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FUEL SYSTEM

TESTING AND ADJUSTING

ENGINE ROTATION
SAE standard engine crankshaft rotation is
counterclockwise as seen from the flywheel end of the
engine.
FINDING TOP CENTER POSITION FOR NO. 1
PISTON
Tools Needed:
9S9082 Engine Turning Tool.

2. Timing bolt. 4. 9S9082 Engine Turning Tool.


4.

1. Cover. 2. Timing bolt. 3. Timing bolt hole In


flywheel housing.
1.

Remove cover (1) and the timing hole plug from


the right front side of the flywheel housing. On
some engines there is a cover and timing bolt
hole located on the left side, also.

2.

Put timing bolt (2) [long bolt that holds cover (1)
on the flywheel housing] through the timing hole
in the flywheel housing. Use the 9S9082 Engine
Turning Tool (4) and 1/2" drive ratchet wrench to
turn the engine flywheel in the direction of
normal engine rotation until the timing bolt
engages with the threaded hole in the flywheel.

NOTE: When the actual stroke position is identified, and


the other stroke position is needed, it is necessary to
remove the timing bolt from the flywheel and turn the
flywheel 3600 in the direction of normal engine rotation.

NOTE: If the flywheel is turned beyond the point that the


timing bolt engages in the threaded hole, the flywheel
must be turned opposite normal engine rotation
approximately 30 degrees. Then turn the flywheel in the
direction of normal engine rotation until the timing bolt
engages with the threaded hole. The reason for this
procedure is to make sure the play is removed from the
gears when the No. 1 piston is put on top center.
3.

The intake and exhaust valves for the No. 1


cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be
moved by hand. If the rocker arms can not be
moved and the valves are slightly open, the No.
1 piston is on the exhaust stroke.
Make
reference to charts
for CRANKSHAFT
POSITIONS FOR INJECTOR TIMING AND
VALVE CLEARANCE SETTING to find the
correct cylinder(s) to be checked/adjusted for the
stroke position of the crankshaft when the timing
bolt has been installed in the flywheel.

Remove the valve cover for the No. I cylinder


head.

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FUEL SYSTEM

TESTING AND ADJUSTING


timing pins (2) from their storage positions.

CAMSHAFT TIMING
Timing Check

5.

Install timing pins (2) through holes (1) in the


engine block and into the groove (slot) in
camshaft (4) on each side of the engine. For the
engine to be timed correctly, the timing pins
must fit into the groove of each camshaft.

6.

If timing pins (2) do not engage in the grooves of


both camshafts, the engine is not in time, and
one or both camshafts must be adjusted.

7.

Both camshafts are adjusted the same way.


See TIMING ADJUSTMENT for the procedure to
put the camshafts in time with the crankshaft.

Tools Needed:
9S9082 Engine Turning Tool.
1.

Remove rear camshaft cover (3) from both sides


of the engine.

NOTICE
If a camshaft is out of time more than 18 degrees
(approximately 1/2 the diameter of timing pin out of
groove), the valves can make contact with the
pistons. This will cause damage that will make
engine repair necessary.

1. Timing hole. 2. Timing pin. 3. Cover.


2.

Make reference to FINDING TOP CENTER


POSITION FOR NO. I PISTON.

Timing Adjustment
Tools Needed:
9S9082 Engine Turning Tool.
6V3010 Puller Group.
9S9089 Two 1/2 - 13 NC Bolts 114.3 mm (4.50
in.) long.
5P1076 Two Washers (Hardened).

NOTE: Since both rear camshaft covers have to be


removed to check the timing, it is not necessary to
remove No. 1 valve cover to find the compression stroke
when timing bolt is installed in flywheel.
3.

With timing bolt installed in flywheel, look at rear


of camshaft to see if timing groove (slot) is
visible on the camshaft. If it is visible, No. 1
piston is on the compression stroke. If it is not
visible, feel the backside of the camshaft for the
groove. If the groove is at the back of the
camshaft, the flywheel will have to be turned
3600 to put No. 1 piston on the compression
stroke.

NOTE: Before any timing adjustments are made, the


timing must be checked first to see if adjustment is
necessary.
See subject TIMING CHECK for this
procedure.
After TIMING CHECK procedure is complete,
timing bolt will be engaged in flywheel with No. 1 piston
at top center (TC) position.

2. Timing pin. 4. Camshaft (L.H.).


4.

1. Bolt. 2. Rocker shaft.

With timing bolt installed in flywheel with No. 1


piston now on compression stroke, remove
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FUEL SYSTEM

1.

TESTING AND ADJUSTING

Remove all valve covers on the same side of the


engine that camshaft needs adjustment. Now
loosen bolts (1) [that hold all rocker shafts (2) to
valve cover bases] until all rocker arms are free
from the injectors and the valves.

camshaft drive gear (7). Remove the bolts and


plate from the left camshaft drive gear.

