3606 and 3608 Engines Caterpillar

Fuel Injector Synchronization

Usage:

3608 6MC

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Table 1
Tools Needed	Quantity
4C-6594 Timing and Fuel Setting Tool	1
6V-9057 Rack Synchronizing Gauge	1
6V-3075 Dial Indicator	1
5P-4814 Collet Clamp	1
5P-7263 Indicator Contact Point	1

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Illustration 1	g01345915
Right rear side of engine (1) Synchronization pin (2) Rod assembly (3) Control housing (A) Location for synchronization pin (B) Location for dial indicator

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

Remove the plugs at locations (A) and (B) from control housing (3) .

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

Install synchronizing pin (1) in location (A) 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	g01345918
Fuel injection control linkage (1) Synchronization pin (2) Rod assembly (3) Control housing (4) Fuel control rod (5) Rod assembly (A) Location for synchronization pin (B) Location for dial indicator

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Illustration 3	g01345922
Fuel injection control housing (3) Control housing (5) Rod assembly (6) Fuel stop lever

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Illustration 4	g00559113
Correct location for the gauge on the rack for the fuel injector (4) Fuel control rod (7) 6V-9057 Rack Synchronizing Gauge

Put 6V-9057 Rack Synchronizing Gauge (7) 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 has 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	g00559188
Adjusting fuel control rod (typical example) (7) 6V-9057 Rack Synchronizing Gauge

While the fuel stop lever is against the synchronizing pin, and the 6V-9057 Rack Synchronizing Gauge (7) 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 rack synchronizing gauge (7) 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 rack synchronizing gauge (7). Any pressure on the linkage by the screwdriver will not give a correct indication when the setting is checked with rack synchronizing gauge (7). 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 the 6V-3075 Dial Indicator at location (Y). When the 5P-7263 Contact Point 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 the 5P-4814 Collet Clamp enough to hold the indicator in the position.

Remove the synchronizing pin (1) from location (B) and return the synchronizing pin to the storage location.

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

Adjust 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. Refer to System Operation, Testing and Adjusting, "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.