A Cert

ACERT 2007
Systems Overview
GLOBAL MANPOWER DEVELOPMENT
Good Old Days

1969 427 Corvette Lowest emissions Ease of service Less service More Power More Torque Best fuel economy 2006 427 CID LS7
435 hp 460 ft-lb 9-14 MPG
505 hp 470 ft-lb 16-26 MPG
1969
When were the good old days?
Today
Regulated Diesel Emissions

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/Opacity
On-Highway Emissions 1988 to 2010

0.6 0.5 0.4 PM 0.3 0.2 0.1 0 0 1 2 3 4 5 6 7 8 9 10 11 NOx (g/bhp.hr)
GLOBAL MANPOWER DEVELOPMENT EPA 07/10 EPA 04 EPA 91 EPA 88
EPA 98
EPA 94
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

Series Turbochargers Flow Sensor Throttle
CGI Valve
C C
CGI Cooler
ATAAC
Intake Valve Actuation
CCV Filter
High Pressure Injection System
Diesel Particulate Filter
ACERT 2007
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?
Single DPF Vertical or Horizontal Mounting
Dual DPF 600 Hp & Up
What is a DPF
Cells Fill Up Soot Collects Along the Inlet Walls
Particulate Matter or Soot
Clean Exhaust Out
How does a DPF work

Substrate
HC Catalyst (Platinum) CO NOx PM (soot+SOF+sulfates) O2
Washcoat
CO2 H2O NOx O2
Ash Distribution
Low density ash plug near outlet of filter High density ash layer on wall thickness increasing from inlet to outlet
Core Materials
Cordierite
Inexpensive raw material (cordierite is basically sand) Low thermal expansion coefficient Good mechanical strength
Cordierite
What does a DPF look like?

Sensors on Center Section CGI Connection DPF Outlet DPF Inlet
Skin Temperature Protection V-Band ClampsTorque 100 inch/pounds

DPF Sensors
Particulate Trap # 1 Intake Temperature Sensor Particulate Trap #1 Outlet Temperature Sensor
Particulate Trap #1 Differential Pressure Sensor Tap

Particulate Trap # 1 Differential Pressure Sensor Tap
Inlet Section
Inlet Section
Distributor Tube Formed Marmon Flange
Condensate Ring Insulation
Lifting Eye
Formed Flange Connections to Center Section
Inlet - Description
Inlet Diffuser Tube Outer Shell Condensation Ring Outer End Cap
Inner End Cap
Insulation
Lifting Eye
Inner Shell
Center Section
Sensor Box Temperature Probe Pressure Boss
Sensor Box Strap
Filter does not slide out of center section
Center Section
1- time use gasket
Ceramic mat material review safety material in Service Manuals
Center Section
Retaining 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

Rock Guards
75 in/lbs
Sensor Box
Insulation
Outlet Section
Outlet Description
Outer Shell Irreversibility Tabs Outer End Cap
Condensation Ring
Inner End Cap Insulation
Inner Shell
Lifting Eye
Outlet Section - Vertical
Drain in this area
Rain Protection System on Verticals
Typical DPF Installation

CGI Line
Air Flow
CGI Line
OEM DPF Harness Connection
Purge Pump Power Connector
DPF 1 & 2 Connectors
Center Section Analysis
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
Failed DPF
Soot collected on outlet side of DPF
What do you think?
Good Filter
Weld 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
LC Lab DPF
Nuked Trap
Whats 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
Products History
Line Haul ACERT 1. 355,515 Miles 2. 480,973 Miles
Cat C15
Cummins
Line Haul Cooled-EGR 360,901 Miles 455,319 Miles
Line Haul Cooled-EGR 381,100 Miles 480,717 Miles
DDC S60
Same Oil Change Intervals

Competitive Tear Down

Inlet Manifolds
Soot Build Up
Detroit Intake
Phase 1 Phase 2
Soot Build Up
Cummins Intake
Soot Build Up
Cat Intake
Competitive Tear Down

Performance Deterioration
Cooled-EGR contaminates the air system with soot, blocking ports and acids attack valve seats
Phase 1
Detroit Valves and Ports

