2/26/2020 3512B Generator Set YAM00001-UP(SEBP5402 - 26) - Documentation

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Product: GENERATOR SET
Model: 3512B GENERATOR SET YAM
Configuration: 3512B Generator Set YAM00001-UP

Testing and Adjusting

3500B and 3500C Generator Set Engines
Media Number -RENR5058-08 Publication Date -01/02/2013 Date Updated -07/01/2020

i08024731

Fuel Injector Adjustment

SMCS - 1290-025

NOTICE
The camshafts must be correctly timed with the crankshaft before an
adjustment of the unit injector lash is made. The timing pins must be
removed from the camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.

Specifications
Table 1
Parameter Value
Indicator Setting 64.34 mm (2.53 inch)
Injector Setting 0.00 ± 0.20 mm (0.000 ± 0.008 inch)

References
Reference: Refer to Tool Operating Manual, NEHS0666, 9U-5132 Timing and Fuel System Setting Tool Group
for additional information.

Introduction

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Use this procedure to adjust the fuel injectors.

Required Tools
Digital Dial Indicator

Table 2
Required Tools
Item Qty Part Number Part Name
T1 1 9U-5132 Engine Timing Tool Group
T1a 1 4C-8753 Extended Collet
T1c 1 8S-3675 Indicator Contact Point
T1d 1 9U-5138 Setting Gauge
T2 1 369-2607 Dial Indicator
T3 1 443-4177 Magnetic Fixture Gp
T3a 1 9U-6272 Nylon Screw

T3b 1 443-4174 Magnetic Fixture

T3c 1 443-4175 Rod As

T4 1 9U-5233 Magnetic Fixture Gp

T4a 1 9U-5137 Magnetic Fixture

T4b 1 9U-6272 Nylon Screw

T4c 1 122-0449 Rod Sleeve Extension

Dial Indicator

Table 3
Required Tools
Item Qty Part Number Part Name

T1 1 9U-5132 Engine Timing Tool Group

T1a 1 4C-8753 Extended Collet

T1b 1 6V-3075 Dial Indicator

T1c 1 8S-3675 Indicator Contact Point

T1d 1 9U-5138 Setting Gauge

T4 1 9U-5233 Magnetic Fixture Gp

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T4a 1 9U-5137 Magnetic Fixture

T4b 1 9U-6272 Nylon Screw

T4c 1 122-0449 Rod Sleeve Extension

T4d 1 122-0451 Rod

Test Preparation - Digital Dial Indicator

Note: Calibration of the engine speed/timing sensor is not required unless the timing wheel has been removed
from the camshaft or the Electronic Control Module (ECM) has been changed.

This adjustment is critical. Ensure that the adjustment of the fuel injector is made properly.

1. Refer to Testing and Adjusting, "Crankshaft Position for Fuel Injector Adjustment and Valve Lash
Setting". All the injectors can be checked or adjusted with the two crankshaft positions in the chart. This
action will make sure that the pushrod lifters are off the lobes and on the base circles of the camshaft.

Before a check or an adjustment can be made, the tooling must be set to the correct dimension.

Illustration 1 g06346380
(T1c) 8S-3675 Indicator Contact Point
(T1d) 9U-5138 Setting Gauge
(T2) 369-2607 Dial Indicator
(T3a) 9U-6272 Nylon Screw
(T3b) 443-4174 Magnetic Fixture
(T3c) 443-4175 Rod As

Note: Magnetic Fixture Gp (T4) that contains the Extended collet (T4c) and indicator contact point
(T1b) can be used to raise the indicator above some interference points as needed.

2. Place rod (T3c) in fixture (T3b) in hole opposite open end. Install contact point (T1c) on digital indicator
(T2). Install digital indicator (T2) in hole opposite open end of fixture (T3b). Screw in nylon screw (keep
loose).

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3. Make sure that the surfaces of the fixture (T3b) and gauge (T1d) are clean and dry.

Illustration 2 g06334978
Adjustment of the fuel timing tools
(T1c) 9U-5138 Setting Gauge
(T2) 369-2607 Digital Dial Indicator
(T3a) 9U-6272 Nylon Screw
(T3b) 443-4174 Magnetic Fixture
(T3c) 443-4175 Rod As

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Illustration 3 g06346346
Adjustment of the fuel timing tools
(T1a) 4C-8753 Extended Collet
(T1b) 5P-7263 Indicator Contact Point
(T1c) 9U-5138 Setting Gauge
(T2) 369-2607 Digital Dial Indicator
(T3a) 9U-6272 Nylon Screw
(T3b) 443-4174 Magnetic Fixture

4. Place digital indicator assembly from Step 2 on the top surface of gauge (T1d). Rod (T1b) must be on the
top step of gauge (T1d).

Note: Gauge (T1d) has two steps. Make sure that the step designation is for the 64.34 mm (2.53 inch)
dimension.

5. Loosen nylon screw (T3a) for digital indicator (T2). Move digital indicator (T2) in fixture until digital
indicator rests on lip inside fixture (T3b). Tighten nylon screw (T3a) for digital indicator (T2). Once set
onto fixture, zero gauge.

