C6.6 Marine Generator Set Caterpillar

Installation Procedure

Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.

1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for further information.
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   Illustration 1	g01335380

2. Ensure that Tooling (B) is installed in Hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.

   Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.

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   Illustration 2	g01335394

3. Ensure that Tooling (A) is installed into Hole (X) in camshaft gear (1).

4. Ensure that shaft (9) of the fuel injection pump is clean and free from damage.

5. Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for further information.

6. Ensure that the fuel pump gear is clean and free from wear of damage. If necessary, replace the fuel pump gear.
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   Illustration 3	g01526857
   Alignment of timing marks

7. Install fuel pump gear (3) to shaft (9) of the fuel injection pump. Ensure that the timing marks on gear (2) and gear (3) are in alignment and that the mesh of the gears is correct.
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   Illustration 4	g01335395
   Typical example

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   Illustration 5	g01621128

8. Install a new spring washer (10) and install nut (8) to shaft (9) of the fuel injection pump. Apply sufficient pressure to fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash.

9. Tighten nut (8) to a torque of 90 N·m (66 lb ft).

10. In order to unlock fuel injection pump (5), loosen locking screw (7) in the fuel injection pump. Slide spacer (6) into Position (BB). Tighten locking screw (7) against the spacer to a torque of 9 N·m (80 lb in).

11. Remove Tooling (A) and Tooling (B). Install a new O-ring seal to plug (4). Install the plug into Hole (Y) in the cylinder block. Refer to Illustration 1. Tighten the plug to a torque of 65 N·m (48 lb ft).

12. Use Tooling (D) in order to check the backlash of gear (2) and gear (3). Refer to the Specifications, "Gear Group (Front)" for further information.

13. Lubricate the teeth of the gears with clean engine oil.

End By:

1. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".

2. Install the expansion tank. Refer to Disassembly and Assembly, "Expansion Tank - Remove and Install" for further information.

3. Install the cover for the V-belts. Refer to Disassembly and Assembly, "V-Belt - Remove and Install" for further information.