Soot Build-Up Airflow Restricitons
Phase 2
Cummins Valves & Ports
Acid Attacking Valve Faces

Soot Build-Up
Reduced Air Flow
Cat Valves & Intake Port

Phase 2
Airflow Unrestricted
Valves Free of Deposits
Cummins EGR Cooler

Inlet Plugging Outlet 60% plugged
Phase 1
Phase 2
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

1,000,000
530,000
490,000
Cat
Cummins
DDC
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

Computer Controlled Valve HEPA Filter Control Panel Filters Disposable Bucket
(Behind Door)
Expansion Tank
Accumulator Tank
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 DPF
Various adaptors for the different DPFs 1 adaptor can be used for multiple sizes
Seal
Bed Hand Pump Raise the bed Seals Unit in Tool Hydraulic Cylinders

Start Process
Air Flow
30 Puffs 45 Minutes Totally Automated
Ash Collection Area

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 Soot in DPF dramatically 14 dia, 30 long shortens Cartridge Filter 2 filters/pack life!
Life
Regen before Cleaning DPF Cost

$ 349.45 USD D/N
15 to 100 DPF Cleanings
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
Additional Adapters
Mass Transit Bus
Use 319-2192 Adaptor-MTB*

Use with 319-1835 cone Cost
$739.74 USD D/N
*This is NOT part of the standard 319-2190 Adaptor Group, it is ordered separately!
Cleaner Costs*
Dealer Net
319-2189 Cleaner Gp
Individual Pricing
319-2187 Cleaner DPF 319-2190 Adaptor group 319-1834 Cone 11 inch - $245.12 319-1835 Cone 13 inch - $249.66 319-1836 Cone 15 inch - $256.90 319-1838 Adaptor-lower large - $747.64 319-1839 Adaptor-lower small - $750.54
*Dealer Net prices as of 14 Sep 07
$16,169.47
$14,787.77 $2,024.87
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 System

Goal: To increase exhaust gas temperature to accelerate regeneration of the Diesel Particulate Filter (DPF)
C (s) + O2 + Energy (heat) = CO2 (g) + H2O

Trapped in the DPF In engine exhaust From Engine or ARD Out tail pipe
Soot and Ash

Definition of Soot Soot is a byproduct of incomplete combustion 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
Definition of Ash Ash is Noncombustible residue of a lubricating oil or fuel
Regeneration Types
Active Regeneration No Regeneration Passive Regeneration
0C 32F
200C 392F
400C 752F
600C 1112F
700C 1292F
Passive Regeneration
Occurs when the engine is under high load Exhaust temperatures alone are enough to regenerate small amounts of soot Passive Regeneration
0C 32F
200C 392F
400C 752F
600C 1112F
700C 1292F
Active Regeneration
Mobile Active (No Interaction) (Moving) Enhanced Passive (No Interaction) (Stationary) Manual (Requires Interaction) Active Regeneration (Stationary)
0C 32F
200C 392F
400C 752F
600C 1112F
700C 1292F
Mobile Active Regeneration

Occurs when a regeneration is needed and vehicle is over 20 MPH No operator notification
Active Regeneration
0C 32F
200C 392F
400C 752F
600C 1112F
700C 1292F
Enhanced Passive Regeneration

Occurs at 0 MPH Maintain soot during extensive idle periods Lower exhaust temp 700 RPM, Fan Passive On Enhanced 400 C for 20 minutes every 2 hours
0C 32F 200C 392F 400C 752F 600C 1112F 700C 1292F
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
Active Regeneration
0C 32F
200C 392F
400C 752F
600C 1112F
700C 1292F
Manual Regen Requirements

Level 1 regeneration warning reached
DPF Light On
Coolant Temp greater than 20C (68F) ARD out Temp greater than 30C (86F) 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 and vehicle 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 Strategies
HC 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 for 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
Trigger Graph
Soot Time
perrylb: perrylb: illustrator illustrator
Pressure
Soot %
Pressure
12 Hrs (5 MR) Time (hours)
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

