9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905} Caterpillar

Caterpillar Products: All Machines

Introduction

European Union Compliant, CE Marked

Important Safety Information

Illustration 1	g02139237
Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

General Information Section

9U-5132 Timing Tool Group

Illustration 3	g03336830

Table 1

9U-5132 Timing Tool Group
Item	Part No.	Description
1	1U-8869 (3)	Digital Dial Indicator
2	9U-6273 (3)	Rod Sleeve Extension
3	9U-6272 (3)	Nylon Screw
4	5P-8414 (3)	Clamp Collet
5	136-4588 (3)	Collet Extension
6	122-0449 (3)	Rod Sleeve Extension
7	136-4587 (3)	Collet Extension
8	6V-3075	Dial Indicator, Metric
9	9U-5137 (2)	Timing Fixture
10	5P-7276	Container
11	5P-7263	Contact Point, 76.2 mm (3.0 in)
12	9S-8883	Contact Point, 12.7 mm (.50 in)
13	4C-8753	Extended Collet
14	8T-2684	Rack Synchronization Gauge, 12.7 mm (.50 in)
15	6V-7918	Wrench (5/8)
16	8S-3675	Contact Point, 3 mm (.12 in)
17	129-8602	Solenoid Driver
18	9U-5138 (1)	Set Gauge
19	9U-5736 (1)	Foam Insert
20	6V-3072 (1)	Plastic Case
21	5P-4160 (1) (3)	Contact Point: 19.0 mm (.75 in)
22	9S-9802 (1) (3)	Engine Turning Tool
23	122-0451 (1) (3)	Extension Rod Assembly
24	443-4177 (3)	Low Height Tool

( 3 )	Additional tooling required, but not part of 9U-5132.
( 2 )	Part of 9U-5233 Magnetic Fixture Group.
( 1 )	Not Shown.

Crankshaft Positions for Unit Injector Lash and Valve Lash Settings

Table 2

Chart A Standard Rotation (Counterclockwise) As Viewed from Flywheel End
Cylinders to Check/Adjust
Engine	Correct Stroke for No. 1 Piston at Top Center Position  (1)	Intake Valves	Exhaust Valves	Injectors
3508	Compression	1-2-6-8	1-2-3-7	3-4-5-7
	Exhaust	3-4-5-7	4-5-6-8	1-2-6-8
3512	Compression	1-3-6-7-10-12	1-4-5-6-9-12	2-4-5-8-9-11
	Exhaust	2-4-5-8-9-11	2-3-7-8-10-11	1-3-6-7-10-12
3516	Compression	1-2-5-7-8-12-13-14	1-2-3-4-5-6-8-9	3-4-6-9-10-11-15-16
	Exhaust	3-4-6-9-10-11-15-16	7-10-11-12-13-14-15-16	1-2-5-7-8-12-13-14
Chart B. Reverse Rotation (Clockwise) As Viewed From Flywheel End
Cylinders to Check/Adjust
3508	Compression	1-3-4-8	1-2-7-8	2-5-6-7
	Exhaust	2-5-6-7	3-4-5-6	1-3-4-8
3512	Compression	1-3-4-6-7-12	1-4-5-8-9-12	2-5-8-9-10-11
	Exhaust	2-5-8-9-10-11	2-3-6-7-10-11	1-3-4-6-7-12
3516	Compression	1-2-5-6-7-8-13-14	1-2-3-4-5-6-9-10	3-4-9-10-12-15-16
	Exhaust	3-4-9-10-11-12-14-15-16	7-8-11-12-13-14-15-16	1-2-5-6-7-8-13-14

( 1 )

Put No. 1 piston at top center (TX) position and make identification for the correct stroke. After top center position for a particular stroke is found and adjustments are made for the correct cylinders, remove timing bolt and turn the flywheel 360 degrees in the direction of normal engine rotation. This will put No. 1 piston at top center (TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.

Table 3

Chart C. Dial Indicator Setting Chart  (1)
Fuel Timing Dimension in Millimeters	Dial Indicator Setting In Millimeters
88.28	+1.28
88.07	+1.07
87.85	+0.85
87.64	+0.64
87.43	+0.43
87.21	+0.21
87.00	+0.00
86.79	-0.21
86.57	-0.43
86.36	-0.64
86.15	-0.84
85.93	-1.07
85.72	-1.28

( 1 )

Refer to Fuel Setting and Related Information Fiche for the correct timing dimension to use.

