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April 1997
TOOL
OPERATING
MANUAL
9U-5132 Timing and Fuel System Setting Tool Group
Using the 1U-8869 Digital Dial Indicator 8 6V-3075 Dial Indicator, Metric
(preferred method). . . . . . . . . . . . . . . . . . . . . . . 5 2
9 9U-5137 Timing Fixture
Using the 6V-3075 Dial Indicator
10 5P-7276 Container
(alternate method) . . . . . . . . . . . . . . . . . . . . . . . 7
1
Using the 6V-3075 Dial Indicator 19 9U-5736 Foam Insert
1, 3
21 5P-4160 Contact Point, 19.0 mm (.75 in)
1, 3
22 9S-9802 Engine Turning Tool
Group 1
2
Not shown.
1 3 5 3
Additional tooling required, but not part of 9U-5132.
7 8
;
S
B
A
.
C
IN
.
V
R
E
90 0
10 10
ON
/O
FF
90
80
6
m
in/
m
/A
BS
20 20
/ -
ZE
RO
80
+ ET
ES 1 0 1
70
2
PR
30 0
1 0 9
9 1
30
28
37
28 70
37
6
60 4 5 6
4
40
5
40
50 60
9 4
10
11 14
12
13
16 18
15
17
2
Crankshaft Positions for Unit Injector Lash and
Valve Lash Settings
Chart A.
Standard Rotation (Counterclockwise) As Viewed From Flywheel End
Cylinders to Check/Adjust
Correct Stroke for
No. 1 Piston at Top Intake Exhaust Injectors
Engine Center Position1 Valves Valves
3508 Compression 1-2-6-8 1-2-3-7 3-4-5-7
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
1
Put No. 1 piston at top center (TC) 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.
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 fuel timing dimension to use.
3
Section 1, Mechanical Tooling
All tools listed are included with 9U-5132 Tool
1
After any repair work is done on the fuel system or 9S-9082 Engine Turning Tool
1
Not included in 9U-5132.
Be careful when plate is put against air inlet secure the dial indicator with the 5P-4814 Clamp
opening. Due to excessive suction, the plate Collet, instead of the nylon screw, parts have been
can be pulled quickly against the air inlet made available for this purpose. In place of
opening. To avoid crushed fingers, do not put 9U-6273 Rod Sleeve Extension, order and use
fingers between plate and air inlet opening. 136-4587 Collet Extension. This extension accepts
4
c.
General Set-up Information A negative () sign should be in the display
window under REV. If that space is blank,
push the +/- button so the display shows
NOTICE (). When this is done, plunger movement
into the indicator will show on the display as
The camshafts must be correctly timed with the
negative () movement, and plunger
crankshaft before an adjustment of fuel timing is
movement out of the indicator as positive
made. The timing pins must be removed from the
(+) movement.
camshafts before the crankshaft is turned, or
damage to the cylinder block will result.
d. Push and hold the preset button down until
there is a flashing (P) in the upper right
corner of the display, and then release the
button.
Refer to the "Crankshaft Positions For Unit Injector
Lash and Valve Lash Setting" chart in this manual e. Push and hold the preset button down until
and put the engine in time. With the two crankshaft the flashing (P) disappears, and a flashing
positions given in the chart, all of the injectors can indicator bar is seen in the lower left corner
be checked or adjusted. This will make sure the of the display, and then release.
pushrod lifters are off the lobes and on the base Momentarily pushing the preset button will
cause a minus sign to appear or disappear
circles of the camshafts.
above the flashing indicator. Use the
Refer to the "Fuel Setting And Related Information" preset button so that this position is blank.
fiche for the correct fuel timing dimension to use.
The range of timing dimensions are given in the f. Push and hold the preset button down until
"Dial Indicator Setting" chart in this manual. flashing indicator begins flashing under the
first number position (fourth position to the
left of the decimal), then release.
Using the 1U-8869 Digital Dial Momentarily pushing the preset will cause
the display number in that position to
Indicator (preferred method) change. Use the preset until this position
reads zero (0).
m
/m S
in B
/A
O
R
E
Z
5
1
S
B
A
.
C
IN
.
V
E
R
FF
/O
ON
m
m
in/ BS
/A
RO
ZE
/ -
+ ET
ES
PR
1 IN
C
.
A
B
S
.
