Caterpillar C6.6 Generator Set Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C6.6 Generator Set, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C6.6 Generator Set 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.
KENR5970 - Schematic (C6.6 Generator Set Electrical System).pdf
KENR6202 - Troubleshooting (C6.6 Generator Set).pdf
KENR8785 - Systems Operation (C6.6 Generator Sets).pdf
KENR8785 - Testing and Adjusting (C6.6 Generator Sets).pdf
KENR9121 - Disassembly and Assembly (C6.6 Generator Sets).pdf
UENR5995 - Schematic (C6.6 Generator Set Engine Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 1,021 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR5970 - Schematic (C6.6 Generator Set Electrical System)...2
Main...3
Collage...5
KENR6202 - Troubleshooting (C6.6 Generator Set)...17
System Overview...22
Glossary...26
Electronic Service Tools...33
Indicator Lamps...40
Replacing the ECM...45
Self-Diagnostics...48
Sensors and Electrical Connectors...49
Engine Wiring Information...54
ECM Harness Connector Terminals...57
Programming Parameters...60
Test ECM Mode...61
Factory Passwords...63
Flash Programming...64
Injector Trim File...66
Speed Demand Input Setup...68
Customer Specified Parameters...72
Customer Specified Parameters Table...77
Customer Specified Parameters Worksheet...79
System Configuration Parameters...80
Alternator Noise...82
Alternator Will Not Charge...84
Battery...86
Can Not Reach Top Engine RPM...87
Coolant in Engine Oil...92
Coolant Temperature Is Too High...94
ECM Will Not Accept Factory Passwords...97
ECM Will Not Communicate with Other Systems or Display Modules...99
Electronic Service Tool Will Not Communicate with ECM...100
Engine Cranks but Will Not Start...102
Engine Has Early Wear...109
Engine Misfires; Runs Rough or Is Unstable...111
Engine Oil in Cooling System...115
Engine Vibration...117
Engine Will Not Crank...120
Excessive Black Smoke...122
Excessive Engine Oil Consumption...126
Excessive Fuel Consumption...129
Excessive Valve Lash...132
Excessive White Smoke...134
Intake Air Temperature Is Too High...137
Intermittent Engine Shutdown...140
Intermittent Low Power or Power Cutout...142
Low Engine Oil Pressure...145
Low Power...148
Mechanical Noise (Knock) in Engine...153
Noise Coming from Cylinder...155
Diagnostic Code Cross Reference...157
CID 001 FMI 02...161
CID 001 FMI 05...162
CID 001 FMI 06...163
CID 001 FMI 07...164
CID 002 FMI 02...165
CID 002 FMI 05...166
CID 002 FMI 06...167
CID 002 FMI 07...168
CID 003 FMI 02...169
CID 003 FMI 05...170
CID 003 FMI 06...171
CID 003 FMI 07...172
CID 004 FMI 02...173
CID 004 FMI 05...174
CID 004 FMI 06...175
CID 004 FMI 07...176
CID 005 FMI 02...177
CID 005 FMI 05...178
CID 005 FMI 06...179
CID 005 FMI 07...180
CID 006 FMI 02...181
CID 006 FMI 05...182
CID 006 FMI 06...183
CID 006 FMI 07...184
CID 041 FMI 03...185
CID 041 FMI 04...186
CID 091 FMI 08...187
CID 100 FMI 03...188
CID 100 FMI 04...189
CID 100 FMI 10...190
CID 110 FMI 03...191
CID 110 FMI 04...192
CID 168 FMI 00...193
CID 168 FMI 01...194
CID 168 FMI 02...195
CID 172 FMI 03...196
CID 172 FMI 04...197
CID 190 FMI 08...198
CID 247 FMI 09...199
CID 253 FMI 02...200
CID 261 FMI 11...201
CID 262 FMI 03CID 0262 FMI 03...202
CID 262 FMI 03...203
CID 268 FMI 02...204
CID 342 FMI 08...205
CID 526 FMI 05...206
CID 526 FMI 06...207
CID 1690 FMI 08...208
CID 1779 FMI 05...209
CID 1779 FMI 06...210
CID 1779 FMI 08...211
CID 1785 FMI 03...212
CID 1785 FMI 04...213
CID 1785 FMI 10...214
CID 1797 FMI 03...216
CID 1797 FMI 04...217
CID 1834 FMI 02...218
CID 2246 FMI 06...219
Event Codes...220
E085 Engine Shutdown Overridden...221
E255 Diagnostic Reset...222
E264 Emergency Stop Activated...223
E360 Low Engine Oil Pressure...224
E361 High Engine Coolant Temperature...226
E362 Engine Overspeed...228
E396 High Fuel Rail Pressure...230
E398 Low Fuel Rail Pressure...232
E539 High Intake Manifold Air Temperature...234
005 Volt Sensor Supply Circuit - Test...236
CAN Data Link Circuit - Test...246