Section 1, Mechanical Unit Injector Engines

This section provides all the testing and adjustment procedures for mechanical unit injector (MUI) engines. For Testing and Adjusting electronic unit injectors (EUI) engines, refer to Section 2 of this manual.

Start-up Procedure

Use the following procedure in order to start an engine following fuel system or governor repair:

1. The technician should be prepared to activate the emergency stop button.

2. Disconnect the air inlet system from the turbochargers.

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Be careful when plate is put against the air inlet opening. Excessive suction can pull the plate quickly against the air inlet opening. To avoid crushed fingers, do not put fingers between plate and air inlet opening.

3. Place a service person in position near each turbocharger air inlet. Equip the service person with a piece of steel plate. Each piece of steel plate must be large enough to cover each turbocharger air inlet.

4. Start the engine. If the engine starts to run too fast or the engine runs out of control, immediately activate the emergency stop button. Also, place the steel plates against the turbocharger air inlets. The plates will stop the air supply to the engine, and the engine will stop.

Tooling

All tools listed are included with 9U-5132 Tool Group, except as noted.

Table 4

Chart A. 9U-5132 Timing and Fuel System Setting Tool Group for MUI Engines
Part No.	Description
5P-4160 (1)	Contact Point, 19 mm (for digital indicator)
8S-3675	Contact Point, 3 mm
9S-9082 (1)	Engine Turning Tool
1U-8869 (1)	Digital Dial Indicator (used in preferred method)
9U-5137	Timing Fixture
9U-5138	Set Gauge
9U-5220	Rod Assembly
9U-6272	Nylon Screw
9U-6273	Rod Sleeve Extension (refer to the note below for alternate parts)
6V-3075	Dial Indicator, Metric (used in alternate method)

( 1 )

Not included in 9U-5132

Note: Some technicians prefer to secure the dial indicator with the 5P-4814 Clamp Collet, instead of the nylon screw. Parts have been made available for this purpose. In place of 9U-6273 Rod Sleeve Extension, order and use 136-4587 Collet Extension. This extension accepts the 5P-4814 Clamp Collet. Use two 6V-7918 Wrenches (or 5/8 inch open-end wrenches) to tighten the collet on the indicator stem.

General Set-up Information

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NOTICE
Camshafts must be timed correctly with the crankshaft before an adjustment of fuel timing is made. The timing pins must be removed from the camshafts before the crankshaft is turned, or damage to the cylinder block will result.

Refer to the "Crankshaft positions For unit Injector Lash and Valve Lash Setting" chart in this manual and put the engine in time. With the two crankshaft positions given in the chart, all of the injectors can be checked or adjusted. This will make sure that the push-rod lifters are off the lobes and on the base circles of the camshafts.

Refer to the "Fuel Setting Adjustment" in this manual for the correct fuel timing dimension to use. The range of timing dimensions are given in the "Dial Indicator Setting" chart in this manual.

Using the 1U-8869 Digital Dial Indicator (preferred method)

Illustration 4	g00322956
1U-8869 Dial Indicator

1. The digital dial indicator must be programmed to read actual timing dimensions. Since the 9U-5138 Setting Gauge in the timing and fuel setting tool group is 87.00 mm (3.4252 inch), set the digital dial indicator for 87.00 mm (3.4252 inch). Use the following steps in order to program the indicator to read 87.00 mm (3.4252 inch).

   1. Turn the indicator to the ON position by pushing the "on/off" button.

   2. Push the "in/mm" button so the display shows "mm".

   3. A negative "-" sign should be in the display window under "REV". If that space is blank, push the "+/−" button so the display shows a negative "-" sign. When this is done, the movement of the plunger into the indicator will be displayed. The display will be shown as a negative movement. The movement of the plunger out of the indicator will be displayed as a positive movement.

   4. Push the preset button and hold the preset button down until there is a flashing "P" in the upper right corner of the display. Then release the button.

   5. Push the preset button and hold the preset button down until the flashing "P" disappears and a flashing indicator bar is seen in the lower left corner of the display. Then release the button. Use the preset button so that this position is blank.

