Competitive Analysis

UPDATE

EGR

vs. TM

ACERT
Whats New In The Update

Page 4 Explanation of ACERT Engine Identification

Page 6 Coolant Diverter Valve

Page 7 All Information

Page 8 All Information

Page 10 Two Diesel Oxidation Catalysts Required

Page 12 All Information

Page 13 All Information

Page 15 Additional Information

Page 16 250,000 Mile Engine Teardown

Page 17 Additional Information

 To Meet
The Emission
Why Doesnt

Requirements CAT Use EGR?

Of October 2002,
Different Engine According To Independent Industry Analysts
Manufacturers
Took Different
Approaches.
CAT Has No Choice.
Cummins adapted CAT cant use EGR due to the many
EGR into their new
series of engines. engines they sell off-highway, and
Volvo and Mack also without ram air, they cant make EGR
chose EGR as the work in slow moving off-highway
best solution.
DDC, with direct
applications. CAT is first a
access to worldwide construction equipment company,
engineering and
advanced technology and second an engine supplier. CAT
through DaimlerChrysler, has to meet the Tier III off-highway
Mercedes-Benz, MTU
and VM Motori, emissions standards in the 300 to
engineered existing 750 HP category in 2005, and cannot
technology into a
proven platform, the use cooled EGR. As a result, they
Series 60 engine and have to go their own way. ACERT is
met the 2002 emission
regulations using EGR. an off-highway based technology that
CAT delivered engines CAT has to adapt for on-highway use.
that did not meet The rest of the world, not handcuffed
emission guidelines and
paid fines, introduced as CAT is, has chosen EGR.
the Bridge engine,
and will launch the
heavy-duty ACERT
engine line-up sometime
in late 2003 and 2004.

1
Detroit Diesel Has Detroit Diesel has the
luxury of looking at,
benchmarking, testing,
Access To A and experimenting with
all kinds of technologies.

Number Of Engine Detroit Diesel is not

married to any particular

Technologies technology and can

provide the best
technology for any given
Worldwide, From
application.
Detroit Diesel already
makes engines with
common rail fuel
injection, sequential
turbocharging, multiple
turbochargers, different
electronics, and a
number of other diverse
technical features.
Detroit Diesel does not
follow the one size fits
all philosophy. CAT, on
the other hand, has no
choice. CAT cannot
share in the continuing
worldwide development
of EGR and other
technologies.
All the other engine
manufacturers, including
Detroit Diesel, are free to
choose and use all sorts
DaimlerChrysler, of technologies,
including all of the ones
being used by CAT, if
Mercedes-Benz, they choose to do so.

VM Motori, MTU,
And Detroit Diesel
On- And Off-Highway
Businesses.
2
 What Exactly Is ACERT ?
TM

ACERT Is A Compilation Of Seven Different Technologies.

1 Basic Engine Design Changes

2 Additional Components In The
Air Intake System

3 An Additional Cooler In The

Cooling System

4 Electro-Hydraulic
On The Camshaft
Actuators

5 A New Fuel System

6 Different Electronic Controls
7 And The Addition Of
Aftertreatment Devices In The
Exhaust System, Called
Diesel Oxidation Catalysts.

3
 1Basic Engine Design
ACERT requires larger engine
displacements. CAT has
Note Pre-ACERT engines are identified with
a dash between the C and the displacement
changed the name and indicator, C-12 for example. ACERT engines
displacement of almost all of are identified without a dash, C13 for example.
its on-highway engines.

3126 Becomes C7 7.2L (no change)

C-9 Becomes C9 8.8L (no change)
C-10 Becomes C11 11.1L (was 10.3)
C-12 Becomes C13 12.5L (was 11.9)
C-15 Becomes C15 15.2L (was 14.6)
C-16 Becomes C18 18.1L (was 15.8)
The increased displacements
of the old C-10, C-12, C-15 and
C-16 were accomplished by an
increase in stroke. Increased
stroke means increased piston
speed and increased sliding friction
between the piston rings and
cylinder wall. Increased sliding
friction inherently results in
increased wear and reduced
fuel economy.

0 1 2 3 4 5 6 7
INCHES

The stroke of the C18 is 7.2 inches, meaning the piston and rings
must travel 28.8 inches for each power stroke.

In Addition, The C13 And C15 Also Require

A New Piston And Cylinder Head Design.