V
E
R
FF
/O
N
O
m
/m S
in B
/A
O
R
ZE
/ -
+ T
E
S
E
R
P
4
2 5
2
7
6
3 8
Illustration 2. Fuel Timing Adjustment Tools Illustration 3. Fuel Timing Tools In Position
(1) 1U-8869 Digital Dial Indicator. (2) 9U-5137 Timing (1) 1U-8869 Digital Dial Indicator. (2) 9U-5137 Timing
Fixture. (3) 9U-5138 Set Gauge. (4) 9U-6272 Nylon Fixture. (7) Injector follower. (8) Shoulder on injector
Screw. (5) 9U-6273 Rod Sleeve Extension. (6) 9U-5520 body.
Rod Assembly.
6
10. If the dial indicator does not read the correct
and/or desired fuel timing dimension, as
Using the 6V-3075 Dial
determined from the "Fuel Setting And Related Indicator (alternate method)
Information" fiche for the engine being
Refer to the "Fuel Setting And Related Information"
checked, proceed with Steps 11 through 14.
fiche for the correct fuel timing dimension to use.
40
5
40
50 60
7
NOTE: Some 6V-3075 Dial Indicators have a 0.25
40
5
40
60
8
NOTE: To obtain a positive indicator setting, move
indicator upward. This will move the large needle Illustration 5. Fuel Timing Tools In Position
(1) 6V-3075 Dial Indicator. (2) 9U-5137 Timing Fixture.
counterclockwise (CCW), or in the negative
(7) Injector follower. (8) Shoulder on injector body.
direction, decreasing the fuel timing dimension
8
NOTE: If the dial indicator reading is greater than
0.00 ± 0.20 mm, then the timing is too far advanced.
2
14. Tighten the adjustment screw locknut to
70 ± 15 N⋅m (50 ± 11 lb ft) and check
1 3
adjustment again. If necessary, repeat
procedure until the adjustment is correct.
AK
E pin (2) and plug (1) from the front drive
INT
cover (3).
Injector Synchronization
Procedure
Chart B.
Injector Synchronization Tools
Part No. Title/Description Qty
8T-2684 Rack Synchronizing Gauge 1
9
3. Turn the governor, or actuator terminal shaft, to d. To make sure the linkage is free and giving
the fuel "ON" position until the flat face of fuel the correct setting, move (flip) the linkage
stop lever (4) contacts synchronizing pin (2). and check the setting again. Put the box
This is the synchronizing position or zero end of a 9/16 or 5/8 inch combination
reference point. Hold the control linkage in this wrench over the nut and bolt that holds
position when the injectors are adjusted. control rod (6) and the bellcrank together.
Pull up on the control rod two or three times;
4. Remove the valve covers. then check the setting again.
5
6
Illustration 9. Typical Example Of Location For Gauge Illustration 10. Typical Example Of Gauge In Position On
And Control Rod Adjustment (Rocker Shaft Removed For Injector Rack (Rocker Shaft Removed For Illustration)
Illustration) (5) 8T-2684 Rack Synchronizing Gauge [12.7 mm
(5) 8T-2684 Rack Synchronizing Gauge [12.7 mm (.50 in)]. (7) Fuel injector rack.
(.50 in)]. (6) Control rod.
5. Adjust synchronization.
6. Use rack synchronizing gauge (5) and, if
a. With the fuel stop lever against the necessary, make the adjustment to the other
synchronizing pin, put 8T-2684 Rack injectors. When all adjustments have been
Synchronizing Gauge (5) on the round part made, release the actuator terminal shaft.
10
2
90 0
10 10
90
80
20 20
80
1 0 1
70
30 0
1 0 9
9 1
30
28
37
28 70
37
6
60 4 5 6
4
40
5
40
50 60
;
5
1
E
AK
INT
procedure.
8. Make a check of the fuel setting and make
adjustments, if necessary. Refer to the subject, 1. Put 6V-3075 Dial Indicator (metric) (2) and
Fuel Setting, for this procedure. 5P-7263 Contact Point (4) in 4C-8753 Extended
Collet (3). Remove the plug from the right side
of fuel setting cover (8, Illustration 15).
Fuel Setting Procedure
Fuel setting is the adjustment of the fuel setting
Group. 30
20
40
10
50
0
60
90
70
80
Chart C.
Chart Fuel Setting Tools
Part No. Title Description Qty 3
11
4. Turn synchronizing pin (5) back out a minimum
of 25 mm (1.0 in) (or remove it completely), and
then slowly move the governor or actuator
terminal shaft in the fuel "ON" direction until the
flat face of the fuel stop lever is against the end
of the fuel setting screw. With the linkage held
in this position, the dial indicator reading will be
2
the present fuel setting.
5
NOTE: Refer to "Fuel Setting And Related
70
20
40
90
60
10
6
1 0 9
0
6 5 4
1
5
0
9
60 4
37
28
40
90
1 0 1
10
70
20
two plugs, and install pin (5) back into cover (8).