Force Regen Switch DPF Lamp
HEST Lamp
Manual Disable Switch
Operator Interface Review

Stop Engine Lamp Engine derate Check engine lamp DPF Lamp - blink DPF Lamp - solid Permanent System Lockout
0
INCREASING SOOT LOAD GLOBAL MANPOWER DEVELOPMENT
100
ARD Combustion System

ARD Head Spark Plug Ignition Coil/cable Combustion Air Line and sensor Fuel Lines/valves/sens ors ARD Housing
Combustion Zones
Secondary Zone Primary Zone
Max length 12
ARD Housings
ARD Head
Nozzle
Swirler Plate
ARD Combustion
Combustion Air Holes
Pilot & Main Exit here
ARD Combustion System
Combustion Air Vents The spark for ignition jumps directly to the swirler plate
ARD Housing Assembly
ARD Head
Combustion Containment Canister
ARD Housing
ARD Housing Assembly
ARD Head
Combustion Containment Canister
ARD Housing
ARD Fuel Supply

Fuel Filter base Fuel Enable Valve Pilot and Main Fuel PWM valves Pilot and Main Fuel Pressure Sensors
ARD Fuel Supply

Fuel Enable Valve
ARD Fuel Supply
Pilot Fuel Line
Main Fuel Line
Pilot Solenoid
Main Solenoid
Pilot Fuel Pressure Sensor
Main Fuel Pressure Sensor
ARD Fuel Supply

Pilot Coolant In Main Coolant Out
Pilot Main
New Fuel Manifold Location
ARD Air Supply

Venturi Differential Pressure Sensor
CRS Combustion Air Valve
CRS Temp Sensors

Flame Detect
Flame Length
DPF Outlet
DPF Inlet Turbo Out
Temp Control & Monitoring

Exhaust gas temperature #1 Exhaust gas temperature #2 Exhaust gas temperature #3 Particulate trap inlet and outlet temperature
Exhaust Gas Temperature #2 Sensor Exhaust Gas Temperature #3 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

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ACERT 2007

GLOBAL MANPOWER DEVELOPMENT

Good Old Days

435 hp 460 ft-lb 9-14 MPG

505 hp 470 ft-lb 16-26 MPG

When were the good old days?

Regulated Diesel Emissions

GLOBAL MANPOWER DEVELOPMENT

On-Highway Emissions 1988 to 2010

New Engine Content

Predominantly external components

GLOBAL MANPOWER DEVELOPMENT

2007 System Overview

Intake Valve Actuation

High Pressure Injection System

Diesel Particulate Filter

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter (DPF)

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter (DPF)

GLOBAL MANPOWER DEVELOPMENT

Diesel Particulate Filter

Single DPF Vertical or Horizontal Mounting

Dual DPF 600 Hp & Up

GLOBAL MANPOWER DEVELOPMENT

Particulate Matter or Soot

Clean Exhaust Out

GLOBAL MANPOWER DEVELOPMENT

How does a DPF work

HC Catalyst (Platinum) CO NOx PM (soot+SOF+sulfates) O2

CO2 H2O NOx O2

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

What does a DPF look like?

Skin Temperature Protection V-Band ClampsTorque 100 inch/pounds

Particulate Trap #1 Differential Pressure Sensor Tap

Particulate Trap # 1 Differential Pressure Sensor Tap

GLOBAL MANPOWER DEVELOPMENT

Condensate Ring Insulation

Formed Flange Connections to Center Section

GLOBAL MANPOWER DEVELOPMENT

Inner End Cap

GLOBAL MANPOWER DEVELOPMENT

Sensor Box Strap

Filter does not slide out of center section

GLOBAL MANPOWER DEVELOPMENT

Ceramic mat material review safety material in Service Manuals

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Center Section Sensor Box

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

GLOBAL MANPOWER DEVELOPMENT

Inner End Cap Insulation

Outlet Section - Vertical

Drain in this area

Rain Protection System on Verticals

GLOBAL MANPOWER DEVELOPMENT

Typical DPF Installation

GLOBAL MANPOWER DEVELOPMENT