&P'() F*o+ Che"ing Too* #!op-S/'( Engine Timing Indi"ato! #!op o!'P0'( Engine Timing Indi"ato! #!op/S&' $ia* Indi"ato!-P&'0' Co**et-S-1) Conta"t Point &.1' in. 2((.' mm3 *ong-S-0( Rod 1.& in. 2&4)./ mm3 *ong'P10' 5dapte!1M&/// T6e 5ssem6*7
1. Pt No. & piston at top "ente! 2TC3 in the "omp!ession position. Mae !efe!en"e to LOC5TIN# TOP CENTER COMPRESSION POSITION FOR NO. & PISTON.
ME5SURIN# PISTON TR58EL
&. -P&'0' Co**et. . /S&' $ia* Indi"ato! +ith -S-1) Conta"t Point. -. 'P10' 5dapte!. (. P!e"om6stion "ham6e!. '. -S-0( Rod. 0. In*et po!t. 1. Piston.
2. $is"onne"t the fe* *ine f!om No. & "7*inde! fe* in9e"tion :a*:e 6od7. Remo:e the :a*:e 6od7 and the fe* :a*:e f!om the p!e"om6stion "ham6e!.
3. Insta** 'P10' 5dapte! 2-3 in p!e"om6stion "ham6e! 2(3. Tighten the adapte! finge! tight on*7 to p!e:ent damage to the fe* in9e"tion :a*:e seat. Pt a sma** amont of oi* on -S-0( Rod 2'3 and pt the !od in the adapte! +ith the sma** end do+n.
4. Insta** -P&'0' Co**et 2&3 on the adapte!. Pt the -S-1) Conta"t Point on /S&' Indi"ato! 23 and pt the indi"ato! in the "o**et.
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5P6524 ENGINE TIMING INDICATOR GROUP INSTALLED
5. Turn the crankshaft a !n!u "f 45 #e$rees !n a #!rect!"n "%%"s!te "f n"ra& r"tat!"n' S&"(&)
turn the crankshaft !n the #!rect!"n "f n"ra& r"tat!"n unt!& a a*!u rea#!n$ !s seen "n the #!a& !n#!cat"r' A#+ust the !n#!cat"r u% "r #"(n !n the c"&&et unt!& the re,"&ut!"n c"unter !s at -'.// !n' 01&ack Nuers3' T!$hten the c"&&et t" h"&# the !n#!cat"r !n th!s %"s!t!"n' L""sen the ee& &"ck an# turn the ee& unt!& the er" "n the face "f the #!a& !s !n a&!$nent (!th the han#' T!$hten the ee& &"ck'
6. S&"(&) turn the crankshaft !n the #!rect!"n "f n"ra& r"tat!"n unt!& the #!a& !n#!cat"r ",es e)"n# '/2/ !n' N"( turn the crankshaft !n the "%%"s!te #!rect!"n unt!& the #!a& !n#!cat"r !s at '/2/
!n'
7. Make a te%"rar) ark "n a r"tat!n$ c"%"nent 0f&)(hee& ,!rat!"n #a%er "r crankshaft %u&&e)3 !n re&at!"n t" a stat!"nar) %"!nter "r ark'
NOTICE
Do not use a hammer and punch to mark a vibration damper.
