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Tool Operating Manual

Using the 223-2454 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit
Injectors (MUI){0374, 0599, 0701, 0706, 1251, 1252, 1254}
Media Number -NEHS0610-11 Publication Date -06/09/2013 Date Updated -09/09/2013
i04943220
Using the 223-2454 Tool Group on 3114, 3116, and 3126 Engines
with Mechanical Unit Injectors (MUI){0374, 0599, 0701, 0706, 1251,
1252, 1254}
SMCS - 0374; 0599; 0701; 0706; 1251; 1252; 1254
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
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 25/09/2015
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Illustration 1 g02139237
Think Safety
Most accidents that involve product operation, maintenance, and repair are caused by failure to obse rve basic
safety rules or precautions. nA accident can often be avoided by recognizing potentially hazardous s ituations
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.
oD not operate or perform any lubrication, maintenance, or repair on this product until you have rea d
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 warn ings are
not heeded, bodily injury or death could occur to oy u or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
"DN
A GER","WARNING", or "CAUTIN
O ". The Safety lA ert "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, procedu re,
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, meas urements,
adjustments, illustrations, and other items can change at any time. These changes can affect the ser vice that is
given to the product. bO tain the complete and most current information before oy u 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, typ e,
strength, and material.
iL terature Information
This manual contains safety information, operation instructions and maintenance information and shou ld be
stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from yo ur 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 t ool,
which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult eD aler Service T ools
S
(D T) 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 performin g
maintenance and repair on this service tool.
General Information Section

The General Information Section describes tooling functions and features. This section provides usef ul
information on individual parts, additional tooling, and resources.
p
O eration Section
The Operation Section is a reference for the new operator and a refresher for the experienced operat or.
Photographs and illustrations guide the operator through correct procedures for using the tool group .
pO erating techniques outlined in this publication are basic. Skill and techniques develop as the ope rator gains
nk owledge 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 oN menclature
eP rsonal rP otection/Important Information
Personal Protection/Important nI of rmation
Hazard o
Av idance
Crushing Hazard (foot)
Crushing Hazard (hand)
iP nch Point
Working Load Limit (WL) mark - oD

not use lifting device unless load
identification (WL) markings are legible.
Safety lA ert - oD not use C-Frame lifting

device for anything other than the intended
purpose.
d
A ditional Contact Information
For additional product support uq estions concerning this tool, contact the Dealer Service Tools Hotl ine at:
USA: 1-800-542-8665, pO tion 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 inject ors and
adjust the av lves.
The new group replaces the 1U-6680, 9U-7305, 128-822 Tool Groups. . The new tools are available
individually to update former groups at a considerable cost savings, and offers the advantage of sim plified
tooling which provides more accurate adjustments in less time.
eF atures of 223-2454 Tool Group
Injector Synchronization
The new 128-9640 Injector Synchronizing Fixture Group replaces the former 9U-7276 iL nkage Spring-
oL ading Tool and 9U-7275 Support. The new fitx ure features a spring-loaded plunger which pushes dire ctly
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 128-823 oL ng Nose oL cking 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. T his ability to
actuate the rack in both directions is necessary for consistent readings when using the new procedur e. The
pliers replace the of rmer 9U-7264 Linkage Lever .
Timing
The 123-4940 Magnetic Timing Indicator Fitx ure , used with the direct-reading 1U-8869 Programmable
iD gital Position Indicator and associated tooling, moves uq ickly from injector to make checking or a djusting
the timing uq ick and easy.
oN te: 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.
oN te: New high-quality, deep offset, box wrenches are also part of this group, making timing adjustment
easier.
u
F el Setting
The 128-827 Fuel Setting Pin is an approved ev rsion of the 9U-7271 Pin . The 128-827 Fuel Setting Pin is
made easier to use in the ev ry 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
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 proceduresprovided
in this manual and in the machine's Service Manual.
Table 1
Nomenclature for 223-2454 Tool Group
Tools eR quired to
Upgrade Former Groups
Item Qty.
aP rt No. Description 9U-7305 1U-6680
Synchronization Tooling
128-9640 Injector Synchronization Fixture Group
1 1 X X
128-8706 Spring Plunger (serviceable part)
9U-7270 Sync Gauge Block, 3.5 mm
2 1 X
220-8706 Sync Gauge Block, 3.0 mm
3 9U-5120 Solenoid Spanner Wrench 1
4 1U-8869 Digital Position Indicator 1
Locking Long Nose Pliers,
5 128-8823 1 X X
150 mm (6.0 inch) long
6 1U-6675 Spring Compressor 6
7 8T-4177 Bolt, Spring Compressor 6
9U-7282 Indicator Fixture Group
8 1
9U-6272 Nylon Screw (serviceable part)
9 8C-4984 Bolt, Indicator Stand 1
Contact Point (
10 9U-7263 1 X
18.5mm (.73 inch) long
Fuel Timing Tooling
11 9U-7269 Timing Gauge Block 1 X
123-49402
12 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
Contact Point,
15 9U-7274 1
85 mm (3.35) long
Miscellaneous Engine Tools
16 5P-03023 Injector Removal Bar 1
17 123-49413 Valve Setting Gauge (feeler gauge for

