June 2009

Introduction
System operation
Input-ECM-Output
Troubleshooting
Common Rail C4.4 & C6.6
C4.2 & C6.4
Acert Technology
1 Tips & Trucs
Lamberts ELOI
 Head Bolt Torque Sequence

11 7 3
10 14
6
2
4
8
12
13
9
5

2
Lamberts ELOI
 Rocker Assembly

Inlet
• Bridge can be installed (Long)
either way
• Single Bolt per Rocker
Lever
• Lash settings the same
for Inlet and Exhaust
• Injectors NEED be
replaced without
removing Rockers
• Special Tool
Exhaust
3 (Short)
Lamberts ELOI
 6 cyl. Oil Pump

• Left Hand filter to

Right Hand filter
requires additional
piping
• Serviced as
Assembly

Pressure
Relief Valve
4
Lamberts ELOI
 Static Timing

• Pinning the Crank to #1 TDC

– Notch in Crank
– Service Tool Available
– Remember to Remove Pin

TDC access
5 point 6Cyl
Lamberts ELOI
 Camshaft Timing

• Camshaft Alignment 4 cyl

Tool
– Not a Tight Fit
– Ease of Assembly

To adjust fuel pump

278-2639
6
Lamberts ELOI
 Camshaft Timing

To adjust fuel pump

278-2639

7
Lamberts ELOI
 Camshaft Timing C4.2 & C6.4

8
Lamberts ELOI
 Crank Speed/Timing

• New Sensor
• Located at Rear of Block
• Reads tooth wheel
attached to the Crank

9
Lamberts ELOI
 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
10
Lamberts ELOI
 Low Pressure Fuel System

11
Lamberts ELOI
 Low Pressure Fuel System

12
Lamberts ELOI
13 Low Pressure Fuel System
Lamberts ELOI
 Low Pressure Fuel System

14
Lamberts ELOI
 High Pressure Fuel System
Injectors

High pressure
fuel rail

High pressure fuel

pump

15
Lamberts ELOI
16
Lamberts ELOI
 Fuel Pump

Lube Oil
Feed
• Two Pumps
– High Pressure
– Transfer
• HP Pump Lubricated by
Engine Oil
– Longer Life

Pump
Speed/Position Transfer
17
Lamberts ELOI Sensor Pump
 High Pressure Fuel Pump

Fuel in to HP Pump
Fuel Leak off to Tank From Secondary Filter

To Fuel HP
Manifold

To
Secondary
Filter

From
Primary
Pump Speed/Position Sensor Filter
18
Lamberts ELOI
 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
19 • Do it Again!
Lamberts ELOI
 Transfer 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
• Driven by High Pressure
20
Pump
Lamberts ELOI
 High Pressure Fuel System

• Do’s & Don’ts Fuel Manifold

– Do Check for leaks Injector Lines
– 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 Feed From High
Connections Immediately when Pressure Pump
HP Pipe is removed
21
Lamberts ELOI
 High Pressure Fuel System

Fuel Manifold Injector Lines

• Do’s & Don’ts

– Do Remove HP Cap just before
installation
– Do Keep your Work Area Clean
– Do Think about Cleanliness
when working on HP System
Feed From High
– Do Make Sure all Clips and Pressure Pump
Clamps are tight and in position
22
Lamberts ELOI
 Fuel Pressure Relief Valve

• Protects System from High Pressure

Over-Pressure Relief Valve

– Opens at Constant Pressure of

160 MPa (23,000 PSI)
– Withstands Spikes to 190 Mpa
(27,500 PSI)
• Returns fuel to Tank
• Event code if Opens !
23
Lamberts ELOI
 C4.2 & C6.4

24
Lamberts ELOI
 Fuel Return from Head

Fuel
Return
from
• Excess Fuel Returned Head
to Transfer Pump LIne
– Not High Pressure

