, seatsCam lobes & bearings Rod bearingsNew Designs, C7 Cylinder head modified Front housing & gear train ADEMTM 4 ECM HEP 10 oil pumpC7 Design StrategyComponent changes to increase peak cylinder pressure capabilityC7 16.5:1 compression ratioImproves cold start

7、characteristicsImproves white smoke clean up timeOptimizes ACERT performanceC7, C9 Fuel Injection SystemHEUI-B and ADEM 4 Variable injection timingElectronic control of injected quantityOptimised fuel injection pressuresTransient control for both speeds and loads C7, C9 Fuel SystemHydraulic Electron

8、ic Unit Injector Proven design - millions in operationExclusive Cat technology Common base injector to C9Enhanced designMultiple injectionsRate shaping capabilityImproved combustionC7, C9 HEUI DevelopmentHEP-10 pump replaces HEP-8 for improved performance and reliabilityHI 315-B injector has increas

9、ed capabilities and is common with C9Larger C7, C9 HEUI Pump Larger displacement pump Higher rail pressure capability Larger reservoirC7 HEUI Pump Drive 36 tooth drive gear for C7 HEP 10 pump Cast Iron pump mounting flangeC9 HEUI Pump Drive31 or 36 tooth drive gear for C9 HEP 10 pump Cast iron mount

10、ing flangeC7, C9 HEUI Pump Variable displacement pump Displacement control vs. pressure control Increased reliabilityC7, C9 Sleeve-meteringPiston MotionSleeve Position (controlled by actuator) Zero Effective StrokeFull Effective StrokeEffective stroke begins at port closing C7, C9 Fuel Transfer Pump

11、 The fuel transfer pump (FTP) is the only serviceable component FTP field service kit available Service instructions included with kitC7, C9, C11, C13 ADEM 4 Electronic Engine Control19878-bitPEEC II1991Advanced8-bitPEEC III1993Two 8-bitADEM II1998 32-bitADEM III2004 32-bitADEM 4Generations of Exper

12、ienceProven ReliabilityC7, C9, C11, C13 ADEM 4 Processing speeds and memory increased New 120 Pin engine connector Retains 70 Pin OEM connector More fuel maps to optimize ACERT technology Better performance Better efficiencyC7, C9, C11, C13 ADEM 4 No change in OEM / machine interface Uses Cat ET Com

13、mon electronics from C6.6 to C32 Allows greater protection and prognostics Full machine integration (Canbus, J1939, etc.)C7, C9, C11, C13 ADEM 4 FeaturesThrottle input strategyMulti-throttle capabilityConfigures throttle input priorityEngine control system optionsFull range governorMin max governorS

14、peed droop controlSimulates mechanical fuel system performanceAdjustable from 0-10% droopC7, C9, C11, C13 ADEM 4 CAN J1939 Data LinkHigh speed 2-way communicationsStandard SAE link for all C-series enginesBroadcasts engine performance, status and diagnostic informationSupports messages for powertrai

15、n integrationInterfaces with Cat Messenger and analog gaugesC7,C9, C11, C13 Turbocharger Provides higher boost over wide range Improves engine response Outstanding low end performance Improved peak torque Single wastegate turbochargerC7, C9, C11, C13 Turbocharger Wastegate FunctionBoostElevated BMEP

16、Improved ResponseRPMC7, C9, C11, C13 Turbocharger Wastegate FunctionWastegate BoostBoostWastegate Active Reduced BMEPRPMC7 Cylinder HeadCrossflow design3 valves per cylinderNew injector bore with improved O-ring sleeveC7 Cylinder HeadImproved airflow with updated port geometry3126C7C7 Head bolt torq

17、ue sequence1234567891011121314151617181920C7 Head bolt torque procedureTighten bolts 1-14 in numerical sequence to 300 +/- 15 NmLoosen bolts 1-14 Tighten bolts 1-14 in numerical sequence to 130 +/- 15 NmRetighten bolts 1-14 in numerical sequence to 130 +/- 15 NmTurn bolts 1-14 in numerical sequence

