Emissions & Fuel Systems Advanced Power Train
Clean Air Act Date 1970
Congress Creates Environmental Protection Agency (EPA)
1990
Clean Air Act Amendments Mandated Regulation for Nonroad Equipment
1996
Nonroad Regulations Become Effective - US and its territories (Puerto Rico, Guam, District of Columbia, the Virgin Islands, American Samoa, and the Commonwealth of the Northern Mariana Islands) - Engines must be Certified - Machines must be equipped with Certified Engines
Environmental Regulations CO2
BACT 9 LAER
72
ppm
NOX
PM
MW-hr 2 5
145
42
96
Tons/yr
48
215 UHC
Technology of Power HP/L
Emissions
HP/Liter
40
Particulates (?/HP-HR)
50
2X
30 20 10 0 1970
1980
1990
10 8
5X
6 4 2 0 1970
2000
1978
1988 Nox
Part.
50
0.40
Efficiency %
BS FC-LB-HP-HR
2004
60
0.50
0.20
1998
Thermal Efficiency (Diesel)
Fuel Economy
0.30
1991
2X
0.10
40 30 20
2X
10
0.00 1930 1940 1950 1960 1970 1980 1990 2000 Production
Research
0 1930 1940 1950 1960 1970 1980 1990 1998 2000
Technology Drivers
EMISSIONS
Sociability
Customer TARGET
OWNING & OPERATING COSTS
Regulated Diesel Emissions Particulate Matter (PM) Carbon from incomplete combustion Soluble organic fractions from the fuel & lubricating oil Sulfates formed from the sulfur in the fuel
Nitrogen oxides (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)
Non Road Emissions Limits - USA Tier 1
Tier 2
Tier 3
<25 hp 25-50 hp 50-100 hp (3054&6) 100-175 hp (3116) 175-300 hp (3306) 300-600 hp (3406) 600-750 hp (3408) >750 hp (3500)
Year
96
97
98
99
00
01
02 03
04
05 06 07 08
PM g/hphr
Non Road Emission Limits - USA
NOx (+HC) g/hphr 12
1.2 1
10 8
0.8
Unregulated
Tier 1
0.6
6
Tier 2
4
1990
0.4
Tier 3
2
0.2 0
1995
2000 Year
2005
09 10
2010
NOx (+HC) PM
Environmental Benefit & Cost EPA estimates that by 2010, NO X emissions will be reduced by about 1 million tons per year; the equivalent of taking 35 million enger cars off the road.
Emission Reduction Building Blocks Combustion Systems Increase Injection Pressure Increase Fuel/Air Control Improve Oil Control Air Motion
Cooler Inlet Air Increase Timing Control
Turbos
Fuels
After Treatment
Increase Cylinder Pressure Inlet Tuning
Electronics
Heat Rejection
Exhaust Gas Recirculation
Emissions R & D Piston Crown
Modeling Simulation
Improve Fuel efficiency Emissions Reliability
Laser Cutting Injector Holes
Casting Core
Engine Research & Development
What % of Engine R&D is spent on emissions?
66%
Development - Alternate Fuels Utilize diesel cycle with range of fuels. Methanol
Diesel or Biodiesel
Ethanol
Water-Fuel Emulsions
Coal Gas
"Flex Fuel" Methanol-Diesel or Gasoline-Diesel
Hydrogen
Propane Natural Gas
Focus On Fuel
Co develop low emission diesel fuel Complementary fit between leaders in diesel engine and chemical technologies New low emission diesel fuel/water blends & blending technology called - PuriNOx No modifications to fuel systems or engine hardware required Estimated reductions of NOx by 5 to 30% & PM by 20 to 50% Currently being tested in a variety of Cat engines and different machine applications
Major Development Programs
EMISSIONS
Sociability
Diesel technology
Alternative fuels
Development process
New concepts Customer
TARGET
OWNING & OPERATING COSTS
The Works And Wears of Fuel Systems
What We Are Going to Talk About
History Types of Fuel Systems Fuel System Applications Differentiation Works & Wears Reman Additional Resources
Caterpillar Products Solar Turbines
Track-Type Tractors
Track-Type Loaders Wheel Loaders
Engines Wheel Tractors and Compactors
Integrated Toolcarriers
Forest Machines
Excavators
Agricultural Equipment
Mining Shovels Fuel Systems
Paving Products Backhoe Loaders
Trucks Scrapers Motor Graders
What does a Fuel System do?
