Using the 223-2454 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI){0374, 0599, 0701, 0706, 1251, 1252, 1254} Caterpillar

Using the 223-2454 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI){0374, 0599, 0701, 0706, 1251, 1252, 1254}

Usage:

120H 124

Engine: Commercial with Mechanical Unit Injection 3126
Engine: Machine with Mechanical Unit Injection 3126
Engine: Truck with Mechanical Unit Injection 3116
Engine:Truck with Mechanical Unit Injection 3114 3116 3126
Engine:Commercial with Mechanical Unit Injection 3114 3116
Engine:Machine with Mechanical Unit Injection 3114 3116
Engine:Machine 3114 3126
Engine:Truck with Hydraulic Electronic Unit Injection (HEUI) 3116 3126
Engine:Truck with Mechanical Unit Injection 3114
Generator Set: 3114 3116
Industrial Engine: 3114 3116 3126
Machine Engines: 3114 3116 3126
Marine Engine: 3116 3126

Introduction

European Union Compliant, CE Marked

Important Safety Information

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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

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Illustration 2	g02166423
Personal Protection/Important Information

Hazard Avoidance

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Crushing Hazard (foot)

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Crushing Hazard (hand)

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Pinch Point

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Working Load Limit (WLL) mark - Do not use lifting device unless load identification (WLL) markings are legible.

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Safety Alert - Do not use C-Frame lifting device for anything other than the intended purpose.

Additional Contact Information

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

USA: 1-800-542-8665, Option 1

International: 1-309-578-7372

General Information Section

Introduction

The 223-2454 Tool Group is used to check and perform all on-engine fuel system adjustments, including injector synchronization, timing and fuel setting (rack) on Cat 3114, 3116 and 3126 Engines equipped with mechanical unit injectors (MUI). The group also includes tools to remove and install the unit injectors and adjust the valves.

The new group replaces the 1U-6680, 9U-7305, 128-8822 Tool Groups. . The new tools are available individually to update former groups at a considerable cost savings, and offers the advantage of simplified tooling which provides more accurate adjustments in less time.

Features of 223-2454 Tool Group

Injector Synchronization

The new 128-9640 Injector Synchronizing Fixture Group replaces the former 9U-7276 Linkage Spring-Loading Tool and 9U-7275 Support. The new fixture features a spring-loaded plunger which pushes directly on the end of the number 1 injector rack head. It is used with the 9U-7270 Synchronizing Gauge Block (3.5 mm) or 220-0123 Synchronizing Gauge Block (3.0 mm) , which can be attached directly to the fixture.

The 128-8823 Long Nose Locking Pliers are used to clamp directly to the control rod (in between two rocker stands), and is used as a lever to actuate the control rod in the fuel-on and fuel-off directions. This ability to actuate the rack in both directions is necessary for consistent readings when using the new procedure. The pliers replace the former 9U-7264 Linkage Lever .

Timing

The 123-4940 Magnetic Timing Indicator Fixture , used with the direct-reading 1U-8869 Programmable Digital Position Indicator and associated tooling, moves quickly from injector to make checking or adjusting the timing quick and easy.

Note: The 123-4940 Magnetic Timing Indicator Fixture replaced the original 9U-7308 Magnetic Base , in order to adapt to an engine change to large-diameter elephant's foot rocker connections.

Note: New high-quality, deep offset, box wrenches are also part of this group, making timing adjustment easier.

Fuel Setting

The 128-8827 Fuel Setting Pin is an approved version of the 9U-7271 Pin . The 128-8827 Fuel Setting Pin is made easier to use in the very tight space that is available. It works on all versions of governors.

The 130-2711 Holding Tool is used to hold the fuel setting pin against the governor housing face. It is a redesigned version of the older 1U-6681 Holding Tool (part of the 1U-6680 Tool Group), with modifications to make it easier to insert and allow alternate handle locations. The 130-2711 Holding Tool replaces the 9U-7265 Clamp Assembly (part of 9U-7305) which would not adapt to the later "Type V" version governor.

Valve Adjustment

The new double-ended (intake/exhaust) 123-4941 Valve Setting Feeler Gauge has special, short, offset 45 degree legs. This design greatly simplifies setting valves on newer engines with a larger diameter elephant's foot, and works on any engine with 0.38 mm (.015 inch) intake and 0.64 mm (.025 inch) exhaust valve lash.

New high-quality, deep offset box wrenches make valve adjustments easier.

Injector Installation

The 1U-8013 Hex Bit Driver (5 mm) is included to tighten the injector hold-down bolt which helps to reduce combustion gas leaks.

Tooling Nomenclature

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Illustration 3	g03129658
223-2454 Tool Group Refer to Tooling Nomenclature for 223-2454 Tool Group chart for item identification.

The tools shown in this chart are required to complete the synchronization and adjusting procedures provided in this manual and in the machine's Service Manual.