25
Lamberts ELOI
 Injector Function

Solenoid
energized

Valve

• ECM Energizes Injector

• Valve Lifts
• Fuel Flows to Nozzle

26 To nozzle
Lamberts ELOI
 Fuel Injector Connections

• Two Types
– High Pressure Fuel
– Electrical
• Three Connectors thru
Valve Cover Base

27
Lamberts ELOI
 Fuel Injector

• Do’s and Don’ts

– 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

28
Lamberts ELOI
 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
ECM with proper Injector
Trim File
– Do Look for the Trim File CD
in the Injector Box
29
Lamberts ELOI
 Cleanliness

• Thoroughly clean
equipment before
disassembling
• Use only NEW
protective caps to seal
fuel connections
• Replace HP Fuel Lines if
they have be loosened 268-1968

30
Lamberts ELOI
 Smart Wastegate

• On All Variable Speed

Engines
Smart Wastegate
• Controls Wastegate Actuator Controller

• Optimizes Engine
Performance
• Driven by PWM Signal from
the ECM
• Service as an Assembly
– 12 or 24 volt
31
Lamberts ELOI
 Wastegate Actuator

• 1 mm Total Travel
• Refer to Service Manual
for Adjustment Procedure
32
Lamberts ELOI
 Smart Wastegate Schematic

Intake Manifold Pressure

Tells Solenoid (Boost)
How much Pressure
To Pass

Looks at:
Desired Speed
Load Intake Manifold Pressure
Boost (Boost)

33
Lamberts ELOI
 Glow plugs
• Installed on ALL Engines
• Improved
– Sheathed Element
• 850 °C in 4 Seconds
• Controlled by ECM 1 - Early Glow plug
– Via OEM Relay 2 - Improved version.

34
Lamberts ELOI
 On Engine Components
C4.4 & C6.6

ECM

Cam Pump

Intake Air
Crank

Coolant
Oil

Smart Wastegate
Solenoid Fuel Rail
6 EUI Injectors
Diagnostic
35 Connector
Lamberts ELOI
Intake Air
 C4.4 & C6.6

Temp = 2 wires
Press = 3 wires

36
Lamberts ELOI
 3 more sensors
37
Lamberts ELOI
 C4.2 & C6.4

38
Lamberts ELOI
 C4.2 & C6.4

39
Lamberts ELOI
 C4.2 & C6.4

40
Lamberts ELOI
 C4.2 & C6.4

41
Lamberts ELOI
 A4-E2 Fuel Cooled (ECM)

4mm Allen Key

Fuel Flow ‘in’

J1 ‘Customer’
Connector

J2 ‘Engine’
Connector

Ground Strap
42
Lamberts ELOI
Fuel Flow ‘out’
 A4-E2 Electronic Control Module (ECM)

6 Cyl cooled by fuel

4 Cyl not cooled!

• ECM Controls:
– Fuel Pressure
– Speed Governing
– Air/Fuel Ratio
– Start/Stop Sequence
– Engine Protection
Devices/ Diagnostics
43
Lamberts ELOI
 Temperature Sensors
Negative Temperature Coefficient (NTC)

(Resistance)
2,500

Ohms
Thermistor
1000
Ground
20 C Increasing Temperature
Pin No
2

Signal
44 Pin No 1
Lamberts ELOI
 Pressure Sensors
Oil Pressure Sensor
Intake Manifold
Pressure Sensor

Fuel Rail Pressure Sensor

45
Lamberts ELOI
 Fuel Rail Pressure Sensors

• Fuel Rail Pressure Sensor

– Determines Fuel Rail Pressure
– Continuous Operating Pressure 200 Mpa
– Maximum without damage, 260 Mpa
(burst at 320 Kpa)
– Temperature Range, -40º to +160ºC
– Sensor has M12 x 1.5 Thread
– Requires Special ‘Crush’ Washer for Sealing
– Ensure there is no Rail Pressure before removal
– Serviced as a Kit with ‘Crush’ Washer
46
Lamberts ELOI
 IMA Pressure Sensors