Meters the amount of fuel to achieve desired power Regulates engine speed and timing sequence Helps control emissions
Fuel System History • Electronic Unit Injectors (Hydraulic) • Electronic Unit Injectors (Mechanical) • Electronic Engine Controls • 3600 UI- World’s Largest • 15,000 PSI Pump & Line •Unit Injector • 7000 Series Nozzle • Sleeve Metering System • Direct Injection • Auto-Timing Advance •En-Bloc System • Fuel/Air Ratio Control •Capsule Nozzle • First Cat Fuel System
1930
1940
1950
1960
1970
1980
1990
2000
The Combustion Process
Air Compressed 1/16 original volume Heats up to 1,000 degrees Fahrenheit Cylinder pressures up to 2200-2700 psi Air volume constant- fuel variable
Intake
Compression
Combustion
Exhaust
The Combustion Process
Types of Fuel Systems
Direct Injection- Pump & Line Sleeve
Metering Current Scroll Fuel System New Scroll Fuel System
Unit Injection MUI EUI HEUI
Pre Combustion & Gas
Fuel Systems Applications Engine Engine 3600 3500 3408 3408 3406 3176 3300 3200 3100 3064 3064 3054 3054 3046 3003 3003 3600 3500 3406 3176 3300 3200 3100 3046 3034 YEAR 3412 3066 3056 YEAR 3412 3066 3056 3034 1993 1993 1994 1994
MUI MUI
MUI CSFS NSFS EUI NSFS P&L 3116 Zexel Stana- Nipp- Zexel MUI CSFS NSFS EUI NSFS P&L 3116 Zexel Stana- Nipp- Zexel NSFS SMFS MUI In-line dyne ond. NSFS SMFS MUI In-line dyne ond. Lucas Lucas EUI 3126 EUI 3126 HEUI All Pump & Line Systems HEUI All Pump & Line Systems
1995 1995 1996 1996
EUI EUI
HEUI HEUI
1997 1997 1998 1998
3196 3196 EUI EUI
Fuel System Service Strategy
Past Strategy: If Caterpillar makes it, dealers can service it.
CCE Engine Strategy: Caterpillar will provide systems that dealers can service cost effectively. This may not include service at the piece part level on inexpensive components.
Fuel System Differentiation
Pump Pump&&Line Line CSFS CSFS NSFS NSFS Sleeve Sleeve Stanadyne Stanadyne Nippondenso Nippondenso Zexel Zexel Lucas Lucas Unit UnitInjector Injector MUI MUI EUI EUI HEUI HEUI
INJECTION INJECTION PRESSURE PRESSURE (psi) (psi)
INJECTION INJECTION TIMING TIMING
INJECTION NOISE FUEL INJECTION EMISSION EMISSION NOISE FUEL RATE CAPABILITY EMISSIONS CONSUMPTION RATE CAPABILITY EMISSIONS CONSUMPTION SHAPE SHAPE
14,000 14,000 18,000 18,000 10,000 10,000
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
Fixed Fixed Fixed Fixed Fixed Fixed
TIER TIERII TIER TIERII None None
Low Low Low Low Low Low
Med Med Med Med Med Med
14,000 14,000
Mechanical Mechanical
Fixed Fixed
TIER TIERII
Low Low
Med/High Med/High
30,000 30,000 30,000 30,000 23,000 23,000
Mechanical Mechanical Electronic Electronic Electronic Electronic
Ramp Ramp Ramp Ramp Variable Variable
TIER TIERII TIER TIERIIII TIER TIERIIII
High High Med-high Med-high Low Low
Med-low Med-low Low Low Med-low Med-low
Sleeve Metering Fuel System
X
Direct Injection - Scroll Metering
Features Pump & line govenor Few moving parts Simple mechanical govenor Fuel lubricates
Benefits Easy starting Easy to service More tolerant of dirt Economical Easily replaced
New Scroll Fuel System
New Scroll vs. Current Scroll (Old)
Old
New
New Scroll vs. Current Scroll (Old)
Old
New
Unit Injection - MUI
Features Mechanically actuated/controlled Mechanical governor connected to unit injectors via mechanical linkage Unit injectors deliver fuel at 20,000 psi
Benefits High reliability Long life
Unit Injection - EUI
Features
Mechanically actuated Electronically controlled Variable fuel delivery Virtually adjustment free Serviceable components • injectors • electronic sensors • harnesses • connectors • ECM
