3500 PDF

3500 SERIES ENGINES
ADJUSTMENTS AND MINOR REPAIRS
TECHNICAL PRESENTATION
3512 ENGINE
LESVO509 ENGINE SERVICE TRAINING 1998 1

3500 SERIES ENGINES
3512 ENGINE
LEVEL II
This presentation tells about procedures and shows the special tools needed to make
adjustments and minor repairs to the 3512 Engine. Reference must be made to the
Service Manual for complete instruction.
The 3512 Engine has different arrangements for different applications (Industrial,
Generator Set, Marine, Marine Auxiliary, and Vehicular Engines). The slides in this
presentation show the 3512 and 3516 Engines.
PREREQUISITES
The serviceman must have completed LESV0508, 3500 Series Engines – Introduction,
Systems and Maintenance, LESV0508. Serviceman must know the construction and
operation of diesel engines and have experiences with the adjustment and minor repair
of these engines.
OBJECTIVES
After learning the information in this Meeting Guide, the serviceman can tell the
procedures and special tools needed to do the following jobs:
1. remove and install a unit injector;

2. check and adjust injector synchronization;
3. check and adjust power settings;
4. check and adjust injector pump plunger timing; and
5. remove and install the water pump water seals.
NOTE: This presentation gives Level II knowledge of the 3500 Engine. The instructor
can give skill training after this presentation skill training will give each serviceman the
ability to do the different jobs that are needed to make adjustments and minor repairs to
the 3500 engine.

3500 SERIES ENGINES
3512 ENGINE
REFERENCES
The following material will be used for instructor and serviceman references:
1. 3512 Engine Service Manual SEBR0548

2. 3512 Engine Parts Book SEBP1292
3. 3512 Engine Operation and Maintenance Guide SEBV5854
4. Engine Literature SEBDO506-01
“Engine Literature” is a list of different service information and training materials which
are available. This list is used by the instructor to find materials which can be used to teach
servicemen to do the different jobs expected of them.
DIRECTIONS TO THE INSTRUCTOR
When you get ready to teach this STMG, do as follows:
1. Read all of the information (script) for each slide in the presentation.
2. Read the recommendation for FOLLOW-UP TRAINING.
3. Show the presentation. Make sure you know exactly what points are to be seen on each
slide and to be learned by the serviceman.
4. Read the script again and add any notes that you will need to teach the presentation.
5. Read service literature (reference) as necessary.
6. Look at a 3500 Engine and learn what you need to teach.
7. ORDER copies of references for use by servicemen.
8. Make a plan for FOLLOW-UP TRAINING.
Estimated Time: 8 hours
Visuals: 144 slides
Form: LESV0509
Date: 8/80 Revised: 8/86

3500 SERIES ENGINES
1
INTRODUCTION TO REPAIR
This presentation is about adjustment and minor

repair of the 3500 Engine. It gives the
important steps and shows the special tools
needed to do these jobs.

3500 SERIES ENGINES
2
INTRODUCTION TO REPAIR
We will show those adjustments and repairs that are

special to the 3500 Engines and different from
other Caterpillar Engines. These adjustments
and repairs are:
1. unit injector replacement

2. injector synchronization
3. check power setting
4. adjust power setting
5. timing camshafts to crankshaft
6. injector pump plunger timing, and
7. water pump seal replacement

3500 SERIES ENGINES
3
UNIT INJECTOR REPLACEMENT
Follow these procedures to replace a unit injector:
1. Remove the valve cover.

2. Remove the bolts from the rocker arm shaft.
Lift the rocker arms and shaft from the valve
cover base.
3. Remove the valve bridge from the dowels.
4. Remove the locknut and washer from the
control rod bolt. Disconnect the control rod
from the bellcrank.
5. Remove the bolts from the brackets of the
bellcrank lever assembly.
6. Slide the bellcrank from the rack of the
injector and remove the bellcrank lever
assembly from the cylinder head.
7. Remove the bolt from the injector clamp and
remove the clamp.
8. Pull the unit injector up and out of the bore of
the cylinder head and remove it from the
engine.
CAUTION: DO NOT pry on rack or location

dowels or points that will cause damage.