   6. Push the preset button and hold the preset button down until the flashing indicator begins flashing under the first number position. The first number position is located in the fourth position to the left of the decimal. Then release the button. Momentarily pushing the preset will cause the display number in that position to change. Use the preset until this position reads zero (0).

   7. Use the preset button to move the flashing indicator and change the display numbers until the display shows 87.00 mm (3.4252 inch). Push the preset button and hold the preset button until the flashing "P" is shown in the upper right corner of the display. Release the preset button. Momentarily push the preset button so the flashing "P" and the zeroes to the left of 87.00 mm (3.4252 inch) disappear.

   8. The indicator can now be turned off. The indicator will retain the preset number in memory. To recall the preset number, repeat Steps 1.a through 1.d.

2. Install a 5P-4160 Indicator Contact Point in the indicator stem.

3. Install the indicator into the 9U-5233 Magnetic Fixture Group . Leave the collet loose.

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Illustration 5	g00323023
Adjustment of fuel timing tools (1) 1U-8869 Dial Indicator (2) 9U-5233 Magnetic Fixture Group (3) 9U-5138 Setting Gauge

4. Place the fixture and the indicator on the 9U-5138 Setting Gauge with the extension rod of the bracket on the step of the gauge. Position the indicator in the bracket so that the indicator plunger can travel adequately. Tighten the collet.

5. Repeat Steps 1.a through 1.d.

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Illustration 6	g00323029
Fuel timing tools in position (1) 1U-8869 Dial Indicator (2) 9U-5233 Magnetic Fixture Group (4) Injector follower (5) Shoulder on fuel injector body

6. Momentarily push the preset button on the digital dial indicator in order to stop the "P" in the upper right-hand corner from flashing. The display should show 87.00 mm (3.4252 inch). Place the 1U-8869 Dial Indicator and the 9U-5233 Magnetic Fixture Group in the correct position on the injector. Make sure that the magnetic base of the timing fixture is on the top surface of injector follower (4). The extension rod rests on the top surface of shoulder on fuel injector body (5) .

   Note: The top surfaces of injector follower (4) and shoulder on fuel injector body (5) must be clean and dry for accurate readings.

7. The digital dial indicator should now read the actual fuel timing dimension of the injector that is being checked.

8. No adjustment is necessary if the dial indicator reads the correct fuel timing dimension. Refer to the TMI (Technical Marketing Information) for the engine that is being checked. Proceed to Step 13.

9. If the dial indicator does not read the correct fuel timing dimension or the desired fuel timing dimension, proceed with Steps 10 through 13.

10. Ensure that the 1U-8869 Dial Indicator and the 9U-5233 Magnetic Fixture Group are in the correct position on the injector. Loosen the locknut for the pushrod adjustment screw.

11. Turn the adjustment screw until the desired fuel timing dimension is read on the digital dial indicator.

    Note: Turning the adjustment screw clockwise will lower the fuel timing dimension. Turning the adjustment screw counterclockwise will increase the fuel timing dimension.

    Tighten the adjustment screw locknut to a torque of 70 ± 15 N·m (50 ± 11 lb ft) and check adjustment again. If necessary, repeat the procedure until the adjustment is correct.

12. Remove the timing bolt from the flywheel when the fuel timing check is completed.

13. Turn the flywheel by 360 degrees in the direction of normal engine rotation. Install the timing bolt for the flywheel. Repeat the procedure for the other half of the engine.

443-4177 Low Height Tool Option

Use only with the Digital Dial Indicator (preferred method).

Illustration 7	g03712647

Table 5

443-4177 Parts List
No.	Quantity	Part No.	Name
1	1	443-4174	Fixture Assembly
2	2	9U-6272	Nylon Screw
3	1	443-4176	Rod Assembly

• Tool is only used with the Digital Dial Indicator (1U-8869)

• Low height tool used on No. 2 Cylinders or injector adjustment on MT4400 Trucks

• Used to test and adjust fuel systems

• Used to test and adjust fuel systems, including fuel timing, rack synchronization, and fuel setting

• Collets to hold digital dial indicator built-in

• Fits all 3516 engines

Specifications

Table 6

Length	155 mm (6.10 in)
Width	40 mm (1.57 in)
Weight	0.18 kg (.40 lb)

Using the 6V-3075 Dial Indicator (alternate method)

Refer to TMI (Technical Marketing Information) for the correct fuel setting for the engine that is being checked.

