3054 and 3056 Industrial and Generator Set Engines Caterpillar

Note: If the cylinder block is replaced or when a new fuel injection pump or a new camshaft is installed, the timing procedure must be performed. The timing procedure must be performed if the fuel injection pump is removed from the engine and the locking bolt is loosened.

Checking the Mark for the Engine Timing for the Bosch EPVE Fuel Injection Pumps

Table 1

Required Tools
Part Number	Part Description	Qty
9U-6188	Timing Fixture Group	1

1. Set the piston of No. 1 cylinder to top center on the compression stroke.

2. Remove the fuel injection pump and the gasket.
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   Illustration 1	g00321405
   Adapter from the 9U-6188 Timing Fixture Group

3. Align the key that is in the adapter with the keyway that is in the gear of the fuel injection pump. Install the adapter to the gear. Ensure that the adapter is against the rear face of the timing case. Secure the adapter to the gear with the nut which is supplied with the adapter.
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   Illustration 2	g00321407
   Engine timing tool from the 9U-6188 Timing Fixture Group (1) Pointer (2) Screw (3) Shaft (4) Screw (5) Screw

4. Loosen screw (5). Set the engine timing tool to the correct engine check angle. Refer to the Specifications, "Fuel Injection Pump" for the correct engine check angle. Tighten screw (5). Loosen screw (4). Install splined shaft (3) into the engine timing tool. Loosen screw (2). Install pointer (1) and tighten screw (2).

5. Install the splined shaft of the engine timing tool into the adapter. Slide the engine timing tool along the splined shaft until the engine timing tool rests against the adapter. Tighten screw (4).

6. Loosen screw (2). Slide the pointer forward until the flat face rests against the rear face of the timing case. Tighten screw (2). If the mark on the timing case is correct, the mark will align with the top edge of pointer (1). If the mark is not correct, remove the engine timing tool and remove the mark on the timing case. Install the engine timing tool. Ensure that the pointer rests against the timing case. Make a new mark on the timing case. Make the new mark along the top of the straight edge of the pointer.

7. Remove the engine timing tool and the adapter.

8. Install a new gasket on the fuel injection pump. Install the fuel injection pump on the engine.

9. Set the valve lash for the inlet valve of the No. 1 cylinder. Refer to Specifications, "Cylinder Head Valves" for the correct valve lash. Install the valve mechanism cover.

10. Purge the air in the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for the procedure.

Timing the Bosch Fuel Injection Pump

Table 2

Required Tools
Part Number	Part Description	Qty
9U-6188	Timing Fixture Group	1
6V-3075	Dial Indicator	1
8S-3675	Indicator contact point	1
192-3331	Timing Gauge (Fuel Injection Pump)	1

Illustration 3	g00559480
(1) Support bracket (2) Fuel injection pump (A) Fuel outlet (F) Fuel outlet

1. Use support bracket (1) to hold fuel injection pump (2) in a vise. The key on the fuel injection pump shaft must be in position between fuel outlet (A) and fuel outlet (F).
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   Illustration 4	g00559484
   (3) Locking bolt

2. Loosen locking bolt (3).
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   Illustration 5	g00559487
   (4) The dial indicator, the timing gauge adapter, and indicator contact point (not shown)

3. Remove the plug and the washer from the rear of the fuel injection pump. Install the following tools: the timing gauge adapter, the dial indicator and indicator contact point (not shown) (4). Set the dial indicator to register approximately 3 mm (0.12 inch) in travel.
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   Illustration 6	g00559492
   (5) Drive adapter

4. Install the drive adapter (5) on the drive shaft of the fuel pump. Secure the adapter to the shaft with the nut of the drive gear (not shown).
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   Illustration 7	g00760943
   (6) Adapter (7) Timing tool (8) Locking screw (9) Pointer (10) Locking screw

5. Install timing tool (7) on drive adapter (5). Install adapter (6) on timing tool (7). Adapter (6) is used to rotate timing tool (7). Adapter (6) also rotates the drive shaft of the fuel injection pump. To rotate the adapter, a handle must be made. Use three set screws in adapter (6) in order to connect the handle to adapter (6).

6. Adjust the automatic timing advance unit (if equipped). The automatic timing advance unit is a device that is used during fuel injection timing. Refer to Testing and Adjusting, "Automatic Timing Advance Unit - Test" for the procedure to adjust the automatic timing advance unit.