3500 SERIES ENGINES
3
9. Clean the injector bore of the cylinder head.

10. Put new O-ring seals (3) on the unit injector and
put clean engine oil on the O-ring seals.
11. Put the unit injector in position with the bore of the
cylinder head. Make sure the two (2) dowels in the
injector’s body are in alignment with each side of
the bridge dowel.
12. Push the unit injector down into the bore of the
cylinder head.
13. Install the clamp and bolt. Tighten the bolt to
Service Manual specifications.
14. put the bellcrank lever assembly in position on the
cylinder head. Make sure the bellcrank is
connected correctly to the rack.
15. Install the two bolts in the brackets and tighten
each bolt to Service Manual specifications.
16. Connect the control rod bolt to the bellcrank, put
on the washer and locknut and tighten each to
Service Manual specifications.
17. Move the control rod, linkage and rack and see that
all controls move freely.
18. Check the synchronization of all injectors and
adjust.
19. Install rocker arm shafts and rocker arms and check
and adjust the valve clearance and injector timing.
20. Put on the valve covers and install the bolts.
Tighten the bolts to Service Manual specifications.

3500 SERIES ENGINES
4
The valve cover, rocker arms and shaft have been

removed so that you can see better. You can
see the injector and rack, the bellcrank lever
assembly and the control rod, and valve
bridges.
NOTICE: Place a clean shop towel below the

bellcrank and control rod bolt. The shop
towel can stop any parts that drop so they will
not fall into the cylinder head and the oil pan.
Remove the locknut and washer from the control rod

bolt, and the two bolts from the bellcrank
lever assembly bracket. Then remove the
valve bridges from the dowels and the bolt
from the injector clamp, and the clamp.

3500 SERIES ENGINES
5
With the bellcrank lever assembly, the valve bridges

and the injector clamp and bolt removed, the
injector is ready to be removed.
You can see the two injector body location dowels

on the right side of the valve bridge dowel.
These two location dowels make it necessary
to remove the valve bridges to remove an
injector. The injector body location dowels
position the injector rack to the bellcrank.

3500 SERIES ENGINES
6
With the injector removed, make sure the injector

bore in the cylinder head is clean.
Install new O-ring seals (3) on the injector housing

(nut) and put clean engine oil on the O-ring
seals.
Make sure the plug is installed in the top of the

cylinder head. Then install the injector body...

3500 SERIES ENGINES
7
...into the bore of the cylinder head. Make sure the

injector location dowels are in position on the
valve bridge dowel. Push the injector down into
the cylinder head. Install the clamp and bolt.
Tighten the bolt to Service Manual
specifications. Check the injector rack to see that
it moves freely.
NOTICE: DO NOT hit the unit injector to make it go

into the cylinder head.
Connect the bellcrank lever to the rack and install the

bolts in the bracket. Put the control rod bolt in
the bellcrank and install the washer and locknut.
Tighten the bolts in the bracket and the locknut
on the control rod bolt.
The shop towel can now be removed from below the

bellcrank assembly. Move the control rod up and
down and make sure the rack and linage moves
freely. The injectors must be synchronized.
Injector synchronization is shown and explained
in slides 8 through 21 of this meeting guide. The
injectors can be synchronized with the rocker
arms and shaft in place, but it is easier to
synchronize the injectors before the rocker arms
and shaft are installed. Now install the rocker
arms and shaft.

3500 SERIES ENGINES
7
Valve clearance (lash) and injector timing must be

checked and adjusted after the rocker arm
shafts have been loosened and tightened.
Valve adjustment procedure was explained in
STMG 398. Also look in the Service Manual
for the specifications and procedures for your
engine. Injector timing will be covered later in
this meeting guide.
Put on the valve covers and install the bolts. Tighten

the bolts to Service Manual specifications.

