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Marine Application of Aftertreatment 3500, C175

1. Bellows End of convolution G H along axis Example Measurements E AE AM x AG x 2013 Caterpillar 111 10Dec2013 All rights reserved Front View Supported Structure Left View End of tube along axis id 2013 Caterpillar 112 10Dec2013 All rights reserved Spreadsheet Step by Step Preview ENGINE INPUTS Mount Specifications Engine Mass kg of mounts No NS pas a w j w s 5 pes p ay a D pS fwj Jfa olola als lz N fe SlSfojojo o ojs Yalloo jin Mount axial displacement above load mm Mount lateral displacement above load mm Measurements Input AM x negative if to the left of engine A mount AM y negative if to the front of the engine A mount AM z negative if below the engine A mount AT x negative if to the left of engine A mount A negative if to the front of the engine A mount ATiz
2. Fig 4 6 Connection to Dosing Cabinet Connection Description Fitting Type Point Service tool connector Electrical harness from Dosing Cabinet to gt 4 Pin Connector Engine ECM Electrical harness from Dosing cabinet to main 3 AUS DEF tank level sensor transfer 24 Pin Connector pump Electrical harness from CEM to Dosing cabinet 24 Pin Connector 2013 Caterpillar 23 10Dec2013 All rights reserved AUS DEF Vent Port see Note below 1 2 Hose Bead SAE AS5131 6 Electrical harness from Dosing cabinet to 120V Grommet for wiring amp 3 Terminal Blocks AC source AUS DEF line from Dosing Cabinet to CEM No 6 STOR Straight Thread O Ring AUS DEF inlet line to strainer on Dosing 4 2 NPT Cabinet 9 Airline from Dosing Cabinet to CEM No 6 STOR Straight Thread O Ring Air line into Dosing cabinet 3 8 NPT Table 4 3 Dosing Cabinet Connection Points Note The AUS DEF Vent port of item 5 above must have a AUS DEF Vent Line installed to route buffer tank fumes to meet local OSHA guidelines for Ammonia fumes and the following routing requirements 1 Vent Line exit must be below AUS DEF injector 2 Vent line must be routed back to storage tank or a local OSHA approved waste container in the unlikely event of buffer tank overfill 3 Vent line must be routed continuously away from vent port without any kinks or loops that would allow AUS DEF pooling in line Dosing Cabinet to AUS
3. Liters 2013 Caterpillar 120 10Dec2013 All rights reserved Revision Summary Due to several changes required Revision 1 will be considered the first release with no Revision Summary listed Revision Summary will begin at Draft Rev 2 release CATERPILLAR Materials and specifications are subject to change without notice CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission 2013 Caterpillar 121 10Dec2013 All rights reserved
4. AUS DEF Level Sensor B AUS DEF Tank Temperature _ _ C Analog Sensor Return ___ D AUS DEF Tank Heater Relay Supply E AUS DEF Tank Heater Relay Return F AUS DEF Line Heater Relay HI Sw Batt _ G___ AUS DEF Line Heater Relay Lo Sw Batt HT AUS DEF Transfer Pump Sw J3 TankHighSwo S K TanklowSw S O L AUS DEF Transfer Pump Relay Batt e a LON e MEJ pG N 00 CO OO 2013 Caterpillar 39 10Dec2013 All rights reserved CEM Side CEM Inlet Box PA C910 to Dosing Cabinet via Junction Box 18 Way Interconnect Harness Connector 331 3598 Mating 331 3592 Term Sockets Connector Wire Size Pin ECM Pin Function Wire ID AWG C es a E E 16 10 e a CEM Outlet Box PF C910 to Dosing Cabinet via Junction Box 19 Way Interconnect Harness Connector 197 7359 Mating 197 7261 Term Sockets Connector Wire Size Pin ECM Pin Function Wire ID AWG 1 a S Ww a a a o C a p a d al d l a T e 2013 Caterpillar 40 10Dec2013 All rights reserved 120V Power Connection The dosing pump requires 120V AC power to operate The connection for the power is made inside the dosing cabinet on a bus bar with the cable routing through a wiring grommet on the dosing cabinet The hot and neutral wire coming into the cabinet will hook to the terminal strip connectors Then the ground wire needs to be hooked up to the grounding stud This will allow the dosi
5. Excel Spreadsheet NO DETERMINE T the proper CEM ISO YES re additional CEM ISO MOUNTS MOUNT or use CAT necessary ISO mounts provided Contact CAT A amp l in the A amp I Guide Installation lt ls the estimate within the Engineer for bellows capability Direction EVALUATE if the addition of ISO mounts Yes between CEM amp Engine is required NO Are CEM vibration PERFORM inputs gt 60Hz See Unknown Perform vibration test with Example section a minimum of 2 3 axis accelerometers on cradle Look for Freq gt 60 Hz A portable vibe meter could YES be used as a back up See A amp I Guide for examples of where to measure Are vib frequencies greater than60Hz Example s of inputs that could cause greater than 60 Hz vibrations Non Iso mounted engines Tracks rippers rock drills A amp I GUIDELINES Limit max shock loads to 5 G on industrial applications Tier 3 engine mounts may need to change in order to meet Flex Pipe bellows design limits Bellows Mount Displacement Calculator The Bellows Mount Displacement calculator should be used to determine if the installation satisfies the required flex pipe capability This calculator must be used with the CEM Mounts Decision Tree to determine CEM vibration acceptability The flex pipe calculator is available in Engipedia Tool Box A amp l Guides 2013 Caterpillar 88 10Dec2013 All rights reserved The installer designed
6. Exhaust Gas Temperature Loss Through Exhaust Pipe Water Ingress Prevention Exhaust gas sampling port VVVVVV 2013 Caterpillar 70 10Dec2013 All rights reserved Flexpipe Design Each application requires understanding of the installation requirements for proper location of the Cat CEM relative to the engine exhaust The actual flexpipe bellows will account for movement during engine operation The following application parameters should be considered before selection of flexible joint that accommodates the application needs e Tolerance Stack Up static Worst Case Engine Operation Duty Cycle Vibratory High cycle low displacement Thermal Growth Shock Loading Low cycle high displacement Temperature Pressure Flange pipe Design Requirements Vee Engines 3500 C140 C175 The Vee Engine design requirements are included in the following sections where appropriate when interfacing with a flange pipe connection Note Additional general guidelines for Exhaust Systems A amp l is available in Media Number LEBW4970 Exhaust Systems Engine Exhaust Flange Loading Careful consideration must be given to the load external piping may induce on the exhaust flange To minimize the load carried by the flange downstream exhaust piping should be self supporting The thermal growth of horizontal piping connected to the flange exhaust must also be accounted for in the design Maximum allowable vertical load and bending moment li
7. JE TF JS D A Note Clearance for servicing the AUS DEF Injector must be maintained by providing 20 inches 508 mm clearance for injector access and removal Spool orientation option above may assist you when designing for CEM installation Enclosure Temperature Limits Ventilating air should enter near the bottom of the enclosure and then flow upward around the engine and or Cat CEM module before exiting above the engine Room Building ventilation should be designed to bring the coolest air to the Cat CEM module If the engines and modules are placed in a building that has a pitched roof then ventilating air should flow out at the peak or near the top of the gable ends The source of the air must be low in the room and rise across the engine and Cat CEM and other equipment For personnel comfort maintain air velocity at 1 5 m sec 5 ft sec in areas of heat sources or areas that exceed 38 C 100 F Potential dead air spaces should be checked for temperature rise during engine operation Check all electrical and mechanical equipment in the dead air space for any detrimental effects caused by excessive temperatures Require corrections if necessary Engine room pressure should not become excessively negative This would indicate a shortage of ventilating air or excessive ventilating fans if equipped 2013 Caterpillar 4T 10Dec2013 All rights reserved Installation Dimensions and General Views Refer to TMI data for weigh
8. system has received a shut down event re and the dosing pump has stopped R m AC Power Connection During the installation of the dosing cabinet external power supply AC power only has to be routed inside the cabinet via appropriate opening The termination of these power lines are inside the cabinet at the junction block as shown below Customer Connections Common Neutral y Fig 4 8 Example AC Power Connection to Dosing Cabinet 2013 Caterpillar 25 10Dec2013 All rights reserved AUS DEF Supply to the Dosing Cabinet Desired fill rate is about 1 5 gallon per min at 5 10 psig AUS DEF supply pressure at the dosing cabinet fill port For example a 10 feet height difference generates 4 7psi AUS DEF pressure Fill rate and overall flow restriction in valves lines and filters upstream to the dosing cabinet need to be accounted for when designing the AUS DEF supply AUS DEF supply to the dosing cabinet must be supplied by a transfer pump The transfer pump must be sized to provide 5 10 psig with max of 10 psig AUS AUS DEF pressure at the dosing cabinet fill port based on the flow rate and total flow restriction in the line from the remote tank to the cabinet Dosing cabinet provides a 24VDC max amp 300 mA signal via aftertreatment ECM connector to control a relay used to control the power supply to the transfer pump as shown in Fig 6 10 Aftertreatment software will energize the rela
9. A tri axial mounting support is recommended within 915 mm 3 ft of the Cat connections A tri axial support provides support to the X Axis Y Axis and Z Axis planes The flexible joints that isolate the CEM from the engine vibrations should be positioned to prevent cantilever arm type loads to the CEM connections Cantilever arm type loads due to pipe weight can easily create vibration resonance that can overload the connection on the CEM causing a joint failure Method 3 The force method is another way to determine if you are exceeding the limits on the turbo and CEM inlets and outlets 2013 Caterpillar Tf 10Dec2013 All rights reserved The external pipe ard flanges can Ce replaced by a combination of a force F and momant M Tre values of F and M can be chiar ecdusing the Following expressions where Pice Leneth F Wool 2W Mee Weight per unit length of pipe Vp L rtr 5 M We L Ha Flange weizht s Flange thickness Refer to the Exhaust Joint Loading Table above for the maximum allowable dynamic load for each specific joint connection 5 Water Ingress Prevention Moisture Limits Introduction The presence of water in the CEM can cause failures such as cracking of catalyst from freeze thaw cycles cracking of catalyst by water causing thermal gradients across the catalyst Exhaust system outlets must be provided with an appropriate means of preventing snow rainwater or sea spray from
10. Failure to properly connect the after treatment will result in poor engine performance engine and after treatment system damage Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are not all inclusive If a tool a procedure a work method or an operating technique that is not specifically recommended by Caterpillar is used you must be certain that it is safe for you and for other people You must also be certain that the product will not be damaged You must also be certain that the product will not be made unsafe by the procedures that are used Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury Always wear a protective face shield protective clothing and protective shoes when cleaning components The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded and used with effective chip guarding if applicable and personal protective equipment The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi High Pressure Wash Notice High pressure wash systems including high pressure spray washers and water cannons are now in frequent use by maintenance people Connector seals will fail when hit directly with high pressure spray Many connection systems have adapters avail
11. Mounting Guidelines There are a number of Sometimes conflicting goals and criteria to keep in mind when designing a CEM mounting system It s important to check several criteria for any given mounting system The specific criteria to check depend on whether or not soft mounts are used in the design Hard mounted A hard mounted design should be evaluated with a stress quality FEA model The model should have at a minimum all structural components meshed between the CEM cradle and whatever is acting as ground An experienced analyst should be involved to ensure that all the important sources of stiffness mass and loads are being accounted for in each application At least the following analyses should be run e Modal analysis Check natural frequencies and compare with the firing frequencies of the engine over the operating engine speeds and other sources of strong vibration for example if the primary load on the engine is a pump compare to the pumping frequency If one of the system natural frequencies is close to a frequency of excitation a harmful resonance condition could occur e Static g loading The model should be run with a number of load cases to simulate both low cycle and high cycle fatigue shock events The specific loads to apply will depend on the application Predicted stresses should be compared to material limits endurance limit for high cycle yield strength for low cycle Loads through bolted joints should
12. PP Marine Petro Offshore 2016 gt 750HP 560KW ang Er Marine Petro Offshore 2000kW 3700 kW only 2016 Marine Petro Offshore gt 3700 kW only 2017 Table 1 1 Caterpillar Clean Emissions Strategy Table Safety Most accidents that involve product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs An OEM Installer must be alert to potential hazards An OEM 2013 Caterpillar T 10Dec2013 All rights reserved Installer should also have the necessary training skills and tools in order to perform these functions properly The information in this publication was based upon current information at the time of publication Check for the most current information before you start any job Caterpillar dealers will have the most current information Warning Improper operation maintenance or repair of this product may be dangerous Improper operation maintenance or repair of this product may result in injury or death Do not operate or perform any maintenance or repair on this product until you have read and understood the operation maintenance and repair information Burn and fire hazards are possible Failure to properly connect the After treatment or properly route the exhaust gases away from the module may result in personal injury or death Notice
13. be below the AUS DEF injector mounting location at the CEM The exit location should meet OSHA safety requirements Please contact local EH amp S organization for related concern p Injector ee D O FND bgs to A PF Eo A iA mn Ga So Solenoid 1 2 Air eo Vee a Solenoid Valve Static State m Air Solenoid 1 Open Regulator Manifold Solenoid 2 Closed Solenoid 3 Open g u Drop 4 wee PSI Solenoid 2 DEF Manifold Ale Source Zoo Rem n m S lll S lll S lll MlM i J rs Max Press ra 29 PSI 10 PSI Max Pressure 5 to 10 Relief Valve D PSI __ ame a gt Lal m Lal Lal m Solenoid 3 Remote DEF Tank Note The DEF Vent port must have a DEF Vent Line installed to route buffer tank fumes to meet local OSHA guidelines for Ammonia fumes and tank or a local OSHA approved waste ntainer in the unlikely event of buffer tank overfi gt Vent line must be routed continuously away ero inuously aw rom vent port without any kinks or loops that would allow DEF pooling in line Fig 4 3 Dosing system schematic Dosing System Operations As shown in Fig 4 3 air pressure must be present at the input to the dosing cabinet before dosing can begin This air pressure is regulated to 64 psig 4 psig at Solenoid Valve 1 When dosing conditions are met the Aftertreatment 2013 Caterpillar 21 10Dec2013 All
14. connection location on dosing cabinet See maintenance schedule for service interval of air filter See service manual for service procedure AUS DEF System AUS DEF Specifications For SCR applications the required AUS DEF solution to be used is SCR Grade AUS32 or Aqueous Urea Solution of 32 5 or 40 concentration with quality properties per ISO 22241 1 A solution 32 5 concentration provides the lowest possible freezing point 11 C 12 F while 40 concentration freezing point is at 0 C 32 F The solution is homogeneous allowing partial or total freezing and thawing without changing the concentration The solution is basic with a pH of about 9 0 and is slightly corrosive Reference ISO 22241 3 standard for Handling Transportation and Storage of AUS32 AUS DEF Fertilizer or technical grade urea may contain elements that will clog the injector nozzle It should not be used to supply the dosing cabinet The AUS DEF supply to the dosing cabinet inlet should be filtered The filtration requirement is 40 microns to protect valves inside the dosing cabinet Caterpillar offers a AUS DEF filter part number 370 6215 Customer needs to have onsite AUS DEF filters with filtration capability of 40y microns using differential pressure gauges across the filters for service Cabinets will include a AUS DEF filter screen assembled and mounted on the front of the cabinet using all stainless steel fittings AUS DEF i
15. e AUS DEF stalactites amp stalagmites Formed from slow leaks and evaporation of water Rate of water evaporation determines size of crystal formation e Need to verify that joints are tight Stop leaks when first noticed gt Solid AUS DEF will continue to accumulate gt AUS DEF solution is corrosive to steel and other metals e Solid AUS DEF is water soluble But may be slow to get into solution e Clean up spills and leaks before components can corrode Minor spills Use paper towels or absorbent mat e Solid AUS DEF is highly water soluble 2013 Caterpillar 118 10Dec2013 All rights reserved Hot water will re dissolve solid AUS DEF faster Small amount of soap or detergent in hot water may enhance clean up Plenty of hot water is key to removing dry AUS DEF e AUS DEF solution contains small amount of ammonia Skin irritant Wear gloves 2013 Caterpillar 119 10Dec2013 All rights reserved NG Oo a lo lo 15 16 17 18 19 20 21 ao 23 24 25 26 2r 26 29 30 31 32 33 34 35 Marine Emission Installation Audit Questions Installation Audit ID Audit Description Selling Dealer Name Selling Dealer Code Sales Model Engine Serial Number ATtentreatment Serial Number Dosing cabinet Serial Number End Customer Name Wessel Name Test Engineer Name Emissions Audit Questions Is the
16. elevated temperatures above 50 C The main storage tank location in a Vessel needs to be taken into consideration for both high and low temperature requirements of urea If the tank is located in a high temperature area of the vessel then insulate the tank or design in some type of cooling design to keep the urea below the maximum temperature limits If Marine Vessel will be spending time in cold operating areas then the urea tanks needs to be keep from freezing This can be accomplished by insulating the tank or by adding heater to the tank to keep the temperatures from freezing 2013 Caterpillar 36 10Dec2013 All rights reserved Energy Source Energy Requirements For AUS DEF thawing the recommended melt rate for frozen AUS DEF is twice the maximum consumption rate This gives a brake specific melting rate of 34 g kKW hr and 21 g kW hr for ratings 175 750 hp and greater than 750 hp respectively These numbers should be used when sizing a heat exchanger or electric heater e Heat Exchanger Design e Pickup Return Location e Flow rate Thaw rate min 2013 Caterpillar 3 10Dec2013 All rights reserved Electrical Block Diagram Dosing Cabinet POV a a Customer Supplied Junction Box Customer Supplied Dosing Tank Tank Heater ZA Fig 4 14 Dosing Cabinet Block Diagram 3516CHD C175 Electrical Connections Interconnect Harness Connectors Dosing Cabinet Side All Applic
17. engine and CEM installed system must satisfy 2 criteria to ensure acceptable flex pipe durability 1 Radial Capability 2 Axial Capability The flex pipe calculator requires several inputs including e Engine v Installed mass of the engine and all loads cantilevered off the flywheel housing Installed center of gravity for the engine and all loads cantilevered off the flywheel housing Number of Engine mounts G Load Engine Mount positions Engine mount stiffness S Mass Center of gravity Number of CEM mounts G Load CEM Mount positions CEM mount stiffness S ASSASSINS The calculator uses this information to determine radial and axial movement at the flex pipe Based on this movement the calculator will designate the radial and axial flex pipe capability as acceptable or unacceptable All installations must achieve flex pipe radial and axial acceptability Installation Handling and shipping The Cat CEM unit will be packed in order to protect the assembly during shipping and delivery Shipping covers will be installed on all flange connections These MUST be removed before the unit is placed into service Lifting Links Lifting Links are available to facilitate handling of Cat CEM units Refer to appropriate Service Manual and OMM for lifting details Important Lifting links are rated to support the weight of the Clean Emissions Module unit ONLY Remove any lifting links after installation is completed Warning Care
