9U-5132 Timing and Fuel System Setting Tool Group

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Product: TRUCK
Model: 773E TRUCK ASK01332
Configuration: 773E Off-Highway Truck ASK00001-UP (MACHINE)
Reuse And Salvage Guidelines

9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905}
Media Number -NEHS0666-04 Publication Date -30/09/2014 Date Updated -30/09/2014
i05891103
9U-5132 Timing and Fuel System Setting Tool Group{1105,

1162, 1290, 1905}
SMCS - 1105; 1162; 1290; 1905
Caterpillar Products: All Machines
Introduction
European Union Compliant, CE Marked
Important Safety Information
Illustration 1 g02139237
Think Safety
Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential
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773E Off-Highway Truck ASK00001-UP (MACHINE)(SEBP4999 - 38) - Systems & ... Page 2 of 33
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.
Do not operate or perform any lubrication, maintenance, or repair on this product until you
have read 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
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
"DANGER","WARNING", or "CAUTION". The Safety Alert "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, procedure, 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,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete and most current
information before you 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, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and
should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from
your 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 tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service
Tools (DST) 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
performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides
useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced
operator.
Photographs and illustrations guide the operator through correct procedures for using the tool
group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the
operator gains knowledge 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 Nomenclature
Personal Protection/Important Information
Personal Protection/Important Information
Hazard Avoidance
Crushing Hazard (foot)
Crushing Hazard (hand)
Pinch Point
General Information Section
9U-5132 Timing Tool Group
Table 1
9U-5132 Timing Tool Group
Item Part No. Description
1 1U-8869 (3) Digital Dial Indicator
2 9U-6273 (3) Rod Sleeve Extension
3 9U-6272 (3) Nylon Screw
4 5P-8414 (3) Clamp Collet
5 136-4588 (3) Collet Extension
6 122-0449 (3) Rod Sleeve Extension
7 136-4587 (3) Collet Extension
8 6V-3075 Dial Indicator, Metric
9 9U-5137 (2) Timing Fixture
10 5P-7276 Container
11 5P-7263 Contact Point, 76.2 mm (3.0 in)
Contact Point,
12 9S-8883
12.7 mm (.50 in)
13 4C-8753 Extended Collet
14 8T-2684 Rack Synchronization Gauge,

12.7 mm (.50 in)
15 6V-7918 Wrench (5/8)
Contact Point,
16 8S-3675
3 mm (.12 in)
17 129-8602 Solenoid Driver
18 9U-5138 (1) Set Gauge
19 9U-5736 (1) Foam Insert
20 6V-3072 (1) Plastic Case
21 5P-4160 (1) (3) Contact Point: 19.0 mm (.75 in)
22 9S-9802 (1) (3) Engine Turning Tool
23 122-0451 (1) (3) Extension Rod Assembly
24 443-4177 (3) Low Height Tool
(3)
Additional tooling required, but not part of 9U-5132.
(2)
Part of 9U-5233 Magnetic Fixture Group.
(1)
Not Shown.
Crankshaft Positions for Unit Injector Lash and Valve Lash Settings
Table 2
Chart A
Standard Rotation (Counterclockwise) As Viewed from Flywheel End
Cylinders to Check/Adjust
Correct Stroke for No. 1
Engine Intake Valves Exhaust
Piston at Top Center Position Injectors
(1) Valves
Compression 1-2-6-8 1-2-3-7 3-4-5-7

3508
Exhaust 3-4-5-7 4-5-6-8 1-2-6-8
1-3-6-7-10-12 2-4-5-8-9-11
Compression 1-4-5-6-9-12
3512
2-4-5-8-9-11 2-3-7-8-10-11 1-3-6-7-10-12
Exhaust
1-2-5-7-8-12- 1-2-3-4-5-6-8-9 3-4-6-9-10-11-

Compression
13-14 15-16
3516
3-4-6-9-10-11- 7-10-11-12-13- 1-2-5-7-8-12-
Exhaust
15-16 14-15-16 13-14
Chart B.
Reverse Rotation (Clockwise) As Viewed From Flywheel End
Cylinders to Check/Adjust
Compression 1-3-4-8 1-2-7-8 2-5-6-7
3508
Exhaust 2-5-6-7 3-4-5-6 1-3-4-8
1-3-4-6-7-12 2-5-8-9-10-11
Compression 1-4-5-8-9-12
3512
2-5-8-9-10-11 2-3-6-7-10-11 1-3-4-6-7-12
Exhaust
1-2-5-6-7-8-13 1-2-3-4-5-6-9- 3-4-9-10-12-