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Table 1
Nomenclature for 223-2454 Tool Group
				Tools Required to Upgrade Former Groups
Item	Part No.	Description	Qty.	9U-7305	1U-6680
Synchronization Tooling
1	128-9640 128-8706	Injector Synchronization Fixture Group Spring Plunger (serviceable part)	1	X	X
2	9U-7270 220-8706	Sync Gauge Block, 3.5 mm Sync Gauge Block, 3.0 mm	1		X
3	9U-5120	Solenoid Spanner Wrench	1
4	1U-8869	Digital Position Indicator	1
5	128-8823	Locking Long Nose Pliers, 150 mm (6.0 inch) long	1	X	X
6	1U-6675	Spring Compressor	6
7	8T-4177	Bolt, Spring Compressor	6
8	9U-7282 9U-6272	Indicator Fixture Group Nylon Screw (serviceable part)	1
9	8C-4984	Bolt, Indicator Stand	1
10	9U-7263	Contact Point ( 18.5mm (.73 inch) long	1		X
Fuel Timing Tooling
11	9U-7269	Timing Gauge Block	1		X
12	123-4940²	Magnetic Base Group	1	X²	X
13	128-8824	Deep Offset Wrench, 16 mm and 18 mm	1	R	R
14	128-8825	Deep Offset Wrench, 17 mm and 19 mm	1	R	R
15	9U-7274	Contact Point, 85 mm (3.35) long	1
Miscellaneous Engine Tools
16	5P-0302³	Injector Removal Bar	1
17	123-4941³	Valve Setting Gauge (feeler gauge for adjusting valves)	1	X	X
18	194-3542³	Hex Socket Bit Driver, 5 mm	1	R	R
Fuel Setting Tooling
19	130-2711	Fuel Setting Holding Tool	1	R
20	136-4149	Governor Connection Pliers	1
21	128-8827	Fuel Setting Pin Assembly	1	R	X
22	1U-7523³	Pin Insert Pilot (use with 128-8827 Pin Assembly)	1		X
23	1U-7299	Adjustment (FRC) Wrench (Type V, 1994 and later trucks)	1	X	X
24	1U-7300	T-Handle Wrench, 3mm hex (Type V, 1994 and later trucks)	1	X	X
25	1U-6673	Injector Sync and FRC Adjust Wrench (all models, except Type V and later trucks)	1
---	6V-7145	Case	1
---	128-8828	Foam Insert Group	1	R	R
---	NEEG2688	Decal		R	R
---	NEHS0610	Tool Operating Manual	1	X	X

(X) Essential tools for new products

(R) Recommended for improved tools

(2) Some of the former 9U-7305 Groups used the new 123-4940 Magnetic Base. Check your specific tool group.

(3) Refer to the appropriate engine Service Manual for additional information on use of these tools.

Tool Placement

The following illustration shows the placement of tools in the foam insert.

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Illustration 4	g03131320
Placement Of Tools in the 223-2454 Tool Group. Refer to Tooling Nomenclature for item identification.

Note: One dial indicator is included in the 223-2454 Tool Group , which is all that is required to perform the procedures described in this manual.

Operation Section

Injector Synchronization

Injector synchronization is the setting of all injector racks to a reference position so each injector gives the same amount of fuel to each cylinder. This is done by setting each injector rack to the same position while the control linkage is in a fixed position (called the synchronizing position).

Synchronizing injectors are accomplished in this procedure by placing the Sync Gauge Block between the injector rack head pin and the injector body of number 1 injector.

Note: There is no adjustment screw in the control linkage lever for number 1 injector, since it is the reference point for all the other injectors. Therefore, no synchronizing adjustment is made for the number 1 injector.

Always synchronize an injector after it has been removed and reused/replaced. If the number 1 injector is reused or replaced, synchronization on ALL injectors must be checked and adjusted.

Tooling and Equipment

The tools shown in Chart A "Injector Synchronization Tooling" are required to complete the synchronizing procedure.

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Table 2
Chart A. Injector Synchronization Tooling
Part No.	Description	Qty.	Item?
128-9640	Injector Synchronization Fixture Group	1	1
9U-7270	Sync Gauge Block	1	2
220-0123	Sync Gauge Block	1	2
9U-5120	Spanner Wrench (solenoid)	1	3
1U-8869	Position Indicator (digital)	1	4
128-8823	Locking Long Nose Pliers 150 mm (6.0 inch) long	1	5
1U-6675	Spring Compressor	6	6
8T-4177	Bolt, Spring Compressor	6	7
9U-7282	Indicator Fixture Group	1	8
8C-4984	Bolt, Indicator Stand	1	9
9U-7263	Contact Point 18.5 mm (.728 inch)	1	10
1U-6673	Adjustment Wrench	1	25

(?) Refer to nomenclature chart at the beginning of this manual for item identification.

Optional Removal of Rocker Arm Assembly

While synchronizing the injectors, removal of rocker arm assemblies will provide greater access and visibility of control linkage and injector rack. This procedure includes steps for removing rocker arm assemblies for both the number 1 injector and the injector being checked. However, removal of rocker arm assemblies is optional for the injector being checked. If the person performing the work is very familiar with the procedures and hardware involved, it is possible to check and adjust injector synchronization with the rocker mechanism in place.

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NOTICE

Since visibility of control linkage and injector is very limited with rocker arm assembly in place, care must be taken to make sure that the tooling is located properly and the procedure is completed correctly.

A complete set of 1U-6675 Spring Compressors is supplied in the 223-2454 Tool Group . This is useful when rebuilding an engine (or when a control linkage has been replaced) to allow all the injectors to be synchronized without the rocker arms in the way.

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NOTICE

The injector spring must be slightly compressed to allow free movement of the injector rack. Either the rocker arm assembly or the 1U-6675 Spring Compressor (6) MUST be installed on all injectors to prevent internal damage to the injectors.

Note: If rocker arm assemblies are removed, checking valve clearance and fuel timing is recommended.

Synchronizing Procedure

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Illustration 5	g03348060
Fuel Shut-Off Solenoid (energize to run). (1) Governor (2) Fuel Shut-Off Solenoid (3) 9U-5120 Spanner Wrench

Stop the engine and turn OFF electrical system.

Remove fuel shut-off solenoid (2) using a 9U-5120 Spanner Wrench (3). Removing the solenoid allows free movement of injector rack control linkage during injector synchronization.

