C4.2/C6.4 AND C4.4/C6.
6 ACERT™
ENGINES
WITH COMMON RAIL FUEL SYSTEM
MACHINE APPLICATIONS
© 2007 Caterpillar Inc.
C4.2 / C6.4 and C4.4 / C6.6 ENGINE FEATURES
- High pressure fuel pump
- Electronically controlled injectors
- Four valves per cylinder
- Rigid structure engine block
- Aluminum pistons
- A4-E2 Engine ECM
- Smart wastegate (C4.4 / C6.6 only)
- Common rail fuel system
ENGINE MAINTENANCE INTERVALS
- Engine Oil S O S 250 Hours
- Coolant S O S 250 Hours
- Oil and Filter Change 500 Hours
- Air Filter Clean/Replace 500 Hours
- Breather 500 Hours
- Fuel Filters 500 Hours
- Engine Valve Lash 1000 Hours
LOW PRESSURE FUEL SYSTEM
C4.4 / C6.6 C4.2 / C6.4
Tertiary (3rd) Fuel Tertiary (3rd)
Fuel Filter Priming Pump Fuel Filter
Secondary Secondary
Fuel Filter Primary Fuel Fuel Filter Primary Fuel
Fuel Filter Tank Fuel Filter Tank
Fuel
Priming
Pump
Fuel Fuel
Transfer Transfer
Pump Pump
Engine Engine
ECM ECM
High Pressure High Pressure
Pump Pump
C6.6 ACERT ENGINE FUEL DELIVERY SYSTEM
Tertiary Electric Fuel
Fuel Filter Priming Pump
Fuel
Tank
Secondary
Fuel Filter Primary
Fuel Filter
Common Rail Manifold
Engine
ECM
High Pressure
Pump
Fuel Transfer
Pump
From Internal
Fuel Gallery
C4.4/C6.6 ACERT AIR INTAKE AND EXHAUST SYSTEM
Intake Air Turbocharger
Manifold Air to Air
AfterCooler
Turbine
Side
Exhaust
Manifold Air Inlet
Intake Exhaust
From
Valve Outlet
Air Filter
Exhaust
Valve Compressor
Side
Wastegate
Engine
Output Actuator
ECM Smart
Pressure
Wastegate
Line
Speed Coolant Inlet Air Solenoid
Timing Temp Pressure
To Atmosphere
Sensor Sensor Sensor
C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM
COMMON COMPONENTS
Engine ECM
Output Input
J1
Fuel
Injectors
J2
(4 or 6)
Secondary
Speed / Timing Sensor
Inlet Air
Temperature Sensor
Wastegate Primary
Solenoid Valve Speed / Timing Sensor
Coolant
Temperature Sensor
Rail Fuel
Fuel Pump Pressure Sensor
Control Solenoid Oil Pressure Sensor
Boost Pressure Sensor
C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM
TYPICAL COMPONENTS
_
+
Key Start
Switch
Engine Machine Monitoring
ECM ECM System
J1 J2
Starter
Relay
CAN Data Link
CAT Data Link
CAT Data Link
Intake Manifold Air
Pressure Sensor Coolant Temp. Sensor
Intake Manifold Fuel Pump
Air Temp. Sensor Common Rail Pressure Control Solenoid
Fuel Pressure Sensor
Engine Oil Ether Aid Solenoid
Pressure Sensor
Secondary
Fuel Smart Wastegate Solenoid
Throttle Speed / Timing Sensor
Injectors
Position Sensor (4 or 6)
Demand Fan Solenoid
Primary Engine Shutdown Switch
Speed / Timing
Sensor
INPUT COMPONENTS OUTPUT COMPONENTS
HYDRAULIC DEMAND FAN SYSTEM
C4.4 / C6.6 ENGINES
Demand Fan Control Manifold Demand Fan
Oil Cooler Outlet
Left Drive Pump
Charge Circuit
and Implement Flow Control
Pilot Supply Valve
Fan
Solenoid
Orifice Valve
Fan Pump
Engine Coolant Hydraulic Oil
CDL Temperature Sensor
Temperature Sensor
Air Inlet
Temperature Sensor
Engine ECM Machine ECM