8. Turn the crankshaft !n the #!rect!"n "%%"s!te "f n"ra& r"tat!"n e)"n# the a*!u !n#!cat"r rea#!n$ an# e)"n# '/2/ !n' N"( turn the crankshaft !n the #!rect!"n "f n"ra& r"tat!"n unt!& the #!a& !n#!cat"r !s at '/2/ !n'
9. Make a sec"n# te%"rar) ark "n the r"tat!n$ c"%"nent !n re&at!"n t" the stat!"nar) %"!nter "r ark' N"( ake a ark "n the r"tat!n$ c"%"nent that !s "neha&f the #!stance et(een the t(" te%"rar) arks' Th!s ark !s the %"!nt "f "st accurac) f"r t"% center N"' 7 %!st"n'
!. Turn the crankshaft !n the #!rect!"n "%%"s!te "f n"ra& r"tat!"n a%%r"*!ate&) 45 #e$rees an# then turn the crankshaft !n the "%%"s!te #!rect!"n t" the t"% center ark that (as a#e !n Ste% 8' If nee#e# a#+ust the #!a& !n#!cat"r as !n Ste% 5'
. Turn the crankshaft !n the #!rect!"n "%%"s!te "f n"ra& r"tat!"n a%%r"*!ate&) 45 #e$rees' M",e the fue& rack t" the fu&& &"a# %"s!t!"n' If the en$!ne has a h)#ra echan!ca& $",ern"r !nsta&& a 8S9578 %&u$ an# 8S9527 R"# an# %ush !n the s%ee# &!!ter %&un$er' T!$hten the %&u$ t" h"&# the r"# !n th!s %"s!t!"n' N"( the $",ern"r can e ",e# t" the fu&& &"a# %"s!t!"n'
". C"nnect h"se 093 fr" the fue& %ressure tank 07/3 t" the fue& %ressure $au$e c"nnect!"n "n the &eft s!#e "f the fue& f!&ter h"us!n$' D!sc"nnect fue& return &!ne 0773 at the fue& c"ntr"& ,a&,e an# !nsta&& a %&u$' D!sc"nnect the fue& &!ne fr" N"' 7 fue& !n+ect!"n %u% an# !nsta&& :M7888 tue Asse&) 083' The "%en en# "f the tue asse&) ust e at an u%(ar# s&"%e'
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1P540 FLOW CHECKING TOOL GROUP
8. 5J4634 Hose assemb!. ". #$1""" T%be &ssemb!. 10. Ta'( assemb!.
5J4634 HO)E &))E$*L+ IN)T&LLE, 8. 5J4634 Hose assemb!. 11. F%e -e%-' /'e.
13. F/ e %e a'( 2/ 1 ao' 3.8 /-es o ea' 7/ese %e. Kee e -ess%-e /' e a'( a 15 s/ 105 (Pa b! e %se o e a'7 %m o- so a/- -ess%-e.
NOTICE
If shop air is used, make an adjustment to the regulator so the air pressure in the tank is a maximum of 15 psi 1!5 k"a#.
1$. W/ %e -ess%-e o e %e /'9e/o' o%s/': so2! %-' e -a'(sa /' e 7/-e/o' o 'o-ma -oa/o'. We' e %e o2 -om e %be /s 6 o 1; 7-os e- m/'%e: so %-'/' e -a'(sa. T/s /s e o/' o /'e o- 6 os/'.
15. Use e a- o a'e e /'7/ao- -ea7/' o /m/' a'e. Te /m/' m%s be 2//' <1 7e-ee o e se//e7 /m/' a'e.
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NOTE: If the timing of the fuel system is different that the correct timing dimension given in the chart, make reference to TIMING THE CAMSHAT !" THE #E$ IN%ECTI!N &#M&'
Timing The Camshaft For The Fuel Injection Pumps
(S)*+ Socket
NOTE: The fuel -um- camshaft timing gear ./0 has a -uller attached' The -uller is used to loosen or tighten the gear on the drive shaft' The -uller has -uller 1olt .20, collar .)0, and -late .30' The -uller 1olt is held in the -late 1y the collar 4hich is 4elded to the 1olt' The -late is fastened to the
gear 4ith 1olts' 5hen the -uller 1olt is turned counterclock4ise, the collar -ushes against the -late and -ulls the gear from shaft .0' 5hen the -uller 1olt is turned clock4ise, the 1olt head -ushes on the -late and -ushes the gear on the shaft'
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CAMSHAT GEA" ASSEM9$B
/' Camshaft gear' 3' &late' 2' &uller 1olt' ' Shaft' +' $ock' )' Collar'
1. &ut No' / -iston at to- center .TC0 in the com-ression -osition' Make reference to $!CATING
T!& CENTE" C!M&"ESSI!N &!SITI!N !" N!' / &IST!N'
2. "emove the -i-e -lug 1et4een the aftercooler su--orts on the fly4heel housing' 9end lock .+0
from -uller 1olt .20 and turn -uller 1olt to loosen gear ./0 from shaft .0'
3. "emove timing -in .;0 and the fuel inlet flange'
TIMING &IN IN TIMING S$!T ! CAMSHAT ;' Timing -in' /*' Timing slot'
4. Install the timing -in finger tight'
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5. Remove the breather from the front of the fuel injection housing.