4
2 New Air Intake System
ACERT requires two turbos
for all CAT models except
C7 and C9. The twin turbos
are required in order to provide
the increased flow and pressure
necessary to make ACERT
work. The second turbo
is equipped with an
electronically controlled
wastegate.

The complexity of two turbos

and an electronic wastegate

5
3New Cooling System
Components
Compressing the air twice and
passing it through two turbos
adds extra heat to the air.
This is why CAT has to use
jacket water aftercooling (JWAC)
in addition to air-to-air charge
cooling. An electronically
controlled coolant diverter valve
is also required to regulate coolant
flow through the cooler.

Jacket Water
Aftercooling
On the C15, the JWAC must be
removed to service the water pump.
6
4Electro-Hydraulic Actuators
ACERT also requires an electro-
hydraulic actuator for each intake
rocker arm bridge, six in all.
These actuators open the intake
valves, independent of the
camshaft. At 1800 rpm, these
actuators open each pair of intake
valves 30 times a second. The
purpose of these actuators is to
create a "Miller cycle" effect in the
cylinder. Ralph Miller invented the
Miller cycle in the 1940s for light
duty gasoline applications. In a
typical diesel engine, the intake
valve is closed as the piston
begins the compression stroke,
and the piston compresses the
air above it.
In a Miller cycle engine, the
intake valve is held open by an
additional device, in the case of
ACERT, the electro-hydraulic
actuator, and high-pressure air
is allowed to continue to enter
the cylinder as the piston
moves upward.
Miller Cycle Designs have been
used in some low speed diesel
engines in ships and electric
power generating plants.

DDC is very familiar with the advantages

and disadvantages of the Miller cycle.
Daimler Benz, at the 1998 SAE
International Congress and Exposition,
presented the following paper.

7
The Miller Cycle
There are several disadvantages cruise at 1350 rpm or lower.
to the Miller cycle, including Caterpillar also recommends that
added weight, added drivers allow engine speed to
complexity, the need for two drop to 1000 rpm before
turbochargers, high pressure downshifting. Water and oil
in the air intake system which pumps, sized to provide
requires more sophisticated adequate flow at low
clamps, pipes and hoses, and engine speeds, become
increased structural inefficient at higher speeds.
requirements for the charge air Such low engine speeds reduce
cooler. The ACERT system uses vehicle performance and
up to 18 different joints in the air driveability and actually
intake system. encourage drivers to downshift
The primary disadvantage of the earlier in order to keep engine
Miller cycle is that it is efficient speeds higher. The Technology
only at relatively low engine and Maintenance Council of ATA
speeds. Caterpillar is has determined that drivers can
recommending that ACERT have up to a 30% impact on
powered vehicles be geared to fuel economy based on their
driving habits.
Lube
Pressure
Oil Rail
High
Pressure
Oil Rail
The Miller cycle is inefficient
at more normal, higher
engine speeds, which is why
no one else in the industry has
adopted this technology for
on-highway engines.
Other disadvantages of using the
electro-hydraulic actuators are:
Added complexity to
the tune-up process.
Six additional steps are
required, and on the C15,
the actuators must be
removed to set normal
valve lash. In addition, the
actuators must be adjusted
precisely in order to function
properly. The tune up
procedure for the actuators
includes the following
cautions: "The valve lash
setting process is extremely
important; please pay
particular attention to how
the settings are made; each
setting must be made in a
particular sequence; lash
settings are critical."
Finally, an external source
of oil must be provided to
power the actuators.
ACERT incorporates an oil
gallery in the rocker cover
base of the C15 and C13,
and includes an additional
electronic intake valve
actuator oil pressure sensor,
and an intake valve actuator
oil regulator valve to control
the flow of oil to the
actuators.
6 Of These
Electro-hydraulic
Actuators Are Required
5New Fuel System
Components
ACERT Requires Up To Five Injection Events Per Power Stroke:

1. Pilot Injection
2. Main Injection Step One ACERT also requires the use of
torsional dampers on the
3. Main Injection Step Two camshaft timing gear.
4. Main Injection Step Three
5. Post Injection

9
6New Electronics
To coordinate the activities between:

Basic Engine Operation

Turbocharger Wastegate
Electro-Hydraulic Actuators
Coolant Diverter Valve
Intake Valve Actuator
Oil Pressure Sensor
And 5 Injection Events
New Software Is
Being Introduced.

7New Aftertreatment
Device
ACERT requires the use of a diesel
oxidation catalyst (DOC), encased
in what looks like a muffler. Diesel
oxidation catalysts are costly to
install and replace.