Compression
-14 10 15-16
3516
3-4-9-10-11- 7-8-11-12-13- 1-2-5-6-7-8-13
Exhaust
12-14-15-16 14-15-16 -14
(1)
Put No. 1 piston at top center (TX) position and make identification for the correct stroke. After top center
position for a particular stroke is found and adjustments are made for the correct cylinders, remove timing bolt
and turn the flywheel 360 degrees in the direction of normal engine rotation. This will put No. 1 piston at top
center (TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for
the cylinders that remain.
Table 3
Chart C.
(1)
Dial Indicator Setting Chart
Fuel Timing Dimension in Millimeters Dial Indicator Setting In Millimeters
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
(1)
Refer to Fuel Setting and Related Information Fiche for the correct timing dimension to use.
Section 1, Mechanical Unit Injector Engines

This section provides all the testing and adjustment procedures for mechanical unit injector (MUI)
engines. For Testing and Adjusting electronic unit injectors (EUI) engines, refer to Section 2 of
this manual.
Start-up Procedure
Use the following procedure in order to start an engine following fuel system or governor repair:
1. The technician should be prepared to activate the emergency stop button.
2. Disconnect the air inlet system from the turbochargers.
Be careful when plate is put against the air inlet opening.
Excessive suction can pull the plate quickly against the air inlet opening.
To avoid crushed fingers, do not put fingers between plate and air inlet
opening.
3. Place a service person in position near each turbocharger air inlet. Equip the service person
with a piece of steel plate. Each piece of steel plate must be large enough to cover each
turbocharger air inlet.
4. Start the engine. If the engine starts to run too fast or the engine runs out of control,
immediately activate the emergency stop button. Also, place the steel plates against the
turbocharger air inlets. The plates will stop the air supply to the engine, and the engine will
stop.
Tooling
All tools listed are included with 9U-5132 Tool Group, except as noted.
Table 4
Chart A.
9U-5132 Timing and Fuel System Setting Tool Group for MUI Engines
Part No. Description
5P-4160 (1) Contact Point, 19 mm (for digital indicator)
8S-3675 Contact Point, 3 mm
9S-9082 (1) Engine Turning Tool
1U-8869 (1) Digital Dial Indicator (used in preferred method)

9U-5137 Timing Fixture
9U-5138 Set Gauge
9U-5220 Rod Assembly
9U-6272 Nylon Screw
9U-6273 Rod Sleeve Extension (refer to the note below for alternate parts)
6V-3075 Dial Indicator, Metric (used in alternate method)
(1)
Not included in 9U-5132
Note: Some technicians prefer to secure the dial indicator with the 5P-4814 Clamp Collet, instead
of the nylon screw. Parts have been made available for this purpose. In place of 9U-6273 Rod
Sleeve Extension, order and use 136-4587 Collet Extension. This extension accepts the 5P-4814
Clamp Collet. Use two 6V-7918 Wrenches (or 5/8 inch open-end wrenches) to tighten the collet
on the indicator stem.
General Set-up Information
NOTICE
Camshafts must be timed correctly 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 result.
Refer to the "Crankshaft positions For unit Injector Lash and Valve Lash Setting" chart in this
manual 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 that the push-rod lifters are off the lobes
and on the base circles of the camshafts.
Refer to the "Fuel Setting Adjustment" in this manual for the correct fuel timing dimension to use.
The range of timing dimensions are given in the "Dial Indicator Setting" chart in this manual.
Using the 1U-8869 Digital Dial Indicator (preferred method)
773E Off-Highway Truck ASK00001-UP (MACHINE)(SEBP4999 - 38) - Systems ... Page 10 of 33
1U-8869 Dial Indicator
1. The digital dial indicator must 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 (3.4252 inch),
set the digital dial indicator for 87.00 mm (3.4252 inch). Use the following steps in order to
program the indicator to read 87.00 mm (3.4252 inch).
a. Turn the indicator to the ON position by pushing the "on/off" button.
b. Push the "in/mm" button so the display shows "mm".
c. 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.
d. 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.
e. 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.
f. 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).
g. Use the preset button to move the flashing indicator and change the display numbers
until the display shows 87.00 mm (3.4252 inch). 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 (3.4252 inch) disappear.
h. 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.
2. Install a 5P-4160 Indicator Contact Point in the indicator stem.
3. Install the indicator into the 9U-5233 Magnetic Fixture Group . Leave the collet loose.
Adjustment of fuel timing tools
(1) 1U-8869 Dial Indicator
(2) 9U-5233 Magnetic Fixture Group
(3) 9U-5138 Setting Gauge
4. 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.
5. Repeat Steps 1.a through 1.d.
Fuel timing tools in position
(2) 9U-5233 Magnetic Fixture Group
(4) Injector follower
(5) Shoulder on fuel injector body
6. 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 (3.4252
inch). 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). The extension rod rests on the top surface of
shoulder on fuel injector body (5) .
Note: The top surfaces of injector follower (4) and shoulder on fuel injector body (5) must
be clean and dry for accurate readings.
7. The digital dial indicator should now read the actual fuel timing dimension of the injector
that is being checked.
8. 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 13.
9. If the dial indicator does not read the correct fuel timing dimension or the desired fuel
timing dimension, proceed with Steps 10 through 13.
10. 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.
11. 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.
12. Remove the timing bolt from the flywheel when the fuel timing check is completed.
13. 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.
443-4177 Low Height Tool Option
Use only with the Digital Dial Indicator (preferred method).
Table 5
443-4177 Parts List
No. Quantity Part No. Name
1 1 443-4174 Fixture Assembly