1 X X
adjusting valves)
18 194-35423 Hex Socket Bit Driver, 5 mm 1 R R
u
F el 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 1 X
Pin Insert Pilot (use with 128-8827 Pin

Assembly)
Adjustment (FRC) Wrench (Type V, 1994
23 1U-7299 1 X X
and later trucks)
T-Handle Wrench, 3mm hex (Type V, 1994
24 1U-7300 1 X X
and later trucks)
Injector Sync and FRC Adjust Wrench (all
25 1U-6673 1
models, except Type V and later trucks)
--- 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 lP acement
The following illustration shows the placement of tools in the foam insert.
Media Search - NEHS0610 - Using the 223-2454 Tool Group on 3114, 3116, and... Página 10 de 42
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.
peO ration Section

Injector n
yS chronization
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 ht e
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 ni jector.
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 u
qE ipment
The tools shown in Chart A "Injector Synchronization Tooling" are required to complete the synchronizing
procedure.
Table 2
Chart A.
Injector Synchronization Tooling
Part No. eD scription Qty. Item¹
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
Locking Long Nose Pliers
128-8823 1 5
150 mm (6.0 inch) long
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
Contact Point
9U-7263 1 10
18.5 mm (.728 inch)
1U-6673 Adjustment Wrench 1 25
(¹) 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.
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.
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
Fuel Shut-Off Solenoid (energize to run). (1) Governor
(2) Fuel Shut-Off Solenoid
(3) 9U-5120 Spanner Wrench
1. Stop the engine and turn OFF electrical system.
2. Remove fuel shut-off solenoid (2) using a U9 -5120 Spanner Wrench (3). Removing the solenoid allows
free movement of injector rack control linkage during injector synchronization.
3. Remove the cylinder head valve cover.
Remove number 1 Rocker Arm Assembly
(4) Bolts
(5) Rocker Arm Assembly
4. 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 t heir
original locations to minimize readjustment of the valves.
Note: To prevent accidental disassembly, hold rocker arm assembly (5) level when removing from the
engine
Install Spring Compressor on number 1 Injector.
(6) 1U-6675 Spring Compressor
(7) 8T-4177 Bolt
5. 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.
NOTICE

movement of the injector rack. Either the rocker arm assembly or the
1U-6675 Spring Compressor (6) MUST be installed on all injectors to
Install 128-9640 Injector Synchronization Fixture Group (8)
6. Install 128-69 40 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.
NOTICE
To prevent engine damage, the 9U-7270 or 220-10 23 Sync Gauge