18. entering the CEM through the exhaust piping This can be accomplished by several methods but must be given careful consideration The selected method can impose significant restrictions that must be taken into account when calculating system backpressure For engine applications with gt 750 HP 560 KW ratings the maximum water ingress is 1 Liter at maximum 5 degree angle One simple method used primarily with horizontal exhaust pipes is to angle cut the end of the exhaust pipe with the point at the top A common method used with vertical exhaust pipes is to angle the pipe at 45 or 90 from vertical using an appropriate elbow then angle cutting the pipe end as previously described Another feature that may be used in conjunction with either of the above methods is Rain Spray Slots as shown in figure below 2013 Caterpillar 18 10Dec2013 All rights reserved RAIN SPRAY DRAIN SLOTS punch engine side slot edges in bend discharge side slot edges out Fig 7 15 Rain Spray Drain Slots Slots are cut into the exhaust pipe to allow rain spray to drain harmlessly The edges of each slot are deformed as shown in the previous graphic The engine side of the slot is bent inward and the downstream side of the slot is bent outward No more than a 60 arc of the pipe circumference should be slotted in this way For applications where none of the above methods are possible it may be necessary to fit some form
19. injury or death Tier 4 IMO Ill Emissions Requirements This Installation Guide is intended for use for engines that must comply with Tier 4 or IMO Ill emission requirements Proper fluids must be used to meet these requirements Refer to the specific Operation and Maintenance Manual OMM for the Caterpillar engine model being installed for the proper fuel lubricants and coolants that are to be used The proper fuels lubricants and coolants must be used to enable the engine to produce its published rated power fuel consumption and conform to emissions regulations 2013 Caterpillar 9 10Dec2013 All rights reserved JP8 Diesel fuel is not compatible with Caterpillar Tier 4 and IMO III Cat CEM U S EPA Tier 4 regulations require the use of commercial ULSD that conforms with the ASTM D975 specification of 15 ppm max sulfur fuel per US EPA Tier 4 requirements IMO III requires that the fuel sulfur levels are below 1 000ppm Using any fuel which is not equivalent to ASTM D975 or EN590 may damage engine and Aftertreatment systems In this case consult Caterpillar or your Caterpillar dealer for further direction Biodiesel is compatible with the Cat CEM up to B20 but can have an affect on some CEM components Refer to SEBU 6251 Caterpillar Fluids Recommendations The following table summarizes the engine operating fluids requirements for engines equipped with the Cat CEM Engine Operating Fluids Tier 4 15 or less IMO III 1 000
20. insulation shall not be used in wire harness designs because of its low operating temperature range 40 to 85 C and melt and flammability characteristics Cross Linked Polyethylene XLPE is the primary wire insulation type used in chassis cab and engine compartment locations It has a temperature rating of 50 to 120 C The voltage rating for Caterpillar 1E0815 wire and SAE J1128 Type GXL is 50 volts The circuit voltage shall be considered when making wire selections This wire insulation is also available with 50 150 300 or 600 volt ratings Outside diameter insulation range is 2 26 to 3 33 mm 0 089 to 0 131 in The table below provides insulation diameter range for each gauge and wire type PJ Connector Wire Insulation and Gauge Size Wire Type Insulation Diameter 0 114 0 125 GXL 0 098 0 112 0 089 0 098 ee Metric Equivalents for AWG Wire Numbers AWG Diameter mm Connector Seal Plug All unused cavities for sockets and pins must be filled with seal plugs in order to ensure that the connector is sealed Two options are available for plugging unused connector cavities Either the Deutsch 114017 Caterpillar part number 81 8737 or PEI Genesis 225 0093 000 Caterpillar part number 9G 3695 sealing plugs can be used 2013 Caterpillar 95 10Dec2013 All rights reserved Plug Insertion in Unused Connector Cavity The seal plugs are installed from the wire insertion side of the plug or
21. is flat on the ground secure all of the lifting eyes to remove off of ground a Warning Failure to follow these instructions could result in accidents potential injury and equipment damage Note The feet are not to be used for lifting Note Unit is shipped without the modules block catalysts installed these blocks will need to be installed after the unit is in its permanent location Mounting the CEM Bolting Instructions Bolting the CEM to the pedestal using the mounting feet provided include 7 8 in slotted holes running parallel to the short axis of the unit The customer installed mounting platform that the unit rests on should have pre fabricated 7 8 in slotted holes running parallel to the long axis of the unit When the mounting feet are set on the mounting frame the slots will form a cross This allows the unit to thermally expand sideways and long ways Flat washers should be used on both the bottom and top when tightening down the unit A torque collar or spacer installed between the two flat plains bolt holes enables the unit to move thermally back and forth or left and right discouraging structural impact on the housing of the SCR reactor Both top and bottom must be secured Secure the top once the bottom has been bolted in place Note Failure to install the torque collar could cause metal fatigue in the SCR housing and cracked welds where exhaust gas leakage is eminent 2013 Caterpillar 59 10Dec2013 All rights res
22. must be used when lifting the CEM Lifting at adverse angles to the lifting bracket may cause damage to the CEM and potential injury to the handler Always lift in line with the bracket Spreader bars are mandatory for lifting the CEM when inline lifting cannot be achieved with chains strap 2013 Caterpillar 89 10Dec2013 All rights reserved Mounting Pads The SCR units will have 6 Mounting Pads using M16X2 weld nuts for the 3516 and 4 mounting pads using SAE 10 X 3 in clearance holes The Cat CEM assembly should be mounted in a location that provides air circulation around the can and yet protects it from possible debris or foreign object damage Only a protective heat shield located away from the Cat CEM allowing airflow around it is acceptable Unless approved by CAT protective heat shields should not be used as they can cause localized heating Note The Cat CEM should be mounted in a location that allows access and removal for service requirements A minimum of 200 mm is required between the engine valve covers and Cat CEM when mounted above the engine for engine service See the Caterpillar Operation and Maintenance Manual OMM for actual service requirements and procedures Notice Welding mounting brackets to the Cat CEM is not permitted this could lead to failure of the unit and emissions non compliance All mounting brackets must be properly adjusted so that the inlet and outlet of the Cat CEM line up properly with
23. negative if below the engine A mount Shortest distance between mounts across width of engine Shortest distance between mounts across length of engine 189 Background Calcs Excel Sheet Directions 1 Max Bellows Capability Radial Max Bellows Capability Axial Max Movement Radially Calculated Max Movement Axially Calculated Acceptable CEM INPUTS Mount Specifications Mass kg of mounts Mount axial displacement above load mm Mount lateral displacement above load mm Measurements Input alue mm AN x negative if to the left of engine A mount AN y negative if to the front of the engine A mount AN z negative if below the engine A mount 53 AR y negative if to the front ofthe engine Amount 80 AR z negative if below the engine Amount 850 Al Zz i se _ I Sa Des pS i fay il AH z negative if below the engine A mount Alx negative ifto the left of engine A mount Ljoj Oje nolo H 13 80 70 80 Choose tube routing nominal diameter 4 or 5 2 Input Engine and CEM mass Mount S ENGINE INPUTS ecifications of mounts G Load ENGINE INPUTS Mount Specifications Engine Mass rr OU TO Cee toa n 2013 Caterpillar All rights reserved CEM INPUTS of mounts G Load 113 This is the mass supported by your mounts if they exist SS E 10Dec2013 6 Use mount load to displacement chart to determine axial and
24. occur in one of the PETU to compete its repair Thermal Control AUS DEF storage and delivery systems must be designed to accommodate freezing as well as perform NOx reduction functionality at ambient temperatures below the freezing point of the fluid AUS DEF Storage Tank The OEM or installer must provide a AUS DEF main storage tank and delivery system The OEM or Installer must provide a means to sample AUS DEF in the tank to determine AUS DEF Quality AUS DEF storage tanks must be designed to the industry best practices for fluid storage tanks but also with consideration for AUS DEF you need to watch for ambient conditions for both high and low temperatures If the tank would have a chance of freezing then the tank needs to be designed with an effective heat exchanger that is capable of thawing the tank Unlike other common operating fluids such as diesel fuel and coolant AUS DEF freezes at a temperature within the operating limits of the engine AUS DEF in the tank freezes from the outside to the center The density of frozen AUS DEF is lower than the density of the liquid AUS DEF This means that the 2013 Caterpillar 31 10Dec2013 All rights reserved frozen AUS DEF floats on the liquid AUS DEF To ensure that the complete tank of AUS DEF is thawed at least part of the heating source has to be located at the bottom of the tank The AUS DEF pick up location has to be very close to the heating source and dra
25. of rain cap to the end of the vertical pipe section This method can provide a positive means of water ingress prevention but not without imposing a significant backpressure restriction 6 Sampling port In accordance with MEPC 103 49 requirements ON BOARD NOx VERIFICATION PROCEDURE DIRECT MEASUREMENT AND MONITORING METHOD the exhaust system must provide a sample port located downstream of the last exhaust treatment system to measure gaseous emissions Please refer to regulations on type and correct location for the sampling port A copy of the requirement is stated below 5 9 3 Sampling for gaseous emissions 5 9 3 1 The sampling probes for the gaseous emissions shall be fitted at least 0 5m or 3 times the diameter of the exhaust pipe whichever is the larger upstream of the exit of the exhaust gas system as far as practicable but sufficiently close to the engine so as to ensure an exhaust gas temperature of at least 343 K 70 C at the probe 5 9 3 2 In the case of a multi cylinder engine with a branched exhaust manifold the inlet of the probe shall be located sufficiently far downstream so as to ensure that the sample is representative of the average exhaust emission from all cylinders In multi cylinder engines having distinct groups of manifolds such as in a Vee engine configuration it is permissible to acquire a sample from each group individually and calculate an average exhaust emission Other methods which have been sho
26. plating provides some marginal improvement in vibration versus nickel plating Caterpillar requires that only Gold plated sockets are used in the ECU connector J1 Note Deutsch nickel plated stamped and formed terminals are not recommended for use because of excessive voltage drop experience in laboratory tests Wire Type and Gauge Size Wire Selection Wire must be of a type suitable for the application Wire must be selected so that the rated maximum conductor temperature is not exceeded for any combination of electrical loading ambient temperature and heating effects of bundles 2013 Caterpillar 94 10Dec2013 All rights reserved protective braid conduit and other enclosures Typical factors to be considered in the selection are voltage current ambient temperature mechanical strength connector sealing range abrasion flexure and extreme environments such as areas or locations susceptible to significant fluid concentrations Wire Size The minimum conductor size used on Caterpillar products is 0 8 mm 18 AWG Smaller conductors are susceptible to breakage and fatigue failures SAE J1614 wiring distribution systems for construction agricultural and off road work machines require wire sizes no smaller than 0 8 mm 18 AWG Jumper harness wire size requirements per connection are defined in the Cat CEM and Engine Jumper Harness Definition tables below Wire Insulation NOTE Thermoplastic Polyvinyl Chloride PVC
27. receptacle Correct installation of either of these cavity plugs Is critical to maintain connector sealing integrity Figure above illustrates the correct insertion of the plug The seal plug cap is designed to rest against the seal not inserted in the hole in the seal 2013 Caterpillar 96 10Dec2013 All rights reserved Harness Routing Wiring shall be routed to ensure reliability and to offer protection from the following Chafing rubbing vibrating against other parts Use as handholds or as support for personal equipment Damage by personnel moving within the Marine Vessel Damage by impact or thrown or falling debris Damage by battery acid fumes engine and hydraulic oil fuel and coolant Abrasion or damage when exposed to rocks ice mud etc Vandalism damage to the maximum extent practicable Damage by moving parts Harsh environment such as nitrite mines high temperatures or areas susceptible to significant fluid or fume concentration Or oS So OS Wire harnesses shall not be located in close proximity to oil and fuel fluid fill areas or below fuel and oil filter locations If these locations cannot be avoided additional protective covers and shields must be provided to protect the harness Harnesses shall be located a minimum of 50 mm from high heat sources e g exhaust manifolds turbochargers hydraulic components etc to avoid insulation and or connector deterioration Harness Maintenance Conside
28. rights reserved ECM energizes Solenoid Valve 1 which looks for the required psig using P1 sensor If pressure is present Solenoid Valve 2 is energized to close and allows AUS DEF to be supplied to the AUS DEF Injector via the AUS DEF Dosing Pump The AUS DEF Dosing Pump pulses AUS DEF from the Dosing tank to AUS DEF injector controlled by the Aftertreatment ECM The P1 pressure signal is fed to the Aftertreatment ECM that in turn inhibits dosing without the required psig pressure from the P1 sensor signal Purging is accomplished by energizing solenoid Valve 1 and de energizing Solenoid Valve 2 providing compressed air back through AUS DEF Injector via Solenoid Valve 2 to Dosing Tank when dosing is not required The AUS DEF fill is controlled by Aftertreatment ECM to the buffer tank for the cabinet shown in Fig 4 3 When the buffer tank AUS DEF level is lowered and the AUS DEF Level Sensor detects a low level condition the Aftertreatment ECM energizes Solenoid Valve 3 which fills the Dosing Tank to maintain adequate supply of AUS DEF to the injector The maximum AUS DEF pressure allowed at the input to Solenoid Valve 3 is 10 psig The allowable range of AUS DEF pressure and flow rate is 5 to 10 psig and 1 25 to 2 5 gallons per minute respectively AUS DEF pressure from the AUS DEF Supply Tank is typically 5 to 8 psig A 10 psig maximum pressure relief valve is recommended in series with AUS DEF Supply Tank D
29. slot on each side 2013 Caterpillar 68 10Dec2013 All rights reserved Perform these steps for each of the 4 layers on the reactor 2013 Caterpillar 69 10Dec2013 All rights reserved 4 0 Exhaust System Introduction The engine Exhaust System discussed in this section consists of the interface of the turbo exhaust gases to the Cat CEM This includes Cat Bellows Assembly or flexpipe assembly Cat CEM or aftertreatment and muffler or exhaust pipe Cat CEM exhaust gas inlet receives the engine exhaust gas through flex bellows joints allowing for misalignment that may occur from the many installation arrangements of the Cat CEM Caterpillar recommends the combination of bellows ball and slip joints Particular attention must be taken to ensure proper design and placement of the Cat CEM to maintain alignment with the engine exhaust and stay within the vibration and industry standard leak tight connection requirements The engine and aftertreatment should be considered as a system The mounts for the engine limit pitch and roll and therefore reduce the requirement on the bellows assembly Refer to Engine A amp I guide for information on Engine Mounts Exhaust System Overview Customer Provided Exhaust Pipe anil N F Flange Connections Fig 7 1 Exhaust System Example Mandatory Requirements e Flexpipe Design e OEM Supplied Exhaust Pipe Requirements Pipe Size Pipe Material Backpressure Apportionment
30. the existing inlet and outlet pipes of the installation application Designated clamping zones will be provided with Cat CEM models to avoid damaging the filter within the can Refer to Section 5 Exhaust System for Flexpipe Bellows Coupling Requirements 2013 Caterpillar 90 10Dec2013 All rights reserved 6 Thermal Management Introduction The main exhaust piping routes exhaust gas from the engine to the Cat CEM Normal operating temperatures can reach up to 525 C at peak torque for C140 through C280 engine families including 3500 series Therefore thermal insulation on the surface of the main exhaust piping may be required Proper precaution should be taken to ensure that the Cat CEM is not mounted in close proximity to components that may be damaged by heat In addition Marine Class Societies have a 220 C skin temperature requirement per SOLAS regulations Chapter Il 2 Regulation 4 Paragraph 2 2 6 1 Thermal Protection The main exhaust piping routes exhaust gas from the engine to the Cat CEM Normal operating temperatures can reach up to 525 C at peak torque Therefore thermal protection from the surface of the main exhaust piping may be required Proper precaution should be taken to ensure that the aftertreatment device is not mounted in close proximity to components that may be damaged by heat Note The aftertreatment skin temperature and the gas temperature are difficult to measure and or simulate and are dependen
31. the pressure drop and leakage specs throughout the life of the installation in order to ensure compliance with emissions regulations A robust flexible joint will accommodate all the various movements of these routings through the many thermal vibration and loading cycles experienced by the application Proper assembly of the flange is necessary to form a strong seal that provides a leak tight joint OEM Supplied Exhaust Pipe Requirements 1 Pipe Material Material The material selection is an important part of ensuring that the system will continue to perform over the life of the Marine Vessel Traditional steel and aluminized steel have lower thermal stability and corrosion resistances than higher grade stainless materials 300 series stainless steel material is required to be used for OEM supplier exhaust piping between the turbo out and CEM inlet CEM and turbo connections are ductile iron and have similar thermal expansion coefficients as the 304SST Required OEM Pipe Material 304 Low carbon Stainless Steel SAE30304L 2 Exhaust Backpressure Exhaust System Apportionment Commercial Engines lf apportioned exhaust backpressure is higher than specified in table below it can result in poor engine performance Refer to TMI for maximum backpressure requirement awer Rann Apportioned Max Press Drop KPA craso an C280 T 7 5 Commercial System Backpressure Table 2013 Caterpillar 12 10Dec2013 All rig
32. to follow Caterpillars Applications and Installation requirements for proper Cat CEM integration with the Caterpillar engine Any deviation from these instructions resulting in improper installation or connection of Cat CEM may be considered an emissions related defect requiring the OEM or installer to report to U S EPA pursuant to 40 C F R 1068 261 h OEM installations are subject to audit by Caterpillar pursuant to 40 C F R 1068 261 d 3 as further set forth in the delegated final assembly agreement Note No aftertreatment component shall be placed between the engine out exhaust and the CEM inlet except for that which this document has specified Note If the available Cat CEM option does not meet the application installation requirements the OEM Installer must contact his or her respective Caterpillar sales manager Any deviation from these instructions resulting in the installation of Cat CEM not included as part of the applicable certified engine configuration will be considered a mis build and must be reported immediately to Caterpillar Cat CEM Identification Caterpillar will provide Auto detection to ensure the proper Cat CEM is fitted to the proper engine The engine will identify the CEM and allow proper operation of the engine and aftertreatment system Failure to detect proper CEM will result in 100 derated engine performance The Caterpillar Clean Emissions Module will be stamped with a Caterpillar part number
