Using the 9U-5219 Tool Group{776} Caterpillar

Introduction

NOTE: The 1U-5540 Tool Group has been canceled and replaced by the 9U-5219 Tool Group.

The 9U-5219 Tool Group contains nine separate tools which are used in combination in order to:

* Set the clearance dimension between the engine speed sensor and the 4W-2485 retainer (pulse wheel).

* Establish the 0 (zero) rack position needed before the Digital Diagnostic Tool (DDT) and/or Electronic Control Analyzer Programmer (ECAP) can be used to check and/or calibrate the rack position sensor without breaking the governor seals.

* Remove and/or install the 6T-9675 Solenoid (fuel shutoff).

* Remove and/or install the 3E-6310 Water Temperature Sensor.

Reference Literature

Parts Book .. SEBP1676, 3406B (PEEC) Truck Engine

Special Instruction .. SEHS8742, Using The 8T8697 Electronic Control Analyzer Programmer (ECAP)

Special Instruction .. SEHS8743, Using The NEXG4508 3406 Truck Functions Service Program Module

Service Manual .. SENR3479, 3406B (PEEC) Truck Engine Test Procedures

9U-5219 Tool Group

9U-5219 Tool Group. (1) 8T-9198 Bracket Assembly. (2) 5P-4814 Clamp Collet. (3) 9U-5120 Spanner Wrench. (4) 6V-4186 Fuel Pump Timing Pin. (5) 1U-5426 Compressor Assembly. (6) 9U-5103 Slotted Socket. (7) 5P-0326 Crowfoot Wrench. (8) 1U-5536 Crowfoot Wrench. (9) 1U-5425 Timing Gauge Assembly.

NOTE: The 6V-3072 Plastic Case, 9U-5225 Foam Block and NEEG2516 Decal are not shown.

NOTE: The 1U-5426 Compressor Assembly includes:

6D-3982 Nut7F-2359 Spring9S-8903 Contact Point

Setting the Speed Sensor Clearance Dimension

1. Remove four bolts (1), cover (2), four bolts (3) and housing (4) for access to speed sensor (5).

2. Install 5P-0326 Wrench (6), using a 3/8 inch drive ratchet (7) and extension (8), on locknut (9).

3. Turn the locknut counterclockwise to loosen.

4. Turn speed sensor (5), by hand, clockwise until contact is made with the 4W-2485 Retainer (not shown). Then turn the speed sensor 1/2 turn ± 30 degrees counterclockwise.

5. Tighten locknut (9) to a torque of 13 ± 2 N·m (10 ± 1 lb ft) to secure the speed sensor.

Setting the Rack Position Sensor

1. Remove four bolts (1) and cover (2) for access to rack position sensor.

2. Remove two bolts (3), cover (4) and zero rack pin plug (5).

3. Install 8T-9198 Bracket Assembly (6) and 6V-4186 Pin (7).

4. Install 1U-5426 Compressor Assembly (8) into the bracket assembly.

5. Push 1U-5426 Compressor Assembly (8) all the way into the bracket assembly to compress the spring (in the compressor assembly).

6. Hold in this position (spring compressed) and tighten locknut (9) on collet (10) on bracket assembly (6).

This will retain the spring (compressed) and hold the rack in 0 (zero) position.

7. Install 1U-5536 Wrench (11) on locknut (12). Use a 3/8 inch drive ratchet (13) and turn it counterclockwise to loosen.

8. Calibrate the rack position sensor to the proper setting as shown in SEHS8742 and/or SEHS8743.

9. Tighten locknut (12) to a torque of 55 ± 7 N·m (40 ± 5 lb ft) to secure the rack position sensor.

NOTE: The tools used in steps 3, 4, and 5 can be installed to verify calibration of the rack position sensor without breaking the governor seals.

Removing/Installing the 6T-9675 Solenoid (Fuel Shutoff)

1. Install 9U-5120 Wrench (1), on 6T-9675 Solenoid (2).

2. Use a 3/8 inch drive ratchet (3) to turn the solenoid.

3. Turn the solenoid counterclockwise to remove, or clockwise to install.

When installing a solenoid, use the tools shown in Step 1 and 3 above and tighten the solenoid to a torque of 70 ± 10 N·m (50 ± 7 lb ft).