6. Use a 9S6054 Socket and ratchet wrench !" to turn the fuel #um# camshaft. $ut the socket and wrench on the end of the fuel #um# camshaft and turn the camshaft until timing slot %0" is at the to#. &ighten the timing #in into the timing slot.
&'(')* &+, -U, ')/,&'1) $U($ 2(S+2-&
3. &iming #in. !. Ratchet wrench handle 4 in. drive". 9. reather o#ening.
7. &ighten the camshaft #uller bolt " to #ush the gear on the shaft. &ighten bolt " to a tor7ue of 865 5 lb.ft. 60 45 ):m". end the lock to the bolt.
8. Remove the timing #in and turn the crankshaft two revolutions in the direction of normal rotation until the engine is again at to# center &" com#ression #osition for )o. % #iston.
9. 'nstall the timing #in. 'f the timing #in engages with the timing slot in the camshaft; the timing is correct. 'f the timing #in does not engage with the timing slot; the timing is not correct and Ste#s % thru ! must be done again.
10. Remove the timing #in. 'nstall the breather; #i#e #lug in fl<wheel housing; fuel inlet flange; and the timing #in.
Setting Fuel Injection Pump Timing Dimension: Off ngine
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1. 1P7410 Plate. 2. 5P6564 Shaft. 3. 1P7415 Pointer. 4. S1594 Bolt. 5. 2S6160 Washer. 6. S509 Bolt. 7. 9M4568 Wrench. 8. 9M4567 Wrench.
The fuel inection !u"! housin# "ust $e re"o%e& fro" the en#ine for the !roce&ure that follo's( 1. )e"o%e the fuel inection !u"!s fro" fuel inection !u"! housin#. Ma*e reference to +,- /-T/ S-)/- )e"o%al of /nection Pu"!. lean the to! surface of the housin# of all !aint an& &irt.
!. hec* the &irection of rotation of the fuel !u"! ca"shaft. +or an en#ine 'ith stan&ar& rotation the + "ar* an& arro' on the en& of the fuel !u"! ca"shaft 'ill $e at the front en& of the !u"! housin#. +or an en#ine 'ith o!!osite rotation the + "ar* an& arro' on the en& of the fuel !u"! ca"shaft 'ill $e at the rear en& of the !u"! housin#.
". /nstall ti"in# !late 1 on shaft 2 'ith $olt 6 an& 'asher 5. Put the ti"in# !late an& shaft on the fuel !u"! ca"shaft at the rear of the !u"! housin#. The *e: in shaft 2 "ust $e in
ali#n"ent an& en#a#e in the slot in the ca"shaft.
#. /nstall !ointer 3 o%er the &o'el in the to! of the !u"! housin# at the rear. /nstall the $olt 4. 5. /n the chart fin& the ti"in# !late settin# for the lifter that is to $e set. Turn the ti"in# !late to this settin# in the &irection of ca"shaft rotation. The &irection of ca"shaft rotation as seen fro" the rear of the !u"! housin# is countercloc*'ise for stan&ar& rotation en#ines an& is cloc*'ise for o!!osite rotation en#ines. The &e#ree "ar*in# on the ti"in# !late "ust $e in ali#n"ent 'ith the insi&e e&#e 9 of !ointer 3.
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TOOLS INSTALLED
1. 1P7410 Plate. 3. 1P7415 Pointer. 9. Edge of pointer. A. Tiing dien!ion to "e ea!#red.
6. $!e t%e &'&9(( Dept% )i*roeter or t%e 5P41&5 Dial Indi*ator +ro#p and ea!#re tiing
dien!ion ,A-. Tiing dien!ion ,A- i! t%e di!tan*e fro t%e top !#rfa*e of t%e f#el p#p %o#!ing to t%e f#el p#p pl#nger *onta*t !#rfa*e in t%e o/e of t%e lifter. T%e ea!#reent for tiing dien!ion ,A- i! (.15&5 .0005 in. ,54.775 0.013 - for all engine!. $!e ren*%e! ,7- and ,2- to ad#!t t%e o/e of t%e lifter to t%e *orre*t tiing dien!ion.
