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Caterpillar Confidential: Green

C6.6 with ACERT ® Technology



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C6.6 with ACERT ® Technology

Note: The information in this

presentation is preliminary and

subject to change and/ormodification!



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C6.6 Features

4 Valve HeadECM

CrankshaftCylinder

BlockFuel

System

Timing



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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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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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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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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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128

4

1

5

913

11

6

10 14

2

37

Head Bolt Torque Sequence



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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

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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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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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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Camshaft Timing

Camshaft Alignment Tool

– Not a Tight Fit

– Ease of Assembly



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Crank Speed/Timing

New Sensor

Located at Rear of Block

Reads tooth wheel

attached to the Crank



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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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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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High Pressure Fuel System



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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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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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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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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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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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FuelReturn

from

Head

LIne

Fuel Return from Head

Excess Fuel Returned

to Transfer Pump

– Not High Pressure



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To nozzle

Solenoid

energized

Valve

Injector Function

ECM Energizes Injector

Valve Lifts

Fuel Flows to Nozzle



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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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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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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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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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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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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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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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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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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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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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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



Crank Speed/Position TargetSignal Output Waveform

Hall Effect Sensor

Produces a conditioned square-wave signal

Old

New

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