• Measures Manifold Air Pressure

– Used to calculate air/fuel ratio
– Used for smoke limiting strategy

• Intake Manifold Air Pressure Sensor

– Measures atmospheric pressure on “key-on”
– Serviced as a Kit with O-ring

Bad := Low oil Pressure

47
Lamberts ELOI
 Oil Pressure Sensors

• Engine Oil Pressure Sensor

– Used for engine protection, Warning/Shutdown
– Provides signal for pressure gauge, via the ECM
– Serviced as a Kit with O-Ring

48
Lamberts ELOI
 Pressure Sensors

• Integrated circuit
• Capacitive sensor
• Voltage output
varies with pressure
• Sensor conditions the
signal voltage output to
the ECM
• Active Sensor (Needs a
external power supply)
49
Lamberts ELOI
 Crank Speed/Timing

• 59 Teeth + 1 Wide tooth

– 6º Between teeth
• Wide tooth “tells” ECM
Crank Position
• Teeth point to Nose of
Crank
• Use proper thread lock
adhesive when re-using
screws Dowel Hole
50
Lamberts ELOI
 HP Pump Speed/Position Sensor

Speed / Timing
Sensor Speed / Timing
Sensor ‘Target’
51
Lamberts ELOI
36 Teeth
 Injector Wiring

• Do’s and Don’ts

– Do make sure wires are
properly routed
– Do make sure clips are
used
• Clips are available in the
Parts System
– Do use the proper
Spring Clip
Service Tool to torque Retainer
Injector Connectors

52
Lamberts ELOI
 Pump Solenoid Wiring

Special Tool Willy

53
Lamberts ELOI
 • Ten Power Wires REQUIRED
– 4 Plus Battery
– 5 Minus Battery
– 1 Ignition Switch
• Beware of “In” Harness Power & Ground
Splices
• Battery Minus should go directly to the
Battery
– Do Not Connect to Battery via the Chassis
• Use Correct Cable Size
– Refer to A&I Guide for details.
54
Lamberts ELOI
 Logged Event Codes

• High Engine Coolant Temperature

• High Intake Air Temperature
• Low Engine Oil Pressure
• High Fuel Temperature
• Engine Over-speed
• High System Supply Voltage (12/24Volt)

Faults That Could cause Engine Damage

55
Lamberts ELOI
 ET Diagnostic Test

• Diagnostic Test
– Injector Solenoid Test
• “Click” Test
– Override Parameters
– Cylinder Cutout Test
• Major Test for finding “Good” or “Bad” Injectors
– Wiggle Test
– Fuel Rail Pressure Test
– Smart Wastegate Click Test
– Injector Verification Test
56
Lamberts ELOI
 Injector Replacement

• If Injector is being replaced because of

– “Injector Data Incorrect”
Or
– “Injector Not Responding” Diagnostics
• Injector Verification Test must be run from
Service Tool

57
Lamberts ELOI
 New Acert ECM Timing Calibration

Test Engine
Flash ECM

Ye Close test Mode

OK s
Activate ECM Go Home
To Test Mode No

ReActivate ECM
To Test Mode Repair
Program all Bad
Parameters Component
Remove New
58
ECM
Lamberts ELOI Install old ECM
 Broken ring, could give more blowby!
59 Also more oil consumsion!
Lamberts ELOI
 Resultaat compressiemeting C6.6 DJY00510

Het verschil tss de

hoogste en laagste
waarde mag maar
3,5bar verschillen
-Wij zitten hier met
een verschil van
7,5bar

Difference
max 3.5 bar

60 Derde cylinder kon niet gemeten worden

Lamberts ELOI
 Easy Quick Connect Fuel Test Tool for low pressure
PARTS…..
1 x 6V1739
1 x 8T0854
2 x 2159513
4 x 1246275
2 x 2280172
4 x 1025758
2 x 3S8743
2 x 8S7169
1 x 1275588
1 x 7B1480
61 Perkings Engine C6.6 & C4.4 1 meter 5P1442
Lamberts ELOI
 4 & 4,5 Bar
on low RPM
Example 4 cyl

62
Lamberts ELOI
 Paraffine….

Or petrol 5%

63
Lamberts ELOI
 Engine 100 hours

64
Lamberts ELOI
 Engine 2060 hours
Big leak………

65
Lamberts ELOI
 For error E398

Low fuel on high RPM

:= 400-550 kpa
Check return line on tank
with engine on full load

Check spring distance when Normaly flow goos down

you have a problem on full load!

