caterpillar 3500 engine

7/21/2019 caterpillar 3500 engine

1/20


2/20

Table of Contents

Section 1, Mechanical Unit Injector Engines

Section 2, Electronic Unit Injector Engines

9U-5132 Timing Tool

Group

9U-5132 Timing Tool Group

Item Part No. Description

01090

2080

3070

406050

4060

3070

20

80

1090

00

1

2

34

56

7

89

9

8

7

65

4

3

2

1

01 1

;

;

;

REV.

INC.

ABS

+/-

in/m

m

ON/OFF

PRES

ETZERO/AB

S

1

9 4

3

2

57 8

10

1211 14

13

18

15

16

17

6


3/20

Chart C. Dial Indicator Setting Chart1

Fuel Timing Dimension inMillimeters

Dial Indicator Setting inMillimeters

Crankshaft Positions for Unit Injector Lash andValve Lash Settings

Chart A.Standard Rotation (Counterclockwise) As Viewed From Flywheel End

Cylinders to Check/Adjust

Engine

Correct Stroke forNo. 1 Piston at Top

Center Position1Intake

ValvesExhaustValves

Injectors

Chart B.Reverse Rotation (Clockwise) As Viewed From Flywheel End

Cylinders to Check/Adjust


4/20

Section 1, MechanicalUnit Injector Engines

Start-Up Procedure

1

2

Be careful when plate is put against air inletopening. Due to excessive suction, the platecan be pulled quickly against the air inletopening. To avoid crushed fingers, do not putfingers between plate and air inlet opening.

3

4

Tooling

Chart A.9U-5132 Timing and Fuel System Setting Tool Group For

MUI Engines

Part No. Description

NOTE:


5/20

General Set-up Information

NOTICE

The camshafts must be correctly timed with thecrankshaft before an adjustment of fuel timing ismade. The timing pins must be removed from thecamshafts before the crankshaft is turned, ordamage to the cylinder block will result.

Using the 1U-8869 Digital DialIndicator (preferred method)

1

a

b

c

d

e

f

g

h

2

REV.

INC.

ABS

+/-

in/mm

ON/OFF

PRES

ETZERO/ABS


6/20

3

4

5

6

7

NOTE:

8

9

1

2

6

3

54

REV.

INC.

ABS

+/ -

in/mm

ON/O

FF

PRES

ETZE

RO/ABS

1

2

7

8

REV.

INC.

ABS

+/ -

in/mm

ON/OFF

PRESET

ZERO/ABS


7/20

10

11

12

13

14

15.

Using the 6V-3075 DialIndicator (alternate method)

1

2

3

4

5

1

2

63

01090

2080

3070

406050

4060

3070

20

80

1090

00

1

2

3

456

7

8

9 9

8

7

65

4

3

2

1

01 1

4

5


8/20

NOTE:

6

NOTE:

a

b

7

8

9

10

11

12

13

1

2

8

7

01090

2080

3070

406050

4060

3070

20

80

1090

00

1

2

34

56

7

89

9

8

7

65

4

3

2

1

01 1


9/20

NOTE:

14. Tighten the adjustment screw locknut to

70

15

Injector SynchronizationProcedure

Chart B.Injector Synchronization Tools

Part No. Title/Description Qty

1

2

EXHA

UST

INTAKE

1 3

2

2 4


10/20

3

4

5

a

b

c

d

6

5

6 5

7


11/20

7

8

Fuel Setting Procedure

Chart C.Chart Fuel Setting Tools

Part No. Title Description Qty

Fuel Setting Check

1

2

EXHA

UST

INTAKE

5

01090

2080

3070

406050

4060

3070

20

80

1090

0

01

2

3

456

7

89

9

8

7

65

4

3

2

1

01 1

2

3

4

;

;

;

1

2

3

0

90

8070

60

50

40

3020

10


12/20

3

4

NOTE:

5

6

Fuel Setting Adjustment

NOTICE

A mechanic with governor and fuel setting trainingis the ONLY one authorized to make adjustmentsto the engine fuel setting.

1

2

5

4 6

0

1 0

9 0

2 0 8

0 3 0

7 0

4 0

6 0

5 0

4 0

6 0

3 0

7 0

2 0

8 0

1 0

9 0

0 0

1

2 3 4

5

6

7 8 9

9

8 7

6

5

4

3 2

1

0

1

1

25

8

0

1090

2080

307

040

60

50

40

60

30

70

20

801

090

00

1

234

5

6

789

9

8

7 6

5

4

3

21

01

1

0

1090

20

80

307

040

60

50

40

60

30

70

20

801

090

00

1

234

5

6

789

9

8

76

5

4

3

21

01

1


13/20

2

3

4

9

8

10

10


14/20

Section 2, ElectronicUnit Injector Engines

Tooling

Chart A.9U-5132 Timing and Fuel System Setting Tool Group For

EUI Engines

Part No. Description

NOTE:

General Set-up Information

NOTICE

The camshafts must be correctly timed with thecrankshaft before an adjustment of the unitinjector lash is made. The timing pins must beremoved from the camshafts before the crankshaftis turned, or damage to the cylinder block willresult.

The electronic control module (ECM) produceshigh voltage. To prevent personal injury makesure the ECM is not powered and the unitinjector solenoids are disconnected.


15/20

Using the 1U-8869 Digital DialIndicator (preferred method)

1

a

b

c

d

e

f

g

h

2

REV.

INC.

ABS

+/-

in/mm

ON/OFF

PRES

ETZERO

/ABS

6

1

2

4

3

5 REV.

INC.

ABS

+/ -

in/m

m

ON/OF

F

PRES

ETZE

RO/ABS


16/20

3

4

5

6

NOTE:

7

8

9

10

11

12

13

14

1

7

8

5REV

.

INC.

ABS

+/-

in/mm

ON/O

FF

PRESET

ZERO/AB

S


17/20


18/20

7

8

9

10

NOTE:

11

12

010

90

2080

3070

4060

5040

60

3070

20

80

1090

0

01

2

3

45

6

7

8

99

8

7

65

4

3

2

1

01 1


19/20

NOTES


20/20

caterpillar 3500 engine

Documents

Transcript of caterpillar 3500 engine