33. to the left of engine mount A AJ y negative if to the front of the engine mount 4 9 Enter CG center of gravity distances above mount locations for engine and CEM 10 Enter average skin temperature of exhaust line between turbo and aftertreatment when gas temperatures are at their highest e Spreadsheet will output estimated movement bellows must absorb Max axial and radial displacement Includes dynamic and thermal displacement 3 potential outputs G If all inputs are correct design should be acceptable Acceptable Max Bellows Capability Radial Max Bellows Capability Axial Max Movement Radially Calculated Max Movernent Axially Calculated Y Contact your A amp l integration engineer Acceptable Max Bellows Capability Radial Max Bellows Capability Axial Max Movement Radially Calculated Max Movement Axially Calculated R Design is not acceptable and will need some tweaking as shown on the next slide Acceptable Max Bellows Capability Radial Max Bellows Capability Axial Max Movernent Radially Calculated Max Movernent Axially Calculated 2013 Caterpillar 115 10Dec2013 All rights reserved Options for redesign e Options if bellows capability is less than calculated displacements Increase mount stiffness New Mount Increase of mounts Decrease distance between turbo outlet and CEM inlet Recommendations Guidelines e If you don t know your G Loads recomm
34. 0 mesh 500 micron filtration Ref Cat PN 108 3730 An Iceberg Catcher must be located at the end of the AUS DEF pickup line in the tank to keep frozen chunks of AUS DEF out of the delivery system This will act as secondary filtration into the AUS DEF delivery system but will not provide enough filtration to meet the requirements for the AUS DEF delivery systems Functional specification for the iceberg catcher is consistent with Euro 4 ES 2084 Technical requirements of the filter are for AUS DEF flow capacity for the delivery system area of the mesh and the filtration requirements size of the mesh 100 um Tank Sensors AUS DEF tank designs must provide for appropriate interfaces with tank sensors The ultrasonic AUS DEF level sensor needs to be installed perpendicular to the fluid when level with a minimum of a 2 space between the sensor and the fluid This requirement drives the placement of the sensor to the top of the tank Additionally the AUS DEF level sensor should be placed as close to the center of the AUS DEF tank as possible and have line of sight to the bottom of the AUS DEF tank The sensor is salt and AUS32 corrosion resistant with an operating temperature range of 40 C to 85 C AUS DEF Temperature Sensor The AUS DEF temperature sensor probe functionally needs to be located very close to the AUS DEF suction line in order to determine if there is liquid AUS DEF available for the system Tempera
35. 60 Hz e lf load frequency input is greater than 60 Hz the CEM must use tuned isolation mounts to reduce loads at greater input frequency than 60 Hz or work with a Caterpillar A amp I engineer to design select a CEM suited for the particular application e Any brackets bolted joints mounts welds or other structural elements supporting the CEM must be able to withstand all mechanical loads seen during operation including thermal growth or shipping Each of these elements may have different load limits and the limits may depend on the direction of loading or number of load cycles expected during the products 2013 Caterpillar 83 10Dec2013 All rights reserved lifetime For non Cat applications the CEM G Loading limits have been evaluated up to 5G s e Any structural elements must provide acceptable strength and durability over the entire temperature range expected to be experienced in the application e Motion of the CEM during operation must not exceed what can be accommodated by the flexible connections attached to the CEM and the clearances between the CEM and surrounding objects Caterpillar strongly recommends keeping the mounting contact points within the perimeter of the cradle mounting feet If the mounting structure extends beyond the cradle mounting feet perimeter care must be taken to ensure that the structure does not interfere with other components on the CEM that may extend below the cradle mounting feet plane
36. DEF Injector Air Line Connection from Dosing Cabinet JIC Flare SAE i DEF Line Connection from Dosing Cabinet JIC Flare SAE J514 9 16X18 J514 3 4 X16 DEF Injector Connections Fig 4 6a AUS DEF Injector Connections 2013 Caterpillar 24 10Dec2013 All rights reserved Dosing cabinet symbols Pictograms Ji DEF Return DEF back to the storage or The following pictograms are on the DC cabinet to Ly day tank aid in the inter connection of system components and explain the lights and switches 18 Pin Connector Wiring connections JL Air In Compressed air in from its source gt from system sensors and 24V power EZ Source t Service Tool Connector For connection lt Air Out Compressed air out to the gt the engine ECM and Comm Adapter a injector 7 ss DC Cabinet On Off Adjacent to main p A In DEF in from the storage OT day d system disconnect switch EA tan EnS 24V Power On Off Lighted pushbutton 4 DEF Out DEF out to the injector as ces Switch which provides power to the sensors gt In is on and out is off Pump Operating The green light vay CAUTION 110VAC 50 60Hz Electric Ey 4 indicates that the dosing pump is running a 2 Power Present Warning Alarm The yellow light 3 indicates that a warming alarm has been E received The dosing pump is still operating Ground Earth Ss Shut Down A red light indicates that the E
37. F solution kJ kg dTiiquia ber Final required temperature of DEF 11C C U Overall heat transfer coefficient kW m K A Heat transfer area m T coolant AECD Coolant temperature C Tper Required temperature of AUS DEF C The overall heat transfer coefficient U can be obtained from the following equation I I i I _ _ UA h K A h A TES T SS SS ice ice Where Ncoolant Convective heat transfer coefficient of the coolant inside the coolant line which can be obtained from the equation Nu hD K Acoolant Surface area of the coolant m ls thickness of the stainless steel tube m Kss hermal conductivity of stainless steel kW m K As Mean surface area of the stainless steel tube m Nice Convective heat transfer coefficient of the frozen AUS DEF solution surrounding the tube kW m K Aice Surface area of the OD of the tube m The heat transfer area A can be calculated from the above equation This area can be translated into an equivalent length and diameter of the coolant line Insulation Requirements Although non metallic AUS DEF tanks are a very poor conductor of heat depending on the proximity of the AUS DEF tank to a heat source additional thermal insulation may be required For metallic tanks thermal insulation is required to help improve the AUS DEF thawing process in addition to heat protection AUS 32 freezes at 11 C and starts to degrade at
38. Forest Service operates a national laboratory that provides spark arrester qualification testing pursuant to U S Forest Service Standard 5100 1c Spark Arresters for Internal Combustion Engines which is currently being revised so as to extend its assessment beyond particle capture measurement 2013 Caterpillar 10 10Dec2013 All rights reserved The CAT CEM with DPF is being validated per SAEJ350 Spark Arrester Test Procedure for Medium Size Engines which will not result in a formal qualification by U S Forest Service but will document spark arresting particle capture capabilities All other CAT CEM s are pass through aftertreatment devices and can not be validated to SAEJ350 If spark arresting is needed for these applications a dedicated device meeting SAEJ350 will need to be installed after the CEM Recorder EPA recognizes that it is unsafe and unacceptable to significantly derate or shut down a marine engine for an aftertreatment failure So in the EPA regulations 40 CFR 1042 does not require engine derates or shutdowns To answer this issue in the engine control panels a recorder of certain faults will be recorded and stored If this fault codes are logged on the recorder than the customer has 30 day to inform the EPA on what cause the recorder to recorder the one of those critical codes Caterpillar will provide an ASN2 recorder ECM which will record the required codes in in non volatile memory It then will be
39. Fuel Tolerance Sulfur ppm Oil Tolerance ash content CJ4 or better Fuel Tolerance biofuels ASTM 6751 075 B100 B20 or less Table 1 2 Tier 4 Engine Operating Fluids Limits NOTICE Oils that have more than 1 total sulfated ash should not be used in Aftertreatment device equipped engines In order to achieve expected ash service intervals performance and life Aftertreatment device equipped diesel engines require the use of Cat DEO ULS or oils meeting the Cat ECF 3 specification and the API CJ 4 oil category Oils that meet the Cat ECF 2 specification and that have a maximum sulfated ash level of 1 are also acceptable for use in most aftertreatment equipped engines Use of oils with more than 1 total sulfated ash in aftertreatment device equipped engines will cause the need for more frequent ash service intervals and or cause loss of performance Refer to your engine specific Operation and Maintenance Manual and refer to your aftertreatment device documentation for additional guidance Warning Use of Oil Renewal System ORS is strictly forbidden Any ORS that extends the oil life through the combustion process and toping off the oil reservoir with new oil will damage the aftertreatment device Failures that result from the use of any oil are not Caterpillar factory defects Therefore the cost of repair would NOT be covered by the Caterpillar warranty for materials and or the warranty for workmanship Note The U S
40. M csn a 44 2013 Caterpillar 2 10Dec2013 All rights reserved Exhaust Connections ccccccecceccecencecceceuceeenssass 44 Sound Attenuation cccce cece ee eeeeceeeceeeeeeeeeeeeeees 46 HASLAM ALI OM ecin neni ees 46 Installation Dimensions and General Views 48 Mounting amp LINING iessen tesserae 49 tial Start UD set secant annia a 60 Service amp Maintenance aasannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 60 4 Exhaust System n nnnsnnssnsnsnnnnnnnnnnnnnnnnnnnnnnnnnn 10 INTOQUCUO M isrnnn in aa E ETE 70 Exhaust System Overview cccccccseeeeeeeneeeeeeeeeenneaees 70 Mandatory Requirements nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 70 Flexpipe DESIGN circeeririneisarinnira sa T1 OEM Supplied Exhaust Pipe Requirements ss00 72 P IDG Material coscctieauscesevassade whe a 72 Exhaust BackpreSSule ccccccccecceceeceeeeeenennnnnenseneeeeees 72 Exhaust Temperature LOSS ccccceceeeeeeeeeeeeeeeeeeessnseeees 74 Joint Loading amp Supports ccc cece eee eee en neeeeneeeens 75 Water Ingress Prevention ccccceeceeeeee eee eennneeeenesenees 78 Exhaust System Verification cccceee eens eee eeeeseeeeeees 80 Sound Pressure Level iicisiccsssierensnrtietccsseneteensiweeeeieetiannds 82 5 Mounting Considerations ccccceeeeeeeeeeesens 83 IFITKOGU CUO cicirine a AE 83 MOUNINO sca a a 83 CEM Vibration Acceptability O
41. Manometer used to Measure Exhaust Backpressure Tip of probe should be cut parallel to exhaust gas flow Preferred Pressure Tap Location amp Installation 3 in 76 2 mm Minimum or 1 2 Pipe Diameter Fig 7 17 Exhaust Backpressure Sensor Recommended Location Pressure Drop Measurement testin rocedure Exhaust system pressure drop is measured while the engine is operating at rated speed and full load conditions refer to the Engine Data Sheet for rated RPM and 2013 Caterpillar 81 10Dec2013 All rights reserved load conditions Either a water manometer or a pressure gauge can be used If not equipped install two pressure taps on a straight length of exhaust pipe The first tap should be located as close as possible to the beginning of the pipe section but at least 12 in downstream of a bend The second tap should be located just before the end of the pipe section If an uninterrupted straight length of at least 18 in is not available 12 in preceding and 6 in following the tap locate the probe as close as possible to the neutral axis of the exhaust gas flow For example a measurement taken on the outside of a 90 bend at the pipe surface will be higher than a similar measurement taken on the inside of the pipe bend A 1 8 NPT half coupling can be welded or brazed to the exhaust pipe to create a pressure tap After the coupling is attached drill a 3 mm 1 8 in diameter hole through the exhaust pipe w
42. Marine Application of Aftertreatment 3500 C175 C280 Cat Clean Emissions Module CEM Application amp Installation Guide Exhaust In Inlet Sensor Box Inlet Spool Urea Injector Mixing Tube As p 2 P A L E 7 La a n Q a f g A my N Mixers Flapper Swirl J h a 4 JS ag P J om a i N 7 i e h aa ts i Exhaust Out Outlet Spool Flute Outlet Sensor Box Outlet Mixer service Door Catalyst Gp SCR Aftertreatment ECM Pump GP DEF Breaker As AC Power IN Wiring GP Tank GP DEF Manifold GP Air Air OUT Air IN DEF OUT DEF IN Manifold GP DEF 2013 Caterpillar 1 10Dec2013 All rights reserved Table of Contents Revision Summary cccceeeceeeeennnnnnneeeeccccensnssens 121 Table of Contents cece ccc ceeeee eee ne eeeeeeeeeeaes 2 1 IMP OOUCTON ccicceccockastccninnssostestevtenctenssceeeetnsiest 5 PUNO OSC se hoses eens E E N 5 Requirements amp Agreements cccceccecee eee eeneeeeeeeeaees 6 DOCUMENT LAYOUT snicceeisuiunieguestcavarnieawieduousiwerorsawends 7 Tier 4 Emissions Strategy Table cccceeeeeeeeeenees 7 SATE YV eaei tesa ols etic ae sect Ea E 7 Pressure AIF and WALEl sisecciveassctenactrcheeteseedent eae 8 High Pressure Wash ssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 8 WV EIAIN O craras iene a e e a a EES 9 PaNNa a EE 9 CleanliNESS rsrsr naa E A AEEA OE REAA 9 Rep
43. S DEF line Inside Diameter Greater than 5 5mm and Less than 7 5mm Length Less than 6 1 meter 20 ft in length Oil resistant Connections per Table 4 1 AUS DEF Lines from storage tank to buffer tank 2013 Caterpillar 30 10Dec2013 All rights reserved A minimum of 5 PSI head pressure on AUS DEF in line and a maximum of 10 PSI is required at all times during operation to assure that the buffer tank can be filled when it runs low AUS DEF line must be capable of delivering AUS DEF in atmospheric conditions down to 40C without AUS DEF freezing and impeding filling of buffer tank when required AUS DEF Lines Installation amp Routing AUS DEF lines are to be installed following instructions based on DIN 20066 part 4 General routing and clipping rules should include keeping these lines from coming in contact with sharp edges that would fatigue and fail the line from vibration or system operating movements Other considerations should include continuous routing without kinks extreme bends and loops that would restrict AUS DEF flow throughout the operating temperature extremes If there is more than one engine PETU CEM installed on a vessel than a shut off valve must be installed before the dosing cabinet PETU in the AUS DEF line from the transfer pump The valve will allow that one PETU to be turned off for service while other engines and PETU are still running The valve can also be used to if a leak would
44. ULSD 2013 Caterpillar All rights reserved Computational Fluid Dynamics Code of Federal Regulations Center of Gravity Compliance and Innovative Strategies Division Carbon Monoxide Clockwise Diesel Exhaust Fluid also referred to as AUS32 Differential Pressure Diesel Oxidation Catalyst Diesel Particulate Filter Delta Pressure Indicator Electronic Control Module Environment of Health amp Safety Environmental Protection Agency Finite Elemental Analysis Failure Modes amp Effects Analysis Ground Hydro Carbon IDentification or Inside Diameter Dimensional Reference International Electro technical Commission International Organization for Standardization Joint Industry Council Mass Air Flow Material Safety Data Sheet Nitrous Oxides NO and NO Original Equipment Manufacturer Operations amp Maintenance Manual Oil Renewal System Particulate Matter Part Number Pounds per Square Inch gauge Product Software Programming System Society of Automotive Engineers Separate Circuit After Cooler Selective Catalytic Reduction Soluable Organic Fraction Straight Thread O Ring Serial Number To Be Determined Ultra Low Sulfur Diesel 12 10Dec2013 2 Cat CEM Overview Caterpillar Clean Emissions Module Cat CEM Systems The Cat CEM consists of the key components necessary to support an engine arrangement for emissions compliance Caterpillar Tier 4 IMO III and Euro IIIB engine systems use a varie
45. able that can be attached to the back of the connector to protect the wire seals from direct high pressure wash Where direct exposure to high pressure wash systems cannot be avoided then protective shields will need to be designed and installed For the benefit of service connectors should be placed in accessible locations 2013 Caterpillar 8 10Dec2013 All rights reserved Welding WARNING Notice Welding on Cat CEM frame chassis is prohibited Painting Painting of Caterpillar CEM is NOT recommended and strongly discouraged Some components skin temperatures on the CEM can get to as high as 525 degrees Celsius during operation and will cause charring or burning of the paint Cleanliness Air lines Fuel lines coolant lines and oil lines that connect to the CEM or engine should meet Caterpillar cleanliness specification contained in A amp l Guide LEBW0019 Replacement Parts When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material When replacement parts are required for this product Caterpillar rec ommends using Caterpillar replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material Failure to heed this warming can lead to premature failures product damage personal
46. ack working your way out towards the hatch opening With one grid in place repeat the procedure to bring in a second grid half that has the corresponding number posted on its triangular beam section Rotate the grid so that the slotted connections align Use the clevis pins to join the two sections together Remove any tape that remains on the grid halves A rubber mallet can be used to adjust the grids into place 2013 Caterpillar 65 10Dec2013 All rights reserved Once the grids are in place the T shaped anchors are pinned into place Ensure that the lanyards remain looped through the T anchors Pin all T anchors on all sides Once the grid is on the first ledge with two pins secured beneath the grids and the T anchors installed insert the first 4 bricks in each corner 2013 Caterpillar 66 10Dec2013 All rights reserved Install the 3 bricks on each side between the corners next Once all bricks are installed around the perimeter install the center bricks ae fi annm Install the T beams in one direction perpendicular to the vertical quarter inch holed connectors The T beams are held in place by a U shaped channel that is pinned to these quarter inch holed bars 2013 Caterpillar 67 10Dec2013 All rights reserved ay Sy Once all of the T beams are placed between the catalyst modules install the U shaped bars across the top of the T beams on each side Insert the clevis pin into each
47. al Connector for Sensor Control Box Inlet Pressure Sensor Inlet Temp Sensor Di 9 Outlet ix n Temp Sensor A inlet NOx g D am s i ogy F Sensor Electrical Connector for Sensor Control Box Fig 4 16 3516CHD Inlet Outlet Spool Electrical Component Locations The above figure shows the electrical component locations for the inlet and outlet exhaust spools that attach to the CEM both U and Z flow configurations 2013 Caterpillar 43 10Dec2013 All rights reserved Outlet Spool Installation e Sensor Box should always be on top e Vertical Installation the spool should be oriented where there is access for servicing the sensor Figure 4 16a Outlet Spool Orientation The installation of the outlet spool requires the Sensor Box to be on top in horizontal installations with adequate clearance to allow service of the NOx sensor CEMs mounted vertically on its end the spool must be oriented to allow easy access to NOx Sensor for service Refer to the Mounting amp Lifting installation subsection below for Horizontal and Vertical installation examples Exhaust System Exhaust Connections Both the inlet and outlet exhaust connections to the CEM utilize a bolted flange connection A gasket and standard bolt torques are required to maintain a leak tight seal Any connections for the exhaust that are between the turbo out and CEM inlet are required to be leak tight and util