3500 SERIES ENGINES
8
INJECTOR SYNCHRONIZATION
The power setting screw is under the cover on the

governor side (right front side shown) of the
engine on the front gear housing. The top bolt
in the cover is the synchronization pin.
Injector synchronization is the setting of all injector

racks to a reference position so that each
injector sends the same amount of fuel to each
combustion chamber. This is done by setting
each injector rack to the reference position
while the control linkage is held in a fixed
position called the synchronizing position.

3500 SERIES ENGINES
9
Remove the cover and gasket of the power setting

screw by taking out the two bolts. The power
setting screw is in the opening in the gasket.
It is not necessary to remove the cover or break the

fuel setting seal to set synchronization.

3500 SERIES ENGINES
10
The top bolt is the synchronizing pin. The bottom

bolt is a standard bolt.
NOTE: Cover can be installed either way so long

bolt can be installed in the upper or lower
location.

3500 SERIES ENGINES
11
Remove the washer from the synchronizing pin and

put it in the threaded hole to the left of the
power setting screw.

3500 SERIES ENGINES
12
REVIEW
Let us review the control linkage of the unit injectors

and the power setting screw arrangement by
looking at this illustration.
We can see the power setting screw (2) in contact with

the fuel stop lever. The synchronization pin,
when installed, will also be in contact with the
fuel stop lever.
The synchronization pin sets the fuel stop lever at the

reference position for rack synchronization of
the fuel injectors. To make this adjustment, the
synchronization gauge is put on the rack (6) (see
slides 19,20, and 21).
The synchronization pin is also the ZERO reference

point for the dial indicator which is installed in
the hole to the right of the power setting screw.
When a check of the power setting is made, the
dial indicator is installed, put at ZERO, and then
used to measure the power setting: the setting of
the power setting screw.
NOTE: This illustration is not correct. The seal goes

through the cover bolt, not the synchronizing pin.

3500 SERIES ENGINES
13
The five holes are:
1. top cover bolt / synchronizing pin storage

hole;
2. bottom cover bolt hole;
3. center is power screw with locknut;
4. hole to left of power screw is synchronizing
pin hole;
5. hole to right of power screw is for collet and
dial indicator.
Turn the synchronizing pin in the threaded hole on

the left side of the power screw.

3500 SERIES ENGINES
14
Turn the synchronizing pin all the way in against the

housing and tighten it.

3500 SERIES ENGINES
15
This is the fuel control linkage with the front

housing off the engine. We can see the flat
face of the fuel stop lever which contacts the
synchronizing pin and the power screw.

3500 SERIES ENGINES
16
Here we see the synchronizing pin installed and

tightened against the face of the fuel stop
lever. The front housing is installed but the
housing adapter cover has been removed.
Turn the governor speed control lever clockwise in

the fuel “ON” direction until the flat face of
the fuel stop lever contacts the synchronizing
pin. This is the synchronizing position for
injector rack synchronization. It is also the
zero reference point for zeroing the dial
indicator for making a power setting
adjustment.
Hold the governor linkage in this position all the

time while each injector rack is being adjusted
and while the power setting adjustment is
made.

3500 SERIES ENGINES
17
This is the tool group used when synchronizing the

injectors and for making a power setting.
1. Synchronizing Gauge 12.7 mm (.500 inch)

[6VV3119].
2. Dial Indicator [6V3075]
3. Collet [5P4814] (Course threads)
4. Contact Point 76.2mm (3.0 inch)
[5P7263]
This is part of the Timing and Fuel Setting Tool

Group. (6V7880).

3500 SERIES ENGINES
18
The valve and injector rocker arms have been

removed so that you can see the:
1. unit injector;
2. rack extending from injector;
3. bellcrank;
4. screw slot on end of the control rod;
5. nut and bolt that holds the control rod to
the bellcrank.
The synchronizing gauge goes on the round part of

the rack between the end of the rack and the
body of the unit injector.

3500 SERIES ENGINES
19
With the synchronizing pin against the face of the

fuel stop lever, put the 12.7mm (.500 inch)
synchronizing gauge on the rack between the
injector body and the end of the rack assembly.

