ACERT™ Technology for 2007 Delivers Customer Value
Enhancements Provide Durability, Fuel Economy, Longer Life-to-Overhaul

The ACERT™ Technology employed by the new Caterpillar^® engine line for 2007 remains a systems solution, refined to meet the more stringent 2007 Environmental Protection Agency (EPA) emissions regulations. Two major enhancements—a refined combustion process called Clean Gas Induction (CGI) and a self-regenerating Diesel Particulate Filter (DPF)—ensure that Cat^® engines meet the 2007 emissions regulations without sacrificing the reliability, durability and fuel economy advantage Caterpillar engines always have delivered, according to Greg Gauger, director, Caterpillar On-Highway Power Systems.

"The four basic systems of ACERT Technology—air management, precision combustion, advanced electronics and effective aftertreatment—are the foundation of our 2007 technology path," Gauger said. "The addition of CGI and the new diesel particulate filter will allow us to meet the 2007 regulations while still providing today's longer life to overhaul, best-in-class fuel economy and the reliability you expect from a Cat engine—all of which contribute to higher resale value."

Clean Gas Induction (CGI)
One of the major system enhancements for 2007 is a refined combustion technology that reduces both oxides of nitrogen (NOx) and particulate matter in the cylinder. Clean Gas Induction (CGI) is a proprietary ACERT Technology process that draws off a small amount of non-combustible gas after it passes through the engine's aftertreatment system. The gas is then cooled, blended with more incoming cool, clean air and returned to the combustion chamber.

The difference between CGI and the technology employed by competitive
engines—cooled exhaust gas recirculation (EGR)—is that cooled-EGR sends unfiltered exhaust back through the system, which exposes engine components to high levels of soot that contribute to shortened engine life, according to Gauger.

"CGI has been in development at Caterpillar for several years—it is part of the original ACERT Technology strategy to further reduce emissions for 2007, while maintaining the reliability and durability engine owners need," he said. "Rather than re-introducing dirty, sooty exhaust back into the system, CGI simply uses more cool, clean air to reduce combustion temperatures and achieve the necessary reduction in NOx and particulate matter."

CGI will enable Caterpillar heavy duty engines for 2007 to provide the same level of fuel economy as today's engines, while mid-range products will deliver up to four percent improved fuel economy. Horsepower ratings also will remain the same as today's engines. And, service intervals for Caterpillar engines will remain the same as today's products, according to Gauger.

Diesel Particulate Filter (DPF)
All engine manufacturers will be required to include some form of diesel particulate filter (DPF) to meet the 2007 regulations. The 2007 Cat engines will feature a new, Caterpillar-manufactured DPF. This design uses wall-flow technology—a ceramic brick substrate allowing the particulate matter, or soot, to be captured in cells in the wall. The exhaust gas then exits as clean exhaust consisting of carbon dioxide and water. The Cat DPF employs active regeneration, which means that when the temperature of the engine isn't high enough to oxidize (burn) the soot that collects in the DPF, the exhaust gas is heated by auxiliary means. The Caterpillar design will automatically regenerate under all conditions without any driver involvement

Cat Regeneration System (CRS)
To regenerate, any DPF requires a temperature up to 1,200 degrees Fahrenheit. The industry is exploring technology options to cause regeneration in the DPF. The Caterpillar DPF will use a technically unique process versus competitive products to produce regeneration. Caterpillar's solution is the Cat Regeneration System (CRS), a process similar to a gas-fired furnace in which fuel is introduced into a closed combustion chamber, rather than being injected directly into the DPF. When the engine ECM detects soot buildup, CRS automatically uses only the precise amount of fuel necessary to heat and oxidize the soot. CRS is completely safe and controllable; and provides the same reliability and durability as the engine because it's self-contained on the engine, according to Gauger.

"We wanted a product that would be able to regenerate under all conditions," Gauger said. "We designed a process to allow our product to accomplish this safely, without the risks created by dosing."

