Using the 4C-8180 Timing Tool Group To Set Fuel Injection Pump Timing{0701, 0706, 1251} Caterpillar


Using the 4C-8180 Timing Tool Group To Set Fuel Injection Pump Timing{0701, 0706, 1251}

Usage:

On 3408C and 3412C High Performance Marine Engines 8RG3JK7BL

Introduction

This Tool Operating Manual provides the information needed to obtain and assemble the necessary components of the 4C-8180 Timing Tool Group. It also provides a procedure to set the tooling and then adjust engine timing using the 4C-8180 Timing Tool Group. The tooling can be used on 3408C and 3412C High Performance Marine Engines. These engine serial number ranges are 8RG, 3JK, and 7BL.

There are two parts to the 4C-8180 Timing Tool Group. First, there are the parts used to perform the actual timing procedure. This includes the parts used to make the 4C-8181 Timing Tool Assembly. Second, there are the parts used to set the timing tool assembly indicator reading to zero. These parts include the 4C-8184 Gauge, 4C-8182 Gauge Collar, and 4C-8183 Gauge Plate.

The use of this equipment will improve the fuel injection pump-to-engine timing accuracy and is intended to replace the flow timing method currently described in many Service Manuals.

Do not perform any procedure outlined in this publication or order any parts until you read and understand the information contained within.


4C-8180 Timing Tool Group

NOTE: The 4C-8180 Timing Tool Group does not include a dial indicator, however, there is a cut-out in the foam insert to store one.

Parts Required for the 4C-8180 Timing Tool Group

To help keep the tool group cost to a minimum, the 4C-8180 Timing Tool Group is not serviced as a group. Since the group contains several tools which dealers may already have on hand and the 4C-8181 Timing Tool Assembly can be made from used engine parts, order only the new parts necessary to make a complete tool group.

Once all the required tools are on hand, store them in a 6V-3073 Plastic Case with an NEEG2651 Decal on the outside of the lid. A 4C-8185 Foam Block Group is also available to keep the tools in place, preventing possible damage. The top foam insert should be glued to the inside lid of the case, using 8T-9021 Adhesive or equivalent.


Parts Required For 4C-8180 Timing Tool Group
Refer to Chart A for item identification.

Assemble and Set the 4C-8180 Timing Tool Group

1. Obtain a 108-2104 Plunger and Barrel Assembly. This part can be new or used. If the part is used, make sure it is in good working condition. The plunger should move freely in the barrel.


4C-8181 Timing Tool Assembly
(9) 8J-3819 Spring. (10) 1N-3257 Retainer Ring. (11) Plunger and barrel from 108-2104 Plunger and Barrel Assembly. (12) 4C-8178 Indicator Mount Bonnet. (14) 4C-8179 Bonnet Nut. (16) 2W-3429 Gear Segment (part of 108-2104). (17) 8N-0669 Bolt (part of 108-2104). (18) 4P-8704 Spring (part of 108-2104). (19) 9Y-2088 Washer.

2. Make a 4C-8181 Timing Tool Assembly out of the 108-2104 Plunger and Barrel Assembly. The 4C-8181 Timing Tool Assembly is not a serviceable part.

a. Remove and discard 8N-0669 Bolt (17), 2W-3429 Gear Segment (16), and 4P-8704 Spring (18) from the 108-2104 Plunger and Barrel Assembly.

b. Assemble 8J-3819 Spring (9) and 9Y-2088 Washer (19) onto plunger. The 9Y-2088 Washer is part of the 108-2104 Plunger and Barrel Assembly.

c. Install the 4C-8178 Indicator Mount Bonnet (12) onto the barrel using a 1N-3257 Retainer Ring (10).

d. Slip 4C-8179 Bonnet Nut (14) over indicator mount bonnet (12).

e. This tool is now a 4C-8181 Timing Tool Assembly (11).

3. Assemble knurled gauge collar (3) onto gauge (5) by threading them together. Hand tighten the two parts.

NOTE: Make sure the gauging surfaces are clean and free of all debris, nicks, etc.

4. Install 4C-8181 Timing Tool Assembly (11) into gauge collar (3).

5. Thread bonnet nut (14) into gauge collar (3) and hand tighten with 9U-5120 Spanner Wrench (13). This will secure timing tool assembly (11) into gauge collar (3).

6. Spring (9) on the timing tool assembly should make the end of the plunger extend approximately 30 mm (1.2 in) past the end of gauge (5).

7. Push on the end of the plunger and make sure it travels freely (under spring force) in and out of the gauge block bore. If there is binding, disassemble and correct the problem.

8. Install either a 5P-4814 Collet (6) or 4C-2982 Collet Assembly (7) into indicator mount bonnet (12).

9. Install an indicator with a 5P-7262 Contact Point into collet (6 or 7). Use either a 6V-6106 Dial Indicator or an 8T-1002 Probe connected to an 8T-1001 Electronic Position Indicator.


NOTICE

Do not over tighten collet (6 or 7) holding the indicator. Over-tightening can result in damage to the indicator or the electronic position indicator probe.


10. Tighten collet (6 or 7) just enough to make sure the indicator or electronic position indicator probe will not move in collet.

