C6.6 Marine Generator Set Caterpillar

Removal Procedure

Start By:

1. Remove the M.C.S panel for the control system and the support bracket. Refer to Disassembly and Assembly, "Control System - Remove and Install".

2. Remove the E.M.C.P panel for the control system and the support bracket. Refer to Disassembly and Assembly, "Control System - Remove and Install".

3. Remove the air cleaner housing. Refer to Disassembly and Assembly, "Air Cleaner Housing - Remove and Install".

1. The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repairs is performed.

2. Turn the air supply at the air reservoir to the OFF position. Ensure that the air pressure is drained from the starting air system.

3. Turn the battery disconnect switch to the OFF position.

4. Turn the fuel supply to the OFF position.
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   Illustration 1	g01722858

5. Disconnect harness assembly and cable assemblies (1) from electric starting motor (2).

   If the engine is equipped with a air starting motor disconnect the air supply. Ref to Disassembly and Assembly, "Air Starting Motor - Remove and Install" for more information

6. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Drain" for the correct draining procedure.

7. For engines with a radiator cooling system, remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove and Install".

8. Remove the fan on a engine with a radiator cooling system. Refer to Disassembly and Assembly, "Fan - Remove and Install".
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   Illustration 2	g01723173

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   Illustration 3	g01724294

9. Turn the valve for the sea water circuit to the OFF position.

10. For a keel cooled engine and a sea water cooled engine, loosen the hose clamp and then disconnect hose (5) from the auxiliary water pump.

11. For a keel cooled engine, loosen hose clamp and disconnect hose (6) from the aftercooler.

12. For a keel cooled engine, loosen hose clamp and disconnect tube assembly (4) from the water temperature regulator housing. Loosen hose clamp and disconnect tube assembly (3) from the water pump inlet.

13. For a keel cooled engine, remove vent hose from the exhaust manifold.

14. Remove blanket (8) from the exhaust elbow and the exhaust outlet. Remove bolts and disconnect exhaust system (7) from the exhaust elbow.
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    Illustration 4	g01722859
    MCS fuel system

15. Disconnect hose assembly (9) and hose assembly (10) from the secondary fuel filters. Disconnect hose assembly (14) (not shown).

    Note: Identify the position on the hose assembly in order to show the correct position of the hose assembly. Plug all hose assembly and cap all connections on the fuel filter base assembly.

16. Disconnect harness assembly (11) from the differential pressure switch for the primary fuel filters.

17. Disconnect harness assembly (12) from the differential pressure switch for the secondary fuel filters. Disconnect harness assembly (13) (not shown) from the fuel pressure sender.
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    Illustration 5	g01724333
    Non-MCS fuel system

18. Disconnect hose assembly (14) from the primary fuel filter.
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    Illustration 6	g01724376

19. Loosen hose clamps (16) and remove breather hose (15) from the breather canister and the valve mechanism cover.

20. Loosen clip (17) and remove breather hose (18) from the breather canister and from the support clip.

21. Remove bolts (20), washers and spacers from cover (19). Remove the cover from the engine.
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    Illustration 7	g01724434
    MCS Duplex oil system

22. Disconnect harness assembly (21) for the oil pressure shutdown sender.

23. Disconnect harness assembly (22) for the oil pressure transmitter.

24. Disconnect harness assembly (28) (not shown) from the differential pressure switch for the oil filters.

25. Disconnect hose assembly (25) and hose assembly (26) from the oil filter base.

    Note: Identify the position on the hose assembly in order to show the correct position of the hose assembly. Plug all hose assembly. Cap all connections on the fuel filter base assembly.

26. Disconnect hose assembly (23), hose assembly (24) and hose assembly (27) from the adapter on the cylinder block.

    Note: Identify the position on the hose assembly in order to show the correct position of the hose assembly. Plug all hose assembly and cap all connections on the fuel filter base assembly.

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    Illustration 8	g01724713

27. Remove cable straps (29) and disconnect harness assembly (30) from the base plate and the screen for the generator on both side of the engine. Position the harness assembly away from the generator.
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    Illustration 9	g01722860

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    Illustration 10	g01722861

28. Remove blank devices (31) from the rear engine lifting eye and the front engine lifting eye.

29. Attach Tooling (B) onto Tooling (A) and attach Tooling (A) to a suitable lifting device.

30. Attach Tooling (A) onto engine (32). The weight of engine (32) is approximately 600 kg (1322 lb).

31. Engines that are keel cooled and sea water cooled remove the front engine mounting bolts (33).

32. Remove bolts and nuts (33) from the engine mounting on the engine that have a radiator cooling system. Loosen the nuts and bolts for the generator mounting.

33. Raise the engine by 12 mm (0.472 inch). Position suitable wooden blocks under the front and the rear of the generator in order to support the generator.

    Note: The generator should be fully supported with wooden blocks in order to stop the generator from tilting.

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    Illustration 11	g01722863

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    Illustration 12	g01722864

34. Remove nuts and bolts (34) and remove screen (35) from the generator.

35. Remove locking nuts and washers (36) from the generator to the flywheel housing. Remove bolts and washers (37) from the generator to the flywheel housing.

36. Remove the locking nut and washers (38) from the generator drive plate (39) to flywheel (40).

37. Slide the engine away from the generator and remove the engine.