Static Injection Timing [Link]

006-025 Static Injection Timing

General Information

The injection timing is the relative

measurement of the distance remaining
between the injector plunger and the injector
cup when the piston is 5.16 mm [0.2032 in], or
19 degrees before top dead center on the
compression stroke.

Injector timing is expressed by the amount of

push rod travel remaining.

The injector timing code appears on the

engine dataplate. Codes are alphabetic letters
that relate to a numerical specification.

Specifications can be found in the Control Part

List (CPL) Manual, Bulletin 4021328.

Below is a brief review of injection timing and

how it can be adjusted.

Advanced timing means the fuel is injected

earlier into the cylinder during the compression
stroke.

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Retarded timing means the fuel injection

occurs closer to top dead center in the cylinder.

The amount of push rod travel determines the

time of fuel injection in relation to the piston
position.

The higher the numerical value of the push rod

travel remaining indicates a greater degree of
retarded or slow timing .

The lower the numerical value of the push rod

travel remaining indicates a greater degree of
advanced or fast timing .

Injection timing changes are accomplished by

advancing or retarding the cam follower action in
relation to the piston position.

This is accomplished by changing the orientation

of the camshaft lobe to the cam follower using
different camshaft gear keys.

Gear train timing (index mark alignment) always

remain the same.

The camshaft key provides a means of indexing

the camshaft with the gear.

Offset keys allow the camshaft profile to be

rotated slightly while the gear train timing
remains the same.

The more the top of the offset is moved in the

direction of the camshaft normal rotation, the
more the injection timing will be retarded. The
push rod travel numerical value will increase.

The direction of normal rotation on a K19

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engine crankshaft is clockwise as viewed from

the front.

Offset keys can be identified by measuring the

offset and referring to the following chart.

Each 0.025 mm [0.001 in] of offset will cause a

0.0127 mm [0.0005 in] change in push rod
travel from a straight key.

If checking or setting the injection timing , it is

recommended to use a testing gear. A testing
gear is a camshaft gear that has been modified
to provide a slip-fit on the camshaft.

The camshaft key part number listed in the

engine performance parts option is a starting
point. Do not assume the listed key will provide
the specified timing . Always measure the
injection timing if the gear, camshaft, or key
have been changed or if during disassembly
the direction of any offset was not noted. Part
of the reason for the existence of the offset key
is to be able to adjust the static timing to all
tolerances for the part used in the engine.

If a slip fit gear is used, the injection timing

must be measured again after installation of
the production gear.

Timing Recommended Direction of

Code Code Offset
Opposite
AE 216782 camshaft
rotation
With camshaft
AJ 200706
rotation
With camshaft
AM 216782
rotation
With camshaft
CI 200711
rotation

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Timing Recommended Direction of

Code Code Offset
CL S-302 None
With camshaft
CU 3000492
rotation

Measure

Use the injection timing tool, Part Number

3824942. The indicators (1) and (2) are
identical.

(1) Push rod travel indicator

(2) Piston travel indicator
(3) Piston plunger support assembly
(4) Push rod plunger support
(5) Hold-down adapter
(6) Extension assembly (adapter wrench)
(7) Indicator stem extension.

The push rod plunger support assembly

alignment is critical.

Install the push rod plunger support (4) in the

outside slot in the piston support (3).

Align the push rod plunger support with the

mark. Tighten the capscrew.

Install indicators (1) and (2) on the posts. Turn

the indicators so they are not over the
plungers.

Install the stem extension on the piston travel

indicators.

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Install the injector push rod (8).

Install the timing tool in the injector bore.

Install the hold-down adapter.

Align the push rod plunger and the rod to be

sure they are straight.

Tighten the support lock (9).

Use only the crankshaft to rotate the engine.

The use of gears will result in false
measurement. Gear lash must be closed up in
the direction of normal rotation (crankshaft
clockwise).

Three guide bolts equally spaced in front of the

crankshaft will aid in engine rotation.

With the engine in the compression stroke, turn

the crankshaft in the direction of normal
rotation and observe both timing tool
plungers.

