ACERT Technology

for Off-Highway C15

Engines
TM

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

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

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What is ACERT Technology?

Multiple technologies
Varies by engine family
Varies by engine application
Medium duty specs,
changes, new design
Heavy duty specs, changes,
new design

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How is the C15 Affected?

C15 ACERT is based off the C-15 platform
Displacement changes from 14.6 to 15.2 ltr.
Bore remains 137mm
Stroke increases to 171mm from 165mm

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C15 ACERT

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Performance Ratings- HP*

Machine Rating

C15
1800-2100 RPM

A
B
C
D
E

440
475
540
580
595

*Preliminary, subject to change

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C15 Power Band

Performance
2100 rpm provides

1800 rpm provides

Best fuel economy
Best heat rejection
Less noise

A
B
C
D
E

POWER

Widest operating
range
Easiest match in
changeover

1300

1500

1700

1900

2100

RPM

Full Power from 1800 to 2100 rpm

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C15 / C18 Heat Rejection

EPA
Tier 3
Tier 3
Tier 2

Engine
C18
C18
C-16

Hp
630
630
630

RPM
1800
2100
2100

Jacket Water
JW* % Change
0.36
0.0%
0.38
5.6%
0.36

Tier 3
Tier 3
Tier 2

C15
C15
C-15

540
540
525

1800
2100
2100

0.36
0.38
0.39

-7.7%
-2.6%

Air
Air
% Change
0.22
10.0%
0.24
20.0%
0.2
0.21
0.23
0.18

16.7%
27.8%

Changing from 2100 rpms to 1800 DECREASES heat rejection

in the C15 and maintains same heat rejection in the C18
C15 / C18 ACERT

* kW of heat rejection per kW

of engine powerjacket water

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C15 / C18 Fuel Efficiency

EPA
Tier 3
Tier 3
Tier 2

Engine
C18
C18
C-16

Hp
630
630
630

RPM
1800
2100
2100

BSFC
219
228
209

% Change
4.8%
9.1%

Tier 3
Tier 3
Tier 2

C15
C15
C-15

540
540
525

1800
2100
2100

217
223
208.6

4.0%
6.9%

Changing from 2100 rpms to 1800 fuel economy is

maximized in the C18 and C15
C15 / C18 ACERT

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Engine Features
C15 ACERT

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Design Strategy
ACERT technology
Few external changes
from Tier 2 / Stage II
Proven heavy duty
workhorse
Easy changeover from
Tier 2 / Stage II
Excellent power density

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Design Strategy
ACERT technology
Externally similar to C-15
One installation for wide
power range
Best in class power
density

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Design Strategy
Increased displacement
C15 increase from 14.6 to 15.2 liters
Supports higher ratings
C15 provides wide power range from a
single installation
Increased power density allows higher
power without increasing machine
weight
More production from same size package

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Design Strategy
Increased compression ratio
C15 - 18:1 compression ratio
Component changes to increase peak
cylinder pressure capability
Improves cold start characteristics
Improves white smoke clean up time
Optimizes ACERT performance

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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

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ACERT Multiple Injection

Capability
MEUI and ADEM 4
TM

Variable injection timing

Controls quantity of fuel
Optimizes fuel pressure
Transient control for
both speeds and loads

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Camshaft Changes

Extra

bump on the injector lobe

Difficult

to see but it can be felt

Facilitates
Injector

pilot injection capability

lobe profile varies depending on HP rating

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Fuel System
Mechanical Electronic
Unit Injector
Proven design
Proven high reliability

Enhancements
Multiple injection
Rate shaping

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ADEM 4 Electronic Engine

Control
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

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ADEM 4 Testing In
Extremes
Extreme
temperature
test
Vibration test
Salt spray test
Electrostatic test

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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 efficiency

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ADEM 4
No change in OEM / machine
interface
Worldwide service network
Using Cat ET
Common electronics from
C6.6 C32

Allows greater protection and

prognostics
Full machine integration
(Canbus, J1939, etc.)

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New ADEM 4 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

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New ADEM 4 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

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Head bolt torque sequence

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Head Bolt Torque Procedure

Tighten

bolts 1-26 in sequence to 270 +/- 15 Nm

Tighten

bolts 1-26 in sequence to 450 +/- 15 Nm

Retighten

bolts 1-26 in sequence to 450 +/- 15 Nm

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Turbocharger
Wastegated turbocharger
Provides higher boost over
wide range

Single turbo
Improves engine
response
Outstanding low end
performance
Improved peak torque

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Turbocharger Wastegate Function

Boost

Elevated BMEP

Improved Response

RPM

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Turbocharger Wastegate Function

Wastegate Active Reduced BMEP

Wastegate
Boost

Boost

RPM

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Cat Compression Brake

Some models equipped with Cat Brake
Developed and manufactured by Caterpillar
Functionally similar to previous compression
brakes