48. al wedge cable and extended socket The harness assembly requirements are unique to typical Caterpillar wire harnesses Caterpillar recommends 2 conductor shielded cable from Raychem Corp Raychem part number 2019D0309 0 Cat part number 153 2707 for all J1939 data link wiring This is twisted pair wiring If the Caterpillar recommended cable is not used the cable must meet J1939 specifications for conductors For additional information regarding the electrical system design see the SAE publication J1939 1 1 Physical Layer The minimum bend radius for the data bus cable is 40 mm 2013 Caterpillar 100 10Dec2013 All rights reserved Table 2 J1939 Conductor Specifications J1939 SPECIFICATIONS FOR CONDUCTORS Terco e l o a Capacitance between conductors pF m o o o a 5 Capacitance between the 70 conductors and the shield pF m In order that the data bus will function as intended the following requirements must be identified on the customer wire harness print 1 Remove 75 mm of the outer jacket of data link shielded cable Reference Cat part number 153 2707 Remove the foil shield from the exposed wires to within 3 mm of the cable jacket end Crimp gold plated socket terminals to the wires and the extended socket terminal to the drain wire Slide heat shrink tube over the cable end Reference Cat part number 125 7876 Install the terminals into the appropriate connector cavity positions Install the we
49. all If possible remove burrs on the inside of the pipe so the gas flow is not disturbed The gauge or gauge hose can then be attached to the half coupling This procedure can be repeated for each pipe section Reference SEBD6 29 for additional information Information that can be used for CFD analysis of the exhaust piping systems is contained in the engine data sheet for the engine rating that the exhaust is being designed The data sheet will contain information required for CFD such as exhaust flow and exhaust stack temperatures Sound Pressure Level Reference TM 080 for procedure in TMI Definitions Performance Def of how to obtain data A muffler may be added if sound attenuation is required in addition to the aftertreatment The muffler or resonator must meet the backpressure requirements described in exhaust backpressure sub section above and must be installed after the Cat CEM The Cat CEM noise attenuation data can be found in TMI for the CEM selected 2013 Caterpillar 82 10Dec2013 All rights reserved 5 Mounting Considerations Introduction This section is comprised of two parts Mounting Requirements and Mounting Guidelines The first part describes metrics that a mounting system must meet for the CEM installation to be successful The second part gives some tips about how to approach the design and validation of a mounting system that should make it easier though not guaranteed to meet the requirements in th
50. als Sealing plugs are to be used in unused wire cavities The DT connector has a wedge that locks the pins and the sockets in place The wedge can be removed and replaced without cutting the wires The wedge removal tool p n 147 6456 can be used to aid in the removal of the wedges When the receptacle is inserted into the plug a click should be heard as the two halves lock together The connector should not be able to be pulled apart The following table contains the Caterpillar part numbers for DT inline connector plug and receptacle kits for all available number of pin positions The kit is comprised of the plug or receptacle and the respective locking wedge Standard DT Connectors Cat Part Number Receptacle Kit 155 2270 102 8802 155 2260 102 8803 155 2274 102 8805 155 2265 102 8806 155 2255 102 8801 Contact the local Deutsch sales contact for more information on these connectors 155 2271 197 7565 Deutsch AEC Jumper Harness Connectors C1 C2 2013 Caterpillar 93 10Dec2013 All rights reserved The connector is available in 24 40 and 70 terminal configurations It can be used for inline or bulkhead mountings The connector is frequently used in electronic box applications The wire size range the connector will accept is 0 8 mm 18 AWG 1 0 mm 16 AWG and 2 0 mm 14 AWG The plug assembly with interface seal accepts socket terminals and the receptacle header assembly accepts pin terminals Sealing plugs a
51. ammonia which is soluble in the liquid will cause the corrosiveness of AUS DEF solution to increase as it ages due to its increasing concentration That is the higher ammonia concentration makes it more caustic Note that high storage temperatures increase the rate of this decomposition 2013 Caterpillar 117 10Dec2013 All rights reserved Since AUS DEF liquid is caustic delivery ae and storage requires materials that are not kia a a susceptible to corrosion Recommended Materials e Stainless steel o 300 series OK o 400 series Slow corrosion o Corrosion rate increases with temperatures gt 60 C e Plastics Materials to Avoid Unalloyed steel Aluminum Brass Galvanized steel Copper Eye contact may cause mild eye irritation including stinging watering and redness Wear safety glasses Safety shield may be needed in some conditions Skin contact may cause mild skin irritation including redness and burning No harmful effects from skin absorption have been reported Use rubber gloves to prevent skin contact All rubber types OK Vapor Inhalation may cause irritation leading to cough or difficulty in breathing Note Contact hazards are from the caustic pH 7 5 10 factor of solution AUS DEF in solution slowly decomposes into ammonia causing the caustic reaction Aged AUS DEF solution is more caustic high pH than fresh Leaks and or Spills There is visible evidence should a leak occur
52. ations Dosing Cabinet PT C674 to Engine via Junction Box 23 Way Interconnect Harness Connector 433 0308 Mating 388 6613 Term Pins Connector Wire Size Pin ECM Pin Function Wire ID AWG B CatDataLink MOR 18 D J199 Global CANA K900 YL 18 CE e a a d a C E lee ee Oe P ECMJ1 Battey 0 0T RD 14 Ee ee ee Q R ECMJ1 Battery A250 BK 14 C A eea ee 2013 Caterpillar 38 10Dec2013 All rights reserved Dosing Cabinet PT C698 to Tank via Junction Box 14 Way Interconnect Harness Connector 425 4537 Mating 433 0310 Term Sockets Connector Wire Size ECM Pin Function Wire ID AWG Pin A AUS DEF Level Sensor H857 PK AUS DEF Tank Temperature Analog Sensor Return AUS DEF Tank Heater Relay Supply AUS DEF Tank Heater Relay Return AUS DEF Line Heater Relay HI Sw Batt AUS DEF Line Heater Relay Lo Sw Batt n ca 00 CO OO 18 18 18 18 AUS DEF Transfer Pump Sw Y719 BU Tank High Sw 410 WH Tank Low Sw A487 PU AUS DEF Transfer Pump Relay Batt a l Le CO P ee i i Dosing Cabinet PT C699 to CEM via Junction Box 23 Way Interconnect Harness Connector 433 0309 Mating 425 4540 Term Pins Connector Wire Size Pin ECM Pin Function Wire ID AWG CS B phe O _ 5V Analog Sensor Supply Der a ae fd F AnalogSensorRetun T99 BR M a e P Outet1 NOx Sensor L921 YL 18 R Outlet 2 NOx Sensor L922 BU 18 E A
53. be compared to joint capacity For non Cat applications the CEM G Loading limits have been evaluated up to 5G s e Hard mounting is recommended if the load input frequency is less than 60 Hz A majority of applications will operate with frequencies of less than 60 Hz Some examples of exceptions to this could be Rock Ripper Rock Drilling and certain track type tractor applications In these applications properly tuned isolation mounts should be used to reduce all vibration inputs into the CEM to less than 60 Hz 2013 Caterpillar 84 10Dec2013 All rights reserved Some applications may need additional analyses run or additional criteria checked Consult with your Caterpillar A amp I Engineer if you require assistance Soft mounted Soft mounted systems must meet the same requirements as hard mounted systems so the same techniques described above can be helpful In practice some additional screening tools can be useful to evaluate soft mounted systems more efficiently using a lower level of detail than a full FEA model One such tool is a rigid body analysis This type of analysis assumes that everything is rigid except the mounts and just uses six degrees of freedom to describe the motion of the CEM Also the mounts are assumed to be the only connection between the CEM and ground i e the pipes hoses and wire harnesses are assumed to contribute negligible stiffness This tool is often used at the early stages of mounting syste
54. cation Designs C280 8 ECK Marine Petro Offshore 2000kW 3700 kW only Marine Petro Offshore gt 3700 kW only The CEM Prefix indicates the 16 brick version of CEM for these engine platforms Currently the prefix designation for the 12 amp 20 brick version of CEMs are not available 3500 C175 Each CEM has a Serial Number that is compatible to a particular engine platform and is shipped as a set This S N must be verified at installation for compatibility to the engine The serial number prefix will identify the CEM for correct application The prefix on the CEM serial number label is indicated on the example below Example Serial Number Prefix MODULE AR PN 345 6789 00 SN CONV GP CTLTC PN 876 5432 00 Refer to Appendix B Initial Startup Procedures for location of serial number on CEM and dosing cabinet documentation and first fit detection 2013 Caterpillar 16 10Dec2013 All rights reserved Cat CEM Mandatory Interface Connections Table 4 6 dosing cabinet to CEM straight thread O ring Table 4 6 Cabinet to CEM Electronic harness from Quantity 1 Table 4 6 Dosing Cabinet to CEM 24 Pin Connectors Table 4 6 ECM Dosing Cabinet to 24 Pin Connectors Engine ECM Table 4 6 DEF Tank Dosing Cabinet to Main 24 Pin Connectors AUS DEF Tank Table 4 6 cabinet from air source Fig 4 6 amp Customer AUS DEF tank to AUS DEF line into 1 2 Male NPT Table 4 6 Dosing Cabinet dosing cab
55. caustic corrosive nature of the liquid 2013 Caterpillar 29 10Dec2013 All rights reserved e Highly alloyed austenitic Cr Ni and Cr Ni Mo Steels or Stainless Steel 304 304L 316L 409 439 materials are recommended for use with AUS32 urea water solution e Titanium is recommended for use with AUS DEF water solution e Metals amp Plastics coated with nickel are not recommended because nickel coating inner diameters of components and durability resistance to flaking of nickel coating are not consistent e Polyethylene Polypropylene Polyisobutylene Perfluoroalkoxyl alkane PFA Polyfluroethylene PFE Polyvinylidenefluoride PVDF Polytetrafluroethylene PTFE are all recommended materials e Seal Hose Materials EPDM 1E0712B and NBR 1E0741 are suggested materials for use with AUS32 e Aluminum and its alloys are not recommended for use as tank material for DEF tanks Only certain grades of anodized aluminum are acceptable but due to variability of anodizing quality it is not recommended as tank material either e Non ferrous metals and alloys copper copper alloys zinc lead are strongly not recommended AUS DEF Lines Connections Typical fittings have mild steel as the base material which will not be compatible with AUS DEF All connection points and fittings for the AUS DEF lines are required to be stainless steel or AUS DEF compatible material Line Specifications Dosing Cabinet to CEM AU
56. cessary for routing Refer to illustration in Figure below 2013 Caterpillar 98 10Dec2013 All rights reserved Correct Example of Wire Harness Routing at the PJ C1 C2 Connectors Wire harness bends near a connector must be no less than twice the wire harness diameter Special consideration shall be given to connectors with large wire counts Stresses placed upon the retention system of the connector can cause contact retention failures and wire pull out In order to avoid this problem consider the following options 1 Pre form the harness to the required bend The harness assembly drawing shall detail the harness bend requirements e g location and radius The harness braid protection should be applied up to the tangent point of the bend furthest from the connector Connector orientation to the bend may be necessary and should be specified on the harness print 2 If harness braiding is used increase the unbraided harness length to 150 mm This will allow the wires to fan out when the harness is bent greatly reducing the forces placed on the connector contact retention system The connector should also be oriented properly with respect to the harness so that upon installation to the product the harness will not need to be twisted to align the connector Drip Loop When a harness is routed downward to a connector terminal block panel or junction box a trap or drip loop shall be provided in the harness This feature will
57. ckpressure The piping size decision assumes a minimum number of short radius bends If a number of sharp bends are required it may be necessary to increase the exhaust pipe diameter Since restriction varies inversely with the fifth power of the pipe diameter a small increase in pipe size can cause an appreciable reduction in exhaust pressure e Itis essential that the system does not impose more than the allowable maximum backpressure The maximum backpressure must not exceed the limit while certifying each engine model for conformity to exhaust smoke and exhaust gas emissions under Federal California and other agency regulations To avoid this problem exhaust system backpressure should be calculated before finalizing the design Testing should be done to validate design is compliant with A amp l requirements e Exhaust piping is a critical component in the Cat CEM operation required to meet emission standards Care should be exercised in configuring and designing the exhaust piping to meet packaging and exhaust component load and operational limits e OEM pipe diameter has a significant impact on the pressure drop through the system The engine and Cat CEM connections have been configured for the recommended pipe diameter in order to meet the pressure drop requirements 3 Exhaust Temperature Loss Exhaust Temperature Introduction The Caterpillar CEM relies on a minimum average temperature during operation to provide the necessary em
58. d montored by Cat ECM correctly Is the factory insulation installed on CEM inlet and outlet spools correctly and no other insulation around and over the sensors Is the pressure sensor on inlet spool mounted in vertical orientation per A amp l quidelines Is the NOx sensor box oriented correctly on the inlet and outlet spool per A amp l guidelines NOx senors box loctated on top Is their a air Tilter dryer installed between Air compressor and dosing cabinet Checked for all electrial codes to make sure all system is operating correctly Was a complete PAR test performed and uploaded into the Cat system ANID inlet restriction at full load rated speed with clean filter element measured at turbo compressor inlet lf Vee Lefty Air inlet restriction at full load rated speed with clean filter element measured at turbo compressor inlet lf Vee Right Enter full load exhaust backpressure at turbo outlet lf Vee Left Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No KPA KPA KPA Enter full load exhaust backpressure at turbo outlet lf Vee Right Enter the full load backpressure at the CEM CEM inlet temp at 100 0b load A PA A PA Deg C UREA Dela P between lance and dozing cabinet Urea pressure to dosing cabinet Air supply pressure to dosing cabinet Urea concentration 32 5 or 40 Wessel fuel tank capacity Urea tank capacity Liters
59. dge into the connector Apply the heat shrink tube over the back of the connector body and the jacket of the cable The above components and assembly procedures must be used to ensure the cable to connector joint will be sealed Failure to conform to these requirements will result in cable contamination and result in loss of shield performance See Figure 6 2013 Caterpillar 101 10Dec2013 All rights reserved Figure 6 SAE J1939 Connector Assembly Extended Socket Shrink Tube TA l Connector Plug Socket Terminals or Receptacle gt Tt NOTE Refer to SAE J7939 17 Physical Layer document for more information Connecting Modules to the CAN Data Link The SAE J1939 data link is used to communicate engine information to an SAE J1939 compatible display or other desired SAE J1939 compatible modules Refer to SENR9764 Installation Guide for Industrial Electronic Engine Displays for more information on connecting J1939 displays to Caterpillar industrial engines The illustration in Figure 7 shows two J1939 modules properly connected to the J1939 data bus The key components to note are as follows e The total length of the data link between terminal resistors must not exceed 40 m 130 ft e Length of each branch or stub length must not exceed 1 m 3 3 ft Reference cable assembly Cat part number 165 0200 that is 15 m long with Deutsch DT 3 pin plug on one end and J1939 signal and shield wires with appropriat
60. dth of engine ff 600 Shortest distance between mounts across length of engine 1890 Avoid entering zeros here Even if hard mounted AJix negative if to the left of engine A mount AJiy negative if to the front of the engine A mount AJjz negative if below the engine A mount enter hard mounting locations Value mm _ 50 S05 40 140 140 SS 2013 Caterpillar 114 10Dec2013 All rights reserved ENGINE INPUTS CEM INPUTS Measurements Input O O Z o y y y AN y negative if to the front of the engine mount A AN z negative if below the engine mount A ative if to the left of engine mount A e mount A AR x nec AT y negative if to the front of the engine mount A Ry negative if to the front of the engine mount A AT z negative if below the engine mount A z L x negative if to the left of engine mount iit eres AG y negative if to the front of the engine mount Vertical distance of Engine i AR z negative if below the engin ongest distance between mounts across width of engine eg AB x A sativa i TERNES S EONI EE UER A ATOE PRY E SA EY ES FE E LAN i E as D P sative i ative i above engine mount A z ne 2 AH x negative if to the left of engine mount 4 negative if to the front of the engine mount A Aly negative if to the front of the engine mount A Alz negative if below the engine mount A x negative i ngine mount A x negative if
61. e first part Every installation is unique so individual customers may have to adapt the methods described here to better fit an individual application The CEM has been designed and validated to provide acceptable durability in a wide variety of applications with load frequencies less than 60 Hz without the use of isolation mounts However certain applications may still require the use of isolation mounts for one of the following reasons e The CEM hard mounted to a particular structure would be exposed to vibrations greater than 60Hz e The mounts supporting the CEM move independently of each other and would cause damage to the CEM or mounting supports e The noise generated by a hard mounted CEM would be objectionable e Some flexibility in the attachments may make assembly easier and or reduce assembly stress e The volume is low enough where it may be preferable to add component cost in order to reduce validation cost Notice Engine mounting of aftertreatment is not recommended Mounting Mounting Requirements The CEM may be attached with or without the use of rubber isolation mounts Regardless of the style of design or the method used to validate it any successful CEM attachments must meet the following criteria e CEM vibration during operation shipping etc must not exceed required limits for CEM component durability for load input frequencies of less than 60 Hz A majority of applications will operate with frequencies less than
62. e crimped socket on the other end for insertion into J1939 module connector e All splices and end nodes can be implemented using a connector tee Reference Deutsch DT receptacle assembly Cat part number 133 0970 e Two terminal resistors must be installed One resistor is required at each end of the data link in order to ensure proper operation These two terminal resistors are critical for the proper operation of the network Reference Deutsch DT plug with integrated termination resistor Cat part number 174 3016 2013 Caterpillar 102 10Dec2013 All rights reserved Figure 7 J1939 Multiple Module Installation Example Terminating Resistor 174 3016 Cable 153 2707 Receptacle Tee LL 133 0970 m S Cable Cable 165 0200 ECM 707 153 2707 P1 J1 a p EEE RE E a Cable z Cable 165 0200 J1939 Z 153 2707 Module x T e Cable able 165 0200 J1939 153 2707 az a Terminating Resistor 174 3016 1 Two terminal resistors are required Optional Customer Harness provides the resistor at the ECM if installed 2 Maximum stub length 1 m 3 3 ft 3 Fabricate 153 2707 cable to length NOTE f the requirements for J1939 data link connections are met any number of display modules or service tool connectors may be connected to the J1939 data link NOTE One terminal resistor for the J1939 data link is included in the optional customer harness If the optional cus