REVERSING DEMAND FAN SYSTEM
C4.4 / C6.6 ENGINES
Oil Cooler Outlet
Left Drive Pump
Charge Circuit
and Implement
Pilot Supply
Motor
FORWARD
Fan Pump
Demand Fan
Flow Control Reversing Solenoid Fan Direction
Valve Valve Valve
Fan Solenoid Makeup Crossover Relief
Valve Valve Valve
Oil Cooler Outlet
Left Drive Pump
Charge Circuit
and Implement
Pilot Supply
REVERSE
Fan Pump
Reversing
Fan Relay
10 A
Hydraulic Oil Fan Control Fuse
Temperature Sensor
Engine Coolant
Temperature Sensor
Reversing
Fan Switch Air Inlet
Temperature Sensor
Machine ECM Engine ECM
C6.4 ACERT ENGINE FUEL DELIVERY SYSTEM
Secondary Tertiary
Primary Fuel Filter Fuel Filter
Fuel Filter
Fuel
Tank
Common Rail Manifold
Priming
Pump
High Pressure
Pump
Engine Fuel Transfer
ECM Pump
C4.2 / C6.4 ACERT AIR INTAKE AND EXHAUST SYSTEM
Intake Air Turbocharger
Manifold Air to Air
Aftercooler
Turbine
Side
Exhaust
Manifold Air Inlet
Intake Exhaust
From
Valve Outlet
Air Filter
Exhaust
Valve Compressor
Side
C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM
COMMON COMPONENTS
Engine ECM
Output Input
J1
Fuel
J2
Injectors
(4 or 6) Inlet Air
Temperature Sensor
Secondary
Speed / Timing Sensor
Coolant
Temperature Sensor
Primary
Speed / Timing Sensor Fuel
Air Inlet Relay Temperature Sensor
Rail Fuel
Fuel Pump Pressure Sensor Oil Pressure Sensor
Control Solenoid
Fuel Differential
Boost Pressure Sensor Pressure Sensor
Fuel
Pressure Sensor
C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM
TYPICAL COMPONENTS
_
+
Key Start
Switch
Engine Machine
ECM ECM Monitoring
System
J1 J2
CAN Data Link
CAT Data Link
CAT Data Link
Intake Manifold Air
Pressure Sensor Coolant Temp. Sensor
Intake Manifold Fuel Pump
Air Temp. Sensor Common Rail Pressure Control Solenoid
Fuel Pressure Sensor
Engine Oil
Pressure Sensor Fuel Air Inlet Relay
Secondary
Throttle Speed / Timing Sensor Injectors
Position Switch (4 or 6)
Start Aid Relay
Primary Engine Shutdown Switch
Speed / Timing
Sensor OUTPUT COMPONENTS
Fuel
Fuel Different ial
Temperat ure
Pressure Sensor
Sensor
Fuel Pressure Sensor
INPUT COMPONENTS
CAT ET DIAGNOSTICS
- View engine derates
- View component status
- Configure engine parameters
- View diagnostic codes and events
- Flash ECM
- Perform diagnostic tests
SRC CODE OCC ACT
36 91-8 10
36 168-0 5
36 168-1 5
OK
HYDRAULIC SCHEMATIC COLOR CODE
Black - Mechanical connection. Seal Red - High pressure oil
Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction
Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure
White - Atmosphere or Pink - 3rd reduction in pressure
Air (No pressure)
Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure
Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil
Cat Yellow - (R estricted usage) Orange / White Stripes -
Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.
Green - Tank, sump, or return oil Blue - Trapped oil
Green / White Stripes -
Scavenge Oil or Hydraulic Void