Installing the 1U-5425 Gage Assembly

NOTE: The 1U-5425 Gage Assembly is used to hold the timing position sensor in the correct position for calibration.

1. Remove two bolts (1) and timing advance cover (2).

2. Disconnect timing solenoid wiring harness electrical connections (3) and (4).

3. Remove timing solenoid (not shown) from timing advance housing (5).

4. Pin the fuel pump camshaft with a 6V-4186 Fuel Pump Timing Pin.

Refer to SENR3479, 3406B (PEEC) Truck Engine Test Procedures, procedure P-403.

NOTE: The crankshaft can be rotated by:

Using a 9S-9082 Engine Turning Tool.

Turning the crankshaft damper bolts.

Turning the flywheel ring gear, if accessible.

5. With the 6V-4186 Pin in fuel pump camshaft slot, rotate the crankshaft, counterclockwise, until a stop is felt.

This insures that the timing advance piston is in the fully retracted position (moves toward rear of engine) and can be seen through opening (6).

NOTE: During the following steps, 1U-5425 Gage Assembly (7) and the area of installation cannot be seen.

The cutaway view photographs are shown to aid in tool installation.

6. Check the position (protrusion) of ball detent (A).

It should protrude only slightly into grooved area (8).

If necessary to adjust the ball detent:

* Turn adjustment screw (B) clockwise to move the ball detent further into the grooved area.

* Turn adjustment screw (B) counterclockwise to move the ball detent out (retract) from the grooved area.

7. Install gage assembly (7), with grooved side (8) toward engine, between power piston bearing (9) and timing sensor bellcrank (10), so that ear (11) is in an approximate 9 o'clock position.

8. Apply slight hand pressure, and push gage assembly (7) towards engine and rotate, counterclockwise, slowly until ear (12) is in an approximate 9 o'clock position.

NOTE: A slight resistance can be felt as the tool starts to seat.

9. Continue to rotate gage assembly (7), counterclockwise, until ear (12) is in an approximate 6 o'clock position.

This will hold the timing position sensor in the correct position for calibration.

10. Install 1U-5536 Wrench (13) on timing position sensor locknut (14).

11. Use a 3/8 inch drive ratchet (15), and turn it counterclockwise to loosen.

12. Calibrate the timing position sensor to the proper setting as shown in SEHS8742 or SEHS8743.

13. Tighten locknut (14) to a torque of 55 ± 7 N·m (40 ± 5 lb ft) to secure the timing position sensor.

14. Remove the gage assembly after calibration has been checked and/or set.

Removing/Installing the 3E-6310 Water Temperature Sensor

Removing the 3E-6310 Water Temperature Sensor

NOTE:

1. Separate 3E-6310 Water Temperature Sensor wiring (1) at pigtail (not shown). The 3E-6310 Water Temperature Sensor may be located at front or on top of engine.

2. Install 9U-5103 Socket (2) over 3E-6310 Water Temperature Sensor and onto adapter. Slot in 9U-5103 Socket fits over wiring (1).

3. Use a 3/8 inch drive ratchet and extension (3), or similar tool to turn and remove adapter and 3E-6310 Water Temperature Sensor together.

Turn the adapter counterclockwise to loosen.

4. Separate 3E-6310 Water Temperature Sensor from adapter using 5/8 inch wrench or socket.

Installing the 3E-6310 Water Temperature Sensor

1. Install 3E-6310 Water Temperature Sensor into adapter using 5/8 inch wrench or socket.

2. Install 9U-5103 Socket (2) over 3E-6310 Water Temperature Sensor onto adapter.

3. Use a 3/8 inch drive ratchet and extension (3), to turn and install adapter and 3E-6310 Water Temperature Sensor together.

Turn the adapter clockwise to tighten.

4. Connect 3E-6310 Water Temperature Sensor wiring (1) at pigtail (not shown).

Tighten 3E-6310 Water Temperature Sensor to a torque of 20 ± 3 N·m (15 ± 2 lb ft).