Usage:
The 5P6524 Engine Timing Indicator Group has all the tools needed to check for piston top center (TC) on most Caterpillar diesel engines. The adapters have internal threads on the dial indicator end, so a collet can be installed to better hold the dial indicator in position. Make reference to the chart on page 2 for the tools needed for a particular engine.
The 1P540 Flow Checking Tool Group supplies pressurized fuel to the fuel injection pump to determine injection timing. The group consists of a fuel tank with a hand pump for field use, a pressure regulator valve (serviced by 5P2413 Air Regulator Assembly) to permit use of shop air, a fuel pump outlet tube and connecting hoses. A 6V2023 Flow Checking Adapter Group is available for use instead of 7M1999 Tube Assembly, when flow checking an engine. This new adapter group must be used for those engines that have a reverse flow check valve in the fuel injection pump.
1 For engines that have the fuel injection nozzle under the valve cover, remove the valve cover and loosen glow plug conduit (1) to clear No. 1 fuel line. On all engines No. 1 piston TC, compression stroke, is the reference point for all timing procedures. On all engines, remove nut (2), No. 1 fuel injection line (3), the fuel injection valve body, and the nozzle assembly from precombustion chamber (4), or the adapter on direct injection engines.
2 Install the correct adapter (5). Tighten the adapter FINGER TIGHT ONLY to prevent damage to the nozzle seat. Put a small amount of clean oil on the correct rod (6) and put the rod in the adapter. Install 3P1565 Collet (7).
3 Install 9S215 Dial Indicator (8), with the correct contact point, and find top center (TC) compression position according to the procedure given in FINDING TOP CENTER (TC).
Finding Top Center (TC)
1 Install the 5P6524 Timing Indicator Group; see the previous topic.
2 Slowly turn the crankshaft in the direction of normal rotation until a maximum reading is observed on the dial indicator. Adjust the indicator in or out until the revolution counter is at +.300" (7.6) (black numbers). Tighten the collet (not too tight) and zero the outer bezel of the dial indicator.
3 Slowly rotate the crankshaft in the same direction (normal rotation) until the dial indicator moves past +.280" (7.1). Now rotate the crankshaft in the opposite direction, moving the piston up, to +280" (7.1). Temporarily mark an accessible rotating member (flywheel, vibration damper, or crankshaft pulley) in relation to a stationary pointer or mark. CAUTION: Do not use a hammer or punch to mark the vibration damper (or any other marking method that could cause damage to the vibration damper).
4 Continue to rotate the crankshaft in the direction that is opposite of normal rotation, past the maximum reading and past +.280" (7.1). Now rotate the crankshaft in the normal direction of rotation, moving the piston up, to +280" (7.1). Make a second temporary mark on the desired rotating member.
5 True TC is a point measured midway between the two temporary marks as determined in steps 3 and 4. Turn the crankshaft to this midway point between the two temporary marks. Look at the permanent TC mark on the flywheel to see if it is in alignment with the timing pointer. If it is not, obliterate the former TC mark, and stamp a new TC mark, that is in alignment with the timing pointer, on the flywheel.
6V2023 Flow Checking Adapter Group
The 6V2023 Flow Checking Adapter Group can be used for the flow check timing procedure for Caterpillar diesel engines. A pin, that is part of the adapter group, can be adjusted to the correct length for flow timing check of those direct injection engines that have a reverse flow check valve. This pin can be removed, and the adapter group can then be used instead of the 7M1999 Tube Assembly for flow timing check of diesel engines that do not have a reverse flow check valve. (The 7M1999 Tube Assembly is part of the 1P540 Flow Checking Tool Group.) The procedure for use of the 6V2023 Flow Checking Adapter Group for each of the two types of fuel system is as follows.
1 Assembly of the adapter group is shown above. The part names and part numbers are: 5P580 Tube (1), 4K9822 Nut (2) and 4K9821 Sleeve, 5P2948 Connector (3), 6V2021 Fitting (4), 6F612 Jam Nut (5), 6L3921 Washer (6), 6V2019 Nut (7), 6V2020 Adapter (8) and 6V2018 Pin (9).
NOTE: 6V2018 Pin (9) is for use only on direct injection engines that have reverse flow check valves. Do not use the 6V2018 Pin (9) when flow checking an engine that does not have reverse flow check valves.