DPF Soot Removal
Since a certain amount of ash collects in the DPF, it needs to be cleaned periodically. The Cat DPF can be serviced without removing it from the vehicle. A special ash collection tool results in less downtime since it only takes roughly the same time as an oil change. The service interval is projected to be approximately 200,000 to 300,000 miles, depending on application.

As a Caterpillar-manufactured part, the DPF is serviced through the genuine network, which includes Cat and authorized truck dealers, and is covered by the company's base warranty. The DPF provides sound attenuation and replaces the conventional muffler on the engine, as well as eliminating the need for today's diesel oxidation catalyst.

"Caterpillar's DPF offers some real advantages in terms of service over competitive products," Gauger said. "It provides easy clean-out and the Cat Regeneration System process allows safe, quick regeneration in all conditions."

Caterpillar Announces On-Highway Engine Line for 2007

The new Caterpillar^® on-highway engine line is comprised of four models—the C7, C9, C13 and C15—all equipped with the company's ACERT™ Technology for 2007. These engines will be available to order beginning in fourth quarter 2006.

"The new engine line demonstrates that Caterpillar continues to deliver on the promises made when ACERT Technology was first introduced," said Greg Gauger, director, Caterpillar On-Highway Power Systems. "Cat^® engines for 2007 meet the more stringent emissions regulations, while still providing customer value in performance and lower operating costs, with no loss—and in the case of mid-range, a gain—in fuel economy. And, they continue to provide the longer life-to-overhaul engine owners need to operate profitably."

The mid-range C7 engine provides truck and bus ratings of 190-300 hp at 2,200 rpm and recreational vehicle and fire truck ratings of 300-350 hp at 2,400 rpm. This 7.2-liter engine provides 520-860 lb-ft. of torque at 1,440 rpm. This versatile engine is a popular choice for a variety of medium-duty applications.

The C9 now provides heavy duty power with increased displacement for expanded horsepower ratings, more torque rating options and a Cat integral brake for heavy duty performance in a lightweight package. Ratings for this 9.3-liter engine include 285-350 hp at 2,100 rpm for truck and bus applications and 335-425 hp at 2,100 rpm for recreational vehicles and fire trucks. The C9 provides 890-1,350 lb-ft. of torque at 1,400 rpm. Caterpillar also will offer a 1,250 lb-ft. C9 rating for truck applications in 2007.

A new Cat Common Rail Fuel System optimizes the performance and fuel economy of the C7 and C9 engines, according to Gauger. "The new fuel system provides greater injection flexibility to help these engines comply with the more stringent 2007 emissions regulations, and even increases fuel economy by up to four percent over previous models," he said.

The new C13 is available in on-highway vocational and heavy duty line haul configurations for expanded versatility. This 12.5-liter engine delivers 1,150-1,750 lb-ft. of torque at 1,200 rpm. It provides vocational truck ratings of 305-370 hp, line haul truck ratings of 380-470 hp and recreational vehicle and fire truck ratings of 485-525 hp, all at 2,100 rpm. "The new vocational C13 will provide higher torque, better response, improved driveability, automatic transmission compatibility, and higher compression braking," Gauger said. "This allows Caterpillar to offer a version of the C13 that exceeds current vocational customer requirements while still meeting emissions regulations at a competitive price."

The heavy duty, 15.2-liter C15 provides the highest horsepower and torque rating in the industry, with the 625 hp "King of the Hill." Truck and bus ratings range from 435-625 hp at 2,100 rpm, with recreational vehicle and fire truck ratings of 600-625 hp at 2,100 rpm, with torque ratings from 1,550-1,850 lb-ft. and a "King of the Hill" torque rating of 1,850-2,150 lb-ft., both at 1,200 rpm.

Issue 41 05/01/06
To learn more about Caterpillar On-Highway Engines, please visit:
http://www.cattruckengines.com/.