Illustration 8	g03401931

(1) 6V-3075 Dial Indicator

(2) 9U-5137 Magnetic Fixture

(3) 9U-5138 Setting Gauge

(4) 9U-6272 Nylon Screw

(5) 9U-6273 Rod Sleeve Extension

(6) 9U-5220 Timing Fixture Rod

1. Install the 8S-3675 Indicator Contact Point onto the dial indicator stem.

2. Install Sleeve Extension (5) in the small diameter tube of Timing Fixture (2). Place Rod Assembly (6) in Sleeve Extension (5) .

3. Install Dial Indicator (1) in Sleeve Extension (5) .

4. Put Dial Indicator (1) and Timing Fixture (2) onto the Set Gauge (3). The Timing Fixture (2) should be on the top surface of the Set Gauge (3) with the Rod Assembly (6) on the bottom 87.00 mm (3.4252 inch) step.

5. Move the Dial Indicator (1) in the Sleeve Extension (5) until both needles indicate zero. Tighten Nylon Screw (4). The dial indicator has now been zeroed to a standard fuel timing dimension of 87.00 mm (3.4252 inch).

Note: Some Dial Indicators (1) have a 0.25 mm (0.010 inch) smaller diameter extending about 4.0 mm (0.158 inch) up from the end of their stems. When zeroing these indicators in the bore of the 122-0449 Rod Sleeve Extension the Nylon Screw (4) will contact the indicator stem on this step. This can cause the indicator to cock in the bore and result in incorrect readings. It is recommended that the 136-4587 Collet Extension and 5P-4814 Collet Clamp be used with these "stepped" indicator or that the 1U-8869 Dial Indicator be used.

6. Subtract 87.00 mm (3.4252 inch) (gauge dimension) from the desired fuel timing dimension (obtained from (TMI) Technical Marketing Information)

   Note: To obtain a positive indicator setting, move the indicator downward. This will move the large needle clockwise or in the positive direction increasing the fuel timing dimension from 87.00 mm (3.4252 inch).
   To obtain a negative indicator setting, move the indicator upward. This will move the large needle counterclockwise or in the negative direction decreasing the fuel timing dimension from 87.00 mm (3.4252 inch).

   1. Example 1: Desired fuel timing dimension is 87.50 mm (3.4449 inch).
      
      Subtract 87.00 mm (3.4252 inch) from the desired fuel timing dimension 87.50 mm (3.4449 inch).
      
      87.50 mm (3.4449 inch) - 87.00 mm (3.4252 inch) = +0.50 mm (0.0197 inch)
      
      In this case loosen Nylon Screw (4) and move the dial indicator downward until the indicator reads a positive 0.50 mm (0.0197 inch). Then tighten the Nylon Screw (4) again.

   2. Example 2: Desired fuel timing dimension is 86.20 mm (3.3937 inch)
      
      Subtract 87.00 mm (3.4252 inch) from the desired fuel timing dimension 86.20 mm (3.3937 inch).
      
      86.20 mm (3.3937 inch) - 87.00 mm (3.4252 inch) = −0.80 mm (−0.03150 inch)
      
      In this case loosen Nylon Screw (4) and move the dial indicator upward until the indicator reads negative 0.80 mm (0.03150 inch). Then tighten the nylon screw again.

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Illustration 9	g03402357
(1) 6V-3075 Dial Indicator (2) 9U-5137 Magnetic Fixture (7) Injector Follower (8) Shoulder on injector body.

7. Make sure the top surfaces of (7) and (8) are clean and dry.

8. Put Dial Indicator (1) and Timing Fixture (2) in position on the injector to be checked. Make sure that the magnetic base of the timing fixture is on top surface of Injector Follower (7) and the extension rod is on the top surface of Injector Shoulder (8) .

9. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch)

10. If the dial indicator pointers indicate zero or are within the tolerance given in 8, no adjustment is necessary. Proceed to step 13.

11. If the dial indicator pointers do not indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), continue with step 11 through step 13.

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Illustration 10	g03402450
Typical example of adjusting fuel timing.

12. Loosen the push rod adjustment screw locknut for the injector to be adjusted.

13. Turn the adjustment screw until zero is read on the dial indicator.

    Note: If the dial indicator reading is greater than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), then turn the adjustment screw counterclockwise (CCW). If the dial indicator is less than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), then turn the adjustment screw clockwise (CW).

