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catmastertech
catmastertech, Technician
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The dial test indicator for setting the fuel injectors..valve timing

Customer Question

Can you please tell me how to use the dial test indicator for setting the fuel injectors and valve timing on the 3516 V16 engine?

XXXXX XXXXX
Submitted: 5 years ago.
Category: Heavy Equipment
Expert:  catmastertech replied 5 years ago.

Here is the fuel timing instructions. I think this is what you are asking for.

 

Fuel Injector Timing

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.

Note: Ensure that the engine is in time. Refer to Testing And Adjusting, "Camshaft Timing".

Note: Refer to Testing and Adjusting, "Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting". All of the injectors can be checked or adjusted with the crankshaft positions that are given in the chart. This check will make sure that the pushrod lifters are off the lobes and on the base circles of the camshafts.

Refer to the TMI (Technical Marketing Information) for the correct fuel timing dimension to use.

Tools Needed


5P-4160 Indicator Contact Point 1
1U-8869 Dial Indicator 1
9U-5138 Setting Gauge 1
9U-5233 Magnetic Fixture Group 1
9S-9082 Engine Turning Tool 1


The digital dial indicator needs to 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, set the digital dial indicator for 87.00 mm. Use the following steps in order to program the indicator to read 87.00 mm.

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

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

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.

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.

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.

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).

Use the preset button to move the flashing indicator and change the display numbers until the display shows 0087.00 mm. 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 disappear.

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.

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

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

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graphic


Adjustment of fuel timing tools

(1) 1U-8869 Dial Indicator

(2) 9U-5233 Magnetic Fixture Group

(3) 9U-5138 Setting Gauge



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.

Repeat Steps 1.a through 1.d.

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graphic


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



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 (4) and that the extension rod is on the top surface of shoulder on fuel injector body (5) .
Note: In order to ensure an accurate fuel timing dimension, the top surfaces of injector follower (4) and shoulder on fuel injector body (5) must be clean and dry.


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

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 12.

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

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.

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.


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

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.

 

Thanks for using Just Answer. If you need more information, please replay to this post.

If you find my answer helpful, please remember to "accept" it.

catmastertech, Technician
Category: Heavy Equipment
Satisfied Customers: 1893
Experience: 19 years Cat, 3 years Case
catmastertech and 3 other Heavy Equipment Specialists are ready to help you
Customer: replied 5 years ago.
Hi Don

This is part of the information required. However, the information i require is: where are the timing pins located that you specify in your first paragraph.

I am aware of having to turn the engine 360 degrees, to pick up the valve and injector timing. I have been used to setting engines using feeler guages, not dial test indicators. I am confused re how to position the dial test indicator for setting the injectors and the valve timing.

I should be grateful if you could respond at your earliest convenience and if at all possible provide me with a diagram/picture.

I thank you in anticipation of your assistance in this matter.

Regards
Expert:  catmastertech replied 5 years ago.

Flywheel timing pin is in the usual location by the starter mounting hole. The engine may have one on each side, just in case the starter motor is in the way.

 

Here is a picture of the cam pin.

 

graphic

 

Location of timing pins (typical example)

(1) Timing hole

(2) Timing pin

(3) Slot in the camshaft for the timing pin




Remove rear camshaft covers from both sides of the engine.

Find the top center position for the number one piston. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for the correct procedure.


Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No. 1 valve cover in order to find the compression stroke. Both rear camshaft covers must be removed in order to check the timing.


When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing ring is visible, then the No. 1 piston is on the compression stroke. If the timing ring is not visible, feel the back of the camshaft for the groove. If the groove is at the back of the camshaft, the flywheel must be turned by 360 degrees in order to put the No. 1 piston on the compression stroke.

When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression stroke, remove timing pins (2) from the storage positions.

Install the timing pins through timing holes (1) on each side of the engine. Install the timing pins into groove (3) in the camshaft on each side of the engine. In order to time the engine correctly, the timing pins must fit into the groove of each camshaft.

If the timing pins do not engage in the grooves of both camshafts, the engine is not in time, and one or both camshafts must be adjusted.

