C6.6 Marine Generator Set Caterpillar

Installation Procedure

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Illustration 1	g01623211

Note: A new fuel injection pump is supplied, locked in the correct position. Do not unlock the fuel injection pump before installation.

1. If the fuel injection pump timing has been lost, it is possible to reset the fuel injection pump timing. Follow Step 1.a through Step 1.e in order to reset the fuel injection pump timing.

   1. Loosen locking screw (26) and slide spacer (25) to Position (AA). Tighten locking screw (26) to a torque of 9 N·m (80 lb in). This will prevent the locking screw from tightening against the shaft of the fuel injection pump.

      The fuel injection pump is now unlocked.

   2. Position Tooling (C) onto the shaft of fuel injection pump (1). Align the lever of Tooling (C) with Keyway (Y) and engage the lever into the keyway.

      Note: The lever of Tooling (C) should be a close fit in the keyway. If the lever is a loose fit in the keyway, it is not possible to reset the fuel injection pump timing.

   3. Rotate the shaft of the fuel injection pump and engage the pin of Tooling (C) into Hole (Z).

      The fuel injection pump timing is now set in the correct position.

   4. Loosen locking screw (26) and slide spacer (25) to Position (BB). Tighten locking screw (26) to a torque of 9 N·m (80 lb in). The locking screw is now tightened against the shaft of the fuel injection pump.

      The fuel injection pump is now locked.

   5. Remove Tooling (C).
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   Illustration 2	g01526390
   Typical example

2. Inspect Bore (X) in front housing (23) for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install".

3. Use Tooling (D) to lubricate a new O-ring seal (24). Install the O-ring seal onto fuel injection pump (1).

4. Align the holes in fuel injection pump (1) with the holes in front housing (23). Carefully install the fuel injection pump to the front housing.

   Note: The fuel injection pump should be supported by hand until the bolts are installed.

5. Install bolts (21) and new sealing washers (22). Tighten the bolts to a torque of 25 N·m (18 lb ft).

   Note: One sealing washer should be installed to each bolt.

6. Rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston".

7. Use Tooling (A) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove" for the correct procedure.

8. Install the fuel injection pump gear to the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install" and refer to Disassembly and Assembly, "Front Cover- Install".

   Note: Ensure that the fuel injection pump is unlocked after the installation of fuel injection pump gear is completed.

9. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
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   Illustration 3	g01526389
   Typical example

10. Position support bracket (20) against fuel injection pump (1). Install bolts (19) finger tight.

11. Install Torx screws (21) finger tight.

12. Tighten Torx screws (21) to a torque of 44 N·m (33 lb ft). Tighten bolts (19) to a torque of 22 N·m (16 lb ft).

    Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened.

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    Illustration 4	g01526388

13. Remove the appropriate plugs and caps in order to install tube assembly (19) for the engine oil supply to the fuel injection pump. Install the banjo bolt and new sealing washers to tube assembly (19). Install tube assembly (19) to the fuel injection pump and to the cylinder block. Tighten the banjo bolt to a torque of 15 N·m (11 lb ft). Tighten the nut for the tube assembly (19) at the fuel injection pump to a torque of 15 N·m (11 lb ft).

14. Remove the appropriate caps in order to install fuel injection line (18). Install a new fuel injection line (18) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".
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    Illustration 5	g01620337

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    Illustration 6	g01526387

15. Install new sealing washers (17) to banjo bolt (16). Connect tube assembly (15) to the fuel transfer pump on fuel injection pump (1). Tighten banjo bolt (16) to a torque of 21 N·m (16 lb ft).
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    Illustration 7	g01526385

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    Illustration 8	g01623141

16. Connect harness assembly (12) to solenoid (10) on the fuel injection pump. Connect harness assembly (13) to position sensor (11) on fuel injection pump (1). Slide the locking tab into the locked position.

17. Remove the plugs and caps from the remaining ports and tube assemblies.

18. Install hose assembly (8) to the customer connection and feed to fuel injection pump (1).

19. Install hose assembly (5) to the customer connection and return pipe from the fuel transfer pump and the return pipe from the fuel filter.

20. Install hose assembly (7) to the customer connection and return pipe from fuel injection pump (1).

21. Install tube assembly (6) to tee union and connection point for customer connection (4).

22. Connect tube assembly (3) to pressure relief valve (9) to tee union (2) on fuel injection pump (1).

23. Connect the drain hose for the crankcase breather.

24. Turn the fuel supply to the ON position.

25. Turn the battery disconnect switch to the ON position.

26. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.

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1. Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install" for the correct procedure.

2. Install the heat exchanger. Refer to Disassembly and Assembly, "Exchanger - Install" for the correct procedure.