2 At first assembly of tube (1) and 4K9822 Nut (2) with the 4K9821 Sleeve, use a wrench to tighten nut (2) and swage the sleeve on tube (1). After this is done the first time, it is normally not necessary to tighten the nut with a wrench for installation of tube (1) if it has been removed. Use of the fingers (finger tight) is normally all that is needed for tube installation.
3 If the engine to be flow checked is a direct injection engine that has a reverse flow check valve in each fuel injection pump, install the 6V2018 Pin (9) according to the procedure that follows. If the fuel injection pumps do not have a reverse flow check valve, do not install pin (9).
4 Loosen adapter (8) so not more than .2" (5) [dimension (A)] of pin (9) extends beyond the end of adapter (8). Temporarily remove tube (1).
5 To install the adapter group on the injection pump for these engines, put the adapter group on the injection pump bonnet and tighten nut (7) to 30 lb.ft. (40 N·m) maximum. Turn fitting (4) down, until pin (9) just starts to contact (resistance is felt) the reverse flow check valve, then turn fitting (4) an additional 1/4 turn.
6 Move washer (6) down so it is against adapter (8) at location (B), then tighten nut (5), with fingers only, so it is against washer (6). Connect tube (1).
| NOTICE |
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It must be remembered, that if the engine does not have a reverse flow check valve in each fuel injection pump, do not install 6V2018 Pin (9). |
Fuel Injection Pump Timing Test
1 Piston travel from the beginning of injection to TC can be measured and converted to crankshaft degrees to determine whether injection timing is correct. Install the appropriate timing indicator components into No. 1 cylinder, locate piston No. 1 TC, and zero the indicator as outlined in preceding topics. Rotate the crankshaft 40° to 50° in a reverse direction to insure removal of all gear backlash. Move the governor control to the full load position.
2 Perform a flow test through No. 1 fuel injection pump to determine the point at which injection begins (point of inlet port closing). Open the fuel shutoff valve, if the engine is so equipped. Use the 1P540 Flow Checking Tool Group (1) to pressurize and maintain 10-15 PSI (0,7 -1,0) in the fuel system during the test. For an alternate method, apply air pressure to the fuel tank and MAINTAIN NO MORE THAN 15 PSI (1,0) with a 4L4454 Valve, or THE TANK CAN BE DAMAGED.
3 If the engine has a constant bleed valve (2), disconnect the fuel return line. Put a cap (3) on the constant bleed valve.
4 Install 7M1999 Tube Assembly (4) or the 6V2023 Flow Checking Adapter Group on No. 1 fuel injection pump. The tube must slant upward as shown and have a container under it.
NOTE: If the engine is direct injection with reverse flow check valves, 6V2023 Flow Checking Adapter Group must be used. Assemble and install it according to the procedure given in the topic, 6V2023 Flow Checking Adapter Group.
5 Connect hose (5) to the injection pump housing fuel inlet, or to the fuel filter inlet. Put 1 gallon (3.8 liter) of clean fuel in tank (6), and pressurize the tank to 15 psi (1.0) by using hand pump (7), or connect a shop air supply hose (8).
| NOTICE |
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If shop air is used, adjust regulator (9) to limit the maximum tank pressure to 15 psi (1.0). |
6 With fuel pressure applied, slowly rotate the crankshaft in the normal direction to approach closing of the fuel pump inlet port (A). Fuel under pressure flows into the barrel through inlet port (A) to outlet (C). Further rotation of the crankshaft causes plunger (B) to rise until inlet port (A) is closed.
7 As the closed position of the pump inlet port is approached, the flow of fuel from tube assembly (4) is reduced to 6 to 12 drops per minute on all engines with two exceptions. On 5.4" Bore engines with 3S1467 Fuel Pumps, the fuel flow rate should be reduced to 12 to 30 drops per minute. If the engine has a Sleeve Metering Fuel System, the fuel flow rate should be reduced to 12 to 18 drops per minute.
8 Stop rotating the crankshaft as soon as the fuel flow is reduced as described. Consult the chart to find the angle corresponding to the dial indicator reading at this point. The tolerance for timing on Caterpillar engines is ± 1°. If this angle is not within Service Manual specifications for fuel pump timing, change the timing as outlined in the Service Manual.
Piston Travel To Top Center (Dimensions In Inches) (Degrees Indicate Crankshaft Rotation From Top Dead Center As Measured Through Prechamber Or Adapter Hole)
Piston Travel To Top Center (Dimensions In mm) (Degrees Indicate Crankshaft Rotation From Top Dead Center As Measured Through Prechamber Or Adapter Hole)