Data Link Circuit - Test...250
ECM Memory - Test...260
Electrical Connectors - Inspect...261
Engine Pressure Sensor Open or Short Circuit - Test...271
Engine Speed_Timing Sensor Circuit - Test...282
Engine Temperature Sensor Open or Short Circuit - Test...292
Fuel Rail Pump Solenoid - Test...300
Ignition Keyswitch Circuit and Battery Supply Circuit - Test...307
Indicator Lamp Circuit - Test...315
Injector Data Incorrect - Test...321
Injector Solenoid Circuit - Test...325
Speed Control (Analog) - Test...339
Speed Control (PWM) - Test...343
Starting Aid (Glow Plug) Relay Circuit - Test...347
Wastegate Solenoid - Test...353
KENR8785 - Systems Operation (C6.6 Generator Sets)...361
General Information...362
Electronic Control System Components...366
Power Sources...377
Cleanliness of Fuel System Components...381
Fuel System...383
Air Inlet and Exhaust System...396
Lubrication System...402
Cooling System...404
Basic Engine...406
Electrical System...422
KENR8785 - Testing and Adjusting (C6.6 Generator Sets)...425
Fuel System - Inspect...427
Air in Fuel - Test...428
Finding Top Center Position for No. 1 Piston...432
Fuel Injection Timing - Check...435
Fuel Quality - Test...439
Fuel System - Prime...440
Gear Group (Front) - Time...443
Air Inlet and Exhaust System - Inspect...447
Turbocharger - Inspect...450
Compression - Test...456
Engine Valve Lash - Inspect_Adjust...458
Valve Depth - Inspect...463
Valve Guide - Inspect...466
Engine Oil Pressure - Test...468
Engine Oil Pump - Inspect...469
Excessive Bearing Wear - Inspect...471
Excessive Engine Oil Consumption - Inspect...472
Increased Engine Oil Temperature - Inspect...473
Cooling System - Check...474
Cooling System - Inspect...476
Cooling System - Test...478
Engine Oil Cooler - Inspect...482
Water Temperature Regulator - Test...490
Water Pump - Inspect...491
Piston Ring Groove - Inspect...492
Connecting Rod - Inspect...495
Cylinder Block - Inspect...499
Cylinder Head - Inspect...500
Piston Height - Inspect...503
Flywheel - Inspect...505
Flywheel Housing - Inspect...508
Gear Group - Inspect...511
Vibration Damper - Check...513
Alternator - Test...516
Battery - Test...518
Charging System - Test...519
Electric Starting System - Test...520
Glow Plugs - Test...524
V-Belt - Test...526
KENR9121 - Disassembly and Assembly (C6.6 Generator Sets)...528
Fuel Priming Pump - Remove and Install - Mechanical Priming Pump...532
Fuel Priming Pump - Remove and Install - Electric Fuel Priming Pump...536
Fuel Filter Base - Remove and Install - Secondary Fuel Filter...540
Fuel Transfer Pump - Remove...544
Fuel Transfer Pump - Install...548
Fuel Manifold (Rail) - Remove and Install...552
Fuel Injection Lines - Remove...558
Fuel Injection Lines - Install...564
Fuel Injection Pump - Remove...571
Fuel Injection Pump - Install...577
Fuel Injection Pump Gear - Remove...584
Fuel Injection Pump Gear - Install...588
Electronic Unit Injector - Remove...592
Electronic Unit Injector - Install...602
Turbocharger - Remove - Turbocharger Top Mounted...614
Turbocharger - Remove - Side Mounted Turbocharger...618
Turbocharger - Install - Turbocharger Top Mounted...621
Turbocharger - Install - Side Mounted Turbocharger...627
Wastegate Solenoid - Remove and Install...632
Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold...634
Exhaust Manifold - Remove and Install - Side Mounted Exhaust Manifold...638
Exhaust Elbow - Remove and Install...642
Inlet Manifold - Remove and Install...644
Inlet and Exhaust Valve Springs - Remove and Install...649
Inlet and Exhaust Valves - Remove and Install...659
Engine Oil Filter Base - Remove and Install...666
Engine Oil Cooler - Remove - Engine Oil Cooler with a High Mounted Filter Base...669
Engine Oil Cooler - Remove - Engine Oil Cooler with a Low Mounted Filter Base...673
Engine Oil Cooler - Install - Engine Oil Cooler with a High Mounted Filter Base...677
Engine Oil Cooler - Install - Engine Oil Cooler with a Low Mounted Filter Base...681
Engine Oil Relief Valve - Remove and Install...685
