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C6.

6 with ACERT® Technology

May 2006 - Page ‹#›

Caterpillar Confidential: Green


C6.6 with ACERT® Technology

Note: The information in this


presentation is preliminary and
subject to change and/or
modification!

May 2006 - Page ‹#›

Caterpillar Confidential: Green


C6.6 Features
4 Valve Head ECM

Timing

Cylinder
Crankshaft Block
Fuel
System
May 2006 - Page ‹#›

Caterpillar Confidential: Green


Engine Features
 6.6 Litres
– Same Bore/Stroke as
3054C
 105mm/127mm
– New Block
 Scalloped
 Ribs
Noise Attenuation
 Closed Top Deck
 Parent Bore
 Oversized Piston
Service Solution

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Piston Design
 Pistons
– Two Types
 Gallery Cooled
 Non - Gallery Cooled
– Aluminium
– Quiescent Bowl Design
– New Ring Pack
 Improved Oil Control
– Graded Rods for Piston
Protrusion
– Square Boss to the Front

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Connecting Rod
 Connecting Rods Dimple
– Fracture Split
 Removal from the Top
– Notches
 Bearing Alignment
 Not Interchangeable Top
to Bottom
– 3 Lengths for Piston
Protrusion
– Always use New Bolts
– Dimples for Orientation
Dimple Notch

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Crankshaft
 Crankshaft
– Balanced Steel Forging
 Induction Hardened
– Larger Mains Diameter
 84mm, 8mm Increase
– Larger Rod Diameter
 72mm, 9mm Increase
– 15mm Bearing Overlap Increase
 Withstands Higher Torsional loads
– Lead free Bearings
– 100% Front PTO

May 2006 - Page ‹#›

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Cylinder Head Details

4 Valve per Cylinder


 Centered Injector
 Service
– Non-Serviceable Valve
Guides and Seats
– Head face can be machined once
 0.006”
– Adapter required for current Valve
Spring Compressor

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Head Bolt Torque Sequence
11 7 3
10 14
6
2
4
8
12
13
9
5

May 2006 - Page ‹#›

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Head
 Head
– Multi-Layered-Steel (MLS)
Head Gasket
– Fourteen - 16mm bolts
 Single Use
– Torque and Angle Tightening
Method

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Rocker Assembly
 Bridge can be installed Inlet
(long)
either way
 Single Bolt per Rocker
Lever
 Lash settings the same
for Inlet and Exhaust
 Injectors can be
replaced without
removing Rockers
Exhaust
(Short)

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Timing Case
Camshaft Idler Hub
 Timing Case locating pin Location
boss
– Increased Clearance for Idler
Hub access
– PTFE Crank Seal with dust
seal
– New Seal Recommended if
Timing Case is removed
– Use “dummy” Sleeve when
front Pulley is Removed
Integral front oil seal to
ensure seal to crank
alignment

May 2006 - Page ‹#›

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Static Timing
 Pinning the Crank to #1 TDC
– Notch in Crank
– Service Tool Available
– Remember to Remove Pin

TDC access
point

May 2006 - Page ‹#›

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Camshaft Timing
 Camshaft Alignment Tool
– Not a Tight Fit
– Ease of Assembly

May 2006 - Page ‹#›

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Crank Speed/Timing
 New Sensor
 Located at Rear of Block
 Reads tooth wheel
attached to the Crank

May 2006 - Page ‹#›

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Fuel System Overview
 Caterpillar Fuel System using common rail
technology
– Low Pressure
 300kPa (43 PSI)
 20 Micron Primary Filter
 2 Micron Secondary Filter
 Fuel Cooler Required on some arrangements
– High Pressure
 Up to 160 MPa (1600bar - 23,200 PSI)
Fluid penetration safety hazard.
 Hardened Fuel Lines
 External Fuel Manifold

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel System Handling
 Cap all fuel passages Immediately after removal
 Do Not “Blow Out” or “Wash Out” any fuel passages

 Place removed parts in clean area


 Do Not pre-fill filters

 Remove packaging and protective caps immediately


before installation
 Fuel Lines can not be reused

May 2006 - Page ‹#›

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Low Pressure Fuel System

May 2006 - Page ‹#›

Caterpillar Confidential: Green


High Pressure Fuel System

May 2006 - Page ‹#›

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Fuel Pump
 Two Pumps Lube Oil
Feed
– High Pressure
– Transfer
 HP Pump Lubricated by
Engine Oil
– Longer Life

Pump
Speed/Position Transfer
Sensor Pump

May 2006 - Page ‹#›

Caterpillar Confidential: Green


High Pressure Fuel Pump
Fuel Leak off to Tank
 Stroke in phase with
Fuel in to HP Pump
Injection From Secondary Filter
 Self Bleeding To Fuel HP
Manifold
– Do Not Crack lines to bleed
 Lock Pump BEFORE
To
removal
Secondary
 Replace HP Fuel Line Filter
when Pump is removed
From
– Check Clips
Primary
Pump Speed/Position Sensor Filter

May 2006 - Page ‹#›

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Fuel Pump
 Two Cams - 3 lobe each
 Solenoid adjusts rail pressure
and return to tank
 Needs to be Timed
– Lock in Place BEFORE Removal

May 2006 - Page ‹#›

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Fuel Pump Function
 Pump Raises Pressure
 ECM tells Injector to Fire
 Rail Pressure Drops
 ECM Detects Pressure Drop
– Sensed by Fuel Rail Pressure
Sensor
 ECM tells Pump Solenoid to
Increase Volume
– Also tells Pump Solenoid to
Spill fuel once pressure is
reached
 Do it Again!