T%e f#el ine*tion p#p! are n#"ered in order fro front to rear on all engine!
7. Set ea*% lifter in t%e firing order ,ine*tion !e#en*e- of t%e engine. )a/e referen*e to t%e
6AT 'O 'IIN+ ODE. %e*/ t%e tiing dien!ion for ea*% lifter again after an ad#!tent %a! "een ade and t%e lo*/n#t tig%tened.
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5P4165 DIAL INDICATOR GROUP INSTALLED A. Timing Dimension.
Fuel Rack Adjustment
9S240 Ra! Posi"ion Too# G$o%&9S240 RAC' POSITION TOOL GROUP
1. (S462) Ci$%i" Tes"e$. 2. 9S22) *$a!e" G$o%&. +. (S22(+ Dia# In,ia"o$. 4. (S+6)5 Con"a" Poin"- .125 in. +.1( mm/ #ong. 5. 9S(519 P#%g. 6. 9S(521 Ro,.
Pgina +) ,e (2 D+99 INDUSTRIAL ENGINE +5*006((UPUEG06+)S 01/*asi Sea$3
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1. Remove the air-fuel ratio control. Disconnect the governor control linkage from the governor
lever.
2. Remove the speed limiter access plug. Install plug (5). Through the opening in the plug, install
rod (6) and push in the speed limiter plunger. Tighten the plug to cause a clamp action on the rod. This ill let the governor control lever move through its complete length of travel.
3. Remove timing pin (!), clamp ("), and the plug and seal #ehind the clamp.
$%&'%T *%$+TI% !. Timing pin. ". $lamp.
4. asten #racket () to the fuel pump housing. &ove the governor lever to the fuel on position
and install dial indicator () ith contact point (/) on #racket ().
5. 'ut spacer (0) #eteen the flange on the rod and the #racket. 'ush the flange toard the fuel
pump housing to hold the spacer tight and ad1ust the dial indicator so that the revolution counter is at 2ero. Tighten the clamp for the indicator. Turn the dial of the indicator until the 2ero is in
alignment ith the hand. Remove the spacer.
3R+$4T R%' +D IDI$+T%R I7T+**D 0. 7pacer. 89. Dust cover.
6. 'ut the clip end of tester (8) on the #rass terminal on the side of the governor. 'ut the other end
of the tester to a good electrical ground.
7. Remove dust cover (89) from the dial indicator. &ove the governor control lever in the fuel on
direction until the tester light #ecomes #right and fasten lever in this position.
8. 'ush on the stem of the dial indicator that as under the dust cover to keep a small amount of
pressure on the fuel rack. se a 8 8:/ in. open end rench on rack shutoff lever (88) and move the lever in the fuel off direction until the tester light #ecomes a dim light.
NOTE: The h;draulic servo-valve that moves the rack hen the engine is running, does not have
a direct connection ith the rack hen the engine is not running. The rack can go #e;ond the set '<gina " de " D00 ID7TRI+* I 53996""-'(96!7 - 98):3asic 7earch
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position approximately .100 in. (2.54 mm). Because of this, the rack setting must be checke !ith an application of force against the rack in the "#$%&'"" irection to remoe the free moement bet!een the rack an the stop collar in the goernor.
*+ -#/'"" %$$ 11. ack shutoff leer.
9. ea the rack setting measurement on the ial inicator. ake reference to the *+ -$//3 3"'*/'3 for the correct rack setting imension.
10./o aust the fuel rack setting, loosen the locknut on austment scre! (12) an turn as neee. /ighten the locknut an check the rack setting again.
"#$% *+ *67#-/$3/ 12. *ustment scre!.
11.*fter the austment proceure is one, tighten the austment scre! locknut to a tor8ue of 9 : ; lb.ft. (12 : 4 3<m).
NOTE: /he same tools that are use in this proceure are also use for the air&fuel ratio control austment.