14. Tighten the adjustment screw locknut to 70 ± 15 N·m (51.63 ± 11.06lb ft). If necessary, repeat procedure until the adjustment is correct.

15. Rotate engine, re-pin the flywheel, and repeat the procedure for the other half of the engine that has not yet been adjusted.

Injector Synchronization Procedure

Table 7

Tools Needed
8T-2684 Rack Synchronization Gauge	1

Injector synchronization is the setting of all fuel injector racks to a reference position. This ensures that each injector gives the same amount of fuel to each cylinder. Injector synchronization is done by setting each fuel injector rack to the same position while the control linkage is in a fixed position. Use the following procedure for the adjustment of injector synchronization:

Illustration 11	g00323443
Location of fuel setting cover and synchronization pin (typical example) (1) Plug (2) Synchronization pin (3) Cover

1. The top bolt that holds the cover (3) in position is the synchronization pin (2). Remove the synchronization pin (2) and plug (1) from the front drive housing. DO NOT destroy the seal or remove cover (3) .

2. Remove the washer from the synchronization pin. Remove the plug and install the synchronization pin into the threaded hole. Tighten the synchronization pin.

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Illustration 12	g00323444
Position of the synchronization pin (typical example) (2) Synchronization pin (4) Fuel stop lever

3. Turn the governor or the actuator terminal shaft to the fuel ON position. The flat face of fuel stop lever (4) will contact synchronization pin (2). This is the synchronizing position or zero reference point. Hold the control linkage in this position when the injectors are adjusted.

4. Remove the valve covers.

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Illustration 13	g00323446
Location for gauge and control rod adjustment (typical example) (5) 8T-2684 Rack Synchronization Gauge (6) Control rod

5. With the fuel stop lever against the synchronization pin, put the 8T-2684 Rack Synchronization Gauge (5) on the round part of the fuel injector rack between the fuel injector body and the end of the rack. Use a screwdriver and make an adjustment of control rod (6). Turn the screw that is located on the control rod one click at a time until the 8T-2684 Rack Synchronization Gauge fits between the fuel injector body and the shoulder at the end of the rack. Remove the screwdriver from the control rod so that no pressure remains on the linkage. Check the setting with the rack synchronization gauge. Any pressure on the linkage with the screwdriver will not give a correct indication when the setting is checked with the rack synchronization gauge. Ensure that the linkage is free and that the linkage is giving an accurate setting by moving the linkage. Check the setting again. Put the box end of a combination wrench over the nut and the bolt. The nut and the bolt connect control rod (6) and the bellcrank. Pull upward on the control rod three times. Check the setting again.

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Illustration 14	g00323448
Gauge in place on the fuel injector rack (typical example) (5) 8T-2684 Rack Synchronization Gauge (7) Fuel injector rack

6. If the other injectors need to be adjusted, use the rack synchronization gauge (5). When all adjustments have been made, release the actuator terminal shaft.

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Illustration 15	g00323450
Adjustment of fuel control rod (typical example) (5) 8T-2684 Rack Synchronization Gauge .

7. Install the valve covers.

8. Check the fuel setting and perform any necessary adjustments. Refer to Fuel Setting Procedure for this procedure.

Fuel Setting Procedure

Table 8

Tools Needed
9U-5132 Engine Timing Tool Group	1
4C-8753 Extended Collet	1
6V-3075 Dial Indicator	1
5P-7263 Indicator Contact Point	1
8T-2684 Rack Synchronization Gauge	1

Refer to Special Instruction, SEHS9278 for the instructions on the use of the 4C-8753 Extended Collet .

Fuel setting is the adjustment of the fuel setting screw to a specified position. The fuel setting screw limits the power output of the engine by setting the maximum travel of all the fuel injector racks.

Illustration 16	g00323603
Synchronization and fuel setting tools (1) 8T-2684 Rack Synchronization Gauge (2) 6V-3075 Dial Indicator (3) 4C-8753 Extended Collet (4) 5P-7263 Indicator Contact Point

Fuel Setting Check

Note: Before the fuel setting is checked, the injectors must be correctly synchronized. Refer to Injector Synchronization Procedure. After the injectors are synchronized correctly, leave the synchronization pin in place for the procedure that follows.