66
Lamberts ELOI
 Injecteurs C6.4 & C4.2

Is there an explanation for this holes,

Open hole = Not OK?
Closed hole = OK?

67
Lamberts ELOI
 Engine C6.4 & C4.2

REHS3428

68
Lamberts ELOI
 Engine C6.6 & C4.4

69
Lamberts ELOI
 Timing gear
inside pump

70
Lamberts ELOI
 New RV 1900 Bar
:= 305-5291

3/8

New sensor
:= 311-6342
71 Anti retour check valve up to C18 Engine
Lamberts ELOI
 C6.4 & C4.2
New bolt for injector
+ special socket !

Torque 30 Nm.
72
Lamberts ELOI
 Cutout C6.4 – 2130 hours

73
Lamberts ELOI
 Heathing problem
Airflow on radiator!

74
Lamberts ELOI
 Leaks of high pressure
Relief valve C6.6 !

1 x 2S-7905
75 1 x 277-6165
Lamberts ELOI
 Old trim file

New trim file

Download trim file

in sisweb

76
Lamberts ELOI
 C6.4

Volle belasting

77
Lamberts ELOI
 On startup engine

78
Lamberts ELOI
 When you order new injectors, order also seals & gasket !

C6.6 & C4.4

C6.2 & C4.2

79
Lamberts ELOI
80
Lamberts ELOI
81
Lamberts ELOI
82
Lamberts ELOI
83
Lamberts ELOI
84
Lamberts ELOI
 Valve lash C6.6

85
Lamberts ELOI
 Valve lash C4.4

86
Lamberts ELOI
 Quick Timing Check ….

87
Lamberts ELOI
 Or ……. Install Pump without tool….

88
Lamberts ELOI
 Screen

Back pressure RV
294-8620

Still ignition with injector disconnected!

89 = leakage on injector…….
Lamberts ELOI
 Engine Oil Consumption

90
Lamberts ELOI
91
Lamberts ELOI
 C6.6 High Pressure Pump Solenoid Malfunction

92
Lamberts ELOI
 C6.6 & C4.4 Fuel Injector Crack

93
Lamberts ELOI
 C6.6 & C4.4 Bridge Piece

• CPI number: 158203

• Status: Open Active
• Issue description: The valve bridge piece
can become misaligned and or out of
position, resulting in catastrophic engine
failure
• Publication(s): In Process
• Timeline:
• ICA: July 07
• PCA: Feb 09
• Corrective action:
• ICA: IPV implemented within the production
process
• PCA: Introduce a retaining clip for holding
the bridge piece in place and prevent it from
being incorrectly fitted
94
Lamberts ELOI
 C6.6 - Fuel tube and fitting from 3rd filter to hp pump
leaking-breaking

• CPI Number: 176777

• Type: Project
• Status: Improve
• Issue Description:
LP inlet cracking on Fuel Injection
Pump
• Timeline: Improve phase target
completion 17 th November 08
• Corrective Action:
ICA Oct 07, PCA under validation
95
• Publication(s): PS51460 (ICA)
Lamberts ELOI
 High Pressure Fuel System

What ever it takes – keep it clean!

• Do’s & Don’ts
– 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
96
Lamberts ELOI
 To Fabricate Break out wire big sigar!

177-9656 177-9653

7T-0094
7T-0093

97
Lamberts ELOI
 Connect break-out cable here!

98
Lamberts ELOI
 Remove Bolt to take fuel
pressure
Min := 7 Bar on Low Rpm

Exact tool

- 4C-3974
- 3B-7263
- 6V-4142

99
Lamberts ELOI
 AA0019
BM991106

100
Lamberts ELOI