3500 SERIES ENGINES
20
Put a screwdriver in the screw slot on the end of the

control rod and turn it one “click” at a time
until the 12.7mm synchronizing gauge just fits
between the end of the rack assembly and the
injector body. To get the setting correct, you
must get the correct “feel” with the gauge.
This “feel” is similar to the “feel” of a
clearance gauge when you check engine
valves.
DO NOT attempt to use the synchronizing gauge as

a stop because deflection of the linkage will
cause an incorrect adjustment.

3500 SERIES ENGINES
21
Remove the screwdriver from the slot so that NO

pressure is on the linkage while checking the
setting with the synchronizing gauge. Any
pressure on the linkage with the screwdriver
will cause the setting (adjustment) to be
wrong. To make sure the linkage is free and
positioned normally, move (flip) the linkage
by placing the box end of a combination
wrench (9/16 or 5/8) over the nut and bolt
that holds the control rod to the bellcrank.
Pull up the control rod a little and release it
two or three times; then check the setting
again. Make the adjustment to all injectors.

3500 SERIES ENGINES
22
CHECK POWER SETTING
Power setting is the adjustment of the power screw to a

measurement given in the specifications. The
power screw is adjusted to set the maximum
power output of the engine by limiting the
maximum travel of the torsion shafts and,
therefore, the movement of all injector racks.
Before the power setting is checked, make sure
that all injectors are correctly synchronized.
Leave the synchronizing pin tightened in place.
Move the governor linkage in the fuel “ON”
direction until the face of the fuel stop lever
contacts the synchronizing pin. Hold the linkage
in this position.
NOTE: For increased accuracy, use an FT1819

Governor Torque Arm (shown in the following
slide). The FT 1819 can’t be used on trucks.
For all power settings, torque rise cam settings, and

synchronization, the governor to engine linkage
must be completely free. If need be,k it can be
freed by loosening the governor mounting bolts
and repositioning the governor slightly. If the
governor linkage is few, THE FT1819 ARM
ISN’T REALLY NEEDED.

3500 SERIES ENGINES
LESVO509 22
CHECK POWER SETTING
Turn the collet (5P4814) for the dial indicator into

the threaded hole to the right of the power
screw. Put the 76.2mm (3.0 inch) contact
point on the dial indicator and install it in the
collet. With the contact point against the fuel
stop lever face, move the indicator until the
indicator reads or is set on zero. Tighten the
nut on the collet.
NOTE: The dust cover on the top of the dial

indicator must be removed to give
clearance with the alternator mount
bracket.
Remove the synchronizing pin.
NOTE: The 3161 Governor was used for

illustration of these procedures.

3500 SERIES ENGINES
23
CHECK POWER SETTING
With the governor and adapter cover removed, we

see the power setting screw and the contact
point of the dial indicator against the face of
the fuel stop lever. Move the governor linkage
in the fuel “ON” direction until the face of the
fuel stop lever contacts the end of the power
screw. With the linkage held against the power
setting screw, the dial indicator reading will
be the power setting.

3500 SERIES ENGINES
24
CHANGE POWER SETTING
To change the power setting, loosen the locknut and

turn the power screw (while holding the
linkage against the power setting screw) in or
out to the correct specifications. The power
setting is on the engine information plate and
in the rack setting charge (RACK SETTING
INFORMATION). When the correct
adjustment is made, tighten the locknut on the
power screw. Make sure the setting does not
change. Remove the collet and dial indicator.

3500 SERIES ENGINES
25
CHANGE POWER SETTING
With the injectors synchronized and the adjustment

made to the power setting, install the power
setting screw cover and gasket.

3500 SERIES ENGINES
26
ENGINE TIMING
Remove the plug (5M2613) from the front face of

the flywheel housing and the two (2) bolts
from the cover plate of the bore for the engine
turning tool. The longer bolt (L1352) is used
as the timing bolt to find the location of No. 1
piston on top center of the compression
stroke.
NOTE: LESV0508 “3512 Engine Introduction,

Systems and Maintenance,” the instruction
which starts with slide No. 92 gives an
explanation of the steps used to find top
center, compression stroke. Teach or review
this procedure, if needed.

