Caterpillar C6.6 Industrial Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C6.6 Industrial Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C6.6 Industrial Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR5290 - Specifications (C6.6 Engines for Caterpillar Built Machines).pdf
KENR5291 - Systems Operation (C6.6 Engines for Caterpillar Built Machines).pdf
KENR5291 - Testing and Adjusting (C6.6 Engines for Caterpillar Built Machines).pdf
KENR5391 - Troubleshooting (C4.4 and C6.6 Engines for Caterpillar Built Machines).pdf
KENR6081 - Disassembly and Assembly (C6.6 Engines for Caterpillar Built Machines).pdf
SERV1837 - Technical Presentation (C4.2, C4.4, C6.4, C6.6 (Acert) Engines with Common Rail Fuel System).pdf
PRODUCT DETAILS:
Total Pages: 1,232 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR5290 - Specifications (C6.6 Engines for Caterpillar Built Machines)....2
Alternator....4
Camshaft Bearings....7
Camshaft....8
Connecting Rod Bearing Journal....10
Connecting Rod....11
Coolant Temperature Sensor....15
Crankcase Breather....16
Crankshaft Seals....19
Crankshaft....21
Cylinder Block....26
Cylinder Head Valves....28
Cylinder Head....30
Electronic Control Module....33
Engine Design....35
Engine Lifting Bracket....37
Engine Oil Cooler....38
Engine Oil Filter Base....42
Engine Oil Pan....44
Engine Oil Pressure Sensor....46
Engine Oil Pressure....47
Engine Oil Pump....48
Exhaust Manifold....51
Flywheel Housing....53
Flywheel....56
Front Housing and Covers....58
Fuel Filter Base....61
Fuel Injection Lines....62
Fuel Injection Nozzles....65
Fuel Injection Pump....67
Fuel Pressure Sensor....69
Fuel Priming Pump....71
Fuel Transfer Pump....73
Gear Group (Front)....75
Glow Plugs....78
Inlet Manifold Air Pressure Sensor....80
Inlet Manifold Temperature Sensor....81
Inlet Manifold....82
Lifter Group....83
Main Bearing Journal....84
Piston Cooling Jet....85
Piston and Rings....87
Rocker Shaft....89
Speed Sensor....92
Starter Motor....93
Turbocharger....95
Valve Mechanism Cover....97
Vibration Damper and Pulley....98
Water Pump....100
Water Temperature Regulator and Housing....102
KENR5291 - Systems Operation (C6.6 Engines for Caterpillar Built Machines)....104
Air Inlet and Exhaust System....105
Basic Engine....111
Cleanliness of Fuel System Components....119
Cooling System....121
Electrical System....123
Electronic Control System Components....126
Fuel System....137
General Information....150
Lubrication System....154
Power Sources....156
KENR5291 - Testing and Adjusting (C6.6 Engines for Caterpillar Built Machines)....160
Air Inlet and Exhaust System - Inspect....162
Air in Fuel - Test....165
Alternator - Test....169
Battery - Test....171
Charging System - Test....172
Compression - Test....173
Connecting Rod - Inspect....175
Cooling System - Check....179
Cooling System - Inspect....181
Cooling System - Test....183
Cylinder Block - Inspect....187
Cylinder Head - Inspect....188
Electric Starting System - Test....191
Engine Oil Cooler - Inspect....195
Engine Oil Pressure - Test....199
Engine Oil Pump - Inspect....200
Engine Valve Lash - Inspect_Adjust....202
Excessive Bearing Wear - Inspect....207
Excessive Engine Oil Consumption - Inspect....208
Finding Top Center Position for No. 1 Piston....209
Flywheel - Inspect....212
Flywheel Housing - Inspect....215
Fuel Injection Timing - Check....218
Fuel Quality - Test....222
Fuel System - Inspect....223
Fuel System - Prime....224
Gear Group (Front) - Time....227
