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Caterpillar hydraulic excavators serie D
SERV1837-01 June 2008 GLOBAL SERVICE LEARNING TECHNICAL PRESENTATION C4.2/C6.4 AND C4.4/C6.6 ACERT™ ENGINES WITH COMMON RAIL FUEL SYSTEM MACHINE APPLICATIONS Service Training Meeting Guide (STMG) C4.2/C6.4 AND C4.4/C6.6 ACERT™ ENGINES WITH COMMON RAIL FUEL SYSTEM MACHINE APPLICATIONS AUDIENCE Level II - Service personnel who understand the principles of machine system operation, diagnostic equipment, and procedures for testing and adjusting CONTENT This presentation provides an introduction and describes the components, systems operation, maintenance, and testing and adjusting procedures for the C4.2/C6.4 and the C4.4/C6.6 ACERT™ engines used in Caterpillar machines This presentation may also be used for self-paced and for self-directed learning OBJECTIVES After learning the information in this presentation, the technician will be able to: identify the safety and contamination control requirements of the C4.2/C6.4 and the C4.4/C6.6 ACERT™ engines; and identify the common components and explain the operation of the common rail fuel system in the C4.2/C6.4 and the C4.4/C6.6 ACERT™ engines; and troubleshoot problems in the C4.2/C6.4 and the C4.4/C6.6 ACERT™ engines REFERENCES "C4.4/C6.6 Awareness and Service Self Study Course" SERV7037 PREREQUISITES "Fundamentals of Electrical Systems Self Study Course" "Fundamentals of Engines Self Study Course" Estimated Time: Hours Illustrations: 67 Handouts: 22 Form: SERV1837-01 Date: 6/08 © 2008 Caterpillar Inc TEMV3004 TEMV3001 SERV1837-01 06/08 -3- Text Reference TABLE OF CONTENTS INTRODUCTION C4.4/C6.6 ACERT™ Engines .9 C4.2/C6.4 ACERT™ Engines .13 MAINTENANCE .17 Contamination Control 17 Safety 18 General Service Procedures 20 Maintenance Intervals 22 COMMON RAIL FUEL SYSTEM 23 Low Pressure Fuel Circuit 23 High Pressure Fuel Circuit 25 C4.4/C6.6 ENGINE COMPONENTS AND OPERATION .32 Fuel system 32 Air inlet system .42 Electrical system 46 Demand Fan 55 Reversing Fan .57 C4.2/C6.4 ENGINE COMPONENTS AND OPERATION .58 Fuel system 58 Air inlet system .65 Electrical system 68 ENGINE DIAGNOSTICS 75 Caterpillar Electronic Technician (Cat ET) 75 Monitoring Systems 83 CONCLUSION 85 VISUAL LIST 86 HYDRAULIC SCHEMATIC COLOR CODE 87 HANDOUTS .88 SERV1837-01 06/08 -4- NOTES Text Reference SERV1837-01 06/08 -5- Text Reference C4.2/C6.4 AND C4.4/C6.6 ACERT™ ENGINES WITH COMMON RAIL FUEL SYSTEM MACHINE APPLICATIONS © 2008 Caterpillar Inc INTRODUCTION This presentation covers the components, systems operation, and testing and adjusting procedures for the C4.2/C6.4 and the C4.4/C6.6 ACERT™ engines The C4.2 and C6.4 ACERT™ engines are the same design and the C4.4 and C6.6 ACERT™ engines are the same design All the engines use a common rail fuel system The C4.2 and the C.4.4 ACERT™ engines are inline four cylinder engines with 4.2 and 4.4 liter displacements The C6.4 and the C.6.6 ACERT™ engines are inline six cylinder engines with 6.4 and 6.6 liter displacements The common rail fuel system includes an electronically controlled high pressure fuel injection pump, a fuel manifold, and electronically controlled injectors The A4-E2 Engine ECM controls the pump solenoid, which controls the injection pump fuel flow through the high pressure pipes to the injectors The Engine ECM also controls the ON/OFF fuel injector solenoids NOTE: This presentation can be used to supplement machine training and covers the common engine components on the C4.2/C6.4 and C4.4/C6.6 ACERT™ engines This presentation may not cover all engine components that may be installed on specific machine applications SERV1837-01 06/08 -6- Text Reference NOTE: Additional C4.4/C6.6 engine training including disassembly, testing, adjusting, and diagnostics is available by attending the "3000 Series C6.6/C4.4 Engine with ACERT™ Technology" currently offered in Peoria, IL and Malaga, Spain SERV1837-01 06/08 -7- Text Reference 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 Some of the C4.2/C6.4 and C4.4/C6.6 ACERT engine features are: - The high pressure fuel pump is controlled by the Engine ECM and provides high pressure fuel to the injectors - The electronically controlled injectors are controlled by the ECM to inject high pressure fuel into the combustion chamber - The cylinder head includes valves per cylinder - The engine block includes a scalloped crank case with extra ribbing, which provides a more ridged structure with a