Remove the cylinder head valve cover.

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Illustration 6	g03348069
Remove number 1 Rocker Arm Assembly (4) Bolts (5) Rocker Arm Assembly

Remove four bolts (4) and number 1 cylinder rocker arm assembly (5). Remove the push rods (intake, exhaust, and injector), making sure to mark their location. The push rods should be reinstalled in their original locations to minimize readjustment of the valves.

Note: To prevent accidental disassembly, hold rocker arm assembly (5) level when removing from the engine

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Illustration 7	g03349035
Install Spring Compressor on number 1 Injector. (6) 1U-6675 Spring Compressor (7) 8T-4177 Bolt

Apply a small amount of clean engine oil to the top of the injector and install 1U-6675 Spring Compressor (6) and 8T-4177 Bolt (7) into the rocker arm bolt hole.

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NOTICE

The injector spring must be slightly compressed to allow free movement of the injector rack. Either the rocker arm assembly or the 1U-6675 Spring Compressor (6) MUST be installed on all injectors to prevent internal damage to the injectors.

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Illustration 8	g03349052
Install 128-9640 Injector Synchronization Fixture Group (8)

Install 128-9640 Injector Synchronization Fixture Group (8) by threading the two pins of the fixture group into the rocker arm bolt holes. Tighten the threaded pins finger tight.

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NOTICE

To prevent engine damage, the 9U-7270 or 220-0123 Sync Gauge should always be attached to the 128-9640 Injector Synchronization Fixture Group with the chain. This will prevent the gauge from being left inside the engine.

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Illustration 9	g03349059
Attach Locking Pliers (9) to Control Rod. (B) Fuel-Off Direction (C) Fuel-On Direction

Attach 128-8823 Locking Pliers (9) firmly to the control rod, as shown. The pliers should be attached at an approximate 45 degree angle.

Note: Slight marring (damage) of the control rod by the locking pliers is acceptable. Do not clamp the locking pliers right next to one of the control shaft bearing supports.

Note: Make sure that there is no interference between the pliers and the sides of the rocker arm assemblies. Also, make sure that the ends of the locking pliers do not contact the cylinder head bolt under the control rod. The locking pliers and control rod must actuate freely and smoothly throughout the rack travel range.

Make sure injector rack stop pin (11), the square shoulder on the injector body (10), and rack head (12) are clean.

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Illustration 10	g03349146
Clean The Area Around The Injector Rack (10) Square Shoulder On Injector Body (11) Injector Rack Head Stop Pin (12) Rack Head

Install proper Sync Gauge Block (13) .

Locate injector part number (see illustration for part number location).

Determine proper Sync Gauge Block using part number and Chart B.

Push locking pliers (9) and rotate the control rod to the "fuel-on" direction (so the rack head pulls away from the injector).

Place the gauge block with the 3.0mm/3.5 mm wide "finger" between injector rack head stop pin (11) and the square shoulder on injector body (10) .

Release the control rod (rotate to "fuel off"), allowing gauge block (13) to be held tightly and squarely against the injector body.

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Table 3
Chart B Sync Gauge Block/Injector Cross Reference
Injector Part No	Sync Gauge Block Used
127-8207	220-0123 (3.0 mm)
127-8213
140-8413
4P-2995
127-8228
127-8225
127-8216
173-4647
127-8220
127-8218
127-8222
162-0212
162-0218
127-8234
127-8209
127-8205
127-8211
127-8226

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Illustration 11	g03349175
(13) Install Sync Gauge Block (8) 128-9640 Injector Synchronization Fixture Group

If desired, remove the rocker arm assembly for the injector to be checked. This step is optional. If the rocker arm assembly is not removed, proceed to Step 11.
1. Apply a small amount of clean engine oil to the top of the injector and install 1U-6675 Spring Compressor (6) .
1. Tighten bolt (7) and compress the injector spring.

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Illustration 12	g03349197
(15) Remove Bolt and Install Indicator Group

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Illustration 13	g03349207
Injector Synchronization Tooling (16) 9U-7282 Indicator Fixture Group (17) 8C-4984 Bolt (18) 9U-7263 Contact Point (19) 1U-8869 Digital Position Indicator (Top-New Version, Botton-Former Version) (20) 9U-6272 Nylon Screw (Part of 9U-7282) (21) Lever (Part of 9U-7282)

Remove bolt (15) nearest the injector to be checked.

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Illustration 14	g03349215
Injector Synchronization Tooling Installed (16) 9U-7282 Indicator Fixture Group (17) 8C-4984 Bolt (19) 1U-8869 Digital Position Indicator

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Illustration 15	g03349221
Injector To Be Checked (10) Square Shoulder On Injector Body (11) Injector Rack Head Stop Pin (12) Rack Head (21) Lever (22) Rack Bar

Install 9U-7263 Contact Point (18) 18.5 mm (0.73) long into 1U-8869 Digital Position Indicator (19). Center the indicator in 9U-7282 Indicator Fixture Group (16) and tighten 9U-6272 Nylon Screw (20) .
Note: The entire face of the 1U-8869 Digital Position Indicator can be rotated for better visibility.

Make sure the end face of rack bar (22) on injector to be checked is clean. Install assembled 9U-7282 Indicator Fixture Group (16) and 1U-8869 Digital Position Indicator (19) with 8C-4984 Bolt (17) (M8 x 1.25 x 150 mm long) where bolt (15) was removed in Step 11. Lever (21), on indicator fixture group, must contact and be centered on the end face of rack bar (22). Tighten bolt (17) .