1. Put 6V-3075 Dial Indicator (2) with 5P-7263 Indicator Contact Point . Install contact Point (4) in 4C-8753 Extended Collet (3). Remove the plug from the right side of fuel setting cover (8) .

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Illustration 17	g00323643
Installed dial indicator (typical example) (2) 6V-3075 Dial Indicator with 5P-7263 Indicator Contact Point (3) 4C-8753 Extended Collet

2. Move the governor or the actuator terminal shaft toward the ON position. The flat face of fuel stop lever (6) should make contact with synchronization pin (5). Hold the linkage in this position.

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Illustration 18	g00323663
(2) 6V-3075 Dial Indicator (4) 5P-7263 Indicator Contact Point (5) Synchronization pin (6) Fuel stop lever

3. Install dial indicator (2) and extended collet (3) in the threaded hole. After indicator contact point (4) touches fuel stop lever (6), slide dial indicator (2) until the indicator reads zero. Keep the dial indicator in this position by tightening collet (3) .

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Illustration 19	g00805403
Checking fuel setting (typical example) (2) 6V-3075 Dial Indicator (5) Synchronization pin (8) Fuel setting cover

4. Unscrew synchronization pin (5) by 25 mm (1 inch) or remove synchronization pin (5). Slowly move the governor or the actuator terminal shaft toward the fuel ON position. The flat face of the fuel stop lever will rest against the end of the fuel setting screw. The dial indicator reading will be the present fuel setting when the linkage is held in this position.

   Note: Refer to the TMI (Technical Marketing Information) for the correct fuel setting.

5. If the fuel setting is correct, remove the dial indicator and the synchronization pin. Install the two plugs, and install the synchronization pin back into cover (8) .

6. If the fuel setting needs adjustment, see Fuel Setting Adjustment.

Fuel Setting Adjustment

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NOTICE
A mechanic with governor and fuel setting training is the ONLY one to make adjustments to the engine fuel setting.

1. Cut the seal wire and remove fuel setting cover (8) and the gasket. Loosen locknut (7). Hold the fuel stop lever against the end of the fuel setting screw. Turn the fuel setting screw clockwise or counterclockwise until the correct reading is on the dial indicator.

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Illustration 20	g00323705
Adjustment of the fuel setting screw (typical example)

2. Now tighten locknut (7). Be sure that the fuel setting screw does not turn when the locknut is tightened. Release the fuel system linkage and move the linkage toward the fuel ON position. Check the dial indicator reading again in order to be sure that the fuel setting is still correct.

3. Remove dial indicator (2) and synchronization pin (5). Install the two plugs.

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Illustration 21	g00323706
Installed cover (typical example) (7) Locknut (8) Fuel setting cover

4. Put fuel setting cover (8) and the gasket in position over the fuel setting screw. Install the bolt and synchronization pin (5) in the cover. Install a new seal wire.

Section 2, Electronic Unit Injector Engines

This section provides all the testing and adjustment procedures for electrical unit injector (EUI) engines. Electronic Injection Timing Calibration is not required unless the timing wheel has been removed from the camshaft or the Electronic Control Module (ECM) has been replaced.

Table 9

Tools Needed	Quantity
5P-4160 Indicator Contact Point  (1)	1
9S-9082 Engine Turning Tool  (1)	1
1U-8869 Dial Indicator  (1)	1
9U-5132 Engine Timing Tool Group	1
6V-3075 Dial Indicator  (2)	1
8S-3675 Indicator Contact Point	1
9U-5138 Setting Gauge	1
9U-5137 Magnetic Fixture	1
122-0451 Timing Fixture Rod  (3)	1
122-0449 Rod Sleeve Extension	1
9U-6272 Nylon Screw	1

( 1 )	Not included in 9U-5132 Engine Timing Tool Group .
( 2 )	Two Dial indicators each with their own procedure are available to set fuel timing. Checking or setting fuel timing with the 1U-8869 Dial Indicator is the preferred method.
( 3 )	Some 122-0451 Timing Fixture Rod Assemblies were manufactured 10 mm (0.40 inch) too long. The correct length for the rod is 124.00 mm (4.8819 inch). If the rod included with the tool group measures 134.00 mm (5.2756 inch) remove 10 mm (0.4 inch) from the end closest to the retaining ring.