2 2 9U-6272 Nylon Screw
3 1 443-4176 Rod Assembly
• Tool is only used with the Digital Dial Indicator (1U-8869)
• Low height tool used on No. 2 Cylinders or injector adjustment on MT4400 Trucks
• Used to test and adjust fuel systems
• Used to test and adjust fuel systems, including fuel timing, rack synchronization, and fuel
setting
• Collets to hold digital dial indicator built-in
• Fits all 3516 engines
Specifications
Table 6
Length 155 mm (6.10 in)
Width 40 mm (1.57 in)
Weight 0.18 kg (.40 lb)
Using the 6V-3075 Dial Indicator (alternate method)
Refer to TMI (Technical Marketing Information) for the correct fuel setting for the engine that is
being checked.
(1) 6V-3075 Dial Indicator
(2) 9U-5137 Magnetic Fixture
(4) 9U-6272 Nylon Screw
(5) 9U-6273 Rod Sleeve Extension
(6) 9U-5220 Timing Fixture Rod
1. Install the 8S-3675 Indicator Contact Point onto the dial indicator stem.
2. Install Sleeve Extension (5) in the small diameter tube of Timing Fixture (2). Place Rod
Assembly (6) in Sleeve Extension (5) .
3. Install Dial Indicator (1) in Sleeve Extension (5) .
4. Put Dial Indicator (1) and Timing Fixture (2) onto the Set Gauge (3). The Timing Fixture
(2) should be on the top surface of the Set Gauge (3) with the Rod Assembly (6) on the
bottom 87.00 mm (3.4252 inch) step.
5. Move the Dial Indicator (1) in the Sleeve Extension (5) until both needles indicate zero.
Tighten Nylon Screw (4). The dial indicator has now been zeroed to a standard fuel timing
dimension of 87.00 mm (3.4252 inch).
Note: Some Dial Indicators (1) have a 0.25 mm (0.010 inch) smaller diameter extending
about 4.0 mm (0.158 inch) up from the end of their stems. When zeroing these indicators in
the bore of the 122-0449 Rod Sleeve Extension the Nylon Screw (4) will contact the
indicator stem on this step. This can cause the indicator to cock in the bore and result in
incorrect readings. It is recommended that the 136-4587 Collet Extension and 5P-4814
Collet Clamp be used with these "stepped" indicator or that the 1U-8869 Dial Indicator be
used.
6. Subtract 87.00 mm (3.4252 inch) (gauge dimension) from the desired fuel timing dimension
(obtained from (TMI) Technical Marketing Information)
Note: To obtain a positive indicator setting, move the indicator downward. This will move
the large needle clockwise or in the positive direction increasing the fuel timing dimension
from 87.00 mm (3.4252 inch).
To obtain a negative indicator setting, move the indicator upward. This will move the large
needle counterclockwise or in the negative direction decreasing the fuel timing dimension
from 87.00 mm (3.4252 inch).
a. Example 1: Desired fuel timing dimension is 87.50 mm (3.4449 inch).
Subtract 87.00 mm (3.4252 inch) from the desired fuel timing dimension 87.50 mm
(3.4449 inch).
87.50 mm (3.4449 inch) - 87.00 mm (3.4252 inch) = +0.50 mm (0.0197 inch)
In this case loosen Nylon Screw (4) and move the dial indicator downward until the
indicator reads a positive 0.50 mm (0.0197 inch). Then tighten the Nylon Screw (4)
again.
b. Example 2: Desired fuel timing dimension is 86.20 mm (3.3937 inch)
Subtract 87.00 mm (3.4252 inch) from the desired fuel timing dimension 86.20 mm
(3.3937 inch).
86.20 mm (3.3937 inch) - 87.00 mm (3.4252 inch) = −0.80 mm (−0.03150 inch)
In this case loosen Nylon Screw (4) and move the dial indicator upward until the
indicator reads negative 0.80 mm (0.03150 inch). Then tighten the nylon screw again.
(7) Injector Follower
(8) Shoulder on injector body.
7. Make sure the top surfaces of (7) and (8) are clean and dry.
8. Put Dial Indicator (1) and Timing Fixture (2) in position on the injector to be checked.
Make sure that the magnetic base of the timing fixture is on top surface of Injector Follower
(7) and the extension rod is on the top surface of Injector Shoulder (8) .
9. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch)
10. If the dial indicator pointers indicate zero or are within the tolerance given in 8, no
adjustment is necessary. Proceed to step 13.
11. If the dial indicator pointers do not indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch),
continue with step 11 through step 13.
Typical example of adjusting fuel timing.