should always be attached to the 128-69 40 Injector Synchronization
iF tx ure Group with the chain. This will prevent the gauge from being
left inside the engine.
Attach Locking Pliers (9) to Control Rod.
(B) Fuel-Off Direction
(C) Fuel-On Direction
7. Attach 128-2
8 3 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.
8. Make sure injector rack stop pin (11), the square shoulder on the injector body (10), and rack head (12)
are clean.
Clean The Area Around The Injector Rack
(10) Square Shoulder On Injector Body
(11) Injector Rack Head Stop Pin
(12) Rack Head
9. Install proper Sync Gauge Block (13) .
a. oL cate injector part number (see illustration for part number location).
b. eD termine proper Sync Gauge Block using part number and Chart B.
c. Push locking pliers (9) and rotate the control rod to the "fuel-on" direction (so the rack head pulls
away from the injector).
d. 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) .
e. Release the control rod (rotate to "fuel off"), allowing gauge block (13) to be held tightly and
squarely against the injector body.
Table 3
Chart B
Sync Gauge Block/Injector Cross Reference
Injector Part No Sync Gauge Block Used
127-8207
127-8213
140-8413
4P-2995
127-8228
127-8225
127-8216
173-4647
220-0123 (3.0 mm)
127-8220
127-8218
127-8222
162-0212
162-0218
127-8234
127-8209
127-8205
127-8211
127-8226
(13) Install Sync Gauge Block
(8) 128-9640 Injector Synchronization Fixture Group
10. 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.
a. Apply a small amount of clean engine oil to the top of the injector and install 1U-6675 Spring
Compressor (6) .
b. Tighten bolt (7) and compress the injector spring.
(15) Remove Bolt and Install Indicator Group
Injector Synchronization Tooling
(16) 9U-7282 Indicator Fixture Group
(17) 8C-4984 Bolt
(18) 9U-7263 Contact Point
(19) 1U-8869 D igital Position Indicator (Top-New Version, Botton-Former V ersion)
(20) 9U-6272 Nylon Screw (Part of 9U-7282)
(21) Lever (Part of 9U-7282)
11. Remove bolt (15) nearest the injector to be checked.
Injector Synchronization Tooling Installed
(17) 8C-4984 Bolt
(19) 1U-8869 D igital Position Indicator
Injector To Be Checked
(10) Square Shoulder On Injector Body
(12) Rack Head
(21) Lever
(22) Rack Bar
12. Install 9U-7263 Contact Point (18) 18.5 mm (0.73) long into 1U-8869 iD gital 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 iD gital Position Indicator can be rotated for better visibility.
13. Make sure the end face of rack bar (22) on injector to be checked is clean. Install assembled U
9 -7228
Indicator Fixture Group (16) and 1U-8869 Digital Position Indicator (19) with 8-C 849 Bolt (17) (M8
x 1.25 x 150 mm long) where bolt (15) was removed in Step 11. eL ver (21), on indicator fixture group ,
must contact and be centered on the end face of rack bar (22). Tighten bolt (17) .
14. Turn indicator (19) to N

O and make sure that the indicator units are set to mm, and ± travel directi on 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.
15. 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.
OT
N CE I
The contact between the injector rack head stop pin and the shoulder
on the injector body is a solid stop. OD NOT put excessive force on it
once contact is made. ceEx ssive of rce will cause damage to the control
assembly.
16. While maintaining the position of the control rod, with indicator (19) N
O , press the "zero-set" butt on.
This defines the zero rack ("fuel-off") position.
17. 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.
18. Repeat this sequence several times, by pressing the zero set button as necessary, until it is certai n that a
consistent zero reading is being obtained.
Injector Assembly Control Linkage
(24) Clamp Assembly
(25) Injector Lever
19. 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.
20. 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 -20
0123 Sync Gauge.
Note: Repeat this step two or three times to confirm the reading. If the readings are not consistent,
check for binding.
21. If the indicator reading is within the specified tolerance, go to STEP 25.
22. If the indicator reading is not within the specified tolerance, go to the next step.
Synchronizing Injector (Side View)
(10) Square Shoulder on Injector Body
(21) Lever
(22) Rack Bar
(25) U-Shaped Lever
(26) Setscrew
(28) Clamp
OT
N CE I
DO NOT loosen screws holding clamps )(28 to control shaft. Loosening