Using the 1U-8869 Digital Dial Indicator (preferred method)

Illustration 22	g00322956
1U-8869 Dial Indicator

1. The digital dial indicator must be programmed to read 64.34 mm (2.5331 inch) since this is the correct dimension for electronic unit injector engines. The following steps show how to program the indicator to read 64.34 mm (2.5331 inch).

   1. Turn the indicator to the ON position by pushing the "on/off" button.

   2. Push the "in/mm" button so the display shows "mm".

   3. A negative "-" sign should be in the display window under "REV". If that space is blank, push the "+/−" button so the display shows a negative "-" sign. When this is done, the movement of the plunger into the indicator will be displayed. The display will be shown as a negative movement. The movement of the plunger out of the indicator will be displayed as a positive movement.

   4. Push the preset button and hold the preset button down until there is a flashing "P" in the upper right corner of the display. Then release the button.

   5. Push the preset button and hold the preset button down until the flashing "P" disappears and a flashing indicator bar is seen in the lower left corner of the display. Then release the button. Use the preset button so that this position is blank.

   6. Push the preset button and hold the preset button down until the flashing indicator begins flashing under the first number position. The first number position is located in the fourth position to the left of the decimal. Then release the button. Momentarily pushing the preset will cause the display number in that position to change. Use the preset until this position reads zero (0).

   7. Use the preset button to move the flashing indicator and change the display numbers until the display shows 64.34 mm (2.5331 inch). Push the preset button and hold the preset button until the flashing "P" is shown in the upper right corner of the display. Release the preset button. Momentarily push the preset button so the flashing "P" and the zeroes to the left of 64.34 mm (2.5331 inch) disappear.

   8. The indicator can now be turned off. The indicator will retain the preset number in memory. To recall the preset number, repeat Steps 1.a through 1.d.

2. Install a 5P-4160 Indicator Contact Point in the indicator stem.

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Illustration 23	g03402901
(1) 9U-5137 Magnetic Fixture (2) 122-0451 Timing Fixture Rod (3) 122-0449 Rod Sleeve Extension (4) 9U-5137 Magnetic Fixture (5) 1U-8869 Dial Indicator (6) 9U-6272 Nylon Screw

3. Install Extension Rod (2) and Extension (3) into the larger diameter tube of Fixture (1). Place the timing fixture onto Set Gauge (4) with the Rod Assembly (2) resting on the 64.34 mm (2.5331 inch) step.

4. Install Indicator (5) into Extension (3). Position the Indicator (1) into the Extension (3) so that the indicator stem has adequate travel. Tighten the Screw (6) .

5. Repeat Steps 1.a through 1.d.

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Illustration 24	g03402922

6. Momentarily push the preset button on the digital dial indicator in order to stop the "P" in the upper right-hand corner from flashing. The display should show 87.00 mm. Place the 1U-8869 Dial Indicator and the 9U-5233 Magnetic Fixture Group in the correct position on the injector. Make sure that the magnetic base of the timing fixture is on the top surface of injector follower (7) and that the extension rod is on the top surface of shoulder on fuel injector body (8) .

   Note: The top surfaces of injector follower (7) and shoulder on fuel injector body (8) must be clean and dry.

7. The digital dial indicator should now read the actual fuel timing dimension of the injector that is being checked.

8. No adjustment is necessary if the dial indicator reads the correct fuel timing dimension. Refer to the TMI (Technical Marketing Information) for the engine that is being checked. Proceed to Step 13.

9. If the dial indicator does not read the correct fuel timing dimension or the desired fuel timing dimension, proceed with Steps 10 through 14.

10. Ensure that the Indicator (5) and the Fixture Group (1) are in the correct position on the injector. Loosen the locknut for the pushrod adjustment screw.

11. Turn the adjustment screw until the desired fuel timing dimension is read on indicator (1).

    Note: Turning the adjustment screw clockwise will lower the fuel timing dimension. Turning the adjustment screw counterclockwise will increase the fuel timing dimension.

12. Tighten the adjustment screw locknut to a torque of 70 ± 15 N·m (50 ± 11 lb ft) and check adjustment again. If necessary, repeat the procedure until the adjustment is correct.