Turn indicator (19) to ON and make sure that the indicator units are set to mm, and ± travel direction is correct (the plunger traveling out of the indicator should read positive).
Note: Make sure that the indicator is able to travel in both directions before proceeding to the next step. If necessary, reposition the indicator in the indicator fixture group.

Using locking pliers (9), rotate control rod in the "fuel-off" direction until injector rack head stop pin contacts the shoulder on the injector body.

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NOTICE

The contact between the injector rack head stop pin and the shoulder on the injector body is a solid stop. DO NOT put excessive force on it once contact is made. Excessive force will cause damage to the control assembly.

While maintaining the position of the control rod, with indicator (19) ON, press the "zero-set" button. This defines the zero rack ("fuel-off") position.

Allow the linkage to spring back. Again rotate the control rod link to the "fuel-off" position and check the zero position of the indicator.

Note: Repeat this step two or three times to confirm the reading. If the readings are not consistent, check for binding.

Repeat this sequence several times, by pressing the zero set button as necessary, until it is certain that a consistent zero reading is being obtained.

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Illustration 16	g03349280
Injector Assembly Control Linkage (24) Clamp Assembly (25) Injector Lever

Using locking pliers (9), rotate the control rod in the "fuel-on" direction. Now, release locking pliers (9). This makes sure the springs and bearings of the control linkage are in their "normal" positions.

Note: Using the method described in Step 20 lets the spring plunger push the linkage against the gauge block, providing the most consistent results.

Rotate the control rod in the "fuel-off" direction with the locking pliers and then release. Indicator (19) should now read 3.50 ± 0.02 mm, if using the 9U-7270 Sync Gauge , or 3.0 ± 0.02, if using the 220-0123 Sync Gauge.

Note: Repeat this step two or three times to confirm the reading. If the readings are not consistent, check for binding.

If the indicator reading is within the specified tolerance, go to STEP 25.

If the indicator reading is not within the specified tolerance, go to the next step.

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Illustration 17	g03425000
Synchronizing Injector (Side View) (10) Square Shoulder on Injector Body (11) Injector Rack Head Stop Pin (21) Lever (22) Rack Bar (25) U-Shaped Lever (26) Setscrew (28) Clamp

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NOTICE

DO NOT loosen screws holding clamps (28) to control shaft. Loosening the clamps will cause poor engine performance and may damage the engine.(The screws can be identified as those with socket heads filled with sealant.) Clamps (28) are factory preset onto the shaft.

Use 1U-6673 Wrench (14) to loosen lock nut and turn setscrew (26) clockwise until indicator (19) reads 3.50 ± 0.02 mm, if using the 9U-7270 Sync Gauge , or 3.0 ± 0.02, if using the 220-0123 Sync Gauge . Turning the adjusting screw clockwise increases reading; counterclockwise decreases reading. Tighten the locknut while holding setscrew (26) in position.

Check the adjustment by rotating the control rod, in the "fuel-off" direction, with the locking pliers and then release. If the indicator does not read 3.50 ± 0.02 mm, if using the 9U-7270 Sync Gauge , or 3.0 ± 0.02, if using the 220-0123 Sync Gauge , re-adjust setscrew (26) again.

After the injector is synchronized, remove indicator fixture group (16) and indicator (19). Install bolt (15) and tighten to 25 ± 25 Nm (18.5 ± 5 lb ft).

If the rocker arm assembly was removed for the injector that was checked, remove spring compressor (6). Install the rocker arm assembly (follow standard torque specifications). Make sure that the push rods are properly seated in the rocker arms and lifters.

Synchronize the remaining injectors as necessary.

When synchronization procedure is complete, remove synchronization fixture (8) and sync gauge block (13) from the number 1 injector. Remove locking pliers (9) .

If fuel setting is to be checked, refer to the "Fuel Setting" section in this manual.

If the fuel setting is known to be correct, remove spring compressor (6) from number 1 injector. Install the rocker arm assembly and tighten the bolts to 25 ± 7 Nm (18.5 ± 5 lb ft). Make sure that the push rods are properly seated in the rocker arms and lifters are in their original positions.

Check valve clearance and fuel timing for cylinders that had rocker arms removed. Refer to the "Fuel Timing" section in this manual, and "Valve Clearance" in the Engine Service Manual.

With the engine stopped and the engine electrical system shut OFF, install the fuel shut-off solenoid. Install the valve cover

Fuel Setting

Tooling and Equipment

The tools shown in Chart C "Fuel Setting Tooling" are required to complete the fuel setting procedure.

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Table 4
Chart C Fuel Setting Tooling
Part No	Description	Qty	Item ⁽¹⁾
9U-5120	Spanner (solenoid) Wrench	1	3
1U-8869	Digital Position Indicator	1	4
9U-7282	Indicator Fixture Group	1	8
9U-6272	Nylon Screw	1	---
130-2711	Holding Tool	1	19
136-4149	Governor Connection Pliers	1	20
1U-7299	Adjustment Wrench	1	23
1U-7300	T-Handle	1	24
1U-6673	Wrench	1	25
128-8827	Fuel Setting Pin Assembly	1	21

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^( 1 )

Refer to nomenclature chart, at the beginning of this manual for item identification.

Fuel Setting Check

Fuel setting is the adjustment of the fuel setting screw to provide a specified injector rack position measured on number 1 injector rack bar. The fuel setting screw limits the power output of the engine by setting the maximum travel of all injector racks.

Before the fuel setting is checked, injectors must be correctly synchronized. Refer to "Injector Synchronization" in this manual.