Benefits
Improved engine starting Precise engine speed control Reduced exhaust black smoke Faster cold starting Improved fuel economy
X
Unit Injection - HEUI
Features
Hydraulically actuated Electronically controlled Injection pressure independent of RPM
HEUI Injector
X
Unit Injection - HEUI
Benefits Higher performance Faster cold starts Lower exhaust emissions Lower engine noise Better fuel economy Higher serviceability Increased reliability
HEUI System Operation
HEUI Nozzle Tip Splitting Due to Tip Fatigue
Improved tip processing – 12/96 Reduced check lift – 3/97 Thicker wall to increase tip strength – 6/97 Dampened check reduces check impact loads – 5/98
Nozzle Tip Breakage Due to Installation Side Load
Improved tip processing – 9/98 Injector tip bore cleaning – 7/98 New gauge and brush Instruction wrapper Improved packaging – 12/97 Special instructions REHS0116-02 included – 9/97
Broken Tips are normally retained in injector
Solenoid Post Loosening Due to Vibration
Added epoxy matrix to terminal posts – 3/99 Rubber washers no longer required Added Material
NEW
OLD
Solenoid Failure Due to Internal Shorting
Frayed wire insulation vibration Bondable wire implemented – 3/98
Bondable Wire
Cavitation Erosion of the Poppet Valve Seat
New software during low delivery, low load operating conditions – 7/97 Typical Cavitation Erosion
Major Improvements for the 3408E and 3412E Service Magazine Article, April 1999 Seal kits for HEUI pump groups available Troubleshooting hard starting 129-0372 primary fuel filter/water separator assembly New o-ring seal improves engine initial combustion gas sealing Improved fuel injectors reduce carryover Correct procedure for installation of HEUI New Injector now available
Proper Fuel System Maintenance
Repair fuel systems in a protected environment
Always install new fuel filter
Do not pre-fill filter, use priming pump
Do not remove injector from package until ready for installation
Return failed injector in replacement injector packaging
Always buy clean fuel
Transport clean fuel in clean containers
Use Caterpillar high efficiency (2 micron) fuel filters
Proper Fuel System Maintenance
Plunger Wear
Stay-Clean Valve
Prevents Pre-Filling
Eliminates Entry of Unfiltered Fuel Into the Fuel System
Fuel Water Separator
Benefits Best-in-Market Water Separation Debris Retention Extends Secondary Filter Life
3054 3056 3114 3116 3126 3176 3204 3208 3304 3306 3406 3408 3412 3508 3512 3516 3606 3608
HEUI
Timing Advance
Fuel/Air Ratio Controls
EUI
MUI
DIFN
Governors
Fuel P & G
Fuel Transfer Pumps
Remanufactured Fuel System Components
X X X X
X X
X X X X X X X
X X X X X X X X X
X
X X X X X
X
X X X X X
X X X
X X X
X X X
Reman - Value
High Quality Remanufactured products Priced at 50% of corresponding new 7000 Series Fuel Nozzles - No price adjustment since 1997 Higher direct purchase program pricing
Additional Resources CD’s
Cat Power Pro Sleeve Metering Fuel System :LERV9802 (CD) Caterpillar HEUI HI300 Fuel System Fuel System and Electronic System Operation and Troubleshooting: RENR1390-01 (CD) Caterpillar EUI Fuel System Fuel System and Electronic System Operation and Troubleshooting: RENR1391-01 (CD)
Videos
Datasheet The New Caterpillar 3408E and 3412E Engines HEUI Fuel Systems LEVN3547 (Video) PEHP9526-01 The HEUI Fuel System LEVN3545 (Video) Caterpillar Intranet site: http://www.pont.cat.com/ Caterpillar Power Train Customer Meeting Package PEKP6026-01