3606 and 3608 Engines Caterpillar

Injector Synchronization And Power Setting

Illustration 1	g01345949
(1) Rod assembly (2) Lever (3) Governor output shaft (4) Synchronization pin (5) Power setting screw (A) Location of the synchronization pin (B) Location for the dial indicator

Illustration 2	g01345962
(6) Shaft (7) Fuel stop lever (8) Rod assembly

1. Assemble rod assembly (1) to the minimum length.

2. Adjust the rod assembly (8) .

   Length between centers of rod ends for rod assembly (8) ... 284.0 ± 2.0 mm (11.18 ± 0.08 inch)

3. Install synchronizing pin (4) in location (A) without the spacer.

   Tighten synchronizing pin (4) to the following torque. ... 10 ± 2 N·m (7 ± 1 lb ft)

4. Rotate fuel stop lever (7) until the fuel stop lever makes contact with the synchronizing pin (4). Fuel stop lever (7) must remain in contact with the synchronizing pin (4) during the linkage adjustment.

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Illustration 3	g00606181

5. Adjust rod assembly (8) in order to ensure that each fuel control rod (9) is approximately positioned with the 6V-9057 Rack Synchronizing Gauge Block (10) between the trim screw and the end of the rack bar. Tighten the nuts on the rod assembly (8) in order to lock the rod assembly (8) in place.

6. Put 6V-9057 Rack Synchronizing Gauge (10) 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.

7. Repeat Step 5 through Step 7 for the remaining racks. If fuel control rod (9) cannot be adjusted, adjust the control housing's rod assembly (8). If the adjustment of the control housing's rod assembly (8) is necessary, all previously adjusted fuel control rods (9) must be adjusted again.

8. Insert the 6V-3075 Dial Indicator into location (Y). Ensure that the 5P-7263 Indicator Contact Point of the 6V-3075 Dial Indicator seats against the fuel stop lever. Use the 5P-4814 Collet Clamp in order to secure the 6V-3075 Dial Indicator in place. Place the indicator's dial on zero.

9. Remove synchronizing pin (4) .

10. Rotate governor output shaft (3) to the minimum fuel setting. Hold governor output shaft (3) in place.

11. Install lever (2) on governor output shaft (3) .

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Illustration 4	g01345967
(C) Rod end in hole (C) (D) Rod end in hole (D) (E) Rod end in hole (E)

12. Install rod assembly (1) in lever (2). Ensure that the proper hole in lever (2) is used.

    Rack setting will determine the installation of rod assembly (1). The rack setting may be found on the engine information plate.

    Rack setting above 7.00 mm (0.276 inch) ... Hole "C"

    Rack setting 3.00 mm (0.118 inch) to 7.00 mm (0.276 inch) ... Hole "D"

    Rack setting below 3.00 mm (0.118 inch) ... Hole "E"

13. Install 6V-5754 Plugs into the remaining holes in lever (2) .

14. Adjust rod assembly (1) in order to obtain a rack setting of −9.33 mm (−0.367 inch). Tighten assembly in order to lock the setting in place.

15. Adjust power setting screw (5) to the desired power setting. Secure the power setting screw (5) with the nut.

16. Attach the cover for the power setting screw (5). Secure the cover with synchronizing pin (4) .