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Transfer Pump
 Driven by High Pressure
Pump
 Draws Fuel through
Primary Filter
 Output Pressure
– 300 to 400 kPa
– 43 to 58 PSI
 Transfer Pump Primed by
Priming Pump
– Hand or Electric
– No Lift Pump Required

May 2006 - Page ‹#›

Caterpillar Confidential: Green


High Pressure Fuel System
 Do’s & Don’ts Fuel Manifold Injector Lines

– Do Check for leaks


– Do Not Loosen HP Connection
with Engine Running
– Do Replace HP Pipes After they
are Loosened
– Do Replace ALL Hp Pipes if new
manifold is Installed
– Do Not Force Pipes to Fit Feed From High
– Do Cap Manifold and Injector Pressure Pump
Connections Immediately when
HP Pipe is removed

May 2006 - Page ‹#›

Caterpillar Confidential: Green


High Pressure Fuel System
Fuel Manifold Injector Lines
 Do’s & Don’ts
– Do Remove HP Cap just before
installation
– Do Keep your Work Area Clean
– Do Think about Cleanliness
when working on HP System
– Do Make Sure all Clips and
Clamps are tight and in position Feed From High
Pressure Pump

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Pressure Relief Valve
High Pressure
 Protects System from Relief Valve
Over-Pressure
– Opens at Constant Pressure of
160 MPa (23,000 PSI)
– Withstands Spikes to 190 Mpa
(27,500 PSI)
 Returnsfuel to Tank
 Replacement?

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Return from Head
 Excess Fuel Returned Fuel
to Transfer Pump Return
– Not High Pressure from
Head
LIne

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Injector Function
 ECM Energizes Injector Solenoid
energized
 Valve Lifts
 Fuel Flows to Nozzle
Valve

To nozzle

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Injector Function
Solenoid de-
 InjectorDe-energizes energized
 Valve Closes
 Unused fuel flows back
to Transfer Pump via
passage in the Head

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Injector Connections
 Two Types
– High Pressure Fuel
– Electrical
 Three Connectors thru
Valve Cover Base

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Injector
 Do’s and Don’ts
– Do Use Proper Torque on Electrical
Connection
 Service Tool Available
– Do Finger Tighten all Clamps and HP
Lines, First, then torque properly
– Do Cap the Injector Immediately After
Removing HP Fuel Line
– Do Make Sure the O-Ring and Copper
Washer are in place
 Do Not Re-use O-Ring or Cooper
Washer

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Injector
 Do’s and Don’ts
– Do Write down the Injector
Serial Number
and Confirmation Code
before you install the Injector
– Do use Cat ET to Program ECM
with proper Injector Trim File
– Do Look for the Trim File CD in
the Injector Box

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Cleanliness
 Thoroughly clean equipment before
disassembling
 Use only NEW protective caps to seal fuel
connections
 Replace HP Fuel Lines if they have be
loosened

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Injection Serviceability
 NEVER loosen high pressure pipes when
engine is running! 23,000 PSI
 Use Electronic Service Tool to Troubleshoot
Injector Problems
 Injectors have no serviceable parts.
– Warranty will only be paid with evidence of the
correct tests.
 Pump Solenoid is non serviceable.
– If the solenoid is removed the whole pump
assembly must be replaced.

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Fuel Injection Serviceability
 Transferpump is a serviceable item, separate
from High Pressure pump.
 Speed sensor is serviceable.

May 2006 - Page ‹#›

Caterpillar Confidential: Green


1106D Smart Wastegate
Smart Wastegate
 On All Variable Speed Engines Controller
 Controls Wastegate Actuator
 Optimizes Engine
Performance
 Driven by PWM Signal from
the ECM
 Service as an Assembly
– 12 or 24 volt

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Smart Wastegate Schematic
Intake Manifold Pressure
Tells Solenoid (Boost)
How much Pressure
To Pass

Looks at:
Desired Speed
Load Intake Manifold Pressure
Boost (Boost)

May 2006 - Page ‹#›

Caterpillar Confidential: Green


A4-E2 Fuel Cooled (ECM)
4mm Allen Key
Fuel Flow ‘in’

J1 ‘Customer’
Connector Anti-Vibration
Mounts

J2 ‘Engine’
Connector

Fuel Flow ‘out’


Ground Strap

May 2006 - Page ‹#›

Caterpillar Confidential: Green


A4-E2 Electronic Control
Module (ECM)
 ECM Controls:
– Fuel Pressure
– Speed Governing
– Air/Fuel Ratio
– Start/Stop Sequence
– Engine Protection
Devices/ Diagnostics

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Crank Speed/Timing
 59 Teeth + 1 Wide tooth
– 6º Between teeth
 Wide tooth “tells” ECM
Crank Position
 Teeth point to Nose of
Crank
 Use proper thread lock
adhesive when re-using
Dowel Hole
screws

May 2006 - Page ‹#›

Caterpillar Confidential: Green


Hall Effect Sensor
 Produces a conditioned square-wave signal

Old

New

Signal Output Waveform Crank Speed/Position Target

May 2006 - Page ‹#›

Caterpillar Confidential: Green

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