Both camshafts are adjusted in the same manner. Refer to "Timing Adjustment" for the procedure to put the camshafts in time with the crankshaft.


--------------------------------------------------------------------------------

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.


--------------------------------------------------------------------------------

Table 1
Counterclockwise Rotation (Standard) from the Flywheel End of the Engine
Cylinders to Check/Adjust
Engine Correct Stroke For No. 1 Piston At Top Center Position (1) Inlet Valves Exhaust Valves Injectors
3508 Compression 1-2-6-8 1-2-3-7 2-3-4-7
Exhaust 3-4-5-7 4-5-6-8 1-5-6-8
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
( 1 ) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, "Finding the Top Center Position for the No 1 Piston". Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the 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 2
Clockwise Rotation (Reverse) from the Flywheel End of the Engine
Cylinders To Check/Adjust
Engine Correct Stroke For No. 1 Piston At Top Center Position (1) Inlet Valves Exhaust Valves Injectors
3508 Compression 1-3-4-8 1-2-7-8 2-6-7-8
Exhaust 2-5-6-7 3-4-5-6 1-3-4-5
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 3-4-9-10-11-12-15-16
Exhaust 3-4-9-10-11-12-15-16 7-8-11-12-13-14-15-16 1-2-5-6-7-8-13-14
( 1 ) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, "Finding the Top Center Position for the No 1 Piston". Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center (TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.

Above is the sequence to follow to set the valves.

 

I will do a seperate post for the valves.

 

 

Expert:  catmastertech replied 5 years ago.

Note: When the(NNN) NNN-NNNNValve Lash Gauge Group is used, it is not necessary for you to remove the rocker arm shaft assemblies. The valves must be fully closed when the adjustment is made. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".


Installation

Assemble the(NNN) NNN-NNNNIndicator Extension and the(NNN) NNN-NNNNIndicator Contact Point on the(NNN) NNN-NNNNDial Indicator or on the(NNN) NNN-NNNNDial Indicator .

--------------------------------------------------------------------------------

graphic



--------------------------------------------------------------------------------

Illustration 4 g00286279
(NNN) NNN-NNNNGauge Support

(1) Knurled knob


--------------------------------------------------------------------------------

graphic



--------------------------------------------------------------------------------

Illustration 5 g00286280

(2) Valve cover base rear bolt hole


--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 6 g00286281

(3)(NNN) NNN-NNNNIndicator Contact Point

(4) Top edge of the valve bridge



Install the(NNN) NNN-NNNNGauge Support in the rear bolt hole (2). The rear bolt hole is located in the valve cover base. Adjust contact point (3) on the top edge of valve bridge (4) .

--------------------------------------------------------------------------------

graphic



--------------------------------------------------------------------------------

Illustration 7 g00286283

(5) Adjustment screw



Loosen the locknut for the adjustment screw. Loosen the adjustment screw (5) by several turns.

Apply a force of 5 N (1 lb) to 45 N (10 lb). Push down on the top contact surface of the valve bridge. Zero the indicator.

Turn adjustment screw (5) in the clockwise direction until the dial indicator reads 0.038 mm (0.0015 inch). This measurement is equal to turning the adjustment screw 20 to 30 degrees clockwise after the screw contacts the end of the valve.

--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 8 g00286364

(6)(NNN) NNN-NNNNBridge Nut Socket



Hold the adjustment screw with the(NNN) NNN-NNNNBridge Nut Socket (6) in order to tighten the locknut to 30 ± 4 N·m (22 ± 3 lb ft). You may use a sliderule torque computer in order to determine the torque wrench dial reading for the different extensions. Refer to Special Instruction, SEHS7150, "Snap On Torque Computer".

Valve Lash Adjustment


The Electronic Control Module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and do not come in contact with the fuel injector solenoid terminals while the engine is running.



Note: Adjust the valve bridges before you make the valve lash adjustments.