Higher Displacement
ACERT Engines Require
Two Diesel Oxidation
Catalysts Per Vehicle. 10
 Can You Afford To Leave Up To 450
Pounds Of Every Load On The Dock?
The New Weights Of The ENGINES ALONE Are:
ACERT C13 MBE 4000 ACERT C15 Series 60 EGR
2256 Lbs. 2040 Lbs. 2944 Lbs. 2585 Lbs.
The extra turbocharger, piping, JWAC system, and electro-hydraulic actuators add 200 pounds to the weight of
the C13 and C15.
The weight of the diesel oxidation catalyst must be added to the weight of the engine-mounted ACERT
components to calculate the total increase in the weight of a vehicle with ACERT.

How Much Will ACERT Cost?

TM

From the March 24, 2003 issue of Transport Topics:

Caterpillars John Campbell/director of on-highway engine products,
acknowledged the exhaust catalyst was expensive and said its cost
would be built into the higher cost of Caterpillars ACERTS.
Caterpillars Parker [VP CAT Engine Business] said the company
would charge truck manufacturers substantially more for the ACERT
engines than for models it will replace. We intend to get a premium, a
significant premium, for it, and it is well-deserved.

TM

ACERT Availability
The announced dates of ACERT
availability are as follows:

C13 October, 2003

C11 December, 2003 C18 Sometime In 2004
C15 October, 2003

By The End Of 2003 Detroit Diesel Will Already Have Built

11
Over 40,000 EGR Equipped Engines!
 We Do Not View Caterpillars ACERT Engine
As A Significant Threat To EGR Engines.
We Believe Caterpillars Claimed Life Cycle
Cost Advantage Is Not Relevant.
We Remain Less Convinced That ACERT Will
Be Superior To What Competitors Are Providing.

The Most Important Part Of All!

Fuel Economy
In July Of 2003, A Major Carrier
Conducted Its Own SAE Test Of A C15
ACERT Engine VS. A Detroit Diesel
Series 60 With EGR. The Results?

At 45,000 GCW The Series 60 Used

3.9% LESS Fuel Than The C15.
At 75,000 GCW, The Series 60 Used
4.1% LESS Fuel Than The C15.
The Series 60 Was The Fuel Economy
Leader In 2001, And 2002, And It Still Is
In 2003 And Will Be In 2004! 12
 ACERT Summary
TM

Basic Engine Changes Aftertreatment

Crankshaft Diesel Oxidation Catalyst
Connecting Rod Two On C13 And C15
Piston Design
Availability
Cylinder Head
Increased Internal Friction Various Dates Have Been
Announced
Cam Timing Gear Dampers
Fuel Economy
Air System
Two Turbos Unknown
Electronic Wastegate Parts/Service/Training
Valve Operating Mechanism Unknown
6 Electro-Hydraulic Special Tools
Valve Actuators
Nine Additional Special Tools Required
Cooling System
Jacket Water Aftercooling Cooler
Tune-Up Procedure
and Plumbing More Complex
Water Pump Output Increased, Weight
Increasing Parasitic Losses
200 Pounds Additional Weight
Coolant Diverter Valve
Price
Lube System
Substantially More
Electronic Intake Valve Actuator
Oil Pressure Sensor Complexity/Reliability
Intake Valve Actuator Oil More Complicated Than EGR
Regulator Valve
Increased Oil Pump Output Residual Value
Increases Parasitic Losses Unknown

Fuel System Recommended

Operating Range
Five Injection Events
Per Power Stroke Limited
Electronics Driveability
New Software to Manage Extremely Low Recommended
Added Complexity Cruise RPM
13
The Series 60 EGR
The NOx Challenge
2002 emission regulations required
a reduction in oxides of nitrogen
(NOx) to 2.5 g/hp-hr. NOx is a by-
product of high temperatures in the
combustion chamber, the higher
the temperature, the higher the
production of NOx.
How Does EGR Work?
EGR (Exhaust Gas Recirculation) is
a simple concept. During certain
conditions of engine operation, the
EGR valve is opened and measured
amounts of exhaust gas are routed
to the intake manifold. The exhaust
gas mixes with the incoming fresh
air and displaces some of the
oxygen. Since there is now slightly
less oxygen in the air, the peak
temperatures created in the
combustion chamber are reduced,
and the levels of NOx are
also reduced.
EGR Is The
Best Solution
EGR is the technology chosen by
all but one major engine maker in
North America. EGR has been in
use on automobile engines since
the mid-1970s.
The challenge faced by Detroit
Diesel and the other engine makers
was to reduce NOx without
adversely affecting fuel economy,
performance, durability, or other
factors of engine operation. EGR
has proven to be the best way to
reduce NOx while maintaining
excellent driveability, performance,
fuel economy, and engine life.
14
 The Rapid Acceptance Of EGR
2002 engines meeting expectations, overall,
the news is good.
(Fleet Owner, May 2003)

