C4.2/C6.4 AND C4.4/C6.

6 ACERT™
ENGINES
WITH COMMON RAIL FUEL SYSTEM
MACHINE APPLICATIONS

© 2007 Caterpillar Inc.

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
ENGINE MAINTENANCE INTERVALS
- Engine Oil S O S 250 Hours
- Coolant S O S 250 Hours
- Oil and Filter Change 500 Hours
- Air Filter Clean/Replace 500 Hours
- Breather 500 Hours
- Fuel Filters 500 Hours
- Engine Valve Lash 1000 Hours
 LOW PRESSURE FUEL SYSTEM
C4.4 / C6.6 C4.2 / C6.4

Tertiary (3rd) Fuel Tertiary (3rd)

Fuel Filter Priming Pump Fuel Filter

Secondary Secondary
Fuel Filter Primary Fuel Fuel Filter Primary Fuel
Fuel Filter Tank Fuel Filter Tank
Fuel
Priming
Pump
Fuel Fuel
Transfer Transfer
Pump Pump
Engine Engine
ECM ECM
High Pressure High Pressure
Pump Pump
 C6.6 ACERT ENGINE FUEL DELIVERY SYSTEM

Tertiary Electric Fuel

Fuel Filter Priming Pump

Fuel
Tank
Secondary
Fuel Filter Primary
Fuel Filter
Common Rail Manifold

Engine
ECM

High Pressure
Pump
Fuel Transfer
Pump
From Internal
Fuel Gallery
 C4.4/C6.6 ACERT AIR INTAKE AND EXHAUST SYSTEM

Intake Air Turbocharger

Manifold Air to Air
AfterCooler
Turbine
Side

Exhaust
Manifold Air Inlet
Intake Exhaust
From
Valve Outlet
Air Filter
Exhaust
Valve Compressor
Side

Wastegate
Engine
Output Actuator
ECM Smart
Pressure
Wastegate
Line
Speed Coolant Inlet Air Solenoid
Timing Temp Pressure
To Atmosphere
Sensor Sensor Sensor
 C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM
COMMON COMPONENTS

Engine ECM

Output Input

J1
Fuel
Injectors

J2
(4 or 6)

Secondary
Speed / Timing Sensor
Inlet Air
Temperature Sensor

Wastegate Primary
Solenoid Valve Speed / Timing Sensor
Coolant
Temperature Sensor

Rail Fuel
Fuel Pump Pressure Sensor
Control Solenoid Oil Pressure Sensor

Boost Pressure Sensor

 C4.4 / C6.6 ENGINE ELECTRONIC CONTROL SYSTEM
TYPICAL COMPONENTS

_
+
Key Start
Switch
Engine Machine Monitoring
ECM ECM System
J1 J2

Starter
Relay
CAN Data Link
CAT Data Link
CAT Data Link

Intake Manifold Air

Pressure Sensor Coolant Temp. Sensor
Intake Manifold Fuel Pump
Air Temp. Sensor Common Rail Pressure Control Solenoid
Fuel Pressure Sensor
Engine Oil Ether Aid Solenoid
Pressure Sensor
Secondary
Fuel Smart Wastegate Solenoid
Throttle Speed / Timing Sensor
Injectors
Position Sensor (4 or 6)
Demand Fan Solenoid
Primary Engine Shutdown Switch
Speed / Timing
Sensor

INPUT COMPONENTS OUTPUT COMPONENTS

 HYDRAULIC DEMAND FAN SYSTEM
C4.4 / C6.6 ENGINES

Demand Fan Control Manifold Demand Fan

Oil Cooler Outlet

Left Drive Pump

Charge Circuit
and Implement Flow Control
Pilot Supply Valve

Fan
Solenoid
Orifice Valve

Fan Pump

Engine Coolant Hydraulic Oil

CDL Temperature Sensor
Temperature Sensor

Air Inlet
Temperature Sensor
Engine ECM Machine ECM
 REVERSING DEMAND FAN SYSTEM
C4.4 / C6.6 ENGINES

Oil Cooler Outlet

Left Drive Pump
Charge Circuit
and Implement
Pilot Supply
Motor

FORWARD

Fan Pump
Demand Fan
Flow Control Reversing Solenoid Fan Direction
Valve Valve Valve

Fan Solenoid Makeup Crossover Relief

Valve Valve Valve
Oil Cooler Outlet

Left Drive Pump

Charge Circuit
and Implement
Pilot Supply

REVERSE

Fan Pump

Reversing
Fan Relay
10 A
Hydraulic Oil Fan Control Fuse
Temperature Sensor
Engine Coolant
Temperature Sensor

Reversing
Fan Switch Air Inlet
Temperature Sensor
Machine ECM Engine ECM
 C6.4 ACERT ENGINE FUEL DELIVERY SYSTEM

Secondary Tertiary
Primary Fuel Filter Fuel Filter
Fuel Filter

Fuel
Tank

Common Rail Manifold

Priming
Pump

High Pressure
Pump

Engine Fuel Transfer

ECM Pump
 C4.2 / C6.4 ACERT AIR INTAKE AND EXHAUST SYSTEM

Intake Air Turbocharger

Manifold Air to Air
Aftercooler
Turbine
Side

Exhaust
Manifold Air Inlet
Intake Exhaust
From
Valve Outlet
Air Filter
Exhaust
Valve Compressor
Side
 C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM
COMMON COMPONENTS

Engine ECM

Output Input

J1
Fuel

J2
Injectors
(4 or 6) Inlet Air
Temperature Sensor

Secondary
Speed / Timing Sensor
Coolant
Temperature Sensor

Primary
Speed / Timing Sensor Fuel
Air Inlet Relay Temperature Sensor

Rail Fuel
Fuel Pump Pressure Sensor Oil Pressure Sensor
Control Solenoid

Fuel Differential
Boost Pressure Sensor Pressure Sensor

Fuel
Pressure Sensor
 C4.2 / C6.4 ENGINE ELECTRONIC CONTROL SYSTEM
TYPICAL COMPONENTS

_
+
Key Start
Switch
Engine Machine
ECM ECM Monitoring
System
J1 J2

CAN Data Link

CAT Data Link
CAT Data Link

Intake Manifold Air

Pressure Sensor Coolant Temp. Sensor
Intake Manifold Fuel Pump
Air Temp. Sensor Common Rail Pressure Control Solenoid
Fuel Pressure Sensor
Engine Oil
Pressure Sensor Fuel Air Inlet Relay
Secondary
Throttle Speed / Timing Sensor Injectors
Position Switch (4 or 6)
Start Aid Relay
Primary Engine Shutdown Switch
Speed / Timing
Sensor OUTPUT COMPONENTS
Fuel
Fuel Different ial
Temperat ure
Pressure Sensor
Sensor

Fuel Pressure Sensor

INPUT COMPONENTS
 CAT ET DIAGNOSTICS
- View engine derates
- View component status
- Configure engine parameters
- View diagnostic codes and events
- Flash ECM
- Perform diagnostic tests
SRC CODE OCC ACT
36 91-8 10
36 168-0 5
36 168-1 5

OK
 HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Red - High pressure oil

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void