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 #
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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 #

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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 #

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Head Bolt Torque Sequence

11

14

10
6

2
8
12
13
9
5
1

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

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 #
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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 #

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 #

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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