the clamps will cause poor engine performance and am y damaeg the
engine.(The screws can be identified as those with socket heads filled
iw th sealant.) Clamps 8)(2 are factory preset onto the shaft.
23. Use 1U-6673 rW ench (14) to loosen lock nut and turn setscrew (26) clockwise until indicator (19)
reads 3.50 ± 0.02 mm, if using the U
9 -7270 Sync Gauge , or 3.0 ± 0.02, if using the 02-10 32 Sync
Gauge . Turning the adjusting screw clockwise increases reading; counterclockwise decreases reading.
Tighten the locknut while holding setscrew (26) in position.
24. 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 02-10 32 Sync Gauge , re-adjust setscrew (26) again.
25. 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).
26. 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 pus h
rods are properly seated in the rocker arms and lifters.
27. Synchronize the remaining injectors as necessary.
28. When synchronization procedure is complete, remove synchronization fixture (8) and sync gauge block
(13) from the number 1 injector. Remove locking pliers (9) .
29. If fuel setting is to be checked, refer to the "Fuel Setting" section in this manual.
30. 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.
31. 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.
32. 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.
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
(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.
NOTICE

movement of the injector rack. Either the rocker arm assembly, or the
1U7-65 Spring Compressor , MUST be installed on all injectors to
1. 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.
(15) Remove Bolt
2. Remove bolt (15) from the inlet manifold.
Fuel Setting Tooling
(17) 8C-4984 Bolt
(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
3. Install 1U6-89 Digital Position Indicator (19) in 98-7U2 Indicator Fixture Group (16). Tighten nylon
setscrew (20) .
Fuel Setting Indicator (Former Style) Installed
(19) 1U-8869 Digital Position Indicator
4. Make sure the end of rack bar (22) is clean. Install assembled 98-7U2 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) .
Number 1 Injector
(10) Square Shoulder On Injector
(12) Rack Head
(21) Lever
(22) Rack Bar
5. Remove clip (39) that keeps sleeve (40) in position between governor (1) and cylinder head (41) .
(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) .
6. With 13-41
6 49 Governor Connection Pliers , slide sleeve (40) away from governor (1) into cylinder
head (41) .
7. Install 12782- 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) .
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.
8. 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.
9. 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).
10. 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.)
11. 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.
12. 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.
13. Refer to the "Engine Information Plate" or the "Fuel Setting and Related Information" area of TMI for
the correct fuel setting.
14. If reading on digital indicator is within ± 0.25 mm of the specified fuel setting, go to Step 17.
15. 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).
NOTCE
I
Do not loosen screw holdngi apmcl esa blym (15) to the control rod.
Thsi crs ew can be identefi d by sentla ni socket hed
a . mlpaC esa ymbl
(15) si ctfa ory preset onto the rod. Loosenig the apmcl lwi useca poor
performance nd a amy daeamg the enineg .
16. 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.
17. 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) .
18. 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.
19. With engine stopped and the engine electrical system turned OFF, install the fuel shut-off solenoid.
Install the valve cover.
Fuel Tiingm
Toolgin nad Eqpuemi tn
The tools shown in Chart D, "Fuel Timing Tooling" are required to complete the fuel timing procedure .
Table 5
rCha t D.Fuel Tiingm Toolngi
(1)
rPa t No Descrpti ion Qty tI em
1U-8869 iD gital 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
(1)
Refer to the nomenclature chart, at the beginning of this manual, for item identification.
nd
I atic or rlibaC atoi n
Before a check or an adjustment of the fuel timing dimension can be made, the 1U-8859 Digital Positi on
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.
tniI lia blriaC ta ion Setup
Calibrate Injector Timing Tooling
(20) 9U-6272 Nylon Holding Screw (Part of 9U-7282)
(29) 123-4940 Indicator Fixture Group
(30) 9U-7269 Timing Gauge Block
1. Install 85mm (3.35 inch) long 9U-7274 Contact Point (31) on the digital position indicator stem.
2. Insert digital position indicator (19) in 123-4904 Magnetic Base Group (29) until it stops. Tighten
nylon holding screw (20) .
3. 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.
4. Push (fully retract) indicator contact point (31) into the digital position indicator and hold it.
NOTCE
I
The gmnea ts in the 123-4904 Indcati or Fixture Group (29) ra e ev ry