63. e not imposed on the turbocharger structure or exhaust manifold e Never allow the turbocharger to support more than allowable loads Reference TMI System Data or Engine Sales Manual for Commercial applications and Engine Technical Specifications e Allowable Distance from Turbocharger to Cat CEM is restricted by the maximum backpressure and maximum length for engine application To determine values of straight pipe equivalent length for smooth elbows use Standard 90 elbow 33 x pipe diameter Long sweep 90 elbow 20 x pipe diameter Standard 45 elbow 15 x pipe diameter Backpressure Verification Excessive pressure drop backpressure in the exhaust will adversely affect the performance of the engine and the Cat CEM system It is required that the 2013 Caterpillar 80 10Dec2013 All rights reserved systems meet these criteria for optimal performance Excessive pressure drops can yield higher than expected exhaust temperatures lower fuel economy reduced altitude capability and less than rated power The maximum pressure drop for these systems is shown in the backpressure Table 7 5 Commercial System Backpressure Table Measuring Backpressure Exhaust backpressure is measured as the engine is operating under full rated load and speed conditions High Idle for Naturally Aspirated engines Either a water manometer or a gauge measuring inches of water may be used Refer to Fig 7 16 or Fig 7 17 Fig 7 16
64. e whole cavity of the CEM reactor without having to wrestle with or stuffing ceramic fiber insulation in and around the SCR blocks This new design makes the installation of the canned blocks much easier to handle and secure in place with little or no tools 2013 Caterpillar 63 10Dec2013 All rights reserved The bottom most part of the reactor has a diffuser pan this pan which allows the exhaust to flow through while keeping the back pressure of the exhaust low This pan can be stood on to install the first grid layer EERE EITEL TITTET CEEI Installing the grid For the bottom most layer bring 1 grid half in rotated as shown to fit in the door The channel support on the ceiling can be used to hoist the grid into place To make installation easier the quarter inch T pinned anchors on the sides can be removed and re pinned after the grids are in place Note The vertical quarter inch beam with the 3 holes in it is located on the inner most triangular support on the grid In the corresponding images it is shown located on the outside which will be the case in the production builds 2013 Caterpillar 64 10Dec2013 All rights reserved Lower the grid half into place by keeping it rotated as shown Once the grid edge is resting on the bottom grid support ledge push the grid edge into this corner and allow the grid to rotate until the other flat surface hits the other side of the ledge Start from the b
65. egory whereas cable mount and stabilizer fall under the flexible mount category The pros and cons associated with the stabilizer and cushion cable mount options are as follows 1 Stabilizer option is more prevalent than the cushion and cable mount options 2 Stabilizer is around 20 cheaper than cushion and cable mount 3 Noise and vibration is more with stabilizer option In order to isolate the vibration from the mounts the mount stiffness requirements are as follows 1 The mounting bracket should be at least 10 times stiffer than the mounts fixed and flexible 2 Foundation should be 10 times stiffer than the mounts fixed amp flexible 2013 Caterpillar 51 10Dec2013 All rights reserved Otherwise no vibration isolation from the mounts U Flow System Level Schematic As shown in the schematic below for U flow the exhaust gas inlet and outlet are on the same side of the CEM The CEM is supported with fixed mount on the inlet amp outlet side to keep this side of the CEM rigid limiting the stresses on the bellows on upstream side of CEM However the other side of the CEM is supported on flexible mount to take care of dynamic conditions and allow thermal expansion of the CEM Converter As Inlet Spool Outlet Spool Cover Gp Mounting As System Level Schematic U Flow Muffler Tailpipe AT Aftertreatment AT System Fixed Mount Flexible Mount 2013 Caterpilla
66. end and flex mount on rear end This is a vertical exhaust flow U Flow Aftertreatment Mounting Vertical Flow From factory changes e NOx sensor Ae moved e Mounting feet relocated Inlet amp Outlet 3 NOx sensor es same as orizontal config a Fixed Mount Door removal for SVC C components Thermal Expansion Flex Mount Side Vertical Mounting Mounted on Floor 2013 Caterpillar 56 10Dec2013 All rights reserved The U flow aftertreatment can be mounted on side vertical with two fixed on bottom front and two flexible on the bottom rear The height of the CEM can be supported using two flexible mounts on rear top of the CEM U Flow Aftertreatment Mounting Side Vertical Supported on bottom i Spool rotated NOx sensor moved Outlet Spool Thermal Expansion Fixed Mount Thermal Expansion Inlet Spool Z Flow Mounting Configuration Z Flow mounting has similar mounting requirements as U Flow mounting but the exhaust flow is from end to end instead of in and out at the same end This difference should drive more consideration for exhaust interface and use of bellows to align engine exhaust to CEM Refer to U flow fixed and flexed mounting The vertical mounting will require additional capabilities for bellows movement Z Flow Aftertreatment Mounting 2013 Caterpillar 5 10Dec2013 All rights reserved Z Flow Aftertreatment Mounting Vertica
67. endation is to use 5G s to evaluate worst case e If CEM or engine is hard mounted mount deflection values should equal O 2013 Caterpillar 116 10Dec2013 All rights reserved Appendix D AUS DEF Handling Refer to Caterpillar Fluid document PELJ1160 01 for additional information on DEF fluids Hazards Identification AUS DEF AUS32 aqueous urea solution 32 or 40 is a colorless liquid with a slight ammonia pungent odor Note Consult the Material Safety Data Sheet MSDS provided by your AUS32 supplier MSDS example is e MSDS Number 2046 Revised October 4 2006 for Urea Liquor supplied by Terra Industries Inc Warning AUS DEF is a stable material but highly reactive with strong oxidizers Avoid contact with all oxidizers AUS DEF reacts violently with sodium hypochlorite such as Clorox or calcium hypochlorite to form the nitrogen trichloride which spontaneously explodes or rapidly decomposes creating toxic fumes which may cause personal injury or death When heated AUS DEF releases ammonia When heated to decomposition such as in a fire it emits toxic fumes of nitrogen oxides NOx ammonia and cyanuric acid Use water to control fires involving AUS DEF liquid if water is compatible with burning material Note that both AUS DEF liquid and solid AUS DEF are non flammable In storage a very small amount of the AUS DEF in the liquid state will hydrolyze forming gaseous ammonia and carbon dioxide The
68. erved Example of Bolting Method Torque collars must be used to provide thermal expansion Note Unit must be bolted to the mount utilizing the Bolts washers torque collars and nuts shown in the diagram Torque collars must be used Bolt Torque is set at 200 40 N m 118 177 lb ft This will ensure proper freedom for thermal expansion and contraction Initial Startup See Appendix B Initial Startup Procedures Service and Maintenance Catalyst storage Caterpillar requires that if the catalyst are not installed in the CEM right away then the catalyst need to be stored indoors out of the weather The shipping pallets that the C280 catalyst arrive on are not totally sealed and are not totally impervious to rain water 3500 and C175 SCR Access SCR catalyst cover access needs to be considered when designing the installation of the CEM The ability to remove the service cover and the SCR catalyst is required The minimum catalyst removal length is 450mm which includes the handle and the catalyst The handle is used for pulling the catalyst out of the CEM and the ability to carry the catalyst The minimum length shown below is only needed on the service side cover side of the CEM The service cover is the only access point into the CEM besides the inlet and out ports Refer to the Assemble and Dissemble guide for complete instructions on to remove the catalyst from the CEM 2013 Caterpillar 60 10Dec2013 All rights rese
69. exhaust temperature loss through the exhaust pipe requirements is to meet temperature loss requirements in table below Engine 10 Rated Load Platform Max Temp Drop Allowable Engine RPM range during test 3500 C175 Rated Speed C280 e Table 7 8 Allowable temperature loss from turbo to CEM 4 Joint Loading amp Supports Loading Flange load limit CEM connection flange load limit for either end of the exhaust pipe connection has a maximum allowable load limit This load is a function of the material and geometry of the flange exhaust outlet and the CEM exhaust inlet 2013 Caterpillar 15 10Dec2013 All rights reserved The flexible joint should typically be positioned to minimize cantilever type loads to the turbo exhaust outlet connection and CEM inlet and outlet The following table provides guidelines for Dynamic loading of the connection interface at the engine turbo exhaust and Cat CEM inlet and outlet All reference to turbo outlet load must be verified with TMI load requirements for the engine of your application Exhaust ae ae Allowable etal nection Joint Joint Type ae load CEM Inlet Outlet 3512 Cat Pattern i ee 400 N m 100N m CEM CEM Inlet Outlet 3516 3516 Cat Pattern Cat Pattern Flange 2x10 12 400 N AO N m 100N m 00 N AO N m 100N m CEM Inlet Outlet C175 16 ANSI DIN ae 100 N m 60 N m Table 7 9 Exhaust Joint Loading Table Guidelines Determining All
70. f the CG location of the supported pipe in meters second squared feet second squared m s2 ft s2 L Distance from the CG of the supported pipe to the Cat CEM joint in meter feet m ft Method 2 Supported Exhaust Pipes If the pipe is connected to the e CEM Inlet or Turbo Outlet connection e Flex joint e And is supported in some way off of the engine or CEM or it s mounting structure This alternative method must be used to evaluate the flange loading Some form of rigid Support is recommended on both sides of the flexible joint to prevent joint failure at the CEM or engine e If supporting between the bellows and engine the support structure should be mounted on the engine e If supporting between bellows and aftertreatment system the support structure should be mounted from the aftertreatment system e This will insure the bellows functionality and not induce undue stress in the flexpipe system components It is critical that exhaust pipe support be done in such a way that thermal growth of the exhaust pipe does not result in loading either the turbo exhaust outlet or the CEM inlet This may mean that the pipe be supported for typical static weight and G loading while also allowed to move such that the exhaust pipe thermal growth is taken up by the flex joint rather than exerting a force on the turbo exhaust outlet or the CEM inlet Allowable loads must not be exceeded when designing the flexpipe interface connections
71. for identification and part service requirements No OEM part numbers or supplier part numbers will be stamped on the device 2013 Caterpillar 6 10Dec2013 All rights reserved Document Layout This document provides application information specifications and installation procedures to install Cat CEM for selected Caterpillar engines that meet US Tier 4 and IMO III emissions regulations To determine which module is available for your engine application please review the following Caterpillar Clean Emissions Strategy Table for the emissions technology provided for the selected engine Platform s After reading and understanding the Cat CEM technology overview proceed to that Cat CEM Components section for detailed design and installation information The Appendix contains additional detailed design and installation information and is referenced throughout the document This document provides the required information for Cat CEM mounting including electrical plumbing and exhaust connections Note There are critical specifications required for proper performance and compliance with U S EPA IMO Ill and European Commission regulations Failure to meet these requirements will constitute a mis build and prompt notification to Caterpillar is required Installation Audits are required for each new application build Tier 4 Emissions Strategy Table Caterpillar Clean Emission Strategy Engine Aftertreatment onleations Platform Technology
72. fy both exhaust flex pipe and CEM vibration considerations CEM Engine Preferred 7 e Mounting _ ae Hard Hard ee Hard Isolation Hard Vibration Isolation Vibration Vibration Isolation Isolation See notes with regard to scenario 3 amp 4 in the detail below Scenario 1 CEM Hard Mounted Engine Hard Mounted This is a not preferred scenario Although this scenario often provides the best case in terms of flex pipe capability it is not preferred because the CEM is exposed directly to engine vibration In some cases this scenario may be used however extensive vibration testing will be required This scenario should be not used if at all possible Scenario 2 CEM Isolation Mounted Engine Hard Mounted This is a preferred scenario When the CEM is attached to the master structure using vibration isolation mounts it is preferable to hard mount the engine to the master structure This scenario allows the CEM to be isolated from engine and Marine Vessel vibration sources A Marine Vessel vibration source may originate from rotating equipment associated with trenching drilling chipping amp grinding road building equipment etc Cat typically prefers to supply these isolation mounts as part of the engine package Flex pipe relative movement due to isolation mounting is minimized since isolation mounts are only used for the CEM 2013 Caterpillar 86 10Dec2013 All rights reserved Scenario 3 CEM Hard Mounted Engi
73. ge can be reasonably estimated as a direct fraction of the engine fuel burn on an average the amount of AUS DEF consumed by the engines will be around 10 for the 3500 engines and upwards of 15 for C280 engines Example for 3500 engine is 1 gallon of AUS DEF for every 10 gallons of fuel usage Such a calculation must be based on the amount of fuel that may be burned by the engine engines between AUS DEF fill up opportunities This value should be based on an operational Knowledge of the vessels expected service and the engines projected fuel usage The AUS DEF tank should then be sized to accommodate the requisite fraction of AUS DEF as outlined in the table below As an example if an analysis of the operating profile of a 3500 sized engine shows that it could burn 1 000 gallons of fuel between AUS DEF fill opportunities then the AUS DEF tank would need to be sized to hold at least 100 gallons of 32 5 AUS DEF over and above any space taken up by any tank inserts such as level switches When figure out the fuel usage and AUS DEF usage the operation profile must be used to determine both fuel tank size and AUS DEF tank size 2013 Caterpillar 32 10Dec2013 All rights reserved The urea AUS DEF tank placement into a Marine Vessel must be designed into a place where the urea will not be allowed to freeze Caterpillars normal tank freeze protection system volume of 2 for freeze expansion volume will not be required Cate
74. hown below The two mounting feet on inlet and outlet sides are fixed and that on the opposite side are allowed to move using flexible mounting U Flow Aftertreatment Mounting Horizontal Factory Position Thermal Expansion 2 Flex Mounts 4 Fixed Mount amp 4 a S Fixed Mount SVC Service 2013 Caterpillar 54 10Dec2013 All rights reserved U Flow Aftertreatment From factory changes Mounting Upside Down Inlet amp Outlet Spools rotated Mounting feet relocated Inlet sensor box on top Door removal for SVC components Intlet NOx sensor 2 O clock position Supported from bottom Outlet NOx sensor 12 O clock position Horizontal Mounting Hanging The U flow CEM can also be mounted horizontally with two fixed support on the inlet and outlet sides whereas other side is allowed to move using two stabilizers on top yi Y 2 stabilizers on rear 4 2 fixed mounts on from k i a In another configuration the aftertreatment can be mounted horizontally with four stabilizers on top allowing flexibility to CEM while one fixed support on bottom front prevents excessive movement of the CEM 2013 Caterpillar 55 10Dec2013 All rights reserved Astabilizers on top 1 fixed mount on bottom Vertical Mounting Vert Flow The U flow aftertreatment can be mounted on rear end with fixed mount on exhaust
75. hts reserved 18 7 kPa Total Max 12 kPa delta P Fig 7 13 Exhaust System Example for Cat Aftertreatment Example of Apportioned Pressure Drop Calculation Reference figure and table above OEM Installer kPa Total Backpressure kPa Cat CEM kPa OEM Installer kPa 18 7 12 6 7 Where Total Backpressure 18 7 kPa Cat CEM 12 kPa Calculating Exhaust Restrictions Estimation of the OEM piping backpressure can be done with this formula p 0 22L Q 460 T D P Pressure drop backpressure measured in inches of water L Total equivalent length of pipe in feet Q Exhaust gas flow in cubic feet per minute at rated conditions D Inside diameter of pipe in inches T Exhaust temperature in F 4 87 2740 Nom Pipe Dia in Actual ID in D 5 in 6576970 8 787 30192 Table 7 6 Pipe Diameter D Calculations 2013 Caterpillar 13 10Dec2013 All rights reserved Based on a tube width of 1 65mm Calculation will vary if thickness is different such as 1 8mm To determine values of straight pipe equivalent length for smooth elbows use Standard 90 elbow 33 x pipe diameter Long sweep 90 elbow 20 x pipe diameter Standard 45 elbow 15 x pipe diameter To determine values of straight pipe equivalent length for flexible tubing use L Lfx2 Important considerations e Sharp bends in the exhaust system will significantly increase exhaust ba
76. inet buffer tank from main tank Table 4 6 manual drain straight thread O ring Table 4 6 vent amp overflow AS5131 dosing cabinet Ya X16 CEM to dosing cabinet 9 16X18 CEM to Dosing Cabinet Cabinet Dosing cabinet to 120V Cabinet AC source from engine to atmosphere Table 4 1 Interface Connections Air System Compressed Air is used e To assist in the atomizing of the liquid AUS DEF as it is injected into the exhaust stream e To shield the liquid AUS DEF in the injector from the exhaust heat until injection so that no crystallization occurs which could plug the injector nozzle e To purge the AUS DEF line during shutdown in order to prevent crystallization Typically compressed air will carry some oil from the compressor and some sediment from the piping This debris can collect in the nozzle and clog the unit Use a coalescing filter separator that is 90 percent effective that is rated for 1069 kPag 155 psig and 849 5 liter min 30 CFM 2013 Caterpillar 17 10Dec2013 All rights reserved Reference Air Filter Requirements in the sub section Air Filter Recommendations for details An air dryer is recommended to keep relative air humidity below 10 The air supply delivered to the dosing cabinet must meet the specifications in Table 4 2 when engine is running and any non parasitic load Oil Content mg m Max Particle Size Max micron 40 micron Particle Density Max mg m _Air delivery c
77. issions reduction Control of the temperature loss through the exhaust pipe from turbo out to CEM inlet is required to maintain this average temperature There are two methods that can be used to determine if this temperature loss is acceptable 2013 Caterpillar 14 10Dec2013 All rights reserved e Meeting Maximum exhaust length requirements e Meeting the exhaust temperature loss requirements Maximum exhaust length One method to meet the temperature loss requirement is to not exceed the specified maximum exhaust lengths Table below provides the maximum allowable OEM exhaust pipe length to maintain an acceptable temperature loss Engine Application Max Length Max Length Platform eed Inches 3512 60in 3516 C175 Table 7 7 Maximum allowable exhaust length Some commercial installations may require an exhaust pipe that is longer than the maximum If the maximum exhaust pipe length requirement cannot be met then the installation must meet exhaust temperature loss requirements Providing insulation of the exhaust pipe in most cases will maintain the necessary exhaust temperature loss requirements Maximum lengths in table above are provided for installations in which the exhaust pipes are not in the direct path of any fan air flow If any portion of the exhaust pipe is in the direct path of fan air flow the exhaust temperature loss requirements must be met Exhaust temperature loss requirement The second method to meet
78. ittings that are made of the above materials The 40 urea solution will have the advantage of smaller storage tanks while maintaining the freezing point of water Caterpillar recommends AUS 32 5 solution per ISO 22241 1 AUS DEF must be kept below 50 C 122 F to keep it from decomposing too quickly and above 11 C 12 F to prevent it from freezing during cold operation According to Caterpillar specification 1E4413 storage near 25 C provides a shelf life of approximately 18 months while storage around 35 C reduces storage life to approximately six months Other storage and handling methods have to be followed The best operating temperature for the urea solution is 5 C to 50 C 23 F to 122 F If ambient temperature goes below 11 C AUS DEF inside tank and lines outside dosing cabinet need thawing before starting AUS DEF dosing 2013 Caterpillar 20 10Dec2013 All rights reserved The thawing time requirement is defined in the EPA SCR guideline CISD 09 04 The dosing cabinet has a freeze prevention strategy Dosing Strategies The dosing cabinet requires a AUS DEF supply of 5 10 psig with a max of 10 psig at the dosing cabinet AUS DEF supply inlet There is no AUS DEF return line back to the remote tank from the tank located inside the dosing cabinet A vent in the dosing cabinet release purged air amp AUS DEF vapor during purge event The vent line connected with the dosing cabinet should
