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
Block
Crankshaft
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
May 2006 - Page #
Caterpillar Confidential: Green
Notch
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 #
Caterpillar Confidential: Green
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
14
10
6
2
8
12
13
9
5
1
May 2006 - Page #
Caterpillar Confidential: Green
Head
Head
Multi-Layered-Steel (MLS)
Head Gasket
Fourteen - 16mm bolts
Single Use
Torque and Angle
Tightening Method
May 2006 - Page #
Caterpillar Confidential: Green
Rocker Assembly
Inlet
Bridge
can be installed
either way
Single Bolt per Rocker
Lever
Lash settings the same
for Inlet and Exhaust
Injectors can be
replaced without
removing Rockers
(long)
Exhaust
(Short)
May 2006 - Page #
Caterpillar Confidential: Green
Timing Case
Timing
Case
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
Camshaft
locating pin
boss
Idler Hub
Location
Integral front oil seal to
ensure seal to crank
alignment
May 2006 - Page #
Caterpillar Confidential: Green
Static Timing
Pinning
the Crank to #1 TDC
Notch in Crank
Service Tool Available
Remember to Remove Pin
TDC access
point
May 2006 - Page #
Caterpillar Confidential: Green
Camshaft Timing
Camshaft
Alignment Tool
Not a Tight Fit
Ease of Assembly
May 2006 - Page #
Caterpillar Confidential: Green
Crank Speed/Timing
New
Sensor
Located at Rear of Block
Reads tooth wheel
attached to the Crank
May 2006 - Page #
Caterpillar Confidential: Green
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 #
Caterpillar Confidential: Green
Low Pressure Fuel System
May 2006 - Page #
Caterpillar Confidential: Green
High Pressure Fuel System
May 2006 - Page #
Caterpillar Confidential: Green
Fuel Pump
Two
Pumps
Lube Oil
Feed
High Pressure
Transfer
HP
Pump Lubricated by
Engine Oil
Longer Life
Pump
Speed/Position
Sensor
May 2006 - Page #
Caterpillar Confidential: Green
Transfer
Pump
High Pressure Fuel Pump
Stroke
in phase with
Injection
Self Bleeding
Fuel Leak off to Tank
Do Not Crack lines to bleed
Pump BEFORE
removal
Replace HP Fuel Line
when Pump is removed
Fuel in to HP Pump
From Secondary Filter
To Fuel HP
Manifold
Lock
Check Clips
Pump Speed/Position Sensor
May 2006 - Page #
Caterpillar Confidential: Green
To
Secondary
Filter
From
Primary
Filter
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 #
Caterpillar Confidential: Green
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
May 2006 - Page #
Caterpillar Confidential: Green
Do it Again!
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
Dos
& Donts
Fuel Manifold
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
Do Cap Manifold and Injector
Connections Immediately when
HP Pipe is removed
May 2006 - Page #
Caterpillar Confidential: Green
Injector Lines
Feed From High
Pressure Pump
High Pressure Fuel System
Dos
& Donts
Fuel Manifold
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
May 2006 - Page #
Caterpillar Confidential: Green
Injector Lines
Feed From High
Pressure Pump
Fuel Pressure Relief Valve
Protects
System from
Over-Pressure
Opens at Constant Pressure of
160 MPa (23,000 PSI)
Withstands Spikes to 190 Mpa
(27,500 PSI)
Returns
fuel to Tank
Replacement?
May 2006 - Page #
Caterpillar Confidential: Green
High Pressure
Relief Valve
Fuel Return from Head
Excess
Fuel Returned
to Transfer Pump
Not High Pressure
May 2006 - Page #
Caterpillar Confidential: Green
Fuel
Return
from
Head
LIne
Injector Function
ECM
Energizes Injector
Valve Lifts
Fuel Flows to Nozzle
Solenoid
energized
Valve
To nozzle
May 2006 - Page #
Caterpillar Confidential: Green
Injector Function
Injector
De-energizes
Valve Closes
Unused fuel flows back
to Transfer Pump via
passage in the Head
May 2006 - Page #
Caterpillar Confidential: Green
Solenoid deenergized
Fuel Injector Connections
Two
Types
High Pressure Fuel
Electrical
Three Connectors thru
Valve Cover Base
May 2006 - Page #
Caterpillar Confidential: Green
Fuel Injector
Dos
and Donts
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
Dos
and Donts
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
Transfer
pump is a serviceable item, separate
from High Pressure pump.
Speed sensor is serviceable.
May 2006 - Page #
Caterpillar Confidential: Green
1106D Smart Wastegate
On
All Variable Speed
Engines
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
Controller
Smart Wastegate Schematic
Tells Solenoid
How much Pressure
To Pass
Looks at:
Desired Speed
Load
Boost
May 2006 - Page #
Caterpillar Confidential: Green
Intake Manifold Pressure
(Boost)
Intake Manifold Pressure
(Boost)
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
6 Between teeth
Wide
tooth tells ECM
Crank Position
Teeth point to Nose of
Crank
Use proper thread lock
adhesive when re-using
screws
May 2006 - Page #
Caterpillar Confidential: Green
Dowel Hole
Hall Effect Sensor
Produces
a conditioned square-wave signal
Old
New
Signal Output Waveform Crank Speed/Position Target
May 2006 - Page #
Caterpillar Confidential: Green