3500 SERIES ENGINES
27
ENGINE TIMING
Remove the right and left rear camshaft

compartment cover. There is a timing pin
(7N3370) stored under the right rear and left
rear camshaft compartment covers. Each
timing pin has a bolt which holds it on the
side of the block when it is not in use.

3500 SERIES ENGINES
28
ENGINE TIMING
Look at the camshaft and see where the slot in the

camshaft is in relation to the timing pin hole
in the block. If you can’t see the slot because
it is on the top side away from you, feel on
the back side of the camshaft for the slot.
Finding the position of the slot in the camshaft to

the timing pin hole in the block will give an
indication where No. 1 piston is in relation to
top center, compression stroke. When the slot
in the camshaft is in alignment with the
timing pin hole, No. 1 piston is at top center
on the compression stroke. The timing bolt
hole in the flywheel will also be in alignment
with the timing hole in the flywheel housing.
The timing bolt will turn into the timing hole
in the flywheel.
Now, put the engine at No. 1 piston at top center,

compression stroke.

3500 SERIES ENGINES
29
ENGINE TIMING
Remove the bolt from the camshaft timing pin. Put

the pin in the timing hole in the block and
push the pin in the slot in the camshaft. When
the pin is in the slot, the camshaft is in time
with the crankshaft. When the pin will not go
in and the slot is not in alignment, the
camshaft will have to be put in time.

3500 SERIES ENGINES
30
ENGINE TIMING
NOTICE: When a camshaft is out of time as much

as 20°, the valves will contact the pistons and
cause damage to the valve system parts.

3500 SERIES ENGINES
31
ENGINE TIMING
We will use only the left camshaft to demonstrate

the timing procedure. When the right
camshaft is not in time, the same procedure is
followed.

3500 SERIES ENGINES
32
ENGINE TIMING
Remove each of the valve covers on the left bank of

the engine. Loosen the rocker arm shaft bolts
on each of the six cylinder heads until the
push rods are not engaged. With the rocker
arm shaft bolts loose, the valves and injectors
are released from the camshaft.
NOTICE:WHEN THE ENGINE IS TURNED,

there is only a small clearance between the
pistons and the valves at top center, exhaust
stroke, etc. If the engine is NOT timed
correctly and the crankshaft is turned, it is
possible for the pistons to contact (strike) the
valves and cause damage.
NOTE: Loosen the rocker arm shaft bolts first, then

force the cam drive gear from the camshaft
taper. The injectors put a large force on
each of the cam lobes and can cause
rotation of the camshaft when the drive
gear is loosened from the taper.

3500 SERIES ENGINES
33
ENGINE TIMING
Remove the cam drive gear retaining bolt.

3500 SERIES ENGINES
34
ENGINE TIMING
Use a crossbar puller arrangement to pull the

camshaft drive gear from the tapered end of
the camshaft.

3500 SERIES ENGINES
35
ENGINE TIMING
The tooling and drive gear are removed from the

camshaft. Put a bolt in the end of the
camshaft and turn the camshaft until the
timing pin can be installed through the timing
hole into the groove in the camshaft.
Turn the gear and hold in the direction of normal

engine rotation to remove backlash. Install the
bolt and plate.

3500 SERIES ENGINES
36
ENGINE TIMING
Tighten the bolt to specified torque, then hit the gear

and tighten it to specified torque again.
Repeat this procedure a second time.
With the timing bolt in the flywheel and timing pin

in the camshaft, the timing is now correct.

3500 SERIES ENGINES
37
ENGINE TIMING
Make sure the push rods are engaged correctly with

the rocker arms. Tighten the rocker arm shaft
bolts.
Valve clearance (lash) and injector timing must be

checked and adjusted after the rocker arm
shaft bolts have been loosened and tightened.
Valve adjustment procedure was explained in
LESC0508. Also look in the Service Manual
for the specifications and procedures for your
engine. Injector timing will be covered later in
slides 42-47 of this meeting guide.

3500 SERIES ENGINES
38
ENGINE TIMING
When the right camshaft is not in time, and the left

camshaft is in time, do the same procedure for
putting the right camshaft in time with the
crankshaft.