Gear Group - Inspect....229
Glow Plugs - Test....231
Increased Engine Oil Temperature - Inspect....233
Piston Height - Inspect....234
Piston Ring Groove - Inspect....236
Turbocharger - Inspect....239
V-Belt - Test....245
Valve Depth - Inspect....247
Valve Guide - Inspect....250
Vibration Damper - Check....252
Water Pump - Inspect....255
Water Temperature Regulator - Test....256
KENR5391 - Troubleshooting (C4.4 and C6.6 Engines for Caterpillar Built Machines)....257
5 Volt Sensor Supply Circuit - Test....262
Alternator Noise....271
Alternator Will Not Charge....273
Battery....275
CAN Data Link Circuit - Test....276
CID 0001 FMI 02....281
CID 0001 FMI 05....282
CID 0001 FMI 06....284
CID 0001 FMI 07....286
CID 0002 FMI 02....287
CID 0002 FMI 05....288
CID 0002 FMI 06....290
CID 0002 FMI 07....292
CID 0003 FMI 02....293
CID 0003 FMI 05....294
CID 0003 FMI 06....296
CID 0003 FMI 07....298
CID 0004 FMI 02....299
CID 0004 FMI 05....300
CID 0004 FMI 06....302
CID 0004 FMI 07....304
CID 0005 FMI 02....305
CID 0005 FMI 05....306
CID 0005 FMI 06....308
CID 0005 FMI 07....310
CID 0006 FMI 02....311
CID 0006 FMI 05....312
CID 0006 FMI 06....314
CID 0006 FMI 07....316
CID 0041 FMI 03....317
CID 0041 FMI 04....318
CID 0100 FMI 03....319
CID 0100 FMI 04....320
CID 0100 FMI 10....321
CID 0110 FMI 03....323
CID 0110 FMI 04....324
CID 0168 FMI 00....325
CID 0168 FMI 01....326
CID 0168 FMI 02....327
CID 0172 FMI 03....329
CID 0172 FMI 04....331
CID 0190 FMI 08....333
CID 0247 FMI 09....334
CID 0247 FMI 12....335
CID 0253 FMI 02....336
CID 0261 FMI 11....337
CID 0262 FMI 03....338
CID 0262 FMI 04....339
CID 0268 FMI 02....340
CID 0291 FMI 05....341
CID 0291 FMI 06....342
CID 0342 FMI 08....343
CID 0526 FMI 05....344
CID 0526 FMI 06....345
CID 0526 FMI 07....346
CID 1639 FMI 09....348
CID 1779 FMI 05....349
CID 1779 FMI 06....350
CID 1785 FMI 03....351
CID 1785 FMI 04....352
CID 1785 FMI 10....353
CID 1797 FMI 03....355
CID 1797 FMI 04....356
CID 1834 FMI 02....357
CID 2246 FMI 06....358
Can Not Reach Top Engine RPM....359
Coolant Temperature Is Too High....363
Coolant in Engine Oil....366
Cooling Fan Control - Test....368
Customer Specified Parameters Table....374
Customer Specified Parameters Worksheet....376
Customer Specified Parameters....377
Data Link Circuit - Test....381
Diagnostic Code Cross Reference....385
E1044 High Intake Manifold Pressure....389
E1045 Low Intake Manifold Pressure....391
E194 High Exhaust Temperature....393
E232 High Fuel_Water Separator Water Level....395
E360 Low Engine Oil Pressure....396
E361 High Engine Coolant Temperature....401
E362 Engine Overspeed....403
E396 High Fuel Rail Pressure....405
E398 Low Fuel Rail Pressure....407
E539 High Intake Manifold Air Temperature....409
ECM Harness Connector Terminals....411
ECM Memory - Test....414
ECM Will Not Accept Factory Passwords....415
ECM Will Not Communicate with Other Systems or Display Modules....416
Electrical Connectors - Inspect....417
Electronic Service Tool Will Not Communicate with ECM....427
Electronic Service Tools....429
Engine Cranks but Will Not Start....436
Engine Has Early Wear....443
Engine Misfires, Runs Rough or Is Unstable....445
Engine Oil in Cooling System....449
Engine Pressure Sensor Open or Short Circuit - Test....451
Engine Speed_Timing Sensor Circuit - Test....462
Engine Stalls at Low RPM....473
Engine Temperature Sensor Open or Short Circuit - Test....475
Engine Vibration....484
Engine Will Not Crank....487