12. Loosen the push rod adjustment screw locknut for the injector to be adjusted.
13. Turn the adjustment screw until zero is read on the dial indicator.
Note: If the dial indicator reading is greater than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch),
then turn the adjustment screw counterclockwise (CCW). If the dial indicator is less than
0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), then turn the adjustment screw clockwise (CW).
14. Tighten the adjustment screw locknut to 70 ± 15 N·m (51.63 ± 11.06lb ft). If necessary,
repeat procedure until the adjustment is correct.
15. Rotate engine, re-pin the flywheel, and repeat the procedure for the other half of the engine
that has not yet been adjusted.
Injector Synchronization Procedure
Table 7
Tools Needed
8T-2684 Rack Synchronization Gauge 1
Injector synchronization is the setting of all fuel injector racks to a reference position. This ensures
that 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:
Location of fuel setting cover and synchronization pin (typical example)
(1) Plug
(2) Synchronization pin
(3) Cover
1. The top bolt that holds the cover (3) in position is the synchronization pin (2). Remove the
synchronization pin (2) and plug (1) from the front drive housing. DO NOT destroy the seal
or remove cover (3) .
2. Remove the washer from the synchronization pin. Remove the plug and install the
synchronization pin into the threaded hole. Tighten the synchronization pin.
Position of the synchronization pin (typical example)
(4) Fuel stop lever
3. Turn the governor or the actuator terminal shaft to the fuel ON position. The flat face of fuel
stop lever (4) will contact synchronization 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.
Location for gauge and control rod adjustment (typical example)
(5) 8T-2684 Rack Synchronization Gauge
(6) Control rod
5. 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.
Gauge in place on the fuel injector rack (typical example)
(7) Fuel injector rack
6. If the other injectors need to be adjusted, use the rack synchronization gauge (5). When all
adjustments have been made, release the actuator terminal shaft.
Adjustment of fuel control rod (typical example)
(5) 8T-2684 Rack Synchronization Gauge .
7. Install the valve covers.
8. Check the fuel setting and perform any necessary adjustments. Refer to Fuel Setting
Procedure for this procedure.
Fuel Setting Procedure
Table 8
Tools Needed
9U-5132 Engine Timing Tool Group 1
4C-8753 Extended Collet 1
6V-3075 Dial Indicator 1
5P-7263 Indicator Contact Point 1
8T-2684 Rack Synchronization Gauge 1
Refer to Special Instruction, SEHS9278 for the instructions on the use of the 4C-8753 Extended
Collet .
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 fuel injector
racks.
Synchronization and fuel setting tools
(3) 4C-8753 Extended Collet
(4) 5P-7263 Indicator Contact Point
Fuel Setting Check
Note: Before the fuel setting is checked, the injectors must be correctly synchronized. Refer to
Injector Synchronization Procedure. After the injectors are synchronized correctly, leave the
synchronization pin in place for the procedure that follows.
1. Put 6V-3075 Dial Indicator (2) with 5P-7263 Indicator Contact Point . Install contact Point
(4) in 4C-8753 Extended Collet (3). Remove the plug from the right side of fuel setting
cover (8) .
Installed dial indicator (typical example)
(2) 6V-3075 Dial Indicator with 5P-7263 Indicator Contact Point
(3) 4C-8753 Extended Collet
2. Move the governor or the actuator terminal shaft toward the ON position. The flat face of
fuel stop lever (6) should make contact with synchronization pin (5). Hold the linkage in
this position.
(4) 5P-7263 Indicator Contact Point
(6) Fuel stop lever
3. Install dial indicator (2) and extended collet (3) in the threaded hole. After indicator contact
point (4) touches fuel stop lever (6), slide dial indicator (2) until the indicator reads zero.
Keep the dial indicator in this position by tightening collet (3) .
Checking fuel setting (typical example)
(8) Fuel setting cover
4. Unscrew synchronization pin (5) by 25 mm (1 inch) or remove synchronization pin (5).

