TIP- 1200102 - Caterpillar

Preparation
Fuel system must be filled and purged from air.
Clean the fuel injection pump and ensure that the fuel injection pump is kept clean. Note: Checking cylinder 1 is sufficient, but all other cylinders can also be checked for cleanliness.
Apply current to the cutoff solenoid, or remove the cutoff solenoid and O-ring from the injection pump, to enable the fuel supply
Set the throttle to HIGH idle.
Illustration 1 g03553596
Remove Cap
(A) Cap
Remove cap (A) on the flywheel housing to view the ring gear.
Illustration 2 g03553661
Timing mark location
(B) Cylinder 1 top dead center timing mark
(C) Timing mark
Put a spanner wrench on the crankshaft pulley. Turn the engine clockwise until the mark for top dead center of cylinder 1 (B) is aligned with timing mark (C) on the engine block.
Illustration 3 g03553716
Flywheel timing marks
(B) Cylinder 1 top dead center timing mark
(D) 15° before top dead center mark
(E) 20° before top dead center mark
(F) 25° before top dead center mark
(G) Direction of rotation
Illustration 4 g03553783
Rated injection point
(C) Timing mark
(H) 16° before top dead center mark (rated injection point)
Turn engine clockwise until mark (C) is aligned with the rated injection point of 16° before top dead center mark (H) 1°.
Mark rated injection point (H) on the flywheel housing and the ring gear. Measuring
Illustration 5 g03552621
Fuel pump
(J) Port
Loosen and push all the high-pressure fuel injection lines to one side. Note: Port (J) on the fuel injection pump must be visible.
Illustration 6 g03553896
Fuel flow ON position
(K) Fuel switch
Turn fuel switch (K) to the ON position.
Illustration 7 g03554096
Optional Step: Attach a fuel injection line with a grandparent pipe to the fuel injection pump for a more precise observation. Refer to Illustration 7. Note: The fuel is pumped to the cylinder every two revolutions of the crankshaft. It may be necessary to turn the crankshaft twice to observe fuel flowing from port (J).
Slowly turn engine clockwise until fuel is discharged through port (J) of the fuel injection pump.
Then slowly turn the engine back (counterclockwise) approximately two rotations until the engine is about 30° before top dead center.
Remove any bubbles at the opening of the injection pump so that the opening of the injection pump is about half filled with fuel.
Slowly keep turning the crankshaft counterclockwise until the fuel rises to the opening of the injection pump. Stop turning the crankshaft immediately after this action is achieved.
Read the degrees on the flywheel to ensure that timing mark (C) is aligned with the rated value of 16° before top dead center mark (H) 1°.
Rotate the engine and measure the injection time for three more times. If the specified value is reached, then the injection timing is correct and move on to Step 10.If the injection time is not correct, then refer to "Setting Injection Timing". Note: Bend the injection lines when the injection lines are installed. This action will ensure that the injection lines are not under tension when installed. Purge injection lines when installed.
Install fuel injection lines.
Install the cutoff solenoid if removed.
Install cap (A).
Check fuel system for leaks. Setting Injection Timing
Variations of the injection time that is