3500 SERIES ENGINES
REVIEW OF
CAMSHAFT TIMING PROCEDURE
Follow these procedures to change the timing of a

camshaft:
1. Put the timing bolt in the flywheel.

2. Put the timing pin the camshaft that is in time.
3. Remove each of the valve comers on the bank that
needs timing.
4. Loosen the rocker arm shaft bolts on each of the
cylinder heads until the push rods are not engaged.
5. Remove the cover of the drive gear of the camshaft
that is out of time.
6. Remove the bolt that holds the plate to the cam
drive gear and the end of the camshaft.
7. Use a cross block puller arrangement on the cam
drive gear until the gear comes loose from the taper
of the camshaft.
8. Remove the puller and leave the drive gear in
position.
9. Install a bolt into the hole in the end of the
camshaft.
10. Use the bolt to turn the camshaft until the timing
pin will go into the slot in the camshaft.
11. With the timing pin in the slot of the camshaft,
remove the bolt from the threaded hole in the end
of the camshaft.
12. Install the plate and bolt in the end of the camshaft.
13. Tighten the bolt and torque to Service Manual
specifications. Strike and torque again. Repeat.
14. Make sure push rods are engaged correctly with the
rocker arms and then tighten the rocker arm shaft
bolts.
15. Remove the timing pin(s) from the camshaft(s) and
the timing bolt from the flywheel.
16. Check and adjust valve clearance and injector
timing.
17. If the other camshaft is not in time with the
crankshaft, do steps 1 through 16.

3500 SERIES ENGINES
39
INJECTOR TIMING
These are the special tools used to check or adjust the

injector pump plunger timing.
1. Timing Fixture (Bracket, Collet – Extension

Rod) [6V7881]
2. Set gauge (6V3117)
3. Dial Indicator (6V3075)
4. 3.048mm (.12 inch) Contact Point (8S3675)
5. Extension Rod (Part of the Timing Fixture)
This is the other part of the Timing and Fuel Tool

Group (6V7880).

3500 SERIES ENGINES
40
TIMING FIXTURE
Assemble and set indicator. Assemble the timing fixture

assembly and zero the dial indicator to check or
make an adjustment to the injector pump longer
timing.
1. Turn a 3.1mm (.12 inch) Contact Point

[8S3675 in the stem of the dial indicator.
2. Put the dial indicator in the collet of the
fixture and tighten the collet just enough to
hold the dial indicator.
3. Move the extension rod and watch the dials
on the indicator. Make sure the extension rod
is free.
4. Position the fixture assembly on the set gauge
with the magnetic base of the fixture on the
top surface and the extension rod on the
bottom step.
5. Move the dial indicator in the collet until the
pointers indicate zero. Now move the dial
indicator in the collet until the large pointer
indicates the setting shown in the Dial
Indicator Setting Chart* (if other than zero
setting) and tighten the collet.
The Dial Indicator Setting Chart is Serviceman

Handout 1.

3500 SERIES ENGINES
41
UNIT INJECTOR TIMING
The dial indicator measures the distance from the

top of the injector follower to the injector
body surface. This measurement gives the
relation of the scroll on the plunger with the
ports in the barrel. Injector pump plunger
timing is a standard that permits the setting of
all unit injectors the same so that the
beginning of injection takes place in each
combustion chamber a specific number of
crankshaft degrees before top center.

3500 SERIES ENGINES
42
Injector pump plunger timing can be checked or

adjusted during the two–crank position
sequence for valve clearance setting, or
turning the crankshaft in the direction of
normal rotation until the injector is at
maximum height and the push rod is at its
lowest point (the lifter assembly is at its
lowers point on the base circle of the cam).
Use a wrench (3/4 inch) and loosen the
adjustment screw locknut of the rocker arm.

3500 SERIES ENGINES
43
With the timing fixture in position, turn the

adjustment screw clockwise until the dial
indicator is on zero*. Hold the adjustment
screw with the screwdriver and tighten the
locknut to Service Manual specifications.
*On-Engine settings are always zero.