NOTE: The above procedure must be done before


camshaft drive gear (7) is pulled off the camshaft taper.

6. Bolt. 7. Drive gear. 8. Accessory drive gear for


hydramechanical protective system.
4.

Install the 6V3010 Puller Group, two 9S9089


Bolts and two 5P1076 Washers. Loosen drive
gears (7) from the taper on the camshafts.
Remove the tooling and the gears.

5.

Remove timing pin(s) (10) from the storage


position (under the rear camshaft covers) on
each side of the engine.

3. Cover.
2.

Remove camshaft drive gear cover (3) from the


left side of the flywheel housing. Remove
hydramechanical shutoff control group (5) and
the shutoff drive (4) from the right side of the
flywheel housing.

NOTE: See DISASSEMBLY AND ASSEMBLY install the


hydramechanical protective system.

9. Timing hole. 10, Timing pin.


6.

REMOVE HYDRAMECHANICAL PROTECTIVE


4. Hydramechanical shutoff drive. 5. Hydramechanical
shutoff control group.
3.

Remove bolts (6) and gear (8) from the right

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Turn the camshafts until timing pins (10) can be


installed through timing holes (9) and into the
grooves (slots) in the camshafts.

FUEL SYSTEM

TESTING AND ADJUSTING


and timing pins.

7. Drive Gear.
7.

Install camshaft drive gears (7) as follows:


a.

Put camshaft drive gears (7) in position on


the camshafts.

b.

Use hand pressure to turn and hold


camshaft drive gears (7) in the direction of
normal engine rotation. This removes all
gear
clearance
(backlash)
between
camshaft drive gears (7) and the idler gear.

c.

10. Timing pin. 11. Cover.

Install the plate (on left side of engine) and


drive gear (8) for the hydramechanical
protective system (on right side of engine)
to hold camshaft drive gears (7) to the
camshaft.

d.

Tighten the bolts in steps to a torque of 100


15 N m (75 11 lb. ft.).

e.

Hit the face of the plate and drive gear and


tighten the bolts to a torque of 100 15
N m (75 11 lb. ft.).

f.

Again hit the face of the plate and drive


gear and again tighten the bolts to a torque
of 100 15 N m (75 11 lb. ft.).

11.

Install the 5M6213 Plug in the flywheel housing


timing hole. Remove the engine turning pinion
and install the cover and gasket.

12.

Make sure the rocker arms are engaged


correctly with the push rods and tighten the bolts
to hold all of the rocker shafts in position.

13.

Make adjustments to the valves and injector


timing. See VALVE CLEARANCE SETTING
and FUEL TIMING for the correct procedures.

START UP PROCEDURE
Use this procedure when an engine is started for
the first time after work is done on the fuel system or
governor.

NOTE: If necessary, do Step 7f until the bolts hold


torque (can not be moved) to make sure the drive gears
are in full contact with the taper on the camshafts.

1.

Disconnect the air inlet system


turbochargers.

from

the

2.

Have a person in position near each


turbocharger air inlet with a piece of steel plate
large enough to completely cover the
turbocharger air inlet.

8.

Install the gasket and cover on the left side of


the flywheel housing.

Be careful when plate is put against air inlet opening.


Due to excessive suction, the plate can be pulled quickly
against air inlet openings. To avoid crushed fingers, do
not put fingers between plate and air inlet opening.

9.

Install the hydramechanical protective system on


the right side of the flywheel housing.

3.

10.

Remove timing pins (10) from the camshafts.


Remove the timing bolt from the flywheel
housing. Install timing pins (10) in their storage
positions. Install covers (11) over the camshafts
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Start the engine. If the engine starts to run too


fast or runs out of control, immediately put the
steel plates against the turbocharger air inlets.
This will stop the air supply to the engine, and
the engine will stop.

FUEL SYSTEM

ENGINE

3508
3512
3516

ENGINE

3508
3512
3516

TESTING AND ADJUSTING


CRANKSHAFT POSITIONS FOR FUEL TIMING AND VALVE CLEARANCE SETTING
STANDARD ROTATION (COUNTERCLOCKWISE)
- as Viewed From Flywheel End
CORRECT STROKE
CYLINDERS TO CHECK/ADJUST
FOR NO.1 PISTON
VALVES
INJECTORS
AT TOP CENTER
POSITION*
INTAKE
EXHAUST
COMPRESSION
EXHAUST
COMPRESSION
EXHAUST
COMPRESSION
EXHAUST

1-2-6-8
3-5-4-7
1-3-6-7-10-12
2-4-5-8-9-11
1-2-5-7-8-12-13-14
3-4-6-9-10-11-15-16