Slowly move the governor or the actuator terminal shaft toward the fuel ON position. The
flat face of the fuel stop lever will rest against the end of the fuel setting screw. The dial
indicator reading will be the present fuel setting when the linkage is held in this position.
Note: Refer to the TMI (Technical Marketing Information) for the correct fuel setting.
5. If the fuel setting is correct, remove the dial indicator and the synchronization pin. Install
the two plugs, and install the synchronization pin back into cover (8) .
6. If the fuel setting needs adjustment, see 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.
1. Cut the seal wire and remove fuel setting cover (8) and the gasket. Loosen locknut (7). Hold
the fuel stop lever against the end of the fuel setting screw. Turn the fuel setting screw
clockwise or counterclockwise until the correct reading is on the dial indicator.
Adjustment of the fuel setting screw (typical example)
2. Now tighten locknut (7). Be sure that the fuel setting screw does not turn when the locknut
is tightened. Release the fuel system linkage and move the linkage toward the fuel ON
position. Check the dial indicator reading again in order to be sure that the fuel setting is
still correct.
3. Remove dial indicator (2) and synchronization pin (5). Install the two plugs.
Installed cover (typical example)
(7) Locknut
(8) Fuel setting cover
4. Put fuel setting cover (8) and the gasket in position over the fuel setting screw. Install the
bolt and synchronization pin (5) in the cover. Install a new seal wire.
Section 2, Electronic Unit Injector Engines

