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8/10/2019 Commom Rail
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
C6.6 with ACERT ® Technology
8/10/2019 Commom Rail
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
C6.6 with ACERT ® Technology
Note: The information in this
presentation is preliminary and
subject to change and/ormodification!
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
C6.6 Features
4 Valve HeadECM
CrankshaftCylinder
BlockFuel
System
Timing
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Caterpillar Confidential: Green
Engine Features
6.6 Litres
–Same Bore/Stroke as3054C105mm/127mm
– New Block
ScallopedRibsNoise Attenuation
Closed Top DeckParent Bore
Oversized PistonService Solution
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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
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Caterpillar Confidential: Green
Connecting Rod
Connecting Rods
– Fracture Split
Removal from the Top
– Notches
Bearing Alignment
Not Interchangeable Topto Bottom
– 3 Lengths for PistonProtrusion
–Always use New Bolts
– Dimples for Orientation
Dimple
Dimple Notch
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Caterpillar Confidential: Green
Cylinder Head Details
4 Valve per CylinderCentered Injector
Service – Non-Serviceable Valve
Guides and Seats
– Head face can be machined once
0.006”
– Adapter required for current Valve
Spring Compressor
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Caterpillar Confidential: Green
128
4
1
5
913
11
6
10 14
2
37
Head Bolt Torque Sequence
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
Head
Head
– Multi-Layered-Steel (MLS)
Head Gasket
– Fourteen - 16mm bolts
Single Use – Torque and Angle
Tightening Method
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Caterpillar Confidential: Green
Rocker Assembly
Bridge can be installed
either way
Single Bolt per Rocker
Lever
Lash settings the samefor Inlet and Exhaust
Injectors can be
replaced without
removing Rockers
Exhaust(Short)
Inlet
(long)
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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
Integral front oil seal to
ensure seal to crank
alignment
Idler Hub
Location
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Caterpillar Confidential: Green
TDC access
point
Static Timing
Pinning the Crank to #1 TDC
– Notch in Crank
– Service Tool Available
– Remember to Remove Pin
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Caterpillar Confidential: Green
Camshaft Timing
Camshaft Alignment Tool
– Not a Tight Fit
– Ease of Assembly
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Caterpillar Confidential: Green
Crank Speed/Timing
New Sensor
Located at Rear of Block
Reads tooth wheel
attached to the Crank
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Caterpillar Confidential: Green
Fuel System Overview
Caterpillar Fuel System using common railtechnology – Low Pressure
300kPa (43 PSI)20 Micron Primary Filter
2 Micron Secondary FilterFuel Cooler Required on some arrangements
– High PressureUp to 160 MPa (1600bar - 23,200 PSI)Fluid penetration safety hazard.
Hardened Fuel LinesExternal Fuel Manifold
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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
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Low Pressure Fuel System
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Caterpillar Confidential: Green
High Pressure Fuel System
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
Lube Oil
Feed
Pump
Speed/Position
Sensor
Fuel Pump
Two Pumps
– High Pressure
– Transfer
HP Pump Lubricated by
Engine Oil – Longer Life
Transfer
Pump
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
Fuel Pump
Two Cams - 3 lobe each
Solenoid adjusts rail pressure
and return to tank
Needs to be Timed
–Lock in Place BEFORE Removal
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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 toIncrease Volume
– Also tells Pump Solenoid to
Spill fuel once pressure is
reached
Do it Again!
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Caterpillar Confidential: Green
Fuel Manifold
Feed From High
Pressure Pump
Injector Lines
High Pressure Fuel System
Do‟s & Don‟ts
–Do Check for leaks
– Do Not Loosen HP Connectionwith 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 whenHP Pipe is removed
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May 2006 - Page ‹#›
Caterpillar Confidential: Green
High Pressure
Relief Valve
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?
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Caterpillar Confidential: Green
FuelReturn
from
Head
LIne
Fuel Return from Head
Excess Fuel Returned
to Transfer Pump
– Not High Pressure
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Caterpillar Confidential: Green
To nozzle
Solenoid
energized
Valve
Injector Function
ECM Energizes Injector
Valve Lifts
Fuel Flows to Nozzle
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Caterpillar Confidential: Green
Solenoid de-
energized
Injector Function
Injector De-energizes
Valve Closes
Unused fuel flows back
to Transfer Pump via
passage in the Head
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Caterpillar Confidential: Green
Fuel Injector Connections
Two Types
– High Pressure Fuel
– Electrical
Three Connectors thru
Valve Cover Base
F l I j
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Fuel Injector
Do‟s and Don‟ts
–Do Use Proper Torque on ElectricalConnection
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 CopperWasher are in place
Do Not Re-use O-Ring or CooperWasher
F l I j t
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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 ECMwith proper Injector Trim File
– Do Look for the Trim File CD in
the Injector Box
Cl li
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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 beloosened
F l I j ti S i bilit
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Caterpillar Confidential: Green
Fuel Injection Serviceability
NEVER loosen high pressure pipes when
engine is running! 23,000 PSIUse Electronic Service Tool to Troubleshoot
Injector Problems
Injectors have no serviceable parts.
– Warranty will only be paid with evidence of thecorrect tests.
Pump Solenoid is non serviceable. – If the solenoid is removed the whole pump
assembly must be replaced.
F l I j ti S i bilit
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Caterpillar Confidential: Green
Fuel Injection Serviceability
Transfer pump is a serviceable item, separate
from High Pressure pump.
Speed sensor is serviceable.
1106D S t W t t
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Caterpillar Confidential: Green
1106D Smart Wastegate
On All Variable Speed
Engines
Controls Wastegate Actuator
Optimizes Engine
PerformanceDriven by PWM Signal from
the ECM
Service as an Assembly
– 12 or 24 volt
Smart Wastegate
Controller
S t W t t S h ti
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Caterpillar Confidential: Green
Smart Wastegate Schematic
Intake Manifold Pressure
(Boost)
Intake Manifold Pressure
(Boost)
Looks at:
Desired Speed
Load
Boost
Tells SolenoidHow much Pressure
To Pass
A4 E2 F l C l d (ECM)
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Caterpillar Confidential: Green
A4-E2 Fuel Cooled (ECM)
Anti-Vibration
Mounts
J1 „Customer‟
Connector
Ground Strap
4mm Allen Key
J2 „Engine‟
Connector
Fuel Flow „out‟
Fuel Flow „in‟
A4 E2 El t i C t l
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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
C k S d/Ti i
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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 ofCrank
Use proper thread lock
adhesive when re-using
screws Dowel Hole
H ll Eff t S