79. ize industry standard exhaust connection components For further Exhaust System Requirements reference Section 4 Exhaust system 2013 Caterpillar 44 10Dec2013 All rights reserved Outlet Sensor Box Inlet Sensor Box Exhaust Outlet Exhaust Inlet DEF Injector Top front view of Z Style SCR CEM for 3516CHD U Flow CEM Sensor Control Box Sensor Control Box DEF Injector Exhaust Exhaust Inlet Outlet Flange Flange Top front view of U Style SCR CEM for 3516CHD 2013 Caterpillar 45 10Dec2013 All rights reserved B635 1 5 I 15369 Al B coy Fig 4 16 3516 CEM Exhaust Inlet amp Outlet Flange Dimensions Sound Attenuation See TMI for sound attenuation data Installation CEM installation considerations should be based on application location environment and serviceability Serviceability includes but not limited to repair and maintenance of CEM System components This may include dosing cabinet sensors catalyst and dosing injectors The inlet spool on the CEM that houses the AUS DEF injector is flexible through orientation for better serviceability Careful attention to details such as this will enhance service and maintenance of Caterpillar aftertreatment systems 2013 Caterpillar 46 10Dec2013 All rights reserved Inlet Spool Orientation Flexibility Option to Enhance Service Access _ Removal distance 20 Min
80. l From factory changes e Mounting feet relocated Outlet Spool e Spool rotated optional Door removal for SVC Thermal components Expansion oe Fixed Mount Inlet Spool Lifting Four lifting links are to be bolted to the CEM assembly and lifted as illustrated below Spreader bar might not be required if lifting straps are used and straps are kept away from all sensors and wiring harness on the inlet spool and CEM Lifting Options aa Do not use forklift As forks may damage skin of module 2013 Caterpillar 58 10Dec2013 All rights reserved C280 CEM Installation Guidelines for Lifting and Installation e Use all lifting lugs when lifting the CEM Clean Emission Module or Reactor into place e Use all mounting feet when securing the CEM housing into its operating position e Make sure all ports openings and connections are clear from obstruction Lifting Instructions 1 The CEM should be delivered lying on its side in the horizontal position the lifting eyes must be used to remove from the bed of the shipping or delivery truck 2 Use 2 or more sets of lifting eyes to rotate the reactor into the upright position while keeping the bottom secured but free to rotate A safety chain can be used on each of the bottom opposing feet to prevent the unit from slipping Do not lift the CEM off of the ground with only 2 lifting eyes 3 Rotate it into the upright position first and only after it
81. lacement Parts cccceeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeaaaaas 9 Tier 4 or IMO Ill Emissions Requirements c csseeee 9 TEFMINOIOGY vautseutvecvem someon a a a N ia 11 2 Cat CEM Overview sssssssnnnnnnnnsnnnsnnnnnnnnnnnnennne 13 Cat CEM Systems aannnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 13 Technology Component Descriptions 2eeeeeeeees 13 3 SCR Clean Emissions Modules 0 008 15 Introduction and Purpose as asnnsnnunnnnnnnnnnnnnnnnnnnnnnnnnnnne 15 System Hardware Overview ssssnnnssnnsnnnnnsnnnnnnnnnnnnnnnn 15 CEM Application Guide nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 16 Cat CEM Mandatory Interface Connections 17 AI OV SCO ected e terete sacecek E AR 17 AUS DEF System sesecccccastessdinccasneaessecamenaenctascececseenaicsce 19 AUS DEF Specifications ccccccceeeeeeeeeeeeeeeeees 19 Dosing Strategies ccc cece eee eee eee ne eeeeeeeeennenes 21 DOSING Cabinet wsicececescaniesescccchenteccessegasersen ekncesctecis 22 AUS DEF Delivery System iscccosci cacceerereceriewtasineivsciicin 29 PATS DEF HandliNg seinni 29 Material Selection for Tank and Piping sceeees 29 AUS DEF LINCS st uescecsasweccdteecentasseceeiewenesetacbetansucsteneenees 30 AUS DEF Storage Tank eiveccccrecoscatsash excaceetceniersecSsetsdeces 31 EOC HICAN aarace aa csacee sac acta ci aaua ease se aanine i 38 EXMAUSE SV SCC
82. lateral displacement at the output load Load per Mount G Load N See step 5 above AXIAL RADIAL This chart will differ by mount LOAD N DEFLECTION mm 7 Input Axial and Radial Lateral displacements into spreadsheet for engine and CEM respectively AXIAL RADIA 30000 25000 20000 LOAD N 15000 10000 5000 cal per od aa 0 0 1 0 2 0 apes 5 0 6 0 ENGINE INPUTS EM INPUTS Calculation Do not edi _ EatulationDonoteqy T Load per mount G Load N 161864 pad per mount G U N 25 Mount axial ais lacement above load mm 5 Mount axial displacement above load mm 0 9 Mount lateral displacement above load mm q Mount lateral displacement g above load mm 2 5 8 Take measurements of all points relative to point A Front left engine mount Measurements npu awim gatie i i D Walue mim gine A moun ATix t jaane AT y negative if to the front of the engine A mount DE Shortest distance between mounts across wi
83. m design in order to quickly evaluate several possible mounting configurations before moving on to more thorough analysis such as FEA This analysis can be run by individual customers on their own commercial or in house software The analyses run with a rigid body code are identical to those described above for FEA The only differences are that the rigid body analysis can be built run interpreted altered and rerun much faster than FEA and that some additional model outputs need to be checked In particular the static g loading results should be checked in the following ways e Peak loads through mounts should be compared with limits associated with the bolted joints e High cycle mount deflections should be compared to the deflection strain limits for the mounts being used e Motion across the exhaust bellows should be compared to their limits e Motion of other critical parts of the CEM extremities near tight clearances for example should also be checked Once a design has been found which meets all the criteria that a rigid body model check can the next step is to move on to a FEA model to check the same things plus stresses of metallic structures with more precision Using analysis results to guide design changes lf a particular design did not pass all the criteria after running rigid body or FEA analysis The results of the failed design can help determine what changes are necessary to improve the design Some examples of correcti
84. mits are provided for each engine model Consult the Technical Marketing Information TMI for the appropriate information Flexible Joints Flexible joints are needed to isolate engine movement vibrations and Marine Vessel frame deflection Bellows take up dynamic axial and lateral movement Ball joints compensate for radial misalignment Slip joints compensate for axial misalignment Additionally they are needed to offset assembly tolerances and thermal expansion and contraction of the main exhaust Great care should be taken to ensure that these factors are accounted for in the design and development of the flexible sections of these systems From its cold state 304L Stainless Steel will expand 0 3mm 0119in per 305mm 1ft per 50 C 122 F temperature rise If not accounted for the thermal growth 2013 Caterpillar 11 10Dec2013 All rights reserved can exert undue stress on the engine and Cat CEM connections as well as the pipe supports See the Allowable Joint Loading section for specific requirements The Cat CEM exhaust outlet piping with additional components such as exhaust temperature cooling devices exhaust stacks and long lengths of unsupported pipe should be designed and reviewed per Caterpillar OEM and installer agreement All installation requirements per this A amp l guide must be complied with per agreement outlined in the introduction of this document It is important that the flexible sections continue to meet
85. ne amp CEM mount information Independently moving engine Independently moving CEM How does the bellows move to compensate 2013 Caterpillar 109 10Dec2013 All rights reserved Spreadsheet Preview ENGINE INPUTS Mount Specifications Engine Mass kg 2201 of mounts G Load Lookup Input Mount axial displacement above load mm Mount lateral displacement above load mm Measurements Input AM x negative if to the left of engine A mount AM AMZ AT X negative if to the front of the engine A mount negative if below the engine A mount negative if to the left of engine A mount A negative if to the front of the engine A mount ATiz negative if below the engine A mount Shortest distance between mounts across width of engine Shortest distance between mounts across length of engine lt D D 3 a AE n gt ic a I co AJO 189 und Calcs The s ickgrc Acceptable Max Bellows Capability Radial Max Bellows Capability Axial Max Movement Radially Calculated Max Movement Axially Calculated CEM INPUTS gt a El Mass k o y Ea foal Value mm Bs no u w ji Ajoji aji j on Ajo A Al g i AR z negative if below the engine A mount AG x negative if to the left of engine A mount A i A AH x negative if to the left of engine A mount negative if to the front
86. ne Isolation Mounted This can be a preferred scenario When the engine is attached to the master structure using vibration isolation mounts it is preferable to hard mount the CEM to the master structure This is typically preferred for installations that do not have Marine Vessel vibration sources See Scenario 2 for examples of Marine Vessel vibration sources If this scenario is to be used with Marine Vessel vibration sources then extensive vibration testing may be necessary In this scenario only 1 of the 2 components is isolation mounted Flex pipe relative movement due to isolation mounting is minimized since isolation mounts are only used for the engine Scenario 4 CEM Isolation Mounted Engine Isolation Mounted This is not a preferred scenario When the engine and CEM are both attached to the master structure using vibration isolation mounts CEM vibration will tend to be acceptable However exhaust flex pipe relative movement capability may be difficult or impossible to satisfy In this scenario relative movement will originate at both the engine and CEM The relative movement at the exhaust flex pipe will be equal to the movement allowed by the isolation mounts at the engine and CEM and their component s relative position to the exhaust flex pipe If the engine and CEM are not in close proximity then achieving flex pipe capability requirements in this scenario may be impossible This scenario may be required for installations tha
87. ng cabinet to meet the grounding requirements Refer to wiring example in Fig 4 8 24volt wire harness J1939 Fig 4 15 120V AC Connection Diagram 2013 Caterpillar 41 10Dec2013 All rights reserved Electrical Loads SCR Component Electrical Load Assume Cold Ambient Temps AC e e Manifold heater heater ac ace Sa k sacs Sa Se O n ECM 0 3 e ea pepe e e fo oe Sensors 3 Air supply enable DC solenoid 4 Reagent return solenoid 5 Pump fill solenoid 6 Pump motor DC Heater 7 AUS DEF Transfer Pump Relay D Optional Customer Supplied Total Component NOTE Power consumption w SCR Aftertreatment system This does not include air compressor and air dryer Table 4 5 Electrical Loads Electrical Component temperature limits There are components on the CEM that are required to stay under specified temperature limits The sensor box on the CEM contains the critical electrical components such as the NOx sensors and temperature sensors The pressure sensors may or may not be located in the sensor box It is necessary that the components in Table 4 6 do not exceed the listed specifications during operation of the engine system 2013 Caterpillar 42 10Dec2013 All rights reserved Component Temperature Limits Temp Limit Component Temperature Sensor NOx Sensor Control Box Delta Pressure Sensor Table 4 6 Electrical Component Temperature Limits Electric
88. nlet port on the screen filter is Male 1 2 NPT If the system will be shut down in freezing conditions or put into storage the screen filter and supply line should be drained Customer is responsible for protecting the supply line from freezing and damage from foreign objects stainless steel supply line is recommended See maintenance schedule for service interval of AUS DEF screen filter The filter is reusable and can be cleaned using an ultrasonic bath Refer to figure below for interface and installation on dosing cabinet 2013 Caterpillar 19 10Dec2013 All rights reserved Air amp AUS DEF Strainer Locations Aur Strainer 3 8 Male NPT Fig 4 2 Dosing Cabinet Air amp AUS DEF Interface Connections ISO 22241 3 has comprehensive list of AUS DEF compatible materials including 300 and 400 series stainless steel Ethylene Propylene Diene Monomer EPDM Polyethylene Polypropylene and etc Any O rings must be EPDM Reference Material Selection for Tank and Piping found later in this section for details regarding tank material size piping fittings etc CAUTION Base material and their alloys of copper zinc aluminum and magnesium are not compatible Also soldering material containing silver and nickel coatings are considered not compatible with AUS DEF Carbon steels zinc coated carbon steels and mild iron are not to be used with AUS DEF Do not store AUS DEF in a tank or use supply lines or f
89. nt the cabinet to the vessels mounting structure 2013 Caterpillar 2 10Dec2013 All rights reserved laa YS i Ty a Hole sized formo is J Bolt X4 Mounting DA Brackets Fig 4 12 Mounting Dosing Cabinet Lifting Slots v Refer to Section 5 Mounting Considerations for additional mounting guidelines Clearance Dosing cabinet is required to have clearances around the outside of the box per Fig 4 13 If one of the sides with 2 ft of clearance is not accessible then it is required to have 4 ft of clearance on the side that is accessible and is not necessary to maintain the 2 ft of clearance on the inaccessible side Fig 4 13 Dosing Cabinet Mounting Clearance Requirements Orientation 2013 Caterpillar 28 10Dec2013 All rights reserved The dosing cabinet has to be mounted per Fig 4 12 in the vertical position The cabinet needs to be mounted with the top of the cabinet parallel with the horizon The dosing cabinet should not be tilted by more than 18 deg from the vertical position Location Mounting location of the Dosing cabinet must be within 10 meters 30ft of the CEM injector and the top of the Dosing cabinet must be at or below the bottom of the CEM Mounting pads The maximum pressure drop in the AUS DEF Line between the Dosing Cabinet and CEM injector nozzle is 29 psi or 200 kPa Environment The dosing cabinet needs to be located
90. of the engine A mount Alx negative ifto the left of engine A mount AH z negative if below the engine A mount N R G y negative if to the front of the engine A mount AG z negative if below the engine A mount H EA fa ES ojo W O amp ojo njoo preadsheet consists of data input from engine and CEM application and installation parameters to determine bellows mount capability Engine setup typical e Top View A B C D Engine mounts G H I J CEM mounts R CEM Inlet T Turbo M Bellows Inlet N Bellows Outlet A Zero Point All points measured relative to A 2013 Caterpillar All rights reserved X XXX TU UUI XXX 0 0 XX 0 110 10Dec2013
91. ompressor capability 0 Air Pressure at Engine Startup 70 PSlg at start up OR 70 PSlg within 3 minutes maintaining lt 30 load or CEM outlet temp lt 250C Table 4 2 Air supply delivery requirements at Dosing Cabinet Inlet Note An optional air compressor system is available from Caterpillar that is designed specifically for use with the Caterpillar CEM SCR Please refer to the air compressor A amp l guidelines for requirements Air Supply Line Requirements The air line that is used for delivering air from the dosing cabinet to the injector is to be sized and routed such that the pressure loss across the line is no greater than 1 0 PSI at the maximum flow capacity Note Routing of this air line must progress continuously without air locks or line bends that would allow condensation to form and freeze preventing air supply to Dosing Cabinet air valve Secondary Air Filter The AUS DEF dosing cabinet requires customer to provide compressed air to the dosing cabinet which meet ISO 8573 1 Class 5 requirements specified in Table 4 2 above A cabinet contains a secondary air screen filter at the dosing cabinet air inlet Air inlet port on the screen filter is Male 3 8 NPT It is recommended to have a dryer installed on the compressed air system to maintain the lt 10 relative air 2013 Caterpillar 18 10Dec2013 All rights reserved humidity See Air amp AUS DEF Filter Installation figure below for interface
92. ons and are necessarily of a general nature since only the installer is familiar with details of the installation The suggestions provided in this guide should be considered general examples only and are in no way intended to cover every possible hazard in every installation The information in this document is the property of Caterpillar Inc and or its subsidiaries Without written permission any copying transmission to others and any use except that for which it is loaned is prohibited Contact the appropriate application support group for the latest information on Cat CEM guidelines and requirements 2013 Caterpillar 5 10Dec2013 All rights reserved CAT CATERPILLAR their respective logos and Caterpillar Yellow as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission This document serves as Caterpillar s instructions required by U S EPA regulations 40 C F R Part 1068 to facilitate the selection and application of the correct Cat CEM module by the OEM or installer based upon engine selection Requirements and Agreements 1 Each OEM shall enter into a delegated final assembly agreement with Caterpillar Inc as required by 40 C F R 1068 261 This publication fulfills Caterpillars obligation under 40 C F R 1068 261 c 2 to provide installation instructions to ensure the engine will be in certified configuration 2 OEM is required
93. original engine emissions label clearly visibile Yes No lf no describe location of duplicate label Is there an oil renewal system present any form of system that attempts to combust used engine oily Is API CJ 4 ACEA E9 or DEO ULS oil sticker visible at all lube Till points Is ULSD sticker clearly visible on all fuel filing points Please describe all locations Yes No Yes No Yes No Are the flexible bellows in the exhaust system supplied by Cat Yes No If wes Caterpillar flexible bellows part s For third party flexible bellows in the exhaust system ts there a copy of the fatigue analysis similar to EJMA calculation Is the exhaust piping stainless steel from the mixing tube urea injection nozzle to CEM The required 300 400 Series Stainless Is the turbo to CEM inlet exhaust piping fully insulated Does the installation provide Engine and SCR system warning fault communication to the operator Specify ether Lamp or type of communication and indication Any customer supplied afttertreatment components installed before or atter the factory CEM Is the Inlet and outlet spool on the CEM oriented and supported correctly per A amp I guide instructions Does CEM installation account for thermo growth per A amp l guidelines Is the Dosing cabinet ts located correctly to the lance nozzle per A amp I instructions Does urea tank meet A amp I guide lines Is their a low level DEF sensor installed in main urea tank an
94. osing Cabinet Normal functions operations of a dosing cabinet include e Monitor and dose AUS DEF e Monitor and regulate compressed air e House Electronic Control Module ECM e Provide customer connections The Aftertreatment ECM in the dosing cabinet will communicate with the engine over J1939 data link via the electronic connector on the cabinet interface illustrated below Dosing cabinet is shipped fully calibrated to work within specified operating conditions If the operating conditions change beyond the specification additional care needs to be taken to address these issues Whenever a critical component is replaced recalibration might be required The dosing pump comes with a tamper evident sticker If this sticker is damaged due to normal wear and tear please contact the local Caterpillar dealer for replacement If this sticker is tampered with this implies EPA violation 2013 Caterpillar 22 10Dec2013 All rights reserved Dosing cabinet Housirg Houses ECM Dosing Pump Air Regulator Dosing Manifold Air Marifold Accumulztor Valves and sensors Connection Panel Contains all dosing cabinet interface conaect on points Mounting Legs Fig 4 5 Dosing Control Cabinet Dosing cabinet connection points Dosing cabinet communicates with external components via its connection points These connections could be electrical air and AUS DEF For descriptions about the connections and their meaning see Table 4 3
