3608 Engine Caterpillar

Fuel Injector Synchronization

Usage:

3608 1ZD

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	4C-6594	Timing and Fuel Setting Tool	1
B	6V-9057	Rack Synchronizing Gauge	1
C	6V-3075	Dial Indicator	1
D	5P-4814	Collet Clamp	1
E	5P-7263	Indicator Contact Point	1

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Illustration 1	g00558660
Right Rear Side Of Engine (1) Synchronizing Pin. (2) Rod assembly. (3) Control housing. (Y) Location for dial indicator. (Z) Location for synchronizing pin.

Loosen the locknuts on the governor rod assembly (2). Adjust the rod to the minimum length.

Remove the plugs at locations (Y) and (Z) from control housing (3) .

Remove the synchronizing pin (1) from the storage location.

Install synchronizing pin (1) in location (Z) without the washer.

Turn the actuator terminal shaft to the "FUEL ON" position. until the flat face of the fuel stop lever (6) contacts synchronizing pin (1). This is the synchronizing position or zero reference point. Hold the control linkage in this position when the injectors are adjusted.

Remove the valve covers.

Use a screwdriver in order to pull up on each fuel control rod (4). This will ensure that the rods and the fuel injector racks are free.

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Illustration 2	g00559067
Fuel Injection Control Linkage (1) Synchronizing pin. (2) Rod assembly. (3) Control housing. (4) Fuel control rod. (5) Rod assembly. (Y) Location for dial indicator. (Z) Location for synchronizing pin.

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Illustration 3	g00559104
Fuel Injection Control Housing (3) Control housing. (5) Rod assembly. (6) Fuel stop lever.

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Illustration 4	g00664102

Put Tool (B) in position on one of the injectors. This gauge sits on the round part of the injector rack bar between the trim screw and the end of the rack bar. The gauge block should make complete contact with the trim screw and the surface of the rack bar. The trim screw is provided on the injectors in order to adjust the rack's zero point. This should be done AT THE FACTORY ONLY. If a unit injector is found to have a loose trim screw, the unit injector must be replaced with a calibrated unit injector. If a trim screw has been moved, the unit injector must be replaced with a calibrated unit injector. The fuel injector cannot be synchronized if the trim screw has been moved.

Note: If the correct adjustment cannot be obtained by adjusting fuel control rod (4), loosen the locknuts on rod assembly (5), and adjust the rod assembly until the correct adjustment can be obtained.

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Illustration 5	g00664104

While the fuel stop lever is against the synchronizing pin, and Tool (B) is in the position that is specified in Step 8, use a screwdriver and make an adjustment of control rod (4). Turn the screw on control rod (4) slowly. This should be done until the Tool (B) just fits between the fuel injector body and the shoulder at the end of the rack. Remove the screwdriver from control rod (4). This will ensure that no pressure is on the linkage while the setting is checked with Tool (B). Any pressure on the linkage by the screwdriver will not give a correct indication when the setting is checked with Tool (B). Move the linkage in order to ensure that the linkage is free and move the linkage in order to ensure that the linkage is giving the correct setting. Check the setting again.

Repeat Steps 8 and 9 for the remaining racks.

Install Tool (C) at location (Y). When Tool (E) seats against fuel stop lever (6), slide the dial indicator inward or slide the dial indicator outward until the dial indicator reads 0.00 mm (0.000 inch). Tighten Tool (D) enough to hold the indicator in the position.

Remove the synchronizing pin (1) from location (Z) and return the synchronizing pin to the storage location.
Note: If a governor actuator linkage is used, see the subject Woodward EGB29P Governor Actuator Linkage.

Rotate the governor terminal shaft to the minimum fuel position and hold the shaft in place.

Adjust governor rod assembly (2) until the dial indicator reads -9.30 mm (-0.366 inch). This dimension is called the governor deadband. The definition of governor deadband is the total amount of travel between the point of actual fuel shutoff and the actual "FUEL OFF" position. Tighten the locknut at each end of the rod assembly.

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NOTICE

If the governor deadband measurement is reduced beyond the specification -9.30 mm (-0.366 inch), engine overspeed can occur whenever the engine is operated at high rpm without a load because it takes less rack movement to operate the engine at high rpm.

Remove the dial indicator, and install the plugs in the housing assembly.

Install the valve covers.

Check the fuel setting. See Fuel Setting .

Before you start the engine, put a mark on the governor position degree indicator at the position of minimum governor. This is the engine's stopped position.

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The engine may overspeed due to incorrect assembly or adjustment.
Engine overspeed could result in personal injury, loss of life and/or property damage.

Be prepared to stop the engine by activating the engine shutdown system or closing the air inlet lines.