Fleets Give Good Marks To EPA-Compliant Engines

Fleet representatives, reporting their first impressions
of new lower-emission diesel engines, gave them
generally high marks for the way they perform in
actual operations.
(Roger Gilroy, Transport Topics, March 24, 2003)

Carriers Say Maintenance

Little Problem in 02s
Representatives of fleets that
are running new diesel engines
designed to meet the federal
New (EGR) engines governments October 2002
running great. emissions standards said they
(Heavy Duty Trucking, April 2003)
have had few major maintenance
problems with them.
(Roger Gilroy, Transport Topics, March 24, 2003)

Drivers should appreciate the new powerplants

as they clearly perform better, especially at the
bottom end, thanks to the changeover to
variable geometry turbochargers and improved
ECU programs. Ive driven all brands with EGR
and have been quite impressed.
15 (Jim Windsor, Editor, Heavy Duty Trucking)
The EGR Advantage
Eight Million Miles Of Durability Testing
Revealed That The Series 60 EGR
Engines Are Showing A 49% Reduction
In Liner Wear, And A 78% Reduction In
Ring Wear Compared To Previous
Engines, Which Translates To Even
Better Life To Overhaul.

Parts Support, Special Tools,

reliabilt Components, And Trained
Technicians Are Already In Place
Throughout North America.

How Good Is The 2003 Series 60?

250,000 Mile Engine Teardown
After 250,000 Miles Of Operation With
EGR, All Components Were Still Within
New Part Specifications

Rod bearings Cylinder liner cross hatch Camshaft Piston pin bushing

EGR And The Proven Series 60

The Winning Combination For 2004. 16
 How Does ACERT Stack Up
TM

Against EGR?
You Decide
ACERT EGR
Miller Cycle Yes No
Limited Operating Range Yes No
Increased Internal Friction Yes No
Changes to All Major Engine Systems Yes No
Two Turbos Yes No
Jacket Water Aftercooling Yes No
Coolant Diverter Valve Yes No
6 Electro-Hydraulic Valve Actuators Yes No
Intake Valve Actuator Oil Pressure Sensor Yes No
Intake Valve Actuator Oil Regulator Valve Yes No
Camshaft Dampers Yes No
Five Injection Events Required Yes No
(Two on high
Diesel Oxidation Catalyst Required displacement engines) Yes No
Weight Increase Yes No
Weight Reduction No Yes
Complex Tune-up Procedures Yes No
The Most
Availability ? Popular Engine
700,000 Engines
Parts & Service Support ? In Operation*
The Fuel
Fuel Economy ? Economy Leader
Significant Price Increase Yes No

* With And Without EGR, As Of November 2003, 40,000 DDC Series 50 And Series 60 Engines Have Been Built With EGR.
17
The Top 10 Reasons Why The
Series 60 Is The Best Choice

EGR Is:
Simple
Proven
Reliable
Fuel Efficient

Weight Lightest Big Bore Engine

Proven 4th Generation DDEC Electronic Controls
Fuel Economy Leader
Over 700,000 Engines In Revenue Generating Operation
Best Selling Heavy-Duty Truck Engine 12 Years In A Row
Improved Jake Brake Braking Performance
Proven Residual Value
Lowest Cost Of Operation
Flexible Power Ratings
Over 1,200 Qualified Service Locations For Quick Turnaround
1-800-445-1980
142,000 Series 60 Engines Have Gone Over The Million Mile Mark
Transferable Warranty
Parts, Trained Technicians, Special Tools All In Place Today!
Access To Engine Technology Worldwide!

18
13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone 313-592-5000
www.detroitdiesel.com

Copyright 2003 Detroit Diesel Corporation. All rights reserved. Detroit Diesel, the spinning arrows design, DDC, DDEC and Series 60 are registered trademarks of
Detroit Diesel Corporation. CAT and Caterpillar are registered trademarks of Caterpillar, Inc. ACERT is a trademark of Caterpillar, Inc.
6SA0584 0310 As technical advancements continue, specifications may change. Printed in U.S.A.