poew rful nd a nca psna nti o acepl when ta tangchi the ebas esa ymbl to
any metailc urs face. To o av d i daiangm the ditgi al potsi oi n indcati or,
hod l the nd i tica or contact ponti in the retracted potsi ion ehilw
attaching the seba .
5. 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) .
Indicator Group (Current Style)
6. 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.
rP esettign the nd
I taic or Group (Former Steyl )
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:
Indicator Group (Former Style)
1. Turn the indicator ON by pressing the ON/OFF button (4) .
2. Press the in/mm button (2) to change the display to millimeters.
3. Indicator bar (6) should be in the display window under REV. If the space is blank, select /+ - butto n (1)
so the display shows the indicator bar, as shown.
4. 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.
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.
5. 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.
6. 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.
7. 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).
8. 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.
9. 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:
Indicator Group (Current Style)
(20) 9U-6272 Nylon Holding Screw (Part of 9U-7282
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
1. Turn the indicator ON by pressing the ON/OFF button (6) .
2. Press in/mm button (1) to change the display to millimeters.
3. 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.
4. Press and hold the preset button until the first character begins to flash. Release the button when
character flashes.
5. Press and release the preset button to set the value of the character.
6. Repeat Steps 4 and 5 until the display numbers read 0062.00 mm (2.4 inch).
Correctly Entered Display Numbers
7. Press and hold the preset button until (P) starts flashing.
8. Press and release the preset button. The indicator is now preset and should read 0+ 062.00 mm (2.4
inch).
Measuring Fuel Timing Setting

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 stroke¹
Injectors 3-4
Inlet aV lves 1-2
Exhaust Valves 1-3
2
Check/adjust with Number 1 piston on TC exhaust stroke
Injectors 1-2
Inlet aV lves 3-4
Exhaust Valves 2-4
Firing Order 1-3-4-2
1. 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 num ber
1 Piston" in this manual.
2. 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).
Note: Refer to Testing and Adjusting Engine Valve Lash - Inspect/Adjust, for more information on adjusting
valves.
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 stroke¹

Injectors 3-5-6
Inlet aV lves 1-2-4
Exhaust Valves 1-3-5
2
Check/adjust with Number 1 piston on TC exhaust stroke
Injectors 1-2-4
Inlet aV lves 3-5-6
Exhaust Valves 2-4-6
Firing Order 1-5-3-6-2-4
1. 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 num ber
1 Piston" in this manual.
2. 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).
3116, 3126 Cylinder and Valve Location
Note: Refer to Testing and Adjusting, Engine aV lve Lash - Inspect/Adjust for more information on adjusting
valves.
With the crankshaft positions given in Charts E, Crankshaft Positions for Fuel Timing Setting, all o f 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.
1. 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.
2. Make sure the top surfaces of the injector tappet (32) and shoulder (34) are clean and dry.
Fuel Timing Dimensions
(32) Injector Tappet
(33) Adjustment Screw
(34) Shoulder
(A) Fuel Timing Dimension
3. Remove indicator and magnetic base from the gauge block. Push (fully retract) indicator contact point
(31) into the digital position indicator.
4. Hold the contact point in the retracted position and carefully position it on top of injector tappet (32)
for the injector to be checked.
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.
Timing Fixture Installed (Current Style)
Timing Fixture (Former Style)
(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) .
5. 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.
(32) Injector Tappet
(34) Shoulder
NOTICE
fA ter the timing tooling has been positioned on an injector, do not

rotate the engine. The timing tooling could be damaged.
6. 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.
7. 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.
8. If indicator (19) does not show the correct timing dimension, use the 128-824 or the 128-28 5 Wrenc h
to loosen the locknut on the push rod adjustment screw (33) for the injector to be adjusted.
9. 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 procedu re
until the adjustment is correct.
10. Sequence for checking the fuel timing dimensions. Refer to explanation at the beginning of this sect ion.
a. Check and adjust fuel timing dimension on half of cylinders with the timing bolt installed.
b. Remove the timing bolt and timing tooling.
c. Rotate flywheel counterclockwise 360 degrees (1 revolution) and install timing bolt.
d. 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.
11. Remove timing bolt from flywheel when the fuel timing check is completed.
Finding Top Center oP sition for Number 1 iP ston