95. owable Joint Loading Joint loading is complicated by several factors that fall within OEM design control Application installation design should be designed to protect the Cat CEM devices from dynamic loading in addition to the resonance concerns that would cause system overload e Exhaust pipe Supports o Support Locations o Type of exhaust support e Pipe Considerations from closest support to Cat CEM connection points o Weight o Length o Center of Gravity CG e Location of Flex Joint The allowable joint load should be evaluated using dynamic load The dynamic load is the combination of factors including weight length of pipe center of gravity and maximum acceleration rate Maximum acceleration rate is typically the maximum anticipated G load As a reference point 5 G is often used in cases where the maximum dynamic load is not well Known CEM or Turbo flange loading will be calculated one of two ways depending upon how the exhaust pipe is supported Method 1 Simple Cantilever Loading If the pipe is simply connected to the e Inlet or Outlet CEM or Turbo connection e To the flex joint Without any other support points then this method can be used to determine the Estimated loading M maL Where M Dynamic load in Newton Meter pound foot N m lb ft 2013 Caterpillar 16 10Dec2013 All rights reserved m Mass of the pipe supported by the joint in kilogram pound kg Ib a Acceleration maximum amplitude o
96. per spool orientation 3500 and C175 U and Z Flow CEM Mounting Cat CEM provisions for mounting are a 4 bolt pattern per pad There are a number of pad locations depending on which way the CEM is mounted in the Vessel Mounting requires the use of at least four mounting pads when mounting in the vessel Bolt requirements are M20 grade 10 9 Bolts 2013 Caterpillar 50 10Dec2013 All rights reserved There are two types of CEM which are based on the exhaust flow direction One type is U flow and another one is Z flow In U flow configuration both the inlet and outlet of exhaust gas are on same side of the CEM Whereas in case of Z flow configuration the inlet and outlet of exhaust gas are on opposite sides of the CEM The mounting components should be able to meet the following requirements 1 Mount should be able to support the weight of the CEM 2 It should be able to withstand the high temperature of exhaust gases 3 It should be able to limit the stresses on bellows from displacement and thermal growth which necessitates the fixed mount on the inlet side 4 There should be flexible mount on the outlet side to take care of dynamic conditions and allow thermal expansion of CEM e L bracket needed for mounting and add to the stiffness e Pipe length has no influence if the weight change is less than 5 There are mainly three types of mounts cushion mount cable mount and stabilizer Cushion mount falls under the fixed mount cat
97. prevent fluids or condensate from running into the above devices Sealing Splices and Ring Terminals Caterpillar requires all ring terminals and splices connected to the engine ECU be sealed using Raychem ES2000 adhesive lined heat shrink tubing or equivalent Refer to Table below for heat shrink tubing sizing information 2013 Caterpillar 99 10Dec2013 All rights reserved I D Before Shrink L D After Shrink Cat Part Number 125 7876 17 78 0 700 0 175 Heat Shrink Tubing Reference Table Wire Connection Guidelines The following requirements ensure the correct installation of solid contacts into connector terminals Do not solder the contact socket or pin to the wire Never crimp more than one wire into a contact Connector contacts are designed to accept only one wire of a specified gauge or gauge range do NOT insert multiple wires of a smaller gauge All contacts should be crimped on the wires Use the Crimp Tool Caterpillar part number 1U 5804 for 12 to 18 AWG wire Perform the pull test on each wire The pull test is used to verify that the wire is properly crimped in the contact and the contact is properly inserted in the connector terminal Each contact and connector terminal should easily withstand 45 N 10 Ib of pull such that the wire remains in the connector body SAE J1939 11 Data Bus Wiring J1939 Data Bus Harness Design The data bus connector that Caterpillar uses is a modified DT connector speci
98. r 52 10Dec2013 All rights reserved Z Flow System Level Schematic As shown in the schematic for Z flow the exhaust gas inlet and outlet are on the opposite side of the CEM The CEM is supported with fixed mount on the inlet side to limit stresses on bellows and flexible mount on the outlet side of the CEM to allow flexibility and thermal expansion of CEM Inlet Sensor Box Insulation Converter As Outlet Sensor Box Cover Gp Mounting As Outlet Spool System Level Schematic Z Flow Inlet High Temp Outlet Low Temp Inlet Spool AT System Mule Fixed Mount Flexible Mount Mounting Support There are three types of CEM support mounts e Fixed Support Exhaust Equipment Category SS Cushion Mount semi custom compression mount 2013 Caterpillar 53 All rights reserved AT Aftertreatment 10Dec2013 e Flexible Support Shock Mounting Category SS Cable Mount Compression mount e Flexible Support hanging Exh Equipment Category Flexible Suspension Tension mount The fixed support which is compression mount falls under the exhaust equipment category The flexible support which is also compression mount is categorized as shock mount However the hanging option which is tension mount is categorized as exhaust equipment U Flow Mounting Configuration Horizontal Mounting Mounted on Floor The basic U flow CEM mounting configuration is the horizontal mounting as s
99. rations The maintainability of the wiring system shall be an important consideration in the selection design and installation of harnesses cable assemblies and other wiring system components All wiring components shall be accessible repairable and replaceable i e connector terminals High pressure wash systems are now in frequent use by maintenance people When locating electrical connectors place them in accessible locations while using other physical elements for protection and prevention of direct exposure to wash systems e g brackets housings sheet metal structure etc Where direct exposure to high pressure wash systems cannot be avoided protective shields will need to be designed and installed Harness Appearance The primary purpose for the wiring system is to provide electrical and electronic component function There is however another important and intangible value to consider when designing the wiring system 2013 Caterpillar 97 10Dec2013 All rights reserved The appearance of the wire harness and its routing path should reflect an orderly well thought out design plan A poorly executed plan can have a negative impact on OEM Installer perceptions of the entire product Use the product s horizontal and vertical lines for routing paths Design preformed bends into large harnesses to facilitate product assembly and improve appearance Use other product elements to shield or hide the harness from view Benchma
100. re to be used in unused wire cavities The Caterpillar OEM Installer harness uses the AEC14 40PAE E019 terminal configuration OEM Installer interface with this harness is the 40 position plug connector Caterpillar part number 324 6267 This connector is labeled as PJ C1 and PJ C2 on Jumper Harness The AEC connectors are keyed to align correctly when the two parts are mated together An Allen head screw holds the two connectors in place Ensure that the Allen head screw is tightened to a torque of 6 1 0 Nem 4 4 0 7 Ib ft Connector Terminal Contacts There are two types of terminal contacts available for production use machined and stamped and formed Machined terminal contact also referred to as a solid contact is used for low volume harness production and for field repair Stamped and formed contact is used for high volume harness production and is the lowest cost terminal contact option Terminal contacts are available with nickel or gold plating Gold plating should be used for applications of 5 volts or less and or less than 100 milliamps Typically these low level circuits require low resistance at the pin socket connection and gold plating is the best low cost choice Nickel plated contacts can be used in power type circuits or circuits where low resistance at the pin socket connection is not a concern Gold plated contacts can be used in all circuit applications regardless of the voltage and current requirements Gold
101. rk new automotive product applications for ideas Harness Bends Routing of the harness should insure connector seals are not stressed because the harness curvature is too close to the connector This applies to routing of OEM Installer lines on or near the engine harness as well as the ECU OEM Installer connector J1 P1 The minimum bend radius for a braided wire harness as measured from the inside of the bend shall be four times the outer diameter of the harness Tighter bends are possible if the bend is preformed during harness manufacture The bend radius size and location must be specified on the wire harness drawing Bends in jacketed cables shall be based on manufacturer recommendations A bend must not adversely affect the operating characteristics of the cable For flexible coaxial cables the bend radius must not be less than six times the outside diameter For semi rigid coaxial cable the bend radius must not be less than ten times the outside diameter of the cable The minimum bend radius for flexible conduit must be six times the outer diameter of the conduit Conduit bends shall not cause internal chafing of the wiring Harness Bends near Connectors Avoid wire harness bends within 25 mm 1 0 in of the connector When a harness bend is too close to the connector the connector seal is stretched away from the wire providing an opening for moisture entry The wire should exit perpendicular to the connector before curving as ne
102. rpillar off road capacity safety margin is 5 of the total tank volume The urea tanks size on Marine Vessels will be designed based on operating load profile of the vessels with a safety factor of never to run out Fuel and urea tank volume will be base on operating profile and normal vessel fueling stop Instances where insufficient AUS DEF is available will be recorded in nonvolatile memory by the engine and the end user must report these instances to the EPA Tank Connections The AUS DEF line suction or pick up connection should be placed at the bottom of the tank and as close to the heat exchanger as possible if installed This location has the greatest potential for the first available liquid AUS DEF during thawing Adequate protection of the pickup tip is recommended to keep unthawed AUS DEF from blocking port On the return side melted AUS DEF returning from the pump has the potential to help thaw the remaining frozen AUS DEF To take advantage of this potential the return port on the tank should be at the top of the tank Tank mounting location in Marine Vessels The ideal location of the AUS DEF tank is as close as possible to the center of gravity of the Vessel This would result in the least sloshing possible Proximity to heat sources should also be considered in tank placement as prolonged exposure to elevated temperatures causes thermal degradation of AUS DEF in the tank The tank should be located in the Ves
103. rved Service Cover The figure above shows the inlet outlet and the service cover for the catalyst The figure below shows the required removal distant to pull the catalyst out of the CEM Catalyst Serviceability To service the catalyst the service cover needs to be removed and then each catalyst can be removed with the service tool by removing the retention bolts and pulling the catalyst out When replace the catalyst all new retention hardware will be required to install the new catalyst 2013 Caterpillar 61 10Dec2013 All rights reserved Important Note Non Caterpillar supplied SCR system components Ex AUS DEF Filter Air Dryer Filter etc that are an integral part of the SCR system must meet the Tier 4 interim EPA requirements for maintenance service intervals The key criteria for meeting the regulation is that any regularly scheduled adjustment replacement cleaning or repair of components must be at a minimum of 4500 engine hours Component life must meet 10 000 engine hours for 3500 and C175 engines and 20 000 engine hours for C280 engines C280 SCR Access Special Instructions Access Hatch Removal Reactor hatches can weigh up to 250 Ibs 113 kg To avoid injury use a hoist when lifting components weighing 50 Ibs 23 kg or more The hatch handles must be used to attach the lifting hooks The lifting hooks must be equipped with a spring latch ensure that the lifting hooks are positioned correctly Ens
104. sel where the tank temperatures will not freeze and not exceed the high temperature requirements for proper storage The proper storage temperature range for AUS DEF is between 15 F and 77 F 9 C and 25 C that is stored above the 95 F 35 C for longer than one month must be tested to make sure quality is not degrading and AUS DEF meets required spec Tank must be location on Vessel to meet the temperatures requirements to avoid degradation of AUS DEF If location of the tank within a Vessel can t meet the temperature requirements for AUS DEF than a way to cool or heat the fluid must be installed in the main AUS DEF tank Use of thermal insulation is another way of keeping the tank temperatures within the proper temperature requirements for storage Although high density polyethylene is a poor conductor of heat additional insulation will help to protect AUS DEF from thermal degradation Tank Materials 2013 Caterpillar 33 10Dec2013 All rights reserved Non cross linked polyethylene PE is the material of choice for AUS DEF tanks It provides a wide temperature range of operation has good strength properties allows for flexibility in shaping low in weight and has been used other AUS DEF applications In Tank Filtration In tank filtration is required to protect the AUS DEF delivery system An inlet strainer is required to prevent large debris from entering the tank The strainer should be made of stainless steel with 3
105. site requires an Installation Audit and 2013 Caterpillar 106 10Dec2013 All rights reserved Serial Number pairing entry on either an individual engine system basis or part of a mass upload performed by the Dealer Engine and Aftertreatment Assembly documentation Documentation of the engine and CEM serial number is to be done to be reported back to Caterpillar to meet the EPA requirements The engine and aftertreatment serial numbers are to be required within the DFA 2013 Caterpillar 107 10Dec2013 All rights reserved Intentionally Blank 2013 Caterpillar 108 10Dec2013 All rights reserved Appendix C Bellows Mount Displacement Calculator Process Purpose This procedure is provided to assist in determining the Bellow Mount capability of the T4 aftertreatment application installation and the need for hard or soft mount CEM This process should be used in concert with the Bellows Mount Calculator Cat CEM A amp l Guide in section 5 Exhaust System Installation Design amp Assembly Instructions and Section 5 Mounting Considerations CEM Vibration Acceptability Overview This tool provides guidance for calculation of bellows mount displacement both axially and radially using distance measurements and engine amp CEM mount information from a typical application installation design Process procedure follows Process e Calculate bellows relative movement axially amp radially using distance measurements and engi
106. so that it will not be subjected to ambient temperatures higher than 55 C or lower than 40 C The components within the dosing cabinet are designed to operate in temperatures per the above specifications AUS DEF Delivery System Caterpillars Selective Catalyst Reduction SCR system is contained in a module and utilizes AUS DEF to reduce engine out NOx AUS DEF is a solid at room temperature but is typically placed into a de ionized water solution to facilitate high resolution metering which is necessary for the DEF SCR system to operate at high efficiencies without inducing ammonia slip Also note that DEF CO NH2 z2 itself is simply a safe transporter of ammonia NH3 which is what ultimately drives this SCR process This is described in the global equations below CO NH2 2 H20 2NH3 CO gt d NO NO 2NH3 2N 3H2O An onsite or in the case of a Marine Vessel an on board AUS DEF storage must be provided by the installer and the piping to deliver the AUS DEF water solution to the pump on the module which will inject the AUS DEF into the engine exhaust stream where the AUS DEF then decomposes into NH3 and reacts with NOx primarily in the presence of the SCR catalyst AUS DEF Handling Refer to Appendix D AUS DEF Handling for appropriate handling methods Material Selection for Tank and Piping Material compatibilities must be considered in the AUS DEF storage and delivery system due to the
107. t e Require the engine to use vibration isolation mounts e Have Marine Vessel vibration sources present See Scenario 2 for examples of Marine Vessel vibration sources Scenario 1 4 Summaries Now that each scenario has been discussed the chart from above as been updated with CEM vibration Exhaust pipe Capability and Vibration measurement requirements CEM Engine Preferred Preferred Preferred Vibration Mounting Mounting Scenario forCEM for exhaust Measuring vibration flex pipe Req ed a ep Vibration Hard ss Vibration In some Hard Isolation cases Vibration Vibration Isolation Isolation See notes with regard to scenario 3 amp 4 in the detail below 2013 Caterpillar 87 10Dec2013 All rights reserved START CEM Mounts Decision Tree Version 4 Draft Connection between Turbo amp CEM designed by CAT i e C 13 IOPU YES MASTER STRUCTURE This is the O structure that supports the engine and N CEM See A amp I Guide for a picture Suggestion The CEM should be ISO NO Are the vibration inputs MOUNTED anytime the engine is to CEM less than 5 g s hard mounted to the same master structure that supports the CEM i e C 13 IOPU If still unknown oe suggest ISO mount CEM Vibrations have been dampened YES without the use of ISO mounts PERFORM Flex pipe Bellows Dynamic Estimate
108. t is compatible the engine will not derate and there will be no fault code No further action for the automatic compatibility check is required The engine will continue the compatibility check of the CEM for the first 25 hours of operation of the installation If for any reason the engine ECM is replaced or aftertreatment is replaced within the first 25 hours of operation the engine ECM will rewrite the CEM serial from the CEM chip The 25 hour clock for compatibility check will also restart after initial compatibility check of the new hardware Verifying that the CEM and dosing cabinet serial numbers match CEM and dosing cabinet are shipped as a matched set from Caterpillar It is required that the installer use a CEM and dosing cabinet with matching serial numbers for any installation Verify that the serial numbers are identical for both the CEM and dosing cabinet 2013 Caterpillar 105 10Dec2013 All rights reserved Location of CEM Serial Number 3516 Marine Part Number Serialization number Located Here Documentation of CEM and Engine Serial Number Documentation of engine serial number and CEM serial number is a requirement for all installations The final installer of the engine and CEM will be required to document the engine and CEM serial number and provide that information to Caterpillar The Dealer will follow the standard reporting requirements through the Web Portal Tier 4 Commercial Engine Application This
109. t upon many factors including the following the nature of the engine aftertreatment failure the design and packaging of the aftertreatment the engine speed load conditions the condition of the aftertreatment and the ambient conditions Therefore the potential temperatures are provided as a guideline for safe design of the installation even under conditions of unexpected engine and or aftertreatment failure and proper precaution should be taken to insure that the aftertreatment device is properly shielded and not mounted in close proximity to surrounding components that may be damaged by heat In general surface temperature will increase with emissivity assuming all else being equal Geometry also plays a role The Rubber Hose has lower surface temperature than the Nylon Strip because of its size and shape and surface orientation to the heat source relative to the CEM Various types of insulation and shielding are readily available and can be applied according to the requirements of the specific application Insure that the chosen thermal management device is adequate for the application under all conditions Special consideration must be given to conduction as well as radiation effects due to each option Thermal Wrapping Caterpillar strongly recommends wrapping the engine exhaust aftertreatment Applications must look into alternative means of reducing radiated heat effects from the aftertreatment device such as increased air 2013 Ca