Note: This procedure is illustrated with the number 1 cylinder rocker arm assembly installed. Greater access to the injector rack and control linkage is provided when the number 1 rocker arm assembly is removed. Instructions for removing the rocker arm assembly are given in the "Injector Synchronization" section. Checking valve clearance and fuel timing is recommended after the rocker arm assembly is reinstalled.

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NOTICE

The injector spring must be slightly compressed to allow free movement of the injector rack. Either the rocker arm assembly, or the 1U-6675 Spring Compressor , MUST be installed on all injectors to prevent internal damage to the injectors.

With engine stopped and the engine electrical system shut off, remove the fuel control solenoid to allow free movement of injector rack control linkage during fuel setting.

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Illustration 18	g03425113
(15) Remove Bolt

Remove bolt (15) from the inlet manifold.

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Illustration 19	g03425120
Fuel Setting Tooling (16) 9U-7282 Indicator Fixture Group (17) 8C-4984 Bolt (18) 9U-7263 Contact Point (19) 1U-8869 Digital Position Indicator (Former and Current Style) (20) 9U-6272 Nylon Screw (Part of 9U-7282) (21) Lever (Part of 9U-7282

Install 1U-8869 Digital Position Indicator (19) in 9U-7282 Indicator Fixture Group (16). Tighten nylon setscrew (20) .

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Illustration 20	g03425143
Fuel Setting Indicator (Former Style) Installed (16) 9U-7282 Indicator Fixture Group (19) 1U-8869 Digital Position Indicator

Make sure the end of rack bar (22) is clean. Install assembled 9U-7282 Indicator Fixture Group (16) and indicator (19). Bolt of indicator group (17) is threaded into hole where bolt (15) was removed from the engine valve base. Position the indicator group so that the indicator stem is parallel to the rack bar of the number 1 injector group so that the indicator stem is parallel to the rack bar of the number 1 injector (perpendicular to the rocker arm shafts). Lever (21) must contact the end face of rack bar (22) .

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Illustration 21	g03425159
Number 1 Injector (10) Square Shoulder On Injector (11) Injector Rack Head Stop Pin (12) Rack Head (21) Lever (22) Rack Bar

Remove clip (39) that keeps sleeve (40) in position between governor (1) and cylinder head (41) .

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Illustration 22	g03425424
(1) Governor (39) Clip (40) Sleeve (41) Cylinder Head

Note: Do not use hard-jaw pliers to move sleeve (40). Damage of the sleeve will result in damage to the wiper seal in cylinder head (41). This damage will occur when sleeve (40) is retracted to allow access to governor link connection pin (42) .

With 136-4149 Governor Connection Pliers , slide sleeve (40) away from governor (1) into cylinder head (41) .

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Illustration 23	g03425439

Install 128-8827 Fuel Setting Pin Assembly (43) into link pin (42) of the governor output shaft. When properly installed, equal lengths of small diameter on pin (43) will extend from both ends of link pin (42) .

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Illustration 24	g03425456
Governor Viewed From Rear Side (1) Governor (40) Sleeve (41) Cylinder Head (42) Link Pin (43) 128-8827 Fuel Setting Pin Assembly (44) 130-2711 Holding Tool (47) Face of Governor

Note: 1U-7523 Pin Insert Pilot is included in this tool group. It is used with the 128-8827 Fuel Setting Pin Assembly to align the links and insert pin (42). The 1U-7523 is only used if the governor has been disconnected.

Note: For "Type V" version governors, the 128-8827 Fuel Setting Pin Assembly (43) must be inserted from the front of the link pin, as shown. For all other governors, the pin can be inserted from the rear of the governor.

Install 130-2711 Holding Tool (44) to hold fuel setting pin assembly (43) tightly against governor housing calibration face (47) .

Note: If the holding tool is installed too tightly, the governor can be deflected away from the engine, making the fuel setting adjustments incorrect.

Note: If the small diameter of calibration pin (43) does not contact governor calibration face (47), remove air line connected to the governor fuel ratio control (FRC). Use FT-1906 Fabricated Tester (or other REGULATED air supply) and apply 105 kPa (15 psi) air pressure to the FRC. Pressurizing the FRC will prevent it from restricting the movement of the governor output, thus allowing the calibration pin to contact governor calibration face (47). After the fuel setting check is completed, remove the FT-1906 Fabricated Tester and install the air line to the FRC.

Turn indicator (19) to ON. Make sure that the indicator units are set to mm and ± travel direction is correct (plunger traveling out of indicator should read positive).

Firmly push rack head (12) of number 1 injector, by hand, toward the injector until rack head stop pin (11) touches square shoulder of injector body (10), and hold in this position. The number 1 injector is now at "fuel-off". Press the "zero-set" button on the indicator to define zero rack at this position.

Note: If rocker arm assembly is installed, rotate the control shaft in the "fuel-off" direction (against spring pressure). Rotate the shaft until ALL injector levers are in the shut-off position before pressing the "zero-set" button. This makes sure that number 1 injector rack is at zero.

Note: The 128-8823 Locking Long Nose Pliers may be used to actuate the control linkage throughout this procedure. (Refer to the description in the "Injector Synchronization" section for additional information.)

Release number 1 rack head (or control rod, if rocker arms were not removed), then push it back into zero rack. Repeat several times to make sure that a consistent zero point has been established.

Push down on rack lever (46) and quickly release it. Flip the lever in this manner several times to make sure that there is smooth movement on the injector rack.

Refer to the "Engine Information Plate" or the "Fuel Setting and Related Information" area of TMI for the correct fuel setting.

If reading on digital indicator is within ± 0.25 mm of the specified fuel setting, go to Step 17.