Engine Wiring Information....490
Event Codes....494
Excessive Black Smoke....498
Excessive Engine Oil Consumption....502
Excessive Fuel Consumption....505
Excessive Valve Lash....509
Excessive White Smoke....511
Factory Passwords....514
Flash Programming....515
Fuel Rail Pump Solenoid - Test....517
Glossary....524
Ignition Keyswitch Circuit and Battery Supply Circuit - Test....531
Injector Data Incorrect - Test....536
Injector Solenoid Circuit - Test....541
Injector Trim File....557
Intake Air Temperature Is Too High....559
Intermittent Engine Shutdown....562
Intermittent Low Power or Power Cutout....565
Low Engine Oil Pressure....568
Low Power_Poor or No Response to Throttle....571
Mechanical Noise (Knock) in Engine....576
No Diagnostic Codes Detected....578
Noise Coming from Cylinder....579
Programming Parameters....585
Replacing the ECM....586
Self-Diagnostics....589
Sensors and Electrical Connectors....590
Starting Aid (Glow Plug) Relay Circuit - Test....597
System Configuration Parameters....603
System Overview....605
Test ECM Mode....610
Wastegate Solenoid - Test....612
KENR6081 - Disassembly and Assembly (C6.6 Engines for Caterpillar Built Machines)....621
Accessory Drive - Remove and Install....625
Air Compressor - Remove and Install....629
Alternator - Install - Alternators with Mounting Lugs....640
Alternator - Install - Alternators with Mounting Pads....642
Alternator - Remove - Alternators with Mounting Lugs....644
Alternator - Remove - Alternators with Mounting Pads....646
Alternator Belt - Remove and Install....648
Bearing Clearance - Check....652
Boost Pressure Sensor - Remove and Install....655
Camshaft - Remove and Install....658
Camshaft Bearings - Remove and Install....662
Camshaft Gear - Remove and Install....665
Connecting Rod Bearings - Install - Connecting rods in position....673
Connecting Rod Bearings - Remove - Connecting rods in position....677
Coolant Temperature Sensor - Remove and Install....681
Crankcase Breather - Install - Filtered Breather....684
Crankcase Breather - Install - Unfiltered Breather....689
Crankcase Breather - Remove - Filtered Breather....694
Crankcase Breather - Remove - Unfiltered Breather....700
Crankshaft - Install....705
Crankshaft - Remove....712
Crankshaft Front Seal - Remove and Install....716
Crankshaft Gear - Remove and Install....721
Crankshaft Main Bearings - Remove and Install - Crankshaft in position....725
Crankshaft Rear Seal - Install....733
Crankshaft Rear Seal - Remove....740
Crankshaft Timing Ring - Remove and Install....742
Cylinder Head - Install....745
Cylinder Head - Remove....753
ECM Mounting Bracket - Remove and Install....760
Electric Starting Motor - Remove and Install....765
Electronic Control Module - Remove and Install....768
Electronic Unit Injector - Install....774
Electronic Unit Injector - Remove....786
Engine Oil Cooler - Install - Engine Oil Cooler with a High Mounted Filter Base....796
Engine Oil Cooler - Install - Engine Oil Cooler with a Low Mounted Filter Base....800
Engine Oil Cooler - Remove - Engine Oil Cooler with a High Mounted Filter Base....804
Engine Oil Cooler - Remove - Engine Oil Cooler with a Low Mounted Filter Base....808
Engine Oil Filter Base - Remove and Install....812
Engine Oil Pan - Install - Aluminum Oil Pan....815
Engine Oil Pan - Install - Cast Iron Oil Pan....819
Engine Oil Pan - Remove - Aluminum Oil Pan....824
Engine Oil Pan - Remove - Cast Iron Oil Pan....828