Both plungers will begin moving upward when

the cylinder is on the compression stroke. The
indicators will be rotating in a clockwise
direction.

If both indicators do not rotate in a clockwise

direction, the engine is on the exhaust stroke.
Rotate the crankshaft one revolution to get to
the compression stroke.

1 - determine the piston top dead center & reset zero indicator for indicator piston

Slowly rotate the crankshaft in the direction of

normal rotation while observing the piston
plunger (10). The plunger will move upward,
stop, then begin to move downward. The stop
point of the plunger is top dead center.

Rotate the engine opposite the direction of

normal rotation until the plunger begins to
move downward. The cylinder is now slightly

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before top dead center.

Turn the indicator so the stem is touching the

plunger.

Carefully lower the indicator until it bottoms

out. Raise the indicator when the needle has
turned a minimum of three revolutions 7.62 mm
[0.300 in]. Lock the indicator in position.

Slowly turn the crankshaft in the direction of

normal rotation until the indicator needle stops
turning clockwise (top dead center). Adjust
the indicator to zero.

Always zero at top dead center with the

crankshaft having just been rotated in the
direction of normal rotation.

Slowly and carefully rotate the crankshaft

backward and forward until the needle stops at
zero before reversing the direction to indicate
the piston is after top dead center.

Turn the push rod indicator so the stem

touches the plunger.

Carefully lower the indicator until it bottoms

out. Raise the indicator when the needle has
turned a minimum of three revolutions 7.62 mm
[0.300 in].

2 - determine out base circle of injector cam & reset zero indicator for injector
Slowly turn the crankshaft in the direction of
normal rotation until the push rod indicator
stops (1), momentarily reverses direction (2),
(this is the crush nose on the camshaft), and
stops again (3). The cam follower is now on the
outer base circle of the camshaft. The piston is
now approximately 90 degrees after top dead
center.

It is important to record the amount of travel

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remaining in the push rod travel indicator for

later reference.

Carefully lower the push rod travel indicator

until it bottoms out. Raise the indicator
approximately ¼ revolution 6.35 mm [0.025 in].
Lock the indicator in position.

Set the indicator at zero.

Observe the piston travel indicator as the

crankshaft is slowly rotated opposite the
direction of normal rotation.

Stop rotating the crankshaft when the piston

travel indicator indicates the piston is at top
dead center (zero).

The crankshaft must be turned slowly to

accurately count the indicator revolutions.

Turn the crankshaft opposite the direction of

normal rotation until the indicator needle moves
2½ revolutions, 6.35 mm [0.250 in].

The piston is now 6.35 mm [0.250 in] before top

dead center.

Only move the piston to 5.16 mm [0.2032 in]

before top dead center by turning the
crankshaft in the direction of normal rotation. If
the crankshaft is turned too far, turn the
crankshaft back opposite the direction of
normal rotation more than 5.16 mm [0.2032 in]
before top dead center. Then very slowly turn
the crankshaft in the direction of normal
rotation until the indicator indicates the piston
is 5.16 mm [0.2032 in] before top dead center.

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All K19 injection timing specifications are

more than one indicator revolution 2.54 mm
[0.100 in].

Read the push rod indicator counterclockwise

from zero. This is the injection timing
measurement. An example of 0.118 in is
illustrated in the graphic.

If unsure of the number of push rod indicator

revolutions, check by carefully lifting the
indicator stem until the indicator has bottomed
out. Lower the stem the amount of excess
travel. Lower the stem to the plunger. Read the
indicator.

If the injection timing is within specification

and a slip fit gear is used, install the standard
camshaft gear. Refer to Procedure 001-012 in
Section 1. Repeat the injection timing
procedure after the gear has cooled.

If the injection timing is still not within

specification, repeat the measurement
procedure to check the tool set up and zero
settings.

If the timing is still not within specification, the

camshaft key must be changed. Remove the
camshaft gear. Refer to Procedure 001-012 in
Section 1.

Record the orientation of the offset of the key.

Use the following worksheet to determine the
alternate key.

The timing measurement must be confirmed

after changing the key.

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Last Modified: 27-Jun-2012

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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