18、an additional 90 deg.Tighten bolts 15-20 to a torque of 55 +/- 7 NmC7, C9 Valve Lash AdjustmentSet number 1 cylinder to TDC compression Adjust number 1,2, and 4 intake valves*Adjust number 1,3, and 5 exhaust valves*Turn crankshaft 360 deg. Adjust number 3,5, and 6 intake valves*Adjust number 2,4, an

19、d 6 exhaust valves*Tighten adjusting screw locknut to 30 +/- 7 Nm* 0.38 mm +/- .08 for intake valves* 0.64 mm +/- .08 for exhaust valvesC7 Noise Reduction ProgramsIsolated valve coverComposite cover with fully isolated base 1 dBa reductionSteel oil panUp to 1 dBa reductionCast front coverUp to 1 dBa

20、 reductionC7 Cylinder BlockIncreased strength block material for peak cylinder pressure increaseIncreased width for improved oil seal and oil pan sealC7 Cylinder BlockCylinder blockIncreased tensile strengthHigher peak cylinder pressuresBurns hot, burns cleanImproved thermal efficiency Enhanced seal

21、ing surfaceSide coverOne side cover group with wiring harness tiesEasy maintenance C7 Cylinder BlockBreatherMoved down to decrease the engine heightOil manifold redesigned to modate breatherStraight thread O ring for fluid connectionsC7 Pistons May be steel or aluminum (based on rating) 16.5:1 C.R.

22、Boost varies with HP ratingC7 Piston and Ring InstallationTop and intermediate rings installed with “up” marking towards the top of the pistonAll ring end gaps to be 120 degrees apartPiston crown boss marked with white spot on the front pin bossSingle orifice piston cooling jet C7, C9 Connecting Rod

23、Heavy duty designForged steel Increased strengthFractured-split designPerfect joint alignment C7 Connecting Rod NotesLubricate rod bolt seating faces on the cap with clean engine oil or anti-seizeOrient the cap so that bearing tabs line up across the joint face.Tighten each bolt to 70 +/- 5 NmTighte

24、n each bolt an additional 120 +/- 5 deg.C7, C9 InjectorsStandardized injector size between C7 or C93126B current designC7 new designC7, C9 Front HousingChanged to modate HEP 10 pumpImproved sealing between pump and housingHigh capacity gear train for 60 hp PTOC7 SpecificationsModelC7Displacement7.2

25、L (440 cu. In.)Bore110 mm (4.331 in.)Stroke127 mm (5.000 in.)C7 SpecificationsModelC7Length1074 mm (42.28 in.)Width774 mm (30.47 in.)Height1059 mm (41.69 in.)Weight588 kg (1294 lbs.)C7 Maintenance Information500 hr. oil change intervalEquipped with new Cats high efficiency oil filtersRefill capaciti

26、esLube oil system (refill) 28L / 7.4 galOther serviceability issues unchangedC9 ACERTC9 Cylinder Head4 valve, Crossflow designDesign to improve engine breath-ability Robust 6 bolt design cylinder head-blockImproved combustion gas sealingMinimize bore / liner distortionC9 Head bolt torque sequence123

27、45678910111213141516171819202122232425262728293031C9 Head bolt torque procedure1.Tighten Bolts 1-26 in sequence to 130 +/- 15 Nm2.Retighten bolts 1-26 in sequence to 130 +/- 15 Nm3.Turn bolts 1-26 in sequence to an angle of 90 degrees4.Loosen bolts 1-26 to a torque of 0 Nm5.Repeat steps 1-36.Tighten

28、 bolts 27-31 to a torque of 28 +/- 7 NmC9 Valve Cover Composite cover Fully isolated base Up to 1 dBA sound power reductionC9 Valve and Seat Changes Increased valve size Improved engine breathing Allows for higher ratings Higher burn efficiencyC9 Intake Port DetailImproved geometrySmooth transitions