Engine Oil Pump - Remove...689
Engine Oil Pump - Install...692
Water Pump - Remove...696
Water Pump - Install...699
Water Temperature Regulator - Remove and Install...703
Flywheel - Remove...707
Flywheel - Install...710
Crankshaft Rear Seal - Remove...713
Crankshaft Rear Seal - Install...715
Flywheel Housing - Remove and Install - Wet Back End Housing...722
Flywheel Housing - Remove and Install - Standard Housing...730
Vibration Damper and Pulley - Remove - Pulleys without Split Lock Rings...737
Vibration Damper and Pulley - Remove - Pulley with Split Lock Rings...739
Vibration Damper and Pulley - Install - Pulley with Split Lock Rings...742
Vibration Damper and Pulley - Install - Pulleys without Split Lock Rings...745
Crankshaft Front Seal - Remove and Install...748
Front Cover - Remove and Install...753
Gear Group (Front) - Remove and Install...757
Idler Gear - Remove...766
Idler Gear - Install...776
Housing (Front) - Remove...789
Housing (Front) - Install...793
Accessory Drive - Remove and Install...799
Crankcase Breather - Remove - Filtered Breather...803
Crankcase Breather - Remove - Unfiltered Breather...809
Crankcase Breather - Install - Filtered Breather...814
Crankcase Breather - Install - Unfiltered Breather...819
Valve Mechanism Cover - Remove and Install...824
Valve Mechanism Cover - Remove and Install - Composite Valve Mechanism Cover...828
Valve Mechanism Cover Base - Remove and Install...832
Valve Mechanism Cover Base - Remove and Install - Composite Valve Mechanism Cover Base...839
Rocker Shaft and Pushrod - Remove...846
Rocker Shaft - Disassemble...848
Rocker Shaft - Assemble...851
Rocker Shaft and Pushrod - Install...855
Cylinder Head - Remove...860
Cylinder Head - Install...867
Lifter Group - Remove and Install...875
Camshaft - Remove and Install...879
Camshaft Gear - Remove and Install...883
Camshaft Bearings - Remove and Install...891
Engine Oil Pan - Remove - Aluminum Oil Pan...894
Engine Oil Pan - Remove - Cast Iron Oil Pan...898
Engine Oil Pan - Install - Aluminum Oil Pan...902
Engine Oil Pan - Install - Cast Iron Oil Pan...906
Engine Oil Pan Plate - Remove and Install - Aluminum Oil Pan...911
Piston Cooling Jets - Remove and Install...917
Pistons and Connecting Rods - Remove...920
Pistons and Connecting Rods - Disassemble...923
Pistons and Connecting Rods - Assemble...927
Pistons and Connecting Rods - Install...932
Connecting Rod Bearings - Remove - Connecting rods in position...936
Connecting Rod Bearings - Install - Connecting rods in position...940
Crankshaft Main Bearings - Remove and Install - Crankshaft in position...944
Crankshaft - Remove...952
Crankshaft - Install...956
Crankshaft Timing Ring - Remove and Install...963
Crankshaft Gear - Remove and Install...966
Bearing Clearance - Check...970
Crankshaft Position Sensor - Remove and Install...973
Position Sensor (Fuel Injection Pump) - Remove and Install...975
Coolant Temperature Sensor - Remove and Install...978
Engine Oil Pressure Sensor - Remove and Install...981
Fuel Pressure Sensor - Remove and Install...984
Boost Pressure Sensor - Remove and Install...987
Inlet Air Temperature Sensor - Remove and Install...990
Glow Plugs - Remove and Install...993
Alternator Belt - Remove and Install...997
Fan - Remove and Install...1001
Fan Drive - Remove and Install...1004
Electronic Control Module - Remove and Install...1006
ECM Mounting Bracket - Remove and Install...1012
Alternator - Remove - Alternators with Mounting Lugs...1017
Alternator - Remove - Alternators with Mounting Pads...1019
Alternator - Install - Alternators with Mounting Pads...1021
Alternator - Install - Alternators with Mounting Lugs...1023
Electric Starting Motor - Remove and Install...1025
Air Compressor - Remove and Install...1028
UENR5995 - Schematic (C6.6 Generator Set Engine Electrical System)...1039
Main...1040
Features...1040
Cover page...1042
Schematic...1043
Engine Views...0
Top View...1044
Left Side...1045
Collage...1046
Caterpillar C6.6 Generator Set Repair Service Manual