7. When the pump plunger is at the lowest position, set the dial indicator to zero. The bar will have no tension as the pump is turned to this position.

8. The drive shaft of the pump is turned clockwise until the pointer on the gauge indicates 1 mm (0.039 inch). The fuel injection pump is viewed from the drive end. Hold the shaft in this position and tighten locking bolt (3).

9. Loosen locking screw (10). Move the setting block (not shown) until the pointer aligns with the center of the top outer slot in the pump flange. Tighten locking screw (10).

10. Loosen locking screw (8) for pointer (9). Slide the pointer forward until the slot in the pointer covers the pump flange. Tighten locking screw (8).

11. Hold timing tool (7) against the direction of the pump rotation in order to remove backlash. Place a mark on the pump flange along the slot in the pointer.

12. Loosen locking screw (8) for pointer (9). Slide the pointer rearward until the slot in the pointer covers half of the pump flange. Tighten locking screw (8).

    Note: The automatic timing advance unit (if equipped) must be energized before the timing is set. Refer to Testing and Adjusting, "Automatic Timing Advance Unit - Test" for the procedure to adjust the automatic timing advance unit.

13. Remove the adapter and the timing tool. The angle that is indicated on the tool should be increased by 50 degrees.

14. Loosen locking bolt (3) on the fuel injection pump. Allow the pump plunger to return to the lowest position. The dial indicator should return to zero.

15. Install timing tool (7) and adapter (6) on the pump drive.

16. Rotate the timing tool counterclockwise until the slot in the pointer is aligned with the mark on the pump flange. Tighten locking bolt (3). Ensure that the key in the pump shaft is aligned with the keyway in the gear.

17. Disconnect the automatic timing advance unit (if equipped).

18. Remove adapter (6) and timing tool (7).

19. Remove adapter (5) from the drive shaft of the fuel injection pump.

20. Remove the following tools: the timing gauge adapter, the dial indicator and indicator contact point (not shown) (4). Install the washer (not shown) and the plug (not shown) in the fuel injection pump.

    Tighten the plug to the following torque: ... 10 N·m (7 lb ft)

21. Install the fuel injection pump on the engine.

Timing the Stanadyne Fuel Injection Pump and the Delphi Fuel Injection Pump

Note: This procedure for timing the fuel injection pump can be used on Stanadyne and Bosch fuel injection pumps.

Table 3

Required Tools
Part Number	Part Description	Qty
150-3992	Timing Pin (Bosch)	1
150-3993	Timing Pin (Stanadyne and Delphi)	1

Illustration 8	g00309806
Timing Gear And Hub Of The Fuel Injection Pump (Delphi and Stanadyne) (1) Timing pin (2) Torx screws (3) Hub nut (4) Hole in pump body (5) Slot for timing gear (6) Slot for the hub

This procedure can only be used when the engine is set to the top center position on No. 1 cylinder on the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston" for more information.

Note: Do not remove hub nut (3) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed on the shaft in the factory in order to ensure that the fuel injection pump is in the correct position for timing. If the hub is removed, the hub must be accurately installed to the pump shaft by the use of special equipment at a Caterpillar Dealer.

Note: Do not release torx screws (2). If the torx screws are released and the timing plate is moved, the timing position that is set at the factory will be lost. If the timing position is lost, the engine must be set to the top center position on the No. 1 cylinder on the compression stroke before the torx screws are tightened.

1. Insert timing pin (1) through the slot for timing gear (5). Continue to insert the timing pin through the slot for hub (6). Push the pin all the way into the hole in pump body (4). If the pin can be inserted all the way, the pump timing is correct. Resistance should not occur until the pin is inserted all the way into the hole in the pump body.

2. Remove the timing pin.

3. If the timing pin cannot be inserted into the hole in the pump body, ensure that the engine is correctly set at the top center compression stroke of the No. 1 cylinder.

4. The fuel injection pump must be removed and replaced or the fuel injection pump must be set by a Caterpillar Dealer when the following conditions exist:

   • The engine is set correctly at the top center.

   • The pin cannot be easily inserted.

   • The pin cannot be inserted all the way into the hole in the fuel injection pump body.

   Refer to the Disassembly and Assembly Module, "Fuel Injection Pump - Remove and Install" topic for removal and installation procedures.