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Engineering and

Installation Issues

Rob Johannsen, Product Manager, LPS Platforms

Engineering and Installation Issues

Production Schedule
Validation Engines
ACERT Price Lists
Installation Parameters
Benefits of 1800 RPM
New Industrial Ratings Structure
ADEM 4 and Software

Validation Engines
39 validation engines built
22 for field validation.
11

field validation engines are installed and


running.
12,500
The

hours to date.

remaining 11 are scheduled for installation.

17 for OEM validation.


8

engines shipped to North American OEMs

engines shipped to European OEMs

Field Validation Engines


Serial No.
C18 Engines
WJH00101
WJH00102
WJH00103
WJH00104
WJH00105
WJH00106
WJH00116
C15 Engines
JRE00100
JRE00102
JRE00103
JRE00104
C13 Engines
LGK00105
LGK00111
LGK00113
LGK00108
LGK00109
LGK00114
C11 Engines
GLS00101
GLS00100
GLS00103
GLS00104
GLS00105

HP Ship Date

Dealer

OEM / Customer

Application

Location

Hours

630
630
630
630
630
630
630

Aug-03
Aug-03
Aug-03
Aug-03
Aug-03
Aug-03
Feb-04

Quinn
Quinn
Quinn
Warren
Warren
Warren
Alban

Azcal Management
Azcal Management
Diamond Farming
Big Dog
Big Dog
Big Dog
Northern Virginia Drilling

Irrigation
Irrigation
Irrigation
Drill Rig
Drill Rig
Drill Rig
Drill Rig

California
California
California
Texas
Texas
Texas
Maryland

1281
864
8
4514
4243
0
0

540
540
540
540

Sep-03
Sep-03
Oct-03
Oct-03

Wagner
Pantropic
Warren
Warren

Energy Air
HJ Foundation
Basic Energy
Basic Energy

Air Drilling New Mexico


Drill
Florida
Well Servicing
Texas
Well Servicing
Texas

981
88
0
0

440
440
440
440
440
440

Jan-04
Feb-04
Feb-04
Feb-04
Feb-04
Mar-04

Wagner
Warren
Warren
Warren
Wagner
Warren

Energy Air
Basic Energy
Basic Energy
Basic Energy
Energy Air
Basic Energy

Air Drilling New Mexico


Well Servicing
Texas
Well Servicing
Texas
Well Servicing
Texas
Air Drilling New Mexico
Well Servicing
Texas

287
314
106
0
0
0

385
385
385
385
385

Jan-04
Jan-04
Mar-04
Mar-04
Mar-04

Quinn
Warren
Quinn
Quinn
Warren

Tony DeGroot
Basic Energy
Tony DeGroot
Tony DeGroot
Basic Energy

Irrigation
Well Servicing
Irrigation
Irrigation
Well Servicing

175
0
0
0
0

California
Texas
California
California
Texas

OEM Validation Engines


Serial No.
C18 Engines
WJH00117
WJH00118
WJH00119
WJH00120
WJH00117
WJH00118
WJH00119
WJH00120
C15 Engines
JRE00105
JRE00106
JRE00107
C13 Engines
LGK00112
C9 Engines
JSC00100
JSC00101
JSC00102
JSC00103

HP

Ship Date

Dealer

OEM / Customer

Application

Location

700
700
630
630
700
700
630
630

Apr-04
Apr-04
Apr-04
Mar-04
Apr-04
Apr-04
Apr-04
Mar-04

Witrakor
Zeppelin
Factory
Factory
Witrakor
Zeppelin
Factory
Factory

Metso
Sennebogen
Sullair
Atlas Copco
Metso
Sennebogen
Sullair
Atlas Copco

Crusher
Crane
Air Compressor
Air Compressor
Crusher
Crane
Air Compressor
Air Compressor

Finland
Germany
Indiana
Belgium
Finland
Germany
Indiana
Belgium

AGCO
Sullair
Metso

MT
Air Compressor
Crusher

Peoria
Indiana
Finland

Claas

Combine

Germany

474
540
540
461
375
375
330
350

Dec-03
Factory
Not shipped Factory
Apr-04
Witrakor
Mar-04

Factory

Mar-04
Zeppelin
Mar-04
Hewitt
Mar-04
Factory
Not shipped Factory

Kassaborher
Bombardier
AGCO
Claas

Snow Groomer Germany


Snow Groomer Canada
MT
Canada
Combine
Germany

LPS ACERT Production Schedule


C11-18 Price Lists Posted in Power Net
On Line Price List 6/1
80% Complete
Production availability 8-16 Weeks following
July 15
C9 Price List 8/1
Production Availability 10/1
C7 and C27/32
Production Availability 7/05

ACERT Price Lists


Consistency

Standard Attachments
Front

Oil Sump

Front

Exhaust

LH

Front Oil Gage

LH

Front Oil Fill

No

flywheel/housing (now attachment)

Fuel
No

between engine platforms

and Oil Sampling valves

Customer Wiring Harness (now additional-cost attachment)

Mandatory attachments
Flywheel

Housing / RPTO

Throttle

position sensor

Primary

fuel filters or customer-supplied filters

ACERT Price Lists

Elimination

of No/Low-usage Attachments

Proliferation

of alternators

Expensive radiator packages

Inclusion
New

of Latest Technology Components


line of air compressors

Latest
New
Rating

alternators

instrument panels

Part No. Identifies charges for different ratings using same


software

ACERT Price Lists

Odds & Ends

No Ag ratings listed

No +/- 3% power trim max ratings provided

C18 D&E tier ratings being developed

to Tier II

shooting for max E rating 800-hp?