lower noise attenuation (sound absorption) - The aluminum pistons have improved oil control - The A4-E2 Engine ECM controls fuel pressure, speed governing, air/fuel ratio, engine start/stop strategy, and provides diagnostics - A smart wastegate controls boost pressure throughout the operating range of the engine (C4.4/C6.6 only) SERV1837-01 06/08 -8- Text Reference - The common rail fuel system allows tight control of injection events and optimizes engine performance across all load and speed ranges The common rail system reduces combustion noise, and NOx and PM emissions SERV1837-01 06/08 -9- Text Reference C4.4/C6.6 ACERT™ Engines The C4.4/C6.6 ACERT™ engines meet U.S Environmental Protection Agency (EPA) Tier III Emissions Regulations for the North America market and Stage IIIa European Emissions Regulations These ACERT engines are being targeted for machine applications where new or upgraded models will meet the latest emissions regulations These include small and medium: - Track-type tractors - Wheel loaders - Track loaders - Underground loaders - Wheeled excavators - Paving products - Motor graders - Backhoe loaders Many of these machines will be common to the rental market SERV1837-01 06/08 - 10 - Basic machine specifications for the C4.4 engine are: - Configuration: Four cylinders inline, 16-valve crossflow cylinder head - Fuel System: Direct injection, common rail - Aspiration: Turbocharged/Turbo-ATAAC - ECM: A4E2 - Gross power: 62 - 106 bkW (83 - 142 bhp) @ 2200 rpm - Displacement: 4.4 liter (269 in3) - Bore: 105 mm (4.13 in.) - Stroke: 127 mm (5 in.) - Compression ratio: 16.2:1 Basic machine specifications for the C6.6 engine are: - Configuration: Six cylinders inline, 24-valve crossflow cylinder head - Fuel System: Direct injection, common rail - Aspiration: Turbo-ATAAC - ECM: A4E2 - Gross power: 89 - 205 bkW (119 - 275 bhp) @ 1800 - 2500 rpm - Displacement: 6.6 liter (402.8 in3) - Bore: 105 mm (4.13 in.) - Stroke: 127 mm (5 in.) - Compression ratio: 16.2:1 Text Reference SERV1837-01 06/08 - 95 - C4.2/C6.4 Engine Component Identification (continued) _ Air inlet heater Function: Location: _ Air inlet heater relay Function: Location: Handout No Safeguard Filter Secondary Fuel Filter Orifice Orifice High Pressure Pump Hand Fuel Priming Pump Primary Fuel Filter Common Rail Manifold Fuel Transfer Pump Injectors Engine ECM ENGINE FUEL DELIVERY SYSTEM WITH HAND FUEL PRIMING PUMP C6.6 ACERT Fuel Return Check Valve High Pressure Relief Valve Fuel Tank SERV1837-01 06/08 - 96 Handout No Intake Valve Output Smart Pressure Wastegate Line Solenoid Turbocharger To Atmosphere Engine ECM Compressor Side Air Inlet From Air Filter Air to Air Aftercooler Wastegate Actuator Exhaust Outlet Turbine Side AIR INTAKE AND EXHAUST SYSTEM - 97 - Speed Coolant Inlet Air Timing Temp Pressure Sensor Sensor Sensor Exhaust Valve Exhaust Manifold Intake Air Manifold C4.4 / C6.6 ACERT SERV1837-01 06/08 Handout No 10 J2 Boost Pressure Sensor Rail Fuel Pressure Sensor Crank Speed / Timing Sensor Cam Speed / Timing Sensor Input Oil Pressure Sensor Coolant Temperature Sensor Inlet Air Temperature Sensor - 98 - Fuel Pump Control Solenoid Output J1 Wastegate Solenoid Valve Fuel Injectors (4 or 6) Engine ECM COMMON COMPONENTS C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM SERV1837-01 06/08 Handout No 11 + Primary Speed / Timing Sensor Throttle Position Sensor Engine Oil Pressure Sensor Intake Manifold Air Temp Sensor Intake Manifold Air Pressure Sensor CAT Data Link CAN Data Link _ Starter Relay J1 J2 Machine ECM Engine Shutdown Switch Secondary Speed / Timing Sensor Common Rail Fuel Pressure Sensor Coolant Temp Sensor Engine ECM INPUT COMPONENTS Key Start Switch CAT Data Link Demand Fan Solenoid Smart Wastegate Solenoid Ether Aid Solenoid Fuel Pump Pressure Control Solenoid Monitoring System - 99 - OUTPUT COMPONENTS Fuel Injectors (4 or 6) TYPICAL COMPONENTS C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM SERV1837-01 06/08 Handout No 12 Engine ECM Fuel Transfer Pump Common Rail Manifold Injectors High Pressure Pump High Pressure Relief Valve Priming Pump (Attach) Primary Fuel Filter Electric Fuel Priming Pump (Attach) ENGINE FUEL DELIVERY SYSTEM Secondary Fuel Filter Safe Fi Fuel Pressu Differential Se - 100 - Fuel Return Check Valve Fuel Tank C6.4 ACERT SERV1837-01 06/08 Handout No 13 Fuel Pump Control Solenoid Input Fuel Pressure Sensor Fuel Differential Pressure Sensor Oil Pressure Sensor Fuel Temperature Sensor