13. Remove the timing bolt from the flywheel when the fuel timing check is completed.

14. Turn the flywheel by 360 degrees in the direction of normal engine rotation. Install the timing bolt for the flywheel. Repeat the procedure for the other half of the engine.

Note: Refer to Section entitled, "443-4177 Low Height Tool Option."

443-4177 Low Height Tool Option

Use only with the Digital Dial Indicator (preferred method).

Illustration 25	g03730469

Table 10

443-4177 Parts List
No.	Quantity	Part No.	Name
1	1	443-4174	Fixture Assembly
2	2	9U-6272	Nylon Screw
3	1	443-4175	Rod Assembly

• Tool is only used with the Digital Dial Indicator (1U-8869)

• Low height tool used on No. 2 Cylinders or injector adjustment on MT4400 Trucks

• Used to test and adjust fuel systems

• Used to test and adjust fuel systems, including fuel timing, rack synchronization, and fuel setting

• Collets to hold digital dial indicator built-in

• Fits all 3516 engines

Specifications

Table 11

Length	155 mm (6.10 in)
Width	40 mm (1.57 in)
Weight	0.18 kg (.40 lb)

Using the 6V-3075 Dial Indicator (alternate method)

Refer to TMI (Technical Marketing Information) for the correct fuel setting for the engine that is being checked.

Illustration 26	g03401931

(1) 6V-3075 Dial Indicator

(2) 9U-5137 Magnetic Fixture

(3) 9U-5138 Setting Gauge

(4) 9U-6272 Nylon Screw

(5) 122-0449 Rod Sleeve Extension

(6) 122-0451 Timing Fixture Rod

1. Install the 8S-3675 Indicator Contact Point onto the indicator (1) .

2. Install Sleeve Extension (5) in the small diameter tube of Timing Fixture (2). Place Rod Assembly (6) in Sleeve Extension (5) .

3. Install Dial Indicator (1) in Sleeve Extension (5) .

4. Put Dial Indicator (1) and Timing Fixture (2) onto the Set Gauge (3). The Timing Fixture (2) should be on the top surface of the Set Gauge (3) with the Rod Assembly (6) on the bottom 64.34 mm (2.5331 inch) step.

5. Move the Dial Indicator (1) in the Sleeve Extension (5) until both needles indicate zero. Tighten Nylon Screw (4). The dial indicator has now been zeroed to a standard fuel timing dimension of 64.34 mm (2.53317 inch).

   Note: Some Dial Indicators (1) have a 0.25 mm (0.010 inch) smaller diameter extending about 4.0 mm (0.158 inch) up from the end of their stems. When zeroing these indicators in the bore of the 122-0449 Rod Sleeve Extension , the Nylon Screw (4) will contact the indicator stem on this step. This can cause the indicator to cock in the bore and result in incorrect readings. It is recommended that the 136-4587 Collet Extension and 5P-4814 Collet Clamp be used with the "stepped" indicator or that the 1U-8869 Dial Indicator be used.

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Illustration 27	g03402357
(1) 6V-3075 Dial Indicator (2) 9U-5137 Magnetic Fixture (7) Injector Follower (8) Shoulder on injector body.

6. Make sure the top surfaces of (7) and (8) are clean and dry.

7. Put Dial Indicator (1) and Timing Fixture (2) in position on the injector to be checked. Make sure that the magnetic base of the timing fixture is on the top surface of Injector Follower (7). The extension rod will rest on the top surface of Injector Shoulder (8) .

8. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch).

9. If the dial indicator pointers indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), or are within the tolerance given in 8, no adjustment is necessary. Proceed to step 13.

10. If the dial indicator pointers do not indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), continue with step 11 through step 13.

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Illustration 28	g03402450
Typical example of adjusting fuel timing.

11. Loosen the push rod adjustment screw locknut for the injector to be adjusted.

12. Turn the adjustment screw until zero is read on the dial indicator.

    Note: If the dial indicator reading is greater than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), then turn the adjustment screw counterclockwise (CCW). If the dial indicator is less than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), turn the adjustment screw clockwise (CW).

13. Tighten the adjustment screw locknut to 70 ± 15 N·m (51.63 ± 11.06lb ft). If necessary, repeat procedure until the adjustment is correct.

14. Rotate engine, re-pin the flywheel, and repeat the procedure for the other half of the engine that has not yet been adjusted.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.