11. Zero the indicator by following this procedure.

a. Place the 4C-8183 Gauge Plate (8) onto a flat surface.

b. Carefully hold the entire 4C-8180 Timing Tool Group and place it on the gauge plate, with the end of the plunger contacting the plate.

c. Push down on the entire assembly, compressing the spring, until the bottom of gauge (5) is in complete contact with gauge plate (8).


Zero The Timing Tool Assembly With Dial Indicator Using Gauge Collar (3), Gauge (5), And Gauge Plate (8) (6) Collet. (12) Indicator mount bonnet. (14) Bonnet nut.


Zero The Timing Tool Assembly With Electronic Position Indicator Using The Gauge, Gauge Collar, And Gauge Plate

d. Hold the assembly tightly against the gauge plate and zero the dial indicator (or electronic position indicator).

NOTE: The dial indicator can be adjusted in the collet to achieve the desired results. The electronic position indicator can be zeroed by using the "zero" button.

e. Verify the zero reading. Raise the assembly slightly from the gauge plate, then press and hold it down tightly. If the indicator does not return to zero, reset it.

On-Engine Fuel Injection Pump Timing Procedure

The following tools are required for this procedure, in addition to the 4C-8180 Timing Tool Group.

1. Remove the No. 1 injection pump plunger and barrel from the fuel pump housing.

2. Remove the fuel nozzle from cylinder No. 1.

3. Position No. 1 piston (7) at top center (TC) on the compression stroke. Locate top center with the timing bolt, but do not install the bolt. For additional information, refer to topic "Top Center (TC) Position For No. 1 Piston" in the Engine Service Manual.

4. Assemble dial indicator (1), 8T-3206 Adapter (2), 7W-2315 Retainer (3), 7W-5435 Direct Injection Fuel Nozzle Adapter (4), and 5S-8090 Rod with 6V-2057 Contact Point (5) from the 8T-5246 Engine Timing Indicator Group. For additional information, refer to Special Instruction SMHS7083, "Using the 5P-6524 Engine Timing Indicator Group and 1P-0540 Flow Checking Group".

5. Install the assembly in place of the No. 1 fuel injection nozzle and zero the indicator.

6. Rotate the crankshaft in the reverse direction 90 degrees. While observing dial indicator (1), rotate the crankshaft in the normal direction until it is past top dead center. Verify that the indicator reading was zero when the piston was at top dead center. Repeat Step 3, if necessary, to re-zero the indicator.

7. Remove the 4C-8181 Timing Tool Assembly (6) with dial indicator (8) installed from the gauge block assembly. Use the 9U-5120 Spanner Wrench to loosen the 4C-8179 Bonnet Nut. Be careful not to move the position of the calibrated indicator.

8. Install timing tool assembly (6) into the No. 1 fuel injection pump bore in the fuel pump housing.

9. Hand tighten the bonnet nut using the spanner wrench.

NOTE: To check fuel injection pump timing, perform Step 10. To set fuel injection pump timing, omit Step 10 and proceed to Step 11.

10. Rotate the crankshaft in the reverse direction 90 degrees. While observing dial indicator (8), rotate the crankshaft in the normal direction until the indicator reads zero. Observe the reading on dial indicator (1) and refer to Chart C to determine the timing in degrees before top dead center.

11. Rotate the crankshaft in the reverse direction 90 degrees. Rotate the crankshaft in the normal direction until dial indicator (1) reads 5.611 ± 0.254 mm (.2209 ± .010 in). Do not move the crankshaft from this position.

NOTE: The piston position in Step 11 is for a timing specification of 19.5 degrees. If a different timing angle is specified, refer to Chart C for the correct piston position.

12. Loosen the fuel pump cam drive. Refer to the Service Manual for additional details. Rotate the pump cam drive until dial indicator (8) on timing tool assembly reads zero.

13. Tighten the pump drive bolts.

14. Repeat Step 11.

15. If dial indicator (8) does not read zero when piston (7) is at the 5.611 ± 0.254 mm (.2209 ± .010 in) position, repeat Step 12.

NOTE: It may take two or three attempts to achieve accurate timing. This procedure must be completed accurately to obtain maximum engine performance.

16. Tighten the fuel pump drive bolts.

17. Remove all tooling and reassemble the engine and fuel injection pump.


Setting Fuel Injection Pump-To-Engine Timing
(A) Fuel pump housing. (B) Cylinder head. (1) Dial indicator. (2) 8T-3206 Adapter. (3) 7W-2315 Retainer. (4) 7W-5435 Direct Injection Fuel Nozzle Adapter. (5) 5S-8090 Rod and 6V-2057 Contact Point. (6) 4C-8181 Timing Tool Assembly. (7) Piston. (8) Dial Indicator.

For information on service tools or shop supplies contact Caterpillar Service Technology Group on:

Caterpillar Service Technology
100 N.E. Adams Street
Peoria, Illinois 61629-9110
1-800-542-8665 (USA)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6618 (Fax)

or

Caterpillar Service Technology
Caterpillar Overseas S.A.
P.O. Box 456
1211 Geneva 6
Switzerland
41 (22) 849 40 36 (Geneva Phone)
41 (22) 849 45 44 (Geneva Fax)
413323 (Geneva Telex)
CATOVERSEA (Geneva Cable)
36CSTG (COSA E-Mail Address)

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