Coolant Temperature Sensor Inlet Air Temperature Sensor - 101 - Boost Pressure Sensor Rail Fuel Pressure Sensor Primary Speed / Timing Sensor Secondary Speed / Timing Sensor J2 Air Inlet Relay J1 Fuel Injectors (4 or 6) Output Engine ECM COMMON COMPONENTS C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM SERV1837-01 06/08 Handout No 14 + J1 J2 Machine ECM Fuel Pressure Sensor Fuel Different ial Pressure Sensor Engine Shutdown Switch Secondary Speed / Timing Sensor Common Rail Fuel Pressure Sensor Coolant Temp Sensor Engine ECM INPUT COMPONENTS Key Start Switch Start Aid Relay Air Inlet Relay Fuel Pump Pressure Control Solenoid OUTPUT COMPONENTS Fuel Injectors (4 or 6) CAT Data Link Monitoring System - 102 - Fuel Temperat ure Sensor Primary Speed / Timing Sensor Throttle Position Switch Engine Oil Pressure Sensor Intake Manifold Air Temp Sensor Intake Manifold Air Pressure Sensor CAT Data Link CAN Data Link _ TYPICAL COMPONENTS C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM SERV1837-01 06/08 Handout No 15 Engine ECM Flow Control Valve CDL Machine ECM Orifice Demand Fan Control Manifold Hydraulic Oil Temperature Sensor Fan Solenoid Valve Demand Fan - 103 - Air Inlet Temperature Sensor Engine Coolant Temperature Sensor Fan Pump Left Drive Pump Charge Circuit And Implement Pilot Supply Oil Cooler Outlet HYDRAULIC DEMAND FAN SYSTEM SERV1837-01 06/08 Handout No 16 REVERSE FORWARD Machine ECM Air Inlet Temperature Sensor Engine Coolant Temperature Sensor Reversing Fan Relay Crossover Relief Valve Fan Direction Valve Engine ECM Makeup Valve Reversing Solenoid Valve 10 A Demand Fan Fan Control Fuse Motor - 104 - Reversing Fan Switch Fan Solenoid Valve Flow Control Valve Hydraulic Oil Temperature Sensor Fan Pump Left Drive Pump Charge Circuit And Implement Pilot Supply Oil Cooler Outlet Fan Pump Left Drive Pump Charge Circuit And Implement Pilot Supply Oil Cooler Outlet REVERSING DEMAND FAN SYSTEM SERV1837-01 06/08 Handout No 17 SERV1837-01 06/08 - 105 - Handout No 18 SERV1837-01 06/08 - 106 - Handout No 19 SERV1837-01 06/08 - 107 - Handout No 20 Posttest The C4.2/C6.4 and C4.4/C6.6 engines meet: A B C D Tier requirements Tier requirements Tier requirements Tier requirements How many valves the C4.2/C6.4 and C4.4/C6.6 engines have per cylinder? A B C D After the high pressure fuel lines are removed from the engine they must be: A B C D Thoroughly cleaned with solvent and compressed air before reinstalling on the engine Capped with plastic caps and placed in an air tight bag Checked for deformities Thrown away and never reused The C4.2 or C4.4 high pressure fuel pump has a camshaft with cam lobes per pumping plunger A B C D If the crankshaft speed timing sensor malfunctions: A B C D The engine will still start and run The engine will still run but not restart The engine will not start and will not run The engine will default to "limp home mode" Which of the following components are installed on the fuel manifold? A B C D Fuel pressure sensor Fuel differential pressure switch Fuel temperature sensor All of the above SERV1837-01 06/08 - 108 - Posttest (continued) Which of the following components controls pump output pressure? A B C D Fuel pressure relief valve Fuel manifold Pump solenoid None of the above Which of the following components on the injection pump are serviceable? A B C D Pump solenoid Transfer pump Secondary speed/timing sensor B and C If the fuel pressure relief valve has opened, which of the following must be done? A B C D Clear the diagnostic code Replace the relief valve Replace the fuel rail manifold All of the above 10 Which of the following sensors is common to all C4.2/C6.4 and C4.4/C6.6 engines? A B C D Air inlet temperature sensor Fuel pressure sensor Atmospheric pressure sensor Oil level sensor Handout No 21 SERV1837-01 06/08 Posttest Answer Key 10 C C D B A A C D A A - 109 - Handout No 22 ... regulations These include small and medium: - Track-type tractors - Wheel loaders - Track loaders - Underground loaders - Wheeled excavators - Paving products - Motor graders - Backhoe loaders Many of... are: - Configuration: Six cylinders inline, 24-valve crossflow cylinder head - Fuel System: Direct injection, common rail - Aspiration: Turbo-ATAAC - ECM: A4E2 - Gross power: 89 - 205 bkW (119 -. .. rail - Aspiration: Turbo-ATAAC - ECM: A4E2 - Rated power: 91 - 98 kW (122 - 131 hp) @ 1700 - 2200 rpm - Displacement: 4.2 liter (256 in3) - Bore: 102 mm (4.02 in.) - Stroke: 130 mm (5.12 in.) -