If the fuel setting needs adjustment, use 1U-6673 Wrench or 1U-7299/1U-7300 Adjustment Wrench to loosen the locknut of fuel setting screw (45). Adjust fuel setting screw (45) until the indicator reading matches the correct fuel setting. Turn screw (45) CCW for more fuel (greater fuel setting) or CW for less fuel (lower fuel setting).

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Illustration 25	g03425471

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NOTICE

Do not loosen screw holding clamp assembly (15) to the control rod. This screw can be identified by sealant in socket head. Clamp assembly (15) is factory preset onto the rod. Loosening the clamp will cause poor performance and may damage the engine.

With the 1U-6673 or 1U-7299/1U-7300 Wrench, hold fuel setting screw (45) in position and tighten the locknut. Recheck the fuel setting by flipping (pushing down and releasing) lever (46). Check the reading on the indicator again. If the fuel setting is not correct, repeat Steps 15 and 16 until the correct settings are obtained.

Remove holding tool (44) and fuel setting pin assembly (43) from the engine. Use 136-4149 Governor Connection Pliers to slide sleeve (40) back into the governor (lubricate the O-ring seal on the sleeve with engine oil, if needed). Install clip (39) .

Remove indicator fixture group (16) and indicator (19). Install bolt (15) into engine valve base and tighten to 25 ± 7Nm (18.5 ± 5 lb ft.

Note: If the rocker arm assembly was removed for this procedure, remove 1U-6675 Spring Compressor. Install rocker arm assembly. Make sure that push rods are properly seated in the rocker arms and lifters. Check valve clearance and fuel timing. Refer to "Valve Clearance" and "Fuel Timing" sections in the engine service manual.

With engine stopped and the engine electrical system turned OFF, install the fuel shut-off solenoid. Install the valve cover.

Fuel Timing

Tooling and Equipment

The tools shown in Chart D, "Fuel Timing Tooling" are required to complete the fuel timing procedure.

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Table 5
Chart D.Fuel Timing Tooling
Part No	Description	Qty	Item ⁽¹⁾
1U-8869	Digital Position Indicator	1	4
9U-7269	Timing Gauge Block	1	11
123-4940	Magnetic Base Group	1	12
9U-6272	Nylon Holding Screw	1	-----
128-8824	Wrench, 16 mm and 18 mm	1	13
128-8825	Wrench, 17 mm and 19 mm	1	14
9U-7274	Contact Point, 85 mm (3.35 in) long	1	15

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^( 1 )

Refer to the nomenclature chart, at the beginning of this manual, for item identification.

Indicator Calibration

Before a check or an adjustment of the fuel timing dimension can be made, the 1U-8859 Digital Position Indicator (19) must be calibrated. Refer to the following calibration procedure. There is a procedure for both the former indicator group and the current indicator group.

Initial Calibration Setup

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Illustration 26	g03425485
Calibrate Injector Timing Tooling (19) 1U-8869 Digital Position Indicator (20) 9U-6272 Nylon Holding Screw (Part of 9U-7282) (29) 123-4940 Indicator Fixture Group (30) 9U-7269 Timing Gauge Block (31) 9U-7274 Contact Point

Install 85mm (3.35 inch) long 9U-7274 Contact Point (31) on the digital position indicator stem.

Insert digital position indicator (19) in 123-4940 Magnetic Base Group (29) until it stops. Tighten nylon holding screw (20) .

Make SURE the magnetic bottom of indicator fixture group (29) is clean (NO particles sticking to magnet). Also make sure both the top and the shoulder of 9U-7269 Timing Gauge Block are clean.

Push (fully retract) indicator contact point (31) into the digital position indicator and hold it.

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NOTICE

The magnets in the 123-4940 Indicator Fixture Group (29) are very powerful and can snap into place when attaching the base assembly to any metallic surface. To avoid damaging the digital position indicator, hold the indicator contact point in the retracted position while attaching the base.

Carefully place the indicator and base assembly on timing gauge block (30). Once the base firmly attaches to the gauge block, release (extend) contact point (31) .

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Illustration 27	g03425489
Indicator Group (Current Style) (19) 1U-8869 Digital Position Indicator (20) 9U-6272 Nylon Holding Screw (Part of 9U-7282) (29) 123-4940 Indicator Fixture Group (30) 9U-7269 Timing Gauge Block (31) 9U-7274 Contact Point

Preset (calibrate) the indicator group. Refer to the appropriate procedure based on the digital indicator group (former style or current style) in use.
Note: Check the travel of the dial indicator. As the contact point is pressed in towards the dial, the reading on the indicator should decrease.

Presetting the Indicator Group (Former Style)

Program 1U-8869 Digital Position Indicator (19) to a preset value of 62 mm (2.4 inch) (the dimension of 9U-7269 Timing Gauge Block ), as follows:

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Illustration 28	g03425531
Indicator Group (Former Style) (19) 1U-8869 Digital Position Indicator (20) 9U-6272 Nylon Holding Screw (Part of 9U-7282) (29) 123-4940 Indicator Fixture Group (30) 9U-7269 Timing Gauge Block (31) 9U-7274 Contact Point

Turn the indicator ON by pressing the ON/OFF button (4) .

Press the in/mm button (2) to change the display to millimeters.

Indicator bar (6) should be in the display window under REV. If the space is blank, select +/- button (1) so the display shows the indicator bar, as shown.

Press and hold the preset button (3) until there is a flashing (P) on the upper right corner of the display. When the flashing (P) appears, release the button.

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Illustration 29	g03425556
1U-8869 Digital Position Indicator (Former Style) (1) Positive/Negative Select Button (2) Inch/Millimeter Select Button (3) Preset Button (4) On/Off Button (5) Zero/ABS Button (6) Indicator Bar

Note: Press and hold the preset button to change the positions of the flashing cursor. Also, press and release the preset button to change the value of the number.