Common Look Price Lists

1800 vs 2100 RPM

Take Advantage of Flat HP Curve


Better BSFC
Lower Heat Rejection

Fuel Consumption @ 1800 RPM


6% @ Full Load

7% @ 75%

Heat Rejection @ 1800 RPM

Jacket Water Heat Rej.


Total BTU's
BTU/HP
Charge Air Heat Rej.
Total BTU's
BTU/HP

Jacket Water Heat Rej.


Total BTU's
BTU/HP
Charge Air Heat Rej.
Total BTU's
BTU/HP

C-16 Tier 2
600 HP "C"
2100 RPM

C18 Tier 3
630 HP "B"
1800 RPM

9099
15.17

9611
15.26

1%

4896
8.16

5880
9.33

13%

C-15 Tier 2
525 HP "C"
2100 RPM

C15 Tier 3
540 HP "C"
1800 RPM

8644
16.46

8246
15.27

-8%

3935
7.50

4811
8.91

16%

Tier 3 Net
Change

Tier 3 Net
Change

A-E Tier Industrial Ratings As Is


Current process
outdated
Ratings Developed
Generically
Limited Criteria
Typically Conservative
Biased to High Hours to
Overhaul

A-E Tier Industrial Ratings To Be

Calculator
Options
Tier Deviation Request
Use ET History
A&I Approval
Filed in OSI

Installation Parameters T3 vs T2
Tier 3

Tier 2

Inlet Air Restriction


(Max)

3 kPa

3.7 kPa

Air Filter Restriction


Indicator (Max)

6.6 kPa

7.5 kPa

Total Restriction (Turbo


to Manifold)

15 kPa

13.5 kPa

49 deg C

49 deg C

104 deg C

99 deg C

10 kPa

6.7 kPa

Intake Manifold Temp


@ 25 deg C ambient
Cooling System Top
Tank Temperature
Exhaust backpressure

ACERT ECM

ECM change from A3 to A4 control platform


4x Processing speed and 2x memory increase from A3
6 20 Cylinder engine support
12 / 24 V operation
140 Watts power (65 % increase)

Additional valve drivers and


sensor inputs
More fuel maps to optimize
ACERT Technology

ACERT ECM
Package
Same X-Y dimensions as A3, some growth in Z
Same A3 70 Pin OEM Connection
New 120 Pin Engine Connection
Air Cooled Option *
Air Cooled Package

Fluid Cooled Package

* Fluid cooled ECM standard OEM installation audit required to


offer air cooled option

ACERT Software Strategy


OEM

interface to ECM

ECM

direct connect

Same ECM 70 pin connector as tier 2

Some pin assignment changes from tier 2

OEM

harness

Option in price list

Same 40 pin connector pin assignment as tier 2

Common

electronics from C4.4 C32

Additional
Full

hard wired control interfaces

machine integration (CAN J1939)

Engine Control Updates


Throttle input strategy
Multi-throttle
Configures
Available

capability

throttle input priority

for test Jul 04 / production Jan 05

Engine control system options


Full

range governor

Min

max governor

Available

for test May 04 / production Jan 05

Engine Control Updates


Speed Droop Control

Simulates mechanical fuel system performance

Adjustable from 0-10% droop

Available for test Aug 04 / production Jan 05

Electronics Publications
Electrical & Electronic Application & Installation Guide
Engine Literature #

Release

C7 C32 LEBH 4623

Late Jul 04

Troubleshooting Guide
Engine Literature #

Release

C7

1st Prod (Jul 05)

C9

1st Prod (Oct 04)

C11/C13

1st Prod (Jul 04)

C15/C18

1st Prod (Jul 04)

C27/C32

1st Prod (Jul 05)

Electronics Publications
Schematic : Industrial Engine Electrical System
Engine

Literature #

Release

C7

RENR tbd

1st Prod (Jul 05)

C9

RENR 7948

1st Prod (Oct 04)

C11/C13

RENR 8045

1st Prod (Jul 04)

C15/C18

RENR 8046

1st Prod (Jul 04)

C27/C32

RENR tbd

1st Prod (Jul 05)

Electronics Information
A&I

Electronics Web Site


Information
Web

updates prior to manual publication

site location:

Power Net -> Industrial -> Application & Installation -> Electronics
(https://engines.cat.com/infocast/frames/industrial/appinst/electronics)
Tier

2 Documentation

Use

tier 2 documentation for wiring instructions

Check

ASC

A&I web site for any special wiring or feature instructions

Help Desk
Call

help desk for information not on web site or in published documentation

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

* Proposed PGN list and program timing


available on PowerNet

Questions?
Power Net
ASC

Rob Johannsen, Product Manager, LPS