Engine Oil Pan Plate - Remove and Install - Aluminum Oil Pan....832
Engine Oil Pressure Sensor - Remove and Install....838
Engine Oil Pump - Install....841
Engine Oil Pump - Remove....845
Engine Oil Relief Valve - Remove and Install....848
Exhaust Elbow - Remove and Install....852
Exhaust Manifold - Remove and Install - Side Mounted Exhaust Manifold....854
Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold....858
Fan - Remove and Install....862
Fan Drive - Remove and Install....865
Flywheel - Install....867
Flywheel - Remove....870
Flywheel Housing - Remove and Install - Standard Housing....873
Flywheel Housing - Remove and Install - Wet Back End Housing....880
Front Cover - Remove and Install....888
Fuel Filter Base - Remove and Install - Secondary Fuel Filter....892
Fuel Injection Lines - Install....896
Fuel Injection Lines - Remove....903
Fuel Injection Pump - Install....909
Fuel Injection Pump - Remove....916
Fuel Injection Pump Gear - Install....922
Fuel Injection Pump Gear - Remove....926
Fuel Manifold (Rail) - Remove and Install....930
Fuel Pressure Sensor - Remove and Install....936
Fuel Priming Pump - Remove and Install - Electric Fuel Priming Pump....939
Fuel Priming Pump - Remove and Install - Mechanical Priming Pump....943
Fuel Transfer Pump - Install....947
Fuel Transfer Pump - Remove....951
Gear Group (Front) - Remove and Install....955
Glow Plugs - Remove and Install....964
Housing (Front) - Install....968
Housing (Front) - Remove....974
Idler Gear - Install....978
Idler Gear - Remove....991
Inlet Air Temperature Sensor - Remove and Install....1001
Inlet Manifold - Remove and Install....1004
Inlet and Exhaust Valve Springs - Remove and Install....1009
Inlet and Exhaust Valves - Remove and Install....1019
Lifter Group - Remove and Install....1026
Piston Cooling Jets - Remove and Install....1030
Pistons and Connecting Rods - Assemble....1033
Pistons and Connecting Rods - Disassemble....1038
Pistons and Connecting Rods - Install....1042
Pistons and Connecting Rods - Remove....1046
Position Sensor (Fuel Injection Pump) - Remove and Install....1049
Rocker Shaft - Assemble....1052
Rocker Shaft - Disassemble....1056
Rocker Shaft and Pushrod - Install....1059
Rocker Shaft and Pushrod - Remove....1064
Turbocharger - Assemble....1066
Turbocharger - Disassemble....1068
Turbocharger - Install - Side Mounted Turbocharger....1070
Turbocharger - Install - Turbocharger Top Mounted....1075
Turbocharger - Remove - Side Mounted Turbocharger....1081
Turbocharger - Remove - Turbocharger Top Mounted....1084
Valve Mechanism Cover - Remove and Install - Composite Valve Mechanism Cover....1088
Valve Mechanism Cover - Remove and Install....1092
Valve Mechanism Cover Base - Remove and Install - Composite Valve Mechanism Cover Base....1096
Valve Mechanism Cover Base - Remove and Install....1103
Vibration Damper and Pulley - Install - Pulley with Split Lock Rings....1110
Vibration Damper and Pulley - Install - Pulleys without Split Lock Rings....1113
Vibration Damper and Pulley - Remove - Pulley with Split Lock Rings....1116
Vibration Damper and Pulley - Remove - Pulleys without Split Lock Rings....1119
Wastegate Solenoid - Remove and Install....1121
Water Pump - Install....1123
Water Pump - Remove....1127
Water Temperature Regulator - Remove and Install....1130
SERV1837 - Technical Presentation (C4.2, C4.4, C6.4, C6.6 (Acert) Engines with Common Rail Fuel System)....1134
Caterpillar C6.6 Industrial Engines Repair Service Manual