3500 SERIES ENGINES
44
Check the setting again to see that the adjustment

has not changed and the dial indicator reads
zero.

3500 SERIES ENGINES
45
INSTALL WATER PUMP WATER SEAL
The water pump water seal can be changed (anew

seal installed) without removing the pump
from the engine. Remove cover. Remove
impeller. The seal is behind the impeller.
You can find a bad seal by looking at the weep hole

of the water pump. When the seal is bad,
coolant will leak out the weep hole.
NOTE: Service Training Video Tape “6.25 Inch

Bore Vee Engines-Cooling System,” also
shows the installation of the jacket water
pump water seal. Video Tape 72
“Reconditioning Water Pumps,” can be used
to supplement this training.

3500 SERIES ENGINES
SERVICEMAN HANDOUT 1
*DIAL INDICATOR SETTING CHART
Fuel Timing Dimension mm Dial Indicator Setting mm
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
*See Fuel Setting Information for the
correct fuel timing dimension to use.

3500 SERIES ENGINES

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3500 SERIES ENGINES

ADJUSTMENTS AND MINOR REPAIRS

LESVO509 ENGINE SERVICE TRAINING 1998 1

1. remove and install a unit injector;

LESVO509 ENGINE SERVICE TRAINING 1998 2

1. 3512 Engine Service Manual SEBR0548

DIRECTIONS TO THE INSTRUCTOR

When you get ready to teach this STMG, do as follows:

LESVO509 ENGINE SERVICE TRAINING 1998 3

This presentation is about adjustment and minor

LESVO509 ENGINE SERVICE TRAINING 1998 4

We will show those adjustments and repairs that are

1. unit injector replacement

LESVO509 ENGINE SERVICE TRAINING 1998 5

UNIT INJECTOR REPLACEMENT

Follow these procedures to replace a unit injector:

1. Remove the valve cover.

CAUTION: DO NOT pry on rack or location

LESVO509 ENGINE SERVICE TRAINING 1998 6

UNIT INJECTOR REPLACEMENT

9. Clean the injector bore of the cylinder head.

LESVO509 ENGINE SERVICE TRAINING 1998 7

UNIT INJECTOR REPLACEMENT

The valve cover, rocker arms and shaft have been

NOTICE: Place a clean shop towel below the

Remove the locknut and washer from the control rod

LESVO509 ENGINE SERVICE TRAINING 1998 8

UNIT INJECTOR REPLACEMENT

With the bellcrank lever assembly, the valve bridges

You can see the two injector body location dowels

LESVO509 ENGINE SERVICE TRAINING 1998 9

UNIT INJECTOR REPLACEMENT

With the injector removed, make sure the injector

Install new O-ring seals (3) on the injector housing

Make sure the plug is installed in the top of the

LESVO509 ENGINE SERVICE TRAINING 1998 10

UNIT INJECTOR REPLACEMENT

...into the bore of the cylinder head. Make sure the

NOTICE: DO NOT hit the unit injector to make it go

Connect the bellcrank lever to the rack and install the

The shop towel can now be removed from below the

LESVO509 ENGINE SERVICE TRAINING 1998 11

UNIT INJECTOR REPLACEMENT

Valve clearance (lash) and injector timing must be

Put on the valve covers and install the bolts. Tighten

LESVO509 ENGINE SERVICE TRAINING 1998 12

The power setting screw is under the cover on the

Injector synchronization is the setting of all injector

LESVO509 ENGINE SERVICE TRAINING 1998 13

Remove the cover and gasket of the power setting

It is not necessary to remove the cover or break the

LESVO509 ENGINE SERVICE TRAINING 1998 14

The top bolt is the synchronizing pin. The bottom

NOTE: Cover can be installed either way so long

LESVO509 ENGINE SERVICE TRAINING 1998 15

Remove the washer from the synchronizing pin and

LESVO509 ENGINE SERVICE TRAINING 1998 16

Let us review the control linkage of the unit injectors

We can see the power setting screw (2) in contact with

The synchronization pin sets the fuel stop lever at the

The synchronization pin is also the ZERO reference

NOTE: This illustration is not correct. The seal goes