This section provides all the testing and adjustment procedures for electrical unit injector (EUI)
engines. Electronic Injection Timing Calibration is not required unless the timing wheel has been
removed from the camshaft or the Electronic Control Module (ECM) has been replaced.
Table 9
Tools Needed Quantity
(1)
5P-4160 Indicator Contact Point 1
(1)
9S-9082 Engine Turning Tool 1
(1)
1U-8869 Dial Indicator 1
9U-5132 Engine Timing Tool Group 1
(2)
6V-3075 Dial Indicator 1
8S-3675 Indicator Contact Point 1
9U-5138 Setting Gauge 1
9U-5137 Magnetic Fixture 1
(3)
122-0451 Timing Fixture Rod 1
122-0449 Rod Sleeve Extension 1
9U-6272 Nylon Screw 1
(1)
Not included in 9U-5132 Engine Timing Tool Group .
(2)
Two Dial indicators each with their own procedure are available to set fuel timing. Checking or setting fuel
timing with the 1U-8869 Dial Indicator is the preferred method.
(3)
Some 122-0451 Timing Fixture Rod Assemblies were manufactured 10 mm (0.40 inch) too long. The correct
length for the rod is 124.00 mm (4.8819 inch). If the rod included with the tool group measures 134.00 mm
(5.2756 inch) remove 10 mm (0.4 inch) from the end closest to the retaining ring.
Using the 1U-8869 Digital Dial Indicator (preferred method)
1U-8869 Dial Indicator
1. The digital dial indicator must be programmed to read 64.34 mm (2.5331 inch) since this is
the correct dimension for electronic unit injector engines. The following steps show how to
program the indicator to read 64.34 mm (2.5331 inch).
a. Turn the indicator to the ON position by pushing the "on/off" button.
b. Push the "in/mm" button so the display shows "mm".
c. 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.
d. 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.
e. 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.
f. 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).
g. Use the preset button to move the flashing indicator and change the display numbers
until the display shows 64.34 mm (2.5331 inch). 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 64.34 mm (2.5331 inch) disappear.
h. 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.
2. Install a 5P-4160 Indicator Contact Point in the indicator stem.
(2) 122-0451 Timing Fixture Rod
(3) 122-0449 Rod Sleeve Extension
3. Install Extension Rod (2) and Extension (3) into the larger diameter tube of Fixture (1).
Place the timing fixture onto Set Gauge (4) with the Rod Assembly (2) resting on the 64.34
mm (2.5331 inch) step.
4. Install Indicator (5) into Extension (3). Position the Indicator (1) into the Extension (3) so
that the indicator stem has adequate travel. Tighten the Screw (6) .
5. Repeat Steps 1.a through 1.d.
6. 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 (7) and that the extension rod is on the top surface of shoulder on fuel
injector body (8) .
Note: The top surfaces of injector follower (7) and shoulder on fuel injector body (8) must
be clean and dry.
7. The digital dial indicator should now read the actual fuel timing dimension of the injector
that is being checked.
8. 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 13.
9. If the dial indicator does not read the correct fuel timing dimension or the desired fuel
timing dimension, proceed with Steps 10 through 14.
10. Ensure that the Indicator (5) and the Fixture Group (1) are in the correct position on the
injector. Loosen the locknut for the pushrod adjustment screw.
11. Turn the adjustment screw until the desired fuel timing dimension is read on indicator (1).
Note: Turning the adjustment screw clockwise will lower the fuel timing dimension.
Turning the adjustment screw counterclockwise will increase the fuel timing dimension.
12. 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.
13. Remove the timing bolt from the flywheel when the fuel timing check is completed.
14. 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.
Note: Refer to Section entitled, "443-4177 Low Height Tool Option."
443-4177 Low Height Tool Option
Use only with the Digital Dial Indicator (preferred method).
Table 10
443-4177 Parts List
No. Quantity Part No. Name
1 1 443-4174 Fixture Assembly
2 2 9U-6272 Nylon Screw
3 1 443-4175 Rod Assembly
• Tool is only used with the Digital Dial Indicator (1U-8869)
• Low height tool used on No. 2 Cylinders or injector adjustment on MT4400 Trucks
• Used to test and adjust fuel systems
• Used to test and adjust fuel systems, including fuel timing, rack synchronization, and fuel
setting
• Collets to hold digital dial indicator built-in
• Fits all 3516 engines
Specifications
Table 11
Length 155 mm (6.10 in)
Width 40 mm (1.57 in)
Weight 0.18 kg (.40 lb)
Using the 6V-3075 Dial Indicator (alternate method)
Refer to TMI (Technical Marketing Information) for the correct fuel setting for the engine that is
being checked.
(5) 122-0449 Rod Sleeve Extension
(6) 122-0451 Timing Fixture Rod
1. Install the 8S-3675 Indicator Contact Point onto the indicator (1) .
2. Install Sleeve Extension (5) in the small diameter tube of Timing Fixture (2). Place Rod
Assembly (6) in Sleeve Extension (5) .
3. Install Dial Indicator (1) in Sleeve Extension (5) .
4. Put Dial Indicator (1) and Timing Fixture (2) onto the Set Gauge (3). The Timing Fixture
(2) should be on the top surface of the Set Gauge (3) with the Rod Assembly (6) on the
bottom 64.34 mm (2.5331 inch) step.
5. Move the Dial Indicator (1) in the Sleeve Extension (5) until both needles indicate zero.
Tighten Nylon Screw (4). The dial indicator has now been zeroed to a standard fuel timing
dimension of 64.34 mm (2.53317 inch).
Note: Some Dial Indicators (1) have a 0.25 mm (0.010 inch) smaller diameter extending
about 4.0 mm (0.158 inch) up from the end of their stems. When zeroing these indicators in
the bore of the 122-0449 Rod Sleeve Extension , the Nylon Screw (4) will contact the
indicator stem on this step. This can cause the indicator to cock in the bore and result in
incorrect readings. It is recommended that the 136-4587 Collet Extension and 5P-4814
Collet Clamp be used with the "stepped" indicator or that the 1U-8869 Dial Indicator be
used.
(7) Injector Follower
(8) Shoulder on injector body.
6. Make sure the top surfaces of (7) and (8) are clean and dry.
7. Put Dial Indicator (1) and Timing Fixture (2) in position on the injector to be checked.
Make sure that the magnetic base of the timing fixture is on the top surface of Injector
Follower (7). The extension rod will rest on the top surface of Injector Shoulder (8) .
8. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch).
9. If the dial indicator pointers indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), or are within
the tolerance given in 8, no adjustment is necessary. Proceed to step 13.
10. If the dial indicator pointers do not indicate 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch),
continue with step 11 through step 13.
Typical example of adjusting fuel timing.
11. Loosen the push rod adjustment screw locknut for the injector to be adjusted.
12. Turn the adjustment screw until zero is read on the dial indicator.
Note: If the dial indicator reading is greater than 0.00 ± 0.20 mm (0.00000 ± 0.0079 inch),
then turn the adjustment screw counterclockwise (CCW). If the dial indicator is less than
0.00 ± 0.20 mm (0.00000 ± 0.0079 inch), turn the adjustment screw clockwise (CW).
13. Tighten the adjustment screw locknut to 70 ± 15 N·m (51.63 ± 11.06lb ft). If necessary,
repeat procedure until the adjustment is correct.
14. Rotate engine, re-pin the flywheel, and repeat the procedure for the other half of the engine
that has not yet been adjusted.
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools
Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Note: Continuing improvement and advancement of product design can mean some photographs
or illustrations in this publication will show details that are different from your service tool.
Copyright 1993 - 2021 Caterpillar Inc. Tue Oct 26 16:16:31 UTC+0330 2021
All Rights Reserved.
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773E Off-Highway Truck ASK00001-UP (MACHINE)(SEBP4999 - 38) - Systems & ...