110. terpillar 91 10Dec2013 All rights reserved flow around the aftertreatment and or heat shields to protect heat sensitive devices There are components and areas on the Cat CEM that require protection from high temperatures Follow the component temperature limit requirements found in this A amp I document to ensure adequate thermal protection is adhered to If the CEM Exhaust Tubes need to be wrapped in an application Maintain the temp limits of electronics as listed in the A amp I guide Component Temperature Limits Clearance must be maintained both inside and outside of soft wrap to avoid points where wear abrasion can take place Wraps must have openings to allow sensor probes to pass through and openings must be sufficient to prevent sensor contact with wraps Do not place wraps over wires or sensor leads 2013 Caterpillar 92 10Dec2013 All rights reserved 7 Appendices Appendix A Cat CEM Harness Installation Guide Back to TOC Wiring Harness Components Deutsch DT Jumper Harness Connectors C3 C4 The DT connector is the low cost preferred choice for inline applications The connector is available in 2 3 4 6 8 and 12 terminal configurations It is also intended for SAE J1939 application use The wire size range the connector will accept is 0 8 mm 18 AWG 1 0 mm 16 AWG and 2 0 mm 14 AWG The plug assembly with interface seal accepts socket terminals and the receptacle assembly accepts pin termin
111. the end user responsible to respond to EPA if a code is record on the ASN2 The codes that will be recorder are in AUS DEF quality is below the spec if vessel ever ran out of AUS DEF and if the system was ever turned off Caterpillar will alarm and record in standard engine ECM memory all other incidents relating to engine and aftertreatment operation Active codes will be displayed and recordings of the first and last incident date and time and the number of occurrences will be recorded in standard engine ECM memory Terminology The terminology used throughout this document will be as follows AMOX API ARD ASTM AT ATAAC AUS AUS32 AWG BPV CAN Cat CEM Cat ECF Cat RS CCW CDPF CEPRU 2013 Caterpillar All rights reserved Ammonia Oxidation Catalyst American Petroleum Institute Auxiliary Regeneration Device American Society for Testing and Materials Aftertreatment Air to Air After Cooler Aqueous Urea Solution Aqueous Urea Solution per ISO Standard 22241 American Wire Gauge Back Pressure Valve Controller Area Network Caterpillar Clean Emissions Module Cat Engine Crankcase Fluid Caterpillar Regeneration System Counter Clockwise Catalyzed Diesel Particulate Filter Caterpillar Electric Priming and Regeneration Unit 11 10Dec2013 DEF Delta P DOC DPF DPI ECM EH amp S EPA FEA FMEA GND HC ID IEC ISO JIC MAF MSDS NOx OEM OMM ORS PM P N PSlg PSPS SAE SCAC SCR SOF STOR S N TBD
112. tomer harness is not present two terminal resistors must be installed Any J1939 data link must have a terminal resistor at each end of the data link NOTE A terminal resistor is required at the terminal ends of the data link cable A terminal resistor is not required at each node on the data link 2013 Caterpillar 103 10Dec2013 All rights reserved Intentionally Blank 2013 Caterpillar 104 10Dec2013 All rights reserved Appendix B Initial Startup Procedure Engine and Aftertreatment Compatibility Check After completing installation of the aftertreatment hardware a hardware compatibility check is required There are three criteria for meeting aftertreatment compatibility check 1 Automatic compatibility check at key on 2 Verifying that the CEM and Dosing cabinet serial numbers match 3 Documentation of CEM and Engine serial number Automatic compatibility check at key on All CEM s contain a chip that will check for proper compatibility with the engine At first start up the engine ECM will read the CEM chip and write the serial information to the engine ECM The engine ECM will then determine if a compatible CEM and dosing cabinet has been installed with the engine e Ifthe CEM and or dosing cabinet are not compatible with the engine the engine will derate and trigger an active fault A compatible CEM and or dosing cabinet for the engine will need to be installed to resolve this issue e Ifthe CEM and dosing cabine
113. ts of CEM Center of Gravity Location 3516 Z flow 16 brick design CEM g 1875 mm S Mass of the Z flow is 1399 kg The catalysts are arranged in an 8 x2 stack design Center of Gravity Location U flow 16 brick design CEM Mass of the U flow is 1390 kg The catalysts are arranged in an 8 x2 stack design 2013 Caterpillar All rights reserved 48 10Dec2013 Mounting amp Lifting For requirements Reference Section 5 Mounting Considerations In addition to the above requirements please note the g load requirements for the following CEM families 1 3500 and C175 U and Z flow design CEM a Fore Aft up to 2 G s b Vertical up to 2 G s c Side to Side up to 2 G s 2 C280 CEM design a Fore Aft up to 2 G s b Vertical up to 2 G s c Side to Side up to 2 G s Warning Standing on top of the CEM and using the top of the CEM as work platform is strictly prohibited Marine Aftertreatment Mounting Thermal Expansion Thermal Expansion 15mm A Thermal Expansion T 8mm La mo H f Lal Lad i aia a es gt i R gaa j a s Thermal Expansion 7 mm to be absorbed by bellows Thermal Expansion 4mm Thermal Insulation Insulation is required for Aftertreatment inlet and outlet Refer to Section 6 Thermal Management for insulation details 2013 Caterpillar 49 10Dec2013 All rights reserved Insulation must be used with pro
114. ture sensor requirements based on the reference sensor include operating temperature range 40C and 150C probe end 40C and 120C connector end vibration limits 30GrmsX3sigma for 0 03 of operational lifetime and it is salt amp AUS DEF corrosion resistant If an electrostatic painting process is used then proper grounding must be in place during the paint process 2013 Caterpillar 34 10Dec2013 All rights reserved AUS DEF Level Sensor A low level urea tank sensor must be placed in the main urea tank The sensor will send a signal to the dosing cabinet ECM when the AUS DEF level in the tank drops to 13 5 left in the tank The dosing cabinet will warn the vessel operator when the AUS DEF main tank reaches the sensor No faults are recorded unless the tank runs empty of AUS DEF The sensor inside the dosing cabinet will record when the system is completely out of AUS DEF The low level sensor in the main AUS DEF tank will only supply a warning to the operator that his AUS DEF tank is running low The low level sensor input into the dosing cabinet ECM is a switch input to GND These two points are required to comply with EPA 1042 rules It is recommended that along with the level sensor a warning light is provided to indicate when AUS DEF level is low The warning light should be set at a level that will provide adequate time to acquire quality AUS DEF and refill the tank Tank Heating Heating of the AUS DEF tank for tha
115. ty of technologies for the reduction of particulate matter and NOx emissions Selection of the optimal module combination is based upon engine rating and application Each of the emission reduction technology combinations is listed in the Cat CEM Strategy table in section above and described in this document Technology Component Descriptions SCR Selective Catalytic Reduction System SCR is one of a combination of several components SCR units will require the use of urea or DEF Diesel Exhaust Fluid also referred to as AUS32 along with flow through honeycomb substrate catalysts AUS DEF fluid is injected into the exhaust stream before entering the SCR When injected into the exhaust stream the AUS DEF is atomized into fine droplets and then sent through a mixer The mixer disrupts the exhaust flow and allows the AUS DEF to be well distributed throughout the exhaust gas The water evaporates due to the high temperature of the exhaust and releases the NH3 that was chemically bound up in the AUS DEF The NHsz is then free to react with the NOx and the oxygen present in the exhaust stream This reaction occurs on the SCR catalyst The NH3 and NOx are converted into harmless gas particles of nitrogen and water 2013 Caterpillar 13 10Dec2013 All rights reserved Mixing Bellows Tube Exhaust Out Egat Injector Turbochargers OOOOOO0O Engine Control OQOOO000 Unit l c ee a Primary La DEF Filter Air Suppl
116. ure that the hoist chains or slings and lifting hooks are in good working condition and can withstand the hatch weight See Fig below Reinstallation of the hatch 1 Align the hatch gasket and flange to the holes These parts need to lay flat against one another with their holes lined up so the bolts can go straight in Apply anti seize compound to all the threads to avoid thread galling 2 The bolts with washers should then be placed through the holes secured using washers and locknuts The bolts must be hand tightened to the point where the hatch gasket and flange are held together The bolts may need to be gently tapped through the holes before the parts are completely lined up See Fig below 4 _ Fig 2 Fasteners used in the Hatch 1 Hex Head Bolt 2013 Caterpillar 62 10Dec2013 All rights reserved 2 Washer Hard 3 Lock Nut 4 Hatch 5 Gasket 6 Flange Fig 3 Hatch Installation Flange Gasket Hatch The recommended torque sequence is as follows start in the center of the hatch then work toward the outside At the end do a second round to verify the torque in all the bolts See Fig 4 o o z a i z z a oO i 5 o oO 4 5 F h o o E o 0 o oO E Oo 3 0 o Fig 4 C280 8 amp 12 SCR Block Installation Grid Installation The C280 Selective Catalyst Reactor Housing has been specially designed to utilize th
117. ve actions are listed below e If component stresses are too high Try using a material with higher stress limits strengthening the section or changing the relative stiffness of different members in order to adjust how the loads are distributed e f mount strain is too high Consider using a stiffer mount using a larger mount or changing relative stiffness or mount pattern in order to change the distribution of loads 2013 Caterpillar 85 10Dec2013 All rights reserved e f motion is too high at bellows Consider using a stiffer mount spreading out the mount pattern putting the plane through the mounts closer to the CEM center of gravity or putting the bellows closer to the CEM center of gravity CEM Vibration Acceptability Overview CEM vibration capability is difficult to assess When vibration isolation mounts are used and properly specified it is understood that CEM vibration will likely be acceptable In some cases extensive vibration measurements may be required Each of the scenarios discussed in this section will designate the need for vibration measurements Exhaust Flexpipe and CEM Vibration Design Considerations Each Installation may have an established choice for engine mounting Considering Tier 3 engine installations either hard or vibration isolation mounts have been used for the engine This choice should be used as a starting point in the design process This design process may be iterative in order to satis
118. ved and required for emission reduction standards The Exhaust System and Cat CEM are an integral part of Caterpillars EPA Tier 4 IMO IIl and Euro Stage IIIB engine solution Caterpillar Engines are designed and built to provide superior value however achieving the end user s value expectations depends greatly on the performance of the complete installation to assure proper function over the design life of the installation This proper detail will allow the engine to produce its published rated power fuel consumption and conform to emissions regulations Caterpillar exercises all reasonable effort to assure engine and Cat CEM perform properly However it is the responsibility of the OEM installer to properly install the engine and Cat CEM Caterpillar assumes no responsibility for deficiencies in the installation It is the responsibility of the OEM installer to meet all of Caterpillar s requirements as provided in this Application and Installation Guide Caterpillar does not guarantee or approve the validity or correctness of any installation Caterpillar s sole obligation with respect to any product is as set forth in the applicable Caterpillar warranty statement It is the installers responsibility to consider and avoid possibly hazardous conditions which could develop from the systems involved in the specific engine installation The suggestions provided in this guide regarding avoidance of hazardous conditions apply to all applicati
119. verview sseeeeees 86 AS CAN AU OM einean EEE 89 LIAO LINKS oeietwecetctiemdoseiutetesetenteeentaceemetuehedsedunwiameceed sec 89 6 Thermal Management ccccsseseeeeeeeeeeeeeeenees 91 STTTE OCUIGCIONN iniii 91 Thermal Protection sascicasedecsicevasieccecassawaneretacadedaessesxweverseaterseaweneen 91 Thermal Wrapping assnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 91 2013 Caterpillar 3 10Dec2013 All rights reserved Fe PAD DOCNGICES moriaka a 93 Appendix A Cat CEM Harness Installation Guide 93 Appendix B Initial Startup Procedures s00seseeseeee 105 Appendix C Bellows Mount Displacement Calculator 109 Appendix D AUS DEF Handling ccceesseeeeeeeeeeeeeeeenees 117 Appendix E Critical Installation Check list csccee 120 2013 Caterpillar 4 10Dec2013 All rights reserved 1 Introduction Purpose This document is intended as a reference and guide for the correct installation of the Caterpillar Clean Emissions Module Cat CEM for Caterpillar Engines The primary purpose is to assist engineers and designers specializing in engine installations The Engine Electrical Applications and Installation Guide Engine Application and Installation Guide and Engine Data Sheets complement this booklet NOTE The information in this document is subject to change as engine exhaust aftertreatments are revised impro
120. w from the bottom of the tank as well As the AUS DEF is consumed the AUS DEF level in the tank reduces and the cold AUS DEF approaches the heater To facilitate the thawing process the tank should have a simple rectangular or trapezoidal shape wherein the base of the tank is slightly larger than the top of the tank a pyramid design no plateaus is recommended for best thawing performance Shapes that do not assure the gradual reduction in the level of AUS DEF have to be avoided Tank shapes vary from application to application based on design and space limitations Irregularity in these shapes is acceptable as long as the air pockets and or stuck chunks of frozen AUS DEF inside the ridges or any other contours of the tank can be avoided It is also preferable to have the width of the tank equal or smaller than the height of the tank Short and long tanks are not favorable for AUS DEF freeze protection Tank Volume Tank volume should be sized based on required refill frequency AUS DEF freeze expansion and the volume of internal tank components The AUS DEF tank size is dependant upon AUS DEF quality over duration of use and delivery infrastructure The AUS DEF tanks must be sized never to run out Tank sizes will depend on vessel designed operating profile and its normal fueling stops AUS DEF tanks must be sized such that sufficient AUS DEF is always available to adequately operate the SCR system The amount of AUS DEF usa
121. wing can be carried out in various ways Heat can come from an electric heater or a heat exchanger using one of the various working fluids on a Marine Vessel including coolant engine oil hydraulic oil and exhaust Out of these sources a heat exchanger using coolant is the optimal solution Electricity is also acceptable for performance but the amperage requirement is very high Although other fluids may have equal or higher temperatures coolant s high specific heat enables it to outperform the others Mass flow rate also plays a major role in determining the heating potential of a fluid While a heat exchanger using coolant has many advantages it also has one major performance disadvantage compared to an electric heater While an electric heater can begin thawing AUS DEF almost immediately after startup engine coolant warms up more slowly Heat Exchanger Design Based on the highest rate of consumption the heat exchanger a stainless steel coolant line can be sized to provide thawing The sizing is accomplished by utilizing the following equation MCp solid DEF T solid DEF MH MCp jiquidd Tiiquia oer UA T coolant DEF where m 2 x DEF consumption kg s Cp solid DEF Specific heat of frozen DEF solution kJ kg K Cy iquia per Specific heat of liquid DEF solution kJ kg K AT solid per 11C Initial temperature of DEF C 2013 Caterpillar 35 10Dec2013 All rights reserved H Latent heat of fusion of AUS DE
122. wn to correlate with the above methods may be used For exhaust emission calculation the total exhaust mass flow must be used 2013 Caterpillar 19 10Dec2013 All rights reserved 5 9 3 3 If the composition of the exhaust gas is influenced by any exhaust after treatment system the exhaust sample must be taken downstream of this device 7 Exhaust System Verification Verification Introduction The exhaust system must be designed to be leak tight and comply with the minimum EPA useful life requirements During the useful life the piping cannot contribute to plugging abrasion exhaust gas leakage or other damage to Cat CEM To ensure proper operation of the engine Cat CEM package during the life of the Marine Vessel care must be taken to ensure these systems are constructed of proper materials with reliable joints flexible sections and mountings Exhaust piping must provide for movement and thermal expansion to ensure undue stresses are not imposed on Cat CEM components or engine connections General Requirements Summary Attention should be given to exhaust gas flow restriction with the following recommendations e The exhaust backpressure must not exceed the limits given for each engine family and Cat CEM installation Reference TMI System Data or Engine Sales Manual for Commercial applications and Engine Technical Specifications e The exhaust piping must allow for movement and thermal expansion so that undue stresses ar
123. y DEF Supply SCR CEM System Diagram Working Principle CO NH2 2 H20 2NH CO NO NO 2NH3 2N 3H2O 2013 Caterpillar 14 All rights reserved 10Dec2013 3 SCR Clean Emissions Modules Introduction and Purpose Caterpillars SCR emissions approach combines emission reduction technologies to comply with Tier 4 emissions requirements Selective Catalyst Reduction SCR catalyst technology is used to reduce NOx emissions and particulate matter PM carbon monoxide CO hydrocarbons HC and soluble organic fraction SOF Caterpillars SCR is packaged in a module that contains the components necessary to support the specific engine configuration for emissions compliance OEM installation will require connections between OEM module engine AUS DEF tank and air source These connections will include engine exhaust piping electrical harness air and AUS DEF lines System Hardware Overview Air Supply Dosing Cabinet w DEF Pump CEM Exhaust Mixer amp SCR SCR Catalyst Injector Fig 4 1 System Block Diagram 2013 Caterpillar 15 10Dec2013 All rights reserved CEM Application Guide The following table provides applicable CEM for a given application and engine platform There will be several CEM illustrations for these applications below in the following subsections of this SCR CEM Technology section CEM Application Guide Engine Platform CEM Prefix Appli
124. y at fill and turn it off when the fill is done This relay is not provided with the dosing cabinet To use this feature the customer needs to wire the relay In addition the customer also need connect a wire from the pin J1 31 of the aftertreatment ECM connector inside the dosing cabinet to the pin 14 of the connector for Cabinet to Engine i e item 1 shown in Fig 4 6 The wiring diagram for the optional installer provided transfer pump example is shown below 120 VAC 120 VAC Hot Neutral Pin 10 Pin 6 Batt 7X6222 7X6222 Manual Light 24V Switch Indicator Relay Transfer Pump Fuse Fig 4 10 Transfer Pump Wiring Diagram with ECM and Relay 2013 Caterpillar 26 10Dec2013 All rights reserved Weight and Dimensions a 3516 Dosing Cabinet C280 Dosing Cabinet a 8 r e a Both the 3516 amp C280 Dosing Cabinet have identical interface connections However the C280 application has a larger footprint and space claim The figure below shows these dimensions and differences Serialization Plate ww 7E9 3516 Dosing Cabinet C280 Dosing Cabinet Fig 4 11 3516 amp C280 Dosing Cabinet Space Claim amp S N Location Lifting and Mounting The preferred method of lifting the dosing cabinet is to use two straps through the openings in the base frame as shown in Fig 4 12 The cabinet can be mounted by the use of bolts The cabinet frame rails have 4 M 10 bolts holes that are to be used to mou

Marine Application of Aftertreatment 3500, C175

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