Press and hold the preset button (3) until the (P) stops flashing, and a flashing indicator bar is seen in the lower left corner of the display. When the indicator bar appears, release the button. Pressing and releasing the preset button will cause a minus sign to appear or disappear above the flashing indicator. Use the preset button to make this position blank.

Press and hold the preset button (3) until the flashing indicator begins to flash under the first number position (fourth position to the left of the decimal), then release the button. Pressing and releasing the preset button will cause the display number in that position to change.

Use the preset button to move the flashing indicator and change the value of the display numbers to read 0062.00 mm (2.4 inch).

Press and hold the preset button until the flashing (P) shows in the upper right corner of the display, and then release the button. Momentarily push the preset button so the flashing (P) and the zeros to the left of 62.0 mm (2.4 inch) disappear.

Note: To recall a preset number, repeat Steps 1 through 4, then press and release the preset button so the flashing (P) and the zeroes to the left of 62.0 mm (2.4 inch) disappear.

Turn the indicator OFF. The indicator will retain the preset number in memory (only one preset number is retained).

Presetting the Indicator Group (Current Style)

Program 1U-8869 Digital Position Indicator (19) to a preset value of 62.0 mm (2.4 inch) (the dimension of 9U-7269 Timing Gauge Block ), as follows:

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Illustration 30	g03425489
Indicator Group (Current Style) (19) 1U-8869 Digital Position Indicator (20) 9U-6272 Nylon Holding Screw (Part of 9U-7282 (29) 123-4940 Indicator Fixture Group (30) 9U-7269 Timing Gauge Block (31) 9U-7274 Contact Point

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Illustration 31	g03425585
1U-8869 Digital Position Indicator (Current Style) (1) Inch/Millimeter Select Button (2) Positive/Negative Select Button (3) Zero/ABS Button (4) Preset Button (5) Tolerance Button (6) On/Off Button

Turn the indicator ON by pressing the ON/OFF button (6) .

Press in/mm button (1) to change the display to millimeters.

Press and hold the preset button (4) until the (+ or -) sign flashes. If the indicator displays (-), reset to (+).

Note: Press preset once to go into programming mode. Press and hold to advance position. Press and release to increase number.

Press and hold the preset button until the first character begins to flash. Release the button when character flashes.

Press and release the preset button to set the value of the character.

Repeat Steps 4 and 5 until the display numbers read 0062.00 mm (2.4 inch).

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Illustration 32	g03425597
Correctly Entered Display Numbers

Press and hold the preset button until (P) starts flashing.

Press and release the preset button. The indicator is now preset and should read +0062.00 mm (2.4 inch).

Measuring Fuel Timing Setting

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Table 6
Chart E-1 3114 Crankshaft Positions For Fuel Timing Setting and Valve Lash Setting
SAE Standard (Counterclockwise) Rotation Engines As Viewed From The Flywheel End
Item	Cylinders to Adjust
Check/adjust with Number 1 piston on TC compression stroke?
Injectors	3 - 4
Inlet Valves	1 - 2
Exhaust Valves	1 - 3
Check/adjust with Number 1 piston on TC exhaust stroke²
Injectors	1 - 2
Inlet Valves	3 - 4
Exhaust Valves	2 - 4
Firing Order	1 - 3 - 4 - 2

Note: The number 1 injector is not checked or adjusted with the number 1 piston on Top Center (TC) compression stroke. Be certain that the number 1 piston is TC on the correct stroke (compression or exhaust) to check or adjust each cylinder (injector). Refer to the topic "Finding Top Center for number 1 Piston" in this manual.

Note: After TC position for a particular stroke is found and the cylinders are checked or adjusted, remove timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC on the exhaust stroke. Install timing bolt in the flywheel and check or adjust the remaining cylinders (injectors).

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Illustration 33	g03425608

Note: Refer to Testing and Adjusting Engine Valve Lash - Inspect/Adjust, for more information on adjusting valves.

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Table 7
Chart E-2 3116, 3126 Crankshaft Positions For Fuel Timing Setting and Valve Lash Setting
SAE Standard (Counterclockwise) Rotation Engines As Viewed From The Flywheel End
Item	Cylinders to Adjust
Check/adjust with Number 1 piston on TC compression stroke?
Injectors	3 - 5 - 6
Inlet Valves	1 - 2 - 4
Exhaust Valves	1 - 3 - 5
Check/adjust with Number 1 piston on TC exhaust stroke²
Injectors	1 - 2 - 4
Inlet Valves	3 - 5 - 6
Exhaust Valves	2 - 4 - 6
Firing Order	1 - 5 - 3 - 6 - 2 - 4

Note: The number 1 injector is not checked or adjusted with the number 1 piston on Top Center (TC) compression stroke. Be certain that the number 1 piston is TC on the correct stroke (compression or exhaust) to check or adjust each cylinder (injector). Refer to the topic "Finding Top Center for number 1 Piston" in this manual.

Note: After TC position for a particular stroke is found, and the cylinders are checked or adjusted, remove timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC on the exhaust stroke. Install timing bolt in the flywheel and check or adjust the remaining cylinders (injectors).

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Illustration 34	g03425620
3116, 3126 Cylinder and Valve Location

Note: Refer to Testing and Adjusting, Engine Valve Lash - Inspect/Adjust for more information on adjusting valves.

With the crankshaft positions given in Charts E, Crankshaft Positions for Fuel Timing Setting, all of the injectors can be checked or adjusted. This will make sure that push rod lifters are off the lobes and on base circles of the camshaft.