Tooling and Equipment
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete t he
procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
(1)
Refer to the nomenclature chart at the beginning of this manual for item identification.
rP ocedure
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.
1. Remove plug from the timing hole (36) on the front of the flywheel housing.
NOTICE
oR tate 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.
2. Put T
8 -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.
3. Remove the cylinder head valve cover.
Valve Cover Removed
4. 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: hW en 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.
5. 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.
eR moval and Installation of n

U it Fuel Injectors
Table 9
Chart G
Injector eR moval and Installation Tools
Part No eD scription Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
(1)
Refer to nomenclature chart, at the beginning of this manual for item identification.
Unit Fuel Injector
(48) Bolt
(49) O-Rings
Note: Not all injectors use a bottom O-ring.
Removal
1. Remove injector hold down bolt (48) .
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.
2. Use the 5P-0302 Injector Removal Bar to loosen the fuel injector.
3. Rotate the injector to disengage the injector rack from the control linkage.
4. Remove the injector and inspect it to be sure the O-rings (49) were removed with the injector.
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.
1. With O-rings in place and lubricated with engine oil, position the injector in the head and then rot ate it
to engage the injector rack with the control linkage.
2. 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.
3. Install bolt (48) using the -941 3542 Hex Socket Bit Driver and tighten it to 12 ±3 Nm (9 ± 2 lb ft).
4. Complete the installation by performing the injector synchronization procedure in this manual.
5. Install the rocker assembly and adjust fuel timing and valve clearance. The fuel setting should alsobe
checked.
Copyright 1993 - 2015 Caterpillar Inc. Fri Sep 25 11:45:48 EST 2015
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Media Search - NEHS0610 - Using the 223-2454 Tool Group on 3114, 3116, and 3...

Product: NO EQUIPMENT SELECTED

Tool Operating Manual

Engine: Commercial with Mechanical Unit Injection 3126

Important Safety Information

General Information Section

eP rsonal rP otection/Important Information

Personal Protection/Important nI of rmation

Crushing Hazard (foot)

Crushing Hazard (hand)

Working Load Limit (WL) mark - oD

Safety lA ert - oD not use C-Frame lifting

USA: 1-800-542-8665, pO tion 1

General Information Section

eF atures of 223-2454 Tool Group

223-2454 Tool Group

13 128-8824 Deep Offset Wrench, 16 mm and 18 mm 1 R R

16 5P-03023 Injector Removal Bar 1

17 123-49413 Valve Setting Gauge (feeler gauge for

18 194-35423 Hex Socket Bit Driver, 5 mm 1 R R

Pin Insert Pilot (use with 128-8827 Pin

(X) Essential tools for new products

(R) Recommended for improved tools

peO ration Section

Optional Removal of Rocker Arm Assembly

Since visibility of control linkage and injector is very limited with

The injector spring must be slightly compressed to allow free

Fuel Shut-Off Solenoid (energize to run). (1) Governor

(2) Fuel Shut-Off Solenoid

(3) 9U-5120 Spanner Wrench

1. Stop the engine and turn OFF electrical system.

3. Remove the cylinder head valve cover.

Remove number 1 Rocker Arm Assembly

(5) Rocker Arm Assembly

Install Spring Compressor on number 1 Injector.

(6) 1U-6675 Spring Compressor

(7) 8T-4177 Bolt

The injector spring must be slightly compressed to allow free

Install 128-9640 Injector Synchronization Fixture Group (8)

To prevent engine damage, the 9U-7270 or 220-10 23 Sync Gauge

Attach Locking Pliers (9) to Control Rod.

(B) Fuel-Off Direction

(C) Fuel-On Direction

Clean The Area Around The Injector Rack

(10) Square Shoulder On Injector Body

(11) Injector Rack Head Stop Pin

(12) Rack Head

9. Install proper Sync Gauge Block (13) .

(13) Install Sync Gauge Block

(8) 128-9640 Injector Synchronization Fixture Group

b. Tighten bolt (7) and compress the injector spring.

(15) Remove Bolt and Install Indicator Group

Injector Synchronization Tooling

(16) 9U-7282 Indicator Fixture Group

(17) 8C-4984 Bolt

(18) 9U-7263 Contact Point