1-2-3-7
4-5-6-8
1-4-5-6-9-12
2-3-7-8-10-11
1-2-3-4-5-6-8-9
7-10-11-12-13-14-15-16

3-4-5-7
1-2-6-8
2-4-5-8-9-11
1-3-6-7-10-12
3-4-6-9-10-11-15-16
1-2-5-7-8-12-13-14

REVERSE ROTATION (CLOCKWISE)


- as Viewed From Flywheel End
CORRECT STROKE
CYLINDERS TO CHECK/ADJUST
FOR NO.1 PISTON
AT TOP CENTER
VALVES
INJECTORS
POSITION*
COMPRESSION
EXHAUST
COMPRESSION
EXHAUST
COMPRESSION
EXHAUST

INTAKE
1-3-4-8
2-5-6-7
1-3-4-6-7-12
2-5-8-9-10-11
1-2-5-6-7-8-13-14
3-4-9-10-11-12-15-16

EXHAUST
1-2-7-8
3-4-5-6
1-4-5-8-9-12
2-3-6-7-10-11
1-2-3-4-5-6-9-10
7-8-11-12-13-14-15-16

2-5-6-7
1-3-4-8
2-5-8-9-10-11
1-3-4-6-7-12
3-4-9-10-11-12-15-16
1-2-5-6-7-8-13-14

*Put No. 1 piston at top center (TC) position and make identification for the correct stroke. Make reference to FINDING
TOP CENTER POSITION FOR NO. 1 PISTON. After top center position for a particular stroke is found and adjustments
are made for the correct cylinders, remove the timing bolt and turn the flywheel 3600 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.

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FUEL SYSTEM

TESTING AND ADJUSTING


2.Install the 8S3675 Contact Point on the dial indicator
stem.

FUEL TIMING
Tools Needed:
6V3139 Timing and Fuel Setting Tool Group.
8S3675 Contact Point, 3.0 mm (.12 in.) long.
6V3075 Dial Indicator (Metric).
6V3117 Set Gauge.
6V3118 Timing Fixture.
9S9082 Engine Turning Tool.

3.

Install 6V3075 Dial Indicator (2) in the collet of


6V3118 Timing Fixture (4).

4.

Put the dial indicator and timing fixture on


6V3117 Set Gauge (1) with the angle of the
timing fixture on the top surface and the
extension rod on the bottom step.

5.

Move the dial indicator in the collet until the


pointers indicate zero. Now move the dial
indicator in the collet until the large pointer
indicates setting shown in the DIAL INDICATOR
SETTING CHART (if other than zero setting) and
tighten the collet.

NOTICE
The camshafts must be correctly timed 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 be the result.

1.

See chart CRANKSHAFT POSITIONS FOR


FUEL TIMING AND VALVE CLEARANCE
SETTING 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 the pushrod lifters are off the
lobes and on the base circles of the camshafts.

NOTE: See the Fuel Setting And Related Information


Fiche for the correct fuel timing dimension to use.
Before a check or an adjustment of the fuel
timing can be made, the tooling must be set to the
correct dimension as follows:

*DIAL INDICATOR SETTING CHART


Fuel Timing
Dial Indicator
Dimension mm
Setting mm
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
*See Fuel Setting Information for the correct fuel timing
dimension to use.

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FUEL SYSTEM
6.

Make sure the top surfaces of injector follower


(5) and shoulder (6) are clean and dry.

7.

Put 6V3075 Dial Indicator (2) and 6V3118


Timing Fixture (4) in position on the injector to be
checked. Make sure the angle of the timing
fixture is on the top surface of follower (5) and
the extension rod is on the top surface of injector
shoulder (6) as shown in illustration.

8.

The dial indicator pointers must indicate 0.00


0.20 mm.

9.

If the dial indicator pointers indicate zero, or are


within the tolerance given in Step 8, no
adjustment is necessary. Proceed to Step 14.

10.

If the dial indicator pointers do not indicate 0.00


0.20 mm, do Steps 11 through 14.

11.

Loosen the push rod adjustment screw locknut


for the injector to be adjusted.

12.

Put 6V3075 Dial Indicator (2) and 6V3118


Timing Fixture (4) in position on the injector to be
adjusted. Make sure that both edges of the
angle of the timing fixture sets flat on the top
surface of follower (5), and the extension rod is
on the top surface of injector shoulder (6).

TESTING AND ADJUSTING

13.

Turn the adjustment screw until zero is read on


the dial indicator. Tighten the adjustment screw
locknut to a torque of 70 15 N-m (50 11 lb. ft.)
and check adjustment again. If necessary, do
this procedure again until the adjustment is
correct.

14.

Remove the timing bolt from the flywheel when


the fuel timing check is completed.