Note: Always rotate the engine crankshaft with four large bolts on the front of the crankshaft. Do not use eight small bolts on the front of the crankshaft pulley.

Note: If the rocker arm assemblies are removed and installed prior to checking the fuel timing dimension, rotate the crankshaft two complete revolutions to allow rocker arms to properly seat on injectors before checking the timing dimension.

Put number 1 piston at top center (TC) position and determine the stroke (compression or exhaust). Refer to Finding Top Center Position for Number 1 Piston, in the engine service manual.

Make sure the top surfaces of the injector tappet (32) and shoulder (34) are clean and dry.

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Illustration 35	g03425630
Fuel Timing Dimensions (32) Injector Tappet (33) Adjustment Screw (34) Shoulder (A) Fuel Timing Dimension

Remove indicator and magnetic base from the gauge block. Push (fully retract) indicator contact point (31) into the digital position indicator.

Hold the contact point in the retracted position and carefully position it on top of injector tappet (32) for the injector to be checked.

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NOTICE

The magnets in the 123-4940 Indicator Fixture Group (29) are very powerful and can snap into place when attaching the base assembly to any metallic surface. To avoid damaging the digital position indicator, hold the indicator contact point in the retracted position while attaching the base.

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Illustration 36	g03425623
Timing Fixture Installed (Current Style)

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Illustration 37	g03425658
Timing Fixture (Former Style) (19) 1U-8869 Digital Position Indicator (33) Adjustment Screw

Note: The shoulder of the injector is not very wide. It is easy to set the contact point on the cylinder head and not the shoulder of the injector. Make sure that the contact point is sitting on the injector shoulder (34) .

Release (extend) the indicator plunger and carefully position indicator contact point (31) on the shoulder of the injector (34). Make sure that it moves freely and the contact point does not bind on the injector spring.

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Illustration 38	g03425676
(32) Injector Tappet (34) Shoulder

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NOTICE

After the timing tooling has been positioned on an injector, do not rotate the engine. The timing tooling could be damaged.

Indicator (19) will display the fuel timing dimension directly.

Note: Refer to the engine information plate or the Fuel Setting and Related Information section in TMI for the correct fuel timing dimension. The indicator must show the correct fuel timing dimension within ± 0.20 mm (0.008 inch). Each injector must be checked separately and adjusted, if necessary.

If indicator (19) displays the correct dimension, or is within the ±0.20 mm (0.008 inch) checking tolerance, no adjustment is necessary. Proceed to Step 14.

If indicator (19) does not show the correct timing dimension, use the 128-8824 or the 128-8825 Wrench to loosen the locknut on the push rod adjustment screw (33) for the injector to be adjusted.

Turn adjustment screw (33) until indicator (19) displays the correct fuel timing dimension. Tighten locknut to 25 ±7 Nm (18.0 ± 5.0 lb ft) and check adjustment again. If necessary, repeat this procedure until the adjustment is correct.

Sequence for checking the fuel timing dimensions. Refer to explanation at the beginning of this section.
1. Check and adjust fuel timing dimension on half of cylinders with the timing bolt installed.
1. Remove the timing bolt and timing tooling.
1. Rotate flywheel counterclockwise 360 degrees (1 revolution) and install timing bolt.
1. Place timing tooling on remaining injectors and check the fuel timing dimension. Refer to Chart E, Crankshaft Positions for Fuel Timing Setting.

Note: Half of the cylinders can be checked in each engine rotation. For more information, refer to Chart E.

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

Finding Top Center Position for Number 1 Piston

Tooling and Equipment

The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.

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Table 8
Chart F Tooling For Finding Top Center (TC) Position
Part No	Description	Qty	Item ⁽¹⁾
8T-4177	Bolt, Spring Compressor	1	7

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^( 1 )

Refer to the nomenclature chart at the beginning of this manual for item identification.

Procedure

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Illustration 39	g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel Housing

Note: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.

Remove plug from the timing hole (36) on the front of the flywheel housing.

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NOTICE

Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.

Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.

Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.

Remove the cylinder head valve cover.

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Illustration 40	g03425694
Valve Cover Removed

The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).

Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.

After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.

Removal and Installation of Unit Fuel Injectors

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Table 9
Chart G Injector Removal and Installation Tools
Part No	Description	Qty	Item ⁽¹⁾
5P-0302	Injector Removal Bar	1	16
194-3542	Hex Socket Bit Driver, 5 mm	1	18

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^( 1 )

Refer to nomenclature chart, at the beginning of this manual for item identification.

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Illustration 41	g03425701
Unit Fuel Injector (48) Bolt (49) O-Rings

Note: Not all injectors use a bottom O-ring.

Removal

Remove injector hold down bolt (48) .

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NOTICE

Do not pry on the injector hold down bracket. Damage to the injector could occur. The injector has a notch on the side opposite the rack that is used for prying the injector loose.

Use the 5P-0302 Injector Removal Bar to loosen the fuel injector.

Rotate the injector to disengage the injector rack from the control linkage.

Remove the injector and inspect it to be sure the O-rings (49) were removed with the injector.

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NOTICE

Do not move the fuel injector rack with the injector spring slightly compressed. Damage to the injector could occur.

Installation

Note: Not all injectors use a bottom O-ring.

With O-rings in place and lubricated with engine oil, position the injector in the head and then rotate it to engage the injector rack with the control linkage.

Push down on the top of the injector so that the O-ring seals slide into the bore of the cylinder head. Be sure that the injector is fully seated in the bore before installing the bolt.

Note: Do not use the bolt to pull the injector down into the cylinder head.