Table 2 Valve Lash Setting: Engine Stopped
Valves Gauge Dimension
Inlet
0.50 mm (0.020 inch)
Exhaust
1.00 mm (0.040 inch)



Ensure that the number 1 piston is at the top center position. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

The number 1 piston should be at the top center position of the correct stroke. Make adjustments to the valves according to the chart: Refer to Testing and Adjusting, "Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting".
Note: Tap each rocker arm on the top of the adjustment screw before you make any adjustments. Use a soft hammer. Make sure that the lifter roller is seated against the base circle of the camshaft.


--------------------------------------------------------------------------------

graphic

--------------------------------------------------------------------------------

Illustration 9 g00286365

(1)(NNN) NNN-NNNNGauge Support

(2)(NNN) NNN-NNNNIndicator Contact Point



Install the(NNN) NNN-NNNNGauge Support (1). Use the(NNN) NNN-NNNNDial Indicator or use the(NNN) NNN-NNNNDial Indicator. Use the(NNN) NNN-NNNNIndicator Contact Point (2). Install the tool in the rear bolt hole. The rear bolt hole is located on the valve cover base.

--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 10 g00286366

(3)(NNN) NNN-NNNNWrench

(4)(NNN) NNN-NNNNTorque Wrench

 

Part two in next post.

 

Expert:  catmastertech replied 5 years ago.

graphic

 

Illustration 11 g00286367

(3)(NNN) NNN-NNNNWrench

(4)(NNN) NNN-NNNNTorque Wrench



Move the rocker assembly upward and move the rocker arm assembly downward. Move the rocker assembly several times. The oil film is removed in order to get a true zero reading on the dial indicator. Use the(NNN) NNN-NNNNWrench (3) and use the(NNN) NNN-NNNNTorque Wrench (4). Install the socket wrench and install the torque wrench on the nut of the rocker arm. Apply upward pressure to the front of the rocker assembly. Set the dial indicator to zero. The weight of the torque wrench (4) allows the valve lash to be read. Do not apply any pressure on the torque wrench.

Loosen the locknut. The locknut is located on the adjustment screw of the pushrod. Turn the adjustment screw until the valve lash is set to specifications. Tighten the nut for the adjustment screw to 70 ± 15 N·m (50 ± 11 lb ft ). The(NNN) NNN-NNNNTorque Wrench is preset to the torque that is required. Check the adjustment again.

 

Let me know if this is the wrong information, The only difference I have seen is if you have adjustable valve bridges. If you do the adjust the same as all other bridges.

Expert:  catmastertech replied 5 years ago.

Fuel Injector Synchronization should be done also.


Table 1 Tools Needed
8T-2684 Rack Synchronization Gauge 1


Injector synchronization is the setting of all fuel injector racks to a reference position so 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:
--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 1 g00323443

Location of fuel setting cover and synchronization pin (typical example)

(1) Plug

(2) Synchronization pin

(3) Cover




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

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

--------------------------------------------------------------------------------

graphic

--------------------------------------------------------------------------------

Illustration 2 g00323444

Position of the synchronization pin (typical example)

(2) Synchronization pin

(4) Fuel stop lever



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

Remove the valve covers.

--------------------------------------------------------------------------------


graphic


--------------------------------------------------------------------------------

Illustration 3 g00323446

Location for gauge and control rod adjustment (typical example)

(5) 8T-2684 Rack Synchronization Gauge

(6) Control rod



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.

--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 4 g00323448

Gauge in place on the fuel injector rack (typical example)

(5) 8T-2684 Rack Synchronization Gauge

(7) Fuel injector rack



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

--------------------------------------------------------------------------------

graphic


--------------------------------------------------------------------------------

Illustration 5 g00323450

Adjustment of fuel control rod (typical example)

(5) 8T-2684 Rack Synchronization Gauge .



Install the valve covers.

Check the fuel setting and perform any necessary adjustments. Refer to Testing And Adjusting, "Fuel Setting" for this procedure.

 

 

Expert:  catmastertech replied 5 years ago.

Sorry for not answering your question. If you could be more specific about the problem you are having, I will be glad to help.

I assumed you did not have any documents to work from. I will look to other manuals if it will help. My experience with the fuel system is limited. I have helped do this job but, only done it once and it has been a few years ago.

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