29、Less flow restrictionsC9 Valve and Seat ChangesReduced stem diameterReduced recessionImproved breathingKeeps cleanNo carbon load-upImproved lifeC9 Mechanical PackagingNew lighter and stiffer rocker armsNew lighter and stiffer rocker bridgeBetter response More reliableC9 Valve Spring Packaging New re

30、tainer Taller / reduced diameter springs New spring seat and stem seal Robust reliable designC9 Cylinder Block Improved block and head material strength Strengthened flywheel housing joint reduces leaks Sculpted design reduces noise Integral oil cooler reduces width, weight and potential leaksC9 Cyl

31、inder BlockMid-supported liner Fewer sealing joints for reduced risk of leaksIntegral oil cooler Reduced weight, leaks and engine widthImproved coolant & oil flowC9 PistonsArticulated two piece designProven technologySteel crown stronger than aluminumAllows more flexibility in ring positionExcel

32、lent wear characteristicsC9 Hardened Plateau Honed LinerTwo step honing process:Cuts deep grooves for oil retentionSmoothes the tops off for better wear surface and oil retentionImproves oil control and consumptionC9 LinersMid-support wet linerRemovable for serviceFewer leak jointsImproved cooling i

33、n combustion areaAllows advantages of higher ring positionC9 Connecting Rod NotesLubricate rod bolt seating faces on the cap with clean engine oil or anti-seizeOrient the cap so that bearing tabs line up across the joint face.Tighten each bolt to 50 +/- 5 NmTighten each bolt an additional 90 +/- 5 d

34、eg.C9 CrankshaftForged steel Increased strength and durabilityInduction hardened journal and filletsC11, C13 ACERTC11, C13 Design StrategyUpdated technologyBased on C-10 / C-12MEUI fuel systemValve train comp.Increased peak cylinder pressureACERT technologyBenefits of new technologyEmissions capabil

35、ityImproved power densityC11 Design StrategyIncreased displacement C11 increase from 10.3 to 11.1 litersBore = 130 mm (5.12 in.)Stroke = 140 mm (5.51 in.)Supports higher ratingsWide power range from a single installationIncreased power density allows higher power without increasing machine weightMor

36、e production from same size packageC11 Design Strategy Increased compression ratio C11 -17.8:1 compression ratio Component changes to increase peak cylinder pressure capability Improves cold start characteristics Improves white smoke clean up time Optimizes ACERT performanceC11, C13 ACERT Multiple I

37、njection Capability MEUI and ADEMTM 4 Variable injection timingControls quantity of fuelOptimises fuel pressureTransient control for both speeds and loads C11, C13 Fuel SystemMechanical Electronic Unit InjectorProven designProven high reliabilityEnhanced designMultiple injectionRate shaping30,000 PS

38、I peak injection pressureSuperior atomizationImproved combustionPrevious C-10, C-12 HeadNon-CrossflowNew Head for the C11, C13CrossflowIntake and exhaust ports on opposite sides of the headC11, C13 Cylinder Head DetailsIntegral water ManifoldEliminates leak jointCrossflow designImproved breathingBet

39、ter combustionSingle piece designOutstanding rigidityProven reliable designC-10, C-12 Valve OrientationIntake ValvesExhaust ValvesC11, C13 Valve OrientationExhaust ValvesIntake ValvesC11, C13 Head Bolt Torque SequenceC11, C13 Head Bolt Torque SequenceC11, C13 Sensor LocationC11, C13 TDC Probe120 Pin

40、 Engine Side ConnectorTDC Probe ConnectionA4 ECMC11, C13 Head GasketsMulti-layered steel head gasketImproved durabilitySealing Crush strength Creep resistanceJoint stabilitySteel Spacer Core Sandwiched Between 2 Layers of Spring SteelC11, C13 PistonsMonosteel pistonForged steel designHigh strengthLight weightBetter tolerance controlRings conform to liner better Better oil controlReduced blow-