INJECTOR SYNCHRONIZATION
Tools Needed:
6V3119 Rack Synchronizing Gauge.
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). The procedure for adjustment of
injector synchronization is as follows:

123

FUEL SYSTEM

1.

2.

TESTING AND ADJUSTING

The top bolt that holds cover (3) in position is


synchronizing pin (2). Remove synchronizing pin
(2) and plug (1) from the front drive housing. DO
NOT destroy seal or remove cover (3).

3.

Turn the governor or actuator terminal shaft to


the fuel "ON" position until the flat face of fuel
stop lever (4) contacts synchronizing 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.

5.

With the fuel stop lever against the


synchronizing
pin,
put
6V3119
Rack
Synchronizing Gauge (5) on the round part of the
injector rack between the injector body and the
end of the rack. Use a screwdriver and make an
adjustment of control rod (6). Turn the screw on
control rod (6) one "click" at a time until rack
synchronizing gauge (5) just Fits between the
injector body and the shoulder at the end of the
rack. Remove the screwdriver from control rod
(6) so no pressure is on the linkage while the
setting is checked with rack synchronizing
gauge(5). Any pressure on the linkage with the
screwdriver will not give a correct indication
when the setting is checked with the rack
synchronizing gauge. To make sure the linkage
is free and giving the correct setting, move (flip)
the linkage and check the setting again. Put the
box end of a 9/16" or 5/8" combination wrench
over the nut and bolt that holds control rod (6)
and the bellcrank together. Pull up on the control
rod two or three times; then check the setting
again.

Remove the washer from synchronizing pin (2)


and install it into the threaded hole where plug
(1) was removed. Tighten synchronizing pin (2).

124

FUEL SYSTEM

TESTING AND ADJUSTING


Fuel Setting Check
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 injector racks.

Before the fuel setting is checked, the injectors must be


correctly synchronized. See the subject INJECTOR
SYNCHRONIZATION.
After the injectors are
synchronized correctly, leave the synchronizing pin in
place for the procedure that follows.
1.

6.

Use rack synchronizing gauge (5) and, if


necessary, make the adjustment to the other
injectors, When all adjustments have been
made, release the actuator terminal shaft.

7.

Install the valve covers.

8.

Make a check of the fuel setting and make


adjustments if necessary. See FUEL SETTING
AND RELATED INFORMATION FICHE for this
procedure.

FUEL SETTING
Tools Needed:
6V3139 Timing and Fuel Setting Tool Group.
5P4814 Collet.
6V3075 Dial Indicator (metric).
5P7263 Contact Point, 76.2 mm (3.00 in.) long.
6V3119 Rack Synchronizing Gauge 12.7 mm (.50
in.).

125

Put 6V3075 Dial Indicator (2) with 5P7263


Contact Point (4) in 5P4814 Collet (3). Remove
the plug from the right side of fuel setting cover
(8).

FUEL SYSTEM
2.

TESTING AND ADJUSTING

Move the governor or actuator terminal shaft in


the fuel "ON" direction until the flat face of fuel
stop lever (6) contacts synchronizing pin (5).
Hold the linkage in this position.

NOTE:
See FUEL SETTING AND
INFORMATION for the correct fuel setting.

RELATED

5.

If fuel setting is correct, remove the dial indicator


and synchronizing pin (5). Install the two plugs,
and install pin (5) back into cover (8).

6.

If fuel setting needs adjustment, go on to Fuel


Setting Adjustment.

Fuel Setting Adjustment

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

3.

4.

1.

Cut the seal wire and remove fuel setting cover


(8) and the gasket. Loosen locknut (7) and (with
fuel stop lever still held against end of the fuel
setting screw) turn the fuel setting screw in or
out until the correct reading is on the dial
indicator.

2.

Now tighten locknut (7). Be sure that the fuel


setting screw does not turn when the locknut (7)
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.

3.

Remove the dial indicator and synchronizing pin


(5), then install the two plugs. (5), then install the
two plugs.

Install the dial indicator and collet (3) in the


threaded hole as shown. When the contact point
seats against fuel stop lever (6), slide the dial
indicator in or out until the indicator reads zero.
Now tighten collet (3) just enough to hold
indicator at this position.

Turn synchronizing pin (5) back out a minimum


of 25 mm (1 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
the present fuel setting.

126

FUEL SYSTEM

TESTING AND ADJUSTING


ENGINE SPEED MEASUREMENT

4.

The 6V3 121 Multitach Group can measure


engine speed from a tachometer drive on the engine. It
also has the ability to measure engine speed from visual
engine parts in rotation.

Put fuel setting cover (8) and gasket in position


over the fuel setting screw and install bolt and
synchronizing pin (5) in cover. Install a new seal
wire.

Special Instruction, Form No. SEHS7807 is with


the 6V3121 Multitach Group and gives instructions for
the test procedure.

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