Reuse And Salvage Guidelines

9U-5132 Timing and Fuel System Setting Tool Group{1105,

Caterpillar Products: All Machines

Important Safety Information

Improper operation, lubrication, maintenance, or repair of this product can be dangerous

The Safety Section lists basic safety precautions.

General Information Section

Personal Protection/Important Information

Personal Protection/Important Information

Crushing Hazard (foot)

Crushing Hazard (hand)

General Information Section

9U-5132 Timing Tool Group

14 8T-2684 Rack Synchronization Gauge,

Compression 1-2-6-8 1-2-3-7 3-4-5-7

1-2-5-7-8-12- 1-2-3-4-5-6-8-9 3-4-6-9-10-11-

1-2-5-6-7-8-13 1-2-3-4-5-6-9- 3-4-9-10-12-

Section 1, Mechanical Unit Injector Engines

1. The technician should be prepared to activate the emergency stop button.

2. Disconnect the air inlet system from the turbochargers.

Be careful when plate is put against the air inlet opening.

1U-8869 (1) Digital Dial Indicator (used in preferred method)

General Set-up Information

Camshafts must be timed correctly with the crankshaft before an

Using the 1U-8869 Digital Dial Indicator (preferred method)

1U-8869 Dial Indicator

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

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

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

Adjustment of fuel timing tools

(1) 1U-8869 Dial Indicator

(2) 9U-5233 Magnetic Fixture Group

(3) 9U-5138 Setting Gauge

5. Repeat Steps 1.a through 1.d.

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

443-4177 Low Height Tool Option

Use only with the Digital Dial Indicator (preferred method).

1 1 443-4174 Fixture Assembly

• Tool is only used with the Digital Dial Indicator (1U-8869)

• Used to test and adjust fuel systems

• Collets to hold digital dial indicator built-in

• Fits all 3516 engines

Using the 6V-3075 Dial Indicator (alternate method)

(1) 6V-3075 Dial Indicator

(2) 9U-5137 Magnetic Fixture

(3) 9U-5138 Setting Gauge

(4) 9U-6272 Nylon Screw

(5) 9U-6273 Rod Sleeve Extension

(6) 9U-5220 Timing Fixture Rod

3. Install Dial Indicator (1) in Sleeve Extension (5) .

a. Example 1: Desired fuel timing dimension is 87.50 mm (3.4449 inch).

87.50 mm (3.4449 inch) - 87.00 mm (3.4252 inch) = +0.50 mm (0.0197 inch)

b. Example 2: Desired fuel timing dimension is 86.20 mm (3.3937 inch)

86.20 mm (3.3937 inch) - 87.00 mm (3.4252 inch) = −0.80 mm (−0.03150 inch)

(1) 6V-3075 Dial Indicator