2
5
70
40
30
60
2080
50
3 7
4 6
1 9 0 1 28
5
37 6 5
10 90
60 40
9
4
0
2 8
1
0
7030
0
1
90
20
10
80
70
40
30
60
2080
50
3 7
4 6
1 9 0 1 28
5
37 6 5
10 90
60 40
9
4
0
2 8
1
0
7030
0
1
90
20
10
80
12
2. Now tighten locknut (9). Be sure that the fuel
setting screw does not turn when locknut (9) is
tightened. Release the fuel linkage and again
move linkage all the way in the fuel "ON"
direction. Check the dial indicator reading
again to be sure that fuel setting is still correct.
10
10
13
NOTE: Because some technicians prefer to
Section 2, Electronic secure the dial indicator with the 5P-4814 Clamp
Unit Injector Engines Collet, instead of the nylon screw, parts have been
Chart A.
9U-5132 Timing and Fuel System Setting Tool Group For
EUI Engines
Part No. Description
1
The electronic control module (ECM) produces
5P-4160 Contact Point, [19 mm (.75 in) (for use with high voltage. To prevent personal injury make
digital indicator)]
sure the ECM is not powered and the unit
8S-3675 Contact Point, 3.0 mm (.12 in) injector solenoids are disconnected.
1
9S-9082 Engine Turning Tool
1
1U-8869 Digital Dial Indicator (used with preferred
method)
Refer to "Crankshaft Positions For Unit Injector
9U-5137 Timing Fixture
Lash and Valve Lash Setting" chart, in this manual,
9U-5138 Set Gauge for the specifications to put the engine in time.
3
Two dial indicators, each with their own procedure, are
available to set fuel timing. Checking or setting fuel timing
with the 1U-8869 Digital Dial Indicator is the preferred method.
14
f.
Using the 1U-8869 Digital Dial Push and hold the preset button down until
flashing indicator begins flashing under the
g.
E
R
O
N
/O
F
F
.
C
5 R
E
V
.
O
N
/O
FF
ZE
R
O
/A
B
S
/ -
+ T
E
S
E
R
6
movement out of the indicator as positive
(+) movement.
3
2
e. Push and hold the preset button down until
4
the flashing (P) disappears, and a flashing
indicator bar is seen in the lower left corner
of the display, and then release.
Momentarily pushing the preset button will
cause a minus sign to appear or disappear
above the flashing indicator. Use the
preset button so that this position is blank.
15
3. Install 122-0451 Extension Rod Assembly (2) 7. The digital dial indicator should now read the
and 122-0449 Rod Sleeve Extension (3) into actual fuel timing dimension of the injector
larger diameter tube of 9U-5137 Timing Fixture being checked.
(1). Place the timing fixture on 9U-5138 Set
Gauge (4) with the rod assembly on the 64.34 8. If the dial indicator reads the correct fuel timing
follower (7) and shoulder (8) are clean and dry. adjustment screw counterclockwise (CCW)
will increase the fuel timing dimension.
FF
O
N/
O
m
/m
in BS
/A
RO
14.
ZE
/ -
16
NOTE:
Using the 6V-3075 Dial Some 6V-3075 Dial Indicators have a 0.25
10
90 0
10
indicators, or that the 1U-8869 Digital Dial Indicator
90
80
20 20
80 be used.
5 70
30
1 0 1
28
0
1 0 9
9 1
28
30
70
37 37
6
60 4 5 6
4
40
5
40
50 60
6
5. Make sure the top surfaces of injector follower
2
4
90 0
10 10
90
80
20 20
80
1 0 1
5 70
30
60
28
37
9
6
0
1 0 9
4 5 6
1
4
28
37
30
70
40
5
40
50 60
7
1. Install 8S-3675 Contact Point [3.0 mm (.12 in)]
on 6V-3075 Dial Indicator (metric) (5). 8
17
7. The dial indicator pointers must indicate 11. After all injectors are checked/adjusted,
0.00 ± 0.20 mm. remove the timing bolt from the flywheel.
8. If the dial indicator pointers indicate 0.00 ± 0.20 12. Rotate engine, re-pin the flywheel, and repeat
mm, no adjustment is necessary. Proceed to procedure for other half.
next injector to be checked and repeat
procedure starting from Step 3. If the dial
indicator pointers do not indicate 0.00 ± 0.20
mm, continue with Steps 9 and 10.
0
90 10
10 90
80 20
20 80
1 0 1
70 1
0
9
30
30 28
9 0 1
28
70
37 37
6 4
60 4 5
5
6
40
40 60
50
18
NOTES
19
For information on service tools or shop supplies
contact Caterpillar Service Technology Group on:
or