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C15 Compression Brake

Oil Flow Schematic
Cylinder 1

Check valves

Drain line

Cylinder 2

Actuator valve

Slave piston

Master piston

Oil Sump

Engine supply oil

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Cat Brake Installation

6

Tightening Sequence

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Valve Cover Base Installation

Tighten to 18 +/- 3 Nm in numerical sequence

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Cat Brake Lash Setting

Set

Cyl. 1 to TDC compression

Set

lash on cylinders 1, 3, and 5 to specification

Tighten
Rotate
Set

locknuts to 15 +/- 3 Nm

crankshaft 360 deg in direction of rotation

lash on cylinders 2, 4 and 6 to specification

Tighten

locknuts to 15 +/- 3 Nm

Recheck

lash setting
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Injector and Valve Lash

Setting Notes
Valve

lash set with engine cold and stopped

Valve

lash adjusting screw locknut torqued to 30 +/- 7 Nm

Injector

Height Gauge 9U-7227

Injector

height adjusting screw locknut torqued to 100 +/-

10 Nm

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Injector and Valve Lash

Setting Procedure
Set

Number 1 piston at TDC compression

Set

intake valves on cylinders 1, 2 and 4

Set

exhaust valves on cylinders 1, 3 and 5

Set

unit injector on cylinders 3, 5 and 6

Turn

crankshaft 360 degrees (direction of engine rotation)

Set

intake valves on cylinders 3, 5 and 6

Set

exhaust valves on cylinders 2, 4 and 6

Set

unit injector on cylinders 1, 2 and 4

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Piston
Monotherm 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

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Piston Ring Installation

Install

top and intermediate rings with up

marking towards top of piston

Orient

piston ring gaps 120 degrees apart

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C15 Piston Assembly

Piston is a one piece design.

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Connecting Rod
Increase rod diameter
Drilled rod for lubrication
4 bolts improve clamping
Designed for durability
Compliments ACERT

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C15 Connecting Rod

Assembly
Connecting
rod cap uses
four bolts

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Rod Bolt Torque Sequence

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Connecting Rod Bolt Torque

Lubricate bolts with engine oil before assembly
Torque bolts 1 and 3 to 70 +/- 4 Nm
Torque bolts 2 and 4 to 70 +/- 4 Nm
Turn bolts 2 and 4 an additional 60 +/- 5 degrees
Retighten bolts 1 and 3 to 70 +/- 4 Nm
Turn bolts 1 and 3 an additional 60 +/- 5 degrees

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Hardened Plateau Honed

Liner
Two step honing process:
- Cuts deep grooves for oil
retention
- Smoothes the tops off to
reduce wear and better contact
Reduces blow by
Improves oil control and
consumption

Smooth Surface

Deep Cuts

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Leak Free 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

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Specifications

C15 ACERT

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Specifications
Model

C15

Rated RPM

1800-2100

Displacement

15.2 Ltr. (927 cu. in.)

Bore

137 mm (5.4 in.)

Stroke

171 mm (6.7 in.)

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Specifications
Model

C15

Length

1651 mm (65 in.)

Width

889 mm (35 in.)

Height

1346 mm (53 in.)

Weight

1335 Kg. (2937 lb.)

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560

1900

540

1800

520

1700

HP

500

1600

480

1500

460

Power
Torque

1400

440
420

1300

400

1200

1200

LB-FT

C15 Power Curve

1400

1600

1800

RPM

2000

2200
* All C15 / C18 ACERT
ratings are preliminary

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Maintenance 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 Cats new high efficiency oil
filter
S.O.S. sampling

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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

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C15 vs. C-15

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C15 ACERT vs. C-15 Tier 2

Model
C15 ACERT
Rated Power
540 HP
Max RPM
2100
Displacement
15.2 L
Bore
137 mm
Stroke
171 mm
Size (LWH)
65 x 36 x 53 in
Weight
2937 lb
Power Density
5.44 lb / hp

C-15
525 HP
2100
14.6 L
137 mm
165 mm
59 x 36 x 50 in
2959 lb
5.64 lb / hp

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Power Curves
560
540
520
500

C15 ACERT

480

BHP

C-15

460
440
420
400
00
22

00
21

00
20

00
19

00
18

00
17

00
16

00
15

00
14

00
13

00
12

RPM

* All C15 / C18 ACERT

ratings are preliminary

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Torque Curves
1900
1800

LB-FT

1700

C15 ACERT
C-15

1600
1500
1400
1300
1200
00
22
00
21
00
20
00
19
00
18
00
17
00
16
00
15
00
14
00
13
00
12

RPM

* All C15 / C18 ACERT

ratings are preliminary

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