Injection Timing Correction Procedure on Certain C3.3B Engines {0781, 0782, 1000, 1920} Caterpillar

Compact Track Loader

259D (S/N: FTL1-UP)

279D (S/N: GTL1-UP)

289D (S/N: TAW1-UP)

Compact Wheel Loader

906M (S/N: H661-UP)

907M (S/N: H771-UP)

908M (S/N: H881-UP)

Mini Hydraulic Excavator

308E2 (S/N: EC21-UP; MY21-UP; TM21-UP; YE21-UP; SR81-UP; FJX1-UP; TMX1-UP)

308E2 CR (S/N: MC51-UP; PC81-UP; W8S1-UP)

308E2SR (S/N: JC51-UP; KC51-UP)

Multi Terrain Loader

257D (S/N: EZW1-UP)

277D (S/N: FMT1-UP)

287D (S/N: HMT1-UP)

Skid Steer Loader

236D (S/N: BGZ1-UP)

242D (S/N: DZT1-UP)

246D (S/N: BYF1-UP)

262D (S/N: DTB1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

If the crankshaft, gear case and/or crank gear are replaced, it is necessary to calibrate the injection timing. The following steps show how to calculate/determine the new injection timing by measuring angular deviation between the crankshaft TDC and Crank Position sensor detected TDC.

Note: Once complete the engine ecm must be reprogrammed with the new injection timing value.

Follow all steps.

Procedure

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Illustration 1	g06220548
(1) TC Mark (Flywheel Housing) (2) TC Mark (Flywheel)

1. Remove valve cover, and injector and rocker arm. Bring the piston of cylinder 4 to TDC.
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   Illustration 2	g06220554
   (3) Dial Gauge (4) Valve (5) O-ring

2. Remove the #4 exhaust valve bridge arm and valve spring. Insert a small O-ring (5) so the valve does not fall into the cylinder.

3. Set dial gauge (3) on the tip of the valve (4).
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   Illustration 3	g06220569
   (6) Tri - Square (7) Flywheel Housing (8) Flywheel

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   Illustration 4	g06220573
   (7) Flywheel Housing (8) Flywheel (9) Reference Line

4. Turn the flywheel counterclockwise and measure the position where the tip of the valve is the highest.

5. Stop the flywheel at the position where the tip of the valve is the highest. Put a tri - square (6) on the flywheel housing (7) and the flywheel (8) and draw a reference line (9).

   Do not drop the valve (4) into the cylinder. When measuring the highest position of the tip of the valve, do not rotate the flywheel clockwise. If you go past the highest point of the valve, back up the flywheel slightly and measure the highest point of the valve. The reference line (9) indicates the TDC of the crankshaft.

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   Illustration 5	g06220579
   Rotation Sensor Signal Interface Unit Application: Use for reading rotation sensor signal. (1) 9V Battery (2) Switch (3) 3-Terminal Regulator (4) LED (5) Clip (Red) (6) Clip (Black) (A) for Panasonic (B) for Denso (C) for Bosch cam angle (D) for Bosch crank angle ((E)) Connector Side (a) +9 V (b) Signal (c) GND (d) +5 V (e) Signal (f) GND

6. Schematic to build Rotation Sensor Signal Interface.
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   Illustration 6	g06220581
   (10) Rotation Sensor Signal Interface (Tool not available. Schematic to build tool available. Refer to Step 6. (11) Tester

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   Illustration 7	g06220587
   (12) Ground Terminal (13) Output Terminal (14) Crankshaft Position Sensor

7. Connect a connector of the rotation sensor signal interface unit (10) to the crankshaft position sensor (14). Connect each clip of the rotation sensor signal interface unit (10) to the same test lead color of the tester (11). Switch on the rotation sensor signal interface unit (10).
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   Illustration 8	g06220590
   (15) Pulsar Gear (16) 14th Tooth (17) Missing Teeth

8. Turn the flywheel and make sure that the voltage of the crankshaft position sensor goes from 0→ 5 V or 5 → 0 V.

9. Rotate the flywheel and align the crankshaft position sensor to the part of the pulsar gear (15) that is missing teeth (17). The 14th tooth (16) from the missing teeth is standard.

10. Slowly turn flywheel counterclockwise and stop flywheel at the point where needle of the tester changes momentarily from 0 → 5 V, the 14th tooth.

    That point is where the crankshaft position sensor detects TDC.

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    Illustration 9	g06220608
    (18) Crankshaft TDC (19) Detection Point of Crankshaft Position Sensor TDC

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    Illustration 10	g06220612
    (20) Interval

11. Set the tri - square (6) on the reference line (9) on the flywheel housing side and mark the detection point of crankshaft position sensor TDC (19) on the flywheel.

12. Measure the interval (20) between the crankshaft TDC (18) and the detection point of the crankshaft position sensor TDC (19).

13. Calculation of fuel injection timing correction 1.0 mm (0.039 in.): 0.321°.

    Corrected Angle = 0.321° X actual interval

14. Overwrite the injection timing correction value on the engine ecm registration website refer to REHS9707, "Registering Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), Fuel Injector and Diesel Exhaust Fluid (DEF) Injector Serial Numbers on C2.4, C3.3B, and C3.8 Machine Engines".

    Once the injection timing correction values have been registered, you may follow the Engine ECM flashing procedure to obtain the new DPK flash file found in REHS9223, "Electronic Control Module (ECM) & Dosing Control Unit (DCU Flashing Procedure for the C2.4, C3.3B and C3.8 Engines".

    Note: When the crankshaft position sensor detects the teeth of the pulsar gear, the tester indicates 0V.

    The position where the needle of the tester changes momentarily from 0 → 5 V is the detection point of crankshaft position sensor TDC (19).

    The reference line indicates the crankshaft TDC (18) of the crankshaft. If the detected TDC is ahead of the crankshaft TDC, it is considered minus. If the detected TDC lags behind the crankshaft TDC, it is considered plus.