C6.6 Marine Generator Set Caterpillar

Fuel Injection Lines - Install - Twin Wall Fuel Injection Lines

Usage:

C6.6 C6T

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	5P-0326	Crowfoot Wrench 3/4"	1

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NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training. Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

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Illustration 1	g01640953

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Illustration 2	g01777917

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Illustration 3	g01640973

Install new seals (33) to the electronic unit injector. Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the caps from the port of the electronic unit injector.
Connect the nuts for fuel injection lines (28), (29), (31) and (32) to the electronic unit injector. Install the nuts to the electronic unit injector by three threads.
Remove caps from fuel manifold (8). Position the fuel manifold onto the mounting bracket.
Connect the nuts for fuel injection lines (28), (29), (31) and (32) to the fuel manifold. Install the nuts to the fuel manifold by three threads.
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Illustration 4 g01777953
Loosely install fuel injection line (30) by three threads. Install clamps, bolts and washers (12).
Note: Ensure that the brackets are installed in the correct position.
Loosely install fuel injection line (27) by three threads. Install clamps, bolts and washers (7).
Note: Ensure that the brackets are installed in the correct position.
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Illustration 5 g01640993
Position bracket (34) onto fuel manifold (8). Install bolts (35) finger tight.
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Illustration 6 g01641015
Tighten the nuts at both ends of all fuel injection lines. Ensure that the ends of all the fuel injection lines are correctly seated in the electronic unit injectors and in the fuel manifold.
Tighten the bolt for fuel manifold (8) to a torque of 22 N·m (16 lb ft).
Use Tooling (A) to tighten the nuts on all fuel injection lines to a torque of 30 N·m (22 lb ft). Ensure that the dust seals are seated correctly against seals.
Tighten the bolts on clamps (7) and clamps (12). Tighten bolts for the clamps securely.
Note: Ensure that fuel injection lines do not contact any other engine component.
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Illustration 7 g01525949

Assembly of the tube clip

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Illustration 8 g01779216

Typical Example
Loosely install tube clips (25) and the allen head screws (26) to the fuel injection line (19).
Place the assembly of fuel injection line (19) into position.
Remove the caps from the fuel injection pump (18) and fuel manifold (8). Remove the caps from new fuel injection line (19).
Loosely connect the nuts at both ends of fuel injection line (19), to fuel manifold (8) and to fuel injection pump (18). Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.
Install the bolts (24) finger tight for tube clips (25) that secure fuel injection line (19).
Use Tooling (A) to tighten the nuts on fuel injection line (20) to a torque of 30 N·m (22 lb ft).
Tighten bolts (25) to a torque of 22 N·m (16 lb ft). Tighten allen head screws (26) to a torque of 10 N·m (89 lb in). Ensure that fuel injection line does not contact any other engine component.
Tighten bolts (35) to a torque of 22 N·m (16 lb ft) for the bracket on fuel manifold (8).
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Illustration 9 g01640995
Connect harness assembly (21) to position sensor (23). Slide locking tab (22) into the locked position. Connect harness assembly (20) to fuel injection pump (18).
For sea water cooled engines, Install the bracket for the aftercooler and the heat exchanger. For keel cooled engines, Install the bracket for the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install" for the correct procedures. Refer to Disassembly and Assembly, "Heat Exchanger- Install" for the correct procedures.
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Illustration 10 g01641017
Install new sealing washers (13) to banjo bolts (10). Install all banjo bolts (10) to leakoff pipe (11) and leakoff pipe (16).
Install bolts (15) finger tight to tube clips (17).
Tighten the banjo bolts (10) to a torque of 25 N·m (18 lb ft). Ensure that the leakoff pipes do not contact any other engine component.
Tighten bolts (15) to a torque of 22 N·m (16 lb ft).
Remove caps from fuel pressure relief valve (9) and connect tube assembly to the fuel pressure relief valve. Tighten the nut for the tube assembly securely.
Connect harness assembly to fuel pressure sensor (14).
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Illustration 11 g01617993
If necessary, install grommets (5) to cover (1). Install washers (3) to bolts (2), and spacers (4). Install the cover and install bolts. Tighten bolts to a torque of 22 N·m (16 lb ft).
Connect breather hose from the valve mechanism cover and tighten hose clamp securely.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operations and Maintenance Manual, "Fuel System - Prime".