Test Procedure - Digital Dial Indicator

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Illustration 4 g06346354
Fuel timing tools in position
(T2) 369-2607 Digital Dial Indicator
(T3b) 443-4174 Magnetic Fixture
(T3c) 443-4175 Rod As
(1) Injector follower
(2) Shoulder

1. Make sure that the top surfaces of injector follower (1) and shoulder (2) are clean and dry.

2. Place digital indicator (T2) and fixture (T3b) in position on the injector that will be checked. Make sure
that the magnetic base of the fixture is on the top surface of injector follower (1). Rod (T3c) must be on
the top surface of shoulder (2).

3. The digital indicator must indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).

4. If the digital indicator indicates 0.00 ± 0.20 mm (0.000 ± 0.008 inch), no adjustment is necessary. Proceed
to the next injector to be checked. Repeat the procedure from Step 2. If the digital indicator does not
indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch), proceed to Adjustment Procedure.

Adjustment Procedure - Digital Dial Indicator

1. Loosen the adjustment screw locknut for the injector that is being adjusted.

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Illustration 5 g00284832
The installed timing and fuel setting tool group

2. Turn the adjustment screw until the digital dial indicator indicates 0.00 ± 0.20 mm (0.000 ± 0.008 inch).
Tighten the adjustment screw locknut to the torque that is listed in the engines Specifications manual.
Then check the adjustment to be certain that the adjustment has not changed. If necessary, repeat this
procedure until the adjustment is correct. When the adjustment is correct, proceed to the next injector to be
checked. Repeat the procedure from Step 3.

3. After all injectors are checked and/or adjusted, remove the timing bolt from the flywheel.

Test Preparation - Dial Indicator

Note: Calibration of the engine speed/timing sensor is not required unless the timing wheel has been removed
from the camshaft or the Electronic Control Module (ECM) has been changed.

This adjustment is critical. Ensure that the adjustment of the fuel injector is made properly.

1. Refer to Testing and Adjusting, "Crankshaft Position for Fuel Injector Adjustment and Valve Lash
Setting". All the injectors can be checked or adjusted with the two crankshaft positions in the chart. This
action will make sure that the pushrod lifters are off the lobes and on the base circles of the camshaft.

Before a check or an adjustment can be made, the tooling must be set to the correct dimension.

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Illustration 6 g06346364
(T1b) 6V-3075 Dial Indicator
(T1c) 8S-3675 Indicator Contact Point
(T1d) 9U-5138 Setting Gauge
(T4a) 9U-5137 Magnetic Fixture
(T4c) 122-0449 Rod Sleeve Extension
(T4d) 122-0451 Rod

2. Place rod (T4d) in fixture (T4a). Install extension (T4c) on fixture (T4a). Install contact point (T1c) on
dial indicator (T1b). Install dial indicator (T1b) in extension (T4c).

3. Make sure that the surfaces of the fixture (T4a) and gauge (T1d) are clean and dry.

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Illustration 7 g06346368
Adjustment of the fuel timing tools
(T1b) 6V-3075 Dial Indicator
(T1d) 9U-5138 Setting Gauge
(T4a) 9U-5137 Magnetic Fixture
(T4b) 9U-6272 Nylon Screw
(T4c) 122-0449 Rod Sleeve Extension
(T4d) 122-0451 Rod

4. Place dial indicator assembly from Step 2 on the top surface of gauge (T1d). Rod (T4d) must be on the top
step of gauge (T1d).

Note: Gauge (T1d) has two steps. Make sure that the step designation is for the 64.34 mm (2.53 inch)
dimension.

5. Loosen the nylon screw for the dial face of dial indicator (T2b). Move the dial face of the dial indicator
(T1b) in rod sleeve extension (T2c) until all the pointers indicate zero. Tighten the nylon screw for the dial
face of dial indicator (T1a).

Test Procedure - Dial Indicator

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Illustration 8 g06346375
Fuel timing tools in position
(T1a) 6V-3075 Dial Indicator
(T2a) 9U-5137 Magnetic Fixture
(T2d) 122-0451 Rod
(1) Injector follower
(2) Shoulder

1. Make sure that the top surfaces of injector follower (1) and shoulder (2) are clean and dry.

2. Place dial indicator (T1a) and fixture (T2a) in position on the injector that will be checked. Make sure that
the magnetic base of the fixture is on the top surface of injector follower (1). Rod (T2d) must be on the top
surface of shoulder (2).

3. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).

4. If the dial indicator pointers indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch), no adjustment is necessary.
Proceed to the next injector to be checked. Repeat the procedure from Step 4. If the dial indicator pointers
do not indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch), proceed to Adjustment Procedure.

Adjustment Procedure - Dial Indicator

1. Loosen the adjustment screw locknut for the injector that is being adjusted.

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Illustration 9 g00284832
The installed timing and fuel setting tool group

2. Turn the adjustment screw until the dial indicator pointers indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).
Tighten the adjustment screw locknut to the torque that is listed in the engine's Specifications manual.
Then check the adjustment to be certain that the adjustment has not changed. If necessary, repeat this
procedure until the adjustment is correct. When the adjustment is correct, proceed to the next injector to be
checked. Repeat the procedure from Step 3.

3. After all injectors are checked and/or adjusted, remove the timing bolt from the flywheel.

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