D4 magneto timing to Pony

[auscuscus]

I appreciate any help . I cannot find any timing marks on the flywheel of my 5T pony. Nor on the pony side of this bulk head. I removed the magneto to have it serviced as I was lacking spark on one side. TDC seems to be with the starting cord V in the vertical position as gauged by the rush of air up the spark plug hole as I approach TDC , but I cant find any fine alignments. My service manual shows alignment marks on the bulk head and the flywheel , but I can’t find anything . Is the bulkhead that holds my pony fuel tank an after market , or should I just look harder ?

I have attached pictures of it all.

The timing mark on the magneto was as per the manual , but it was took my reading glasses and a torch to spy it well hidden , much lower that the pictures. I have marked it with white marker to give me a fighting chance.

Cheers

David

[SJ]

Look behing the gear in the starting engine on the outside of the housing and you,ll see a pipe plug screwed in so take that plug out and with a flashlight if it,s a little dark in there turn the engine arund and the mark on that gear wil come up for TDC so then match the gear tooth mark on the mag. with that gear.Take the mag cover off to get the rotor to match up with the correct wire or otherwise if they,re wrong all you do is switch the plug wires from one to the other in the cap but with the cap off you,ll know for sure then which is #1 so you don,t have to cross the wires.If I recall the #1 is with the cap off your looking at the rotor and it pointing to the left side when the drive gear on the rear tooth mark is pointing down.

[jmvmopar]

The timing mark is on the pony itself. I'll go and get a picture later today as my pony is laying on the floor at the moment.

Mine showed a "M" in the plugged hole.

[auscuscus]

Thanks guys. SJ does that mean I need to look on the main engine side of my fourth picture , that being the housing the magneto bolts into. I hope the picture JMVMOPAR is going to post will teach me. My D4 is a five hours drive away. I just spent Friday staring at it wondering who stole my timing marks. My operator instructions are for 6U and 7U D4's which show very easy to find timing marks on the flywheel and crankcase just behind it. Obviously the 5T differs. SJ that manual shows the magneto rotor in about a 8 o'clock position as per your wire advice. In that same position I see an upside down "V" in the distributor gear. Was damn hard to see. Seems to be an "I" also at another timing mark. Thanks again. david

[jmvmopar]

Ok Got the pic. I marked it with a silver sharpie to help see it. You line the notches in the flywheel with the mark.

[auscuscus]

Thanks for taking that pic JMVMOPAR. What serial is your machine ? Is that looking from the driver side or main engine side. Seems driver side by the fact I can see a flywheel pulley , and guessing that is a 6 or 7U machine ?

I think from what SJ is saying I need on my machine to find a pipe bolt and remove it to see timing marks on a 5T machine , and guessing it to be on the main engine side of the housing the magneto bolts. Seems the newer machines got it simpler and aligned marks on the crankcase behind the flywheel.

So what is your pony doing on the floor ?

[SJ]

They have the pipe plug in the housing behind the mag.toward the diesel head and the start.engine camshaft has the mark to line up with the mag. mark.

[jmvmopar]

She's a 7J. I have another pic of the timing marks on the flywheel. One is marked MAG and the others TC and EXCEL. It's not that great of a pic but you can see them. Mine is on the floor waiting an overhaul which it may or maynot get this year. It might go back on and direct start added.

Here is that pic

Here is the link to my rebuild. http://www.antiquecaterpillar.net/AC...ad.php?t=14805

[rditz]

I have the same setup as what is shown here, but on my flywheel I do not see any marks at all.. my pony also has two belts on it, 1 for starter, 2 for what appears to be a water pump... it would be so much easier, if they simply put a timing mark on the cam gear.. then you can't be out 180 degrees...

I guess, i have to is turn the motor over to compression on #1 cyl and then scrap the paint off of the flywheel to locate the mark more accurately...

any other thoughts on how to get this close...

thanks

rod

[ol Grump]

This is the quote from the Cat Diesel Engine SRB Form 30522-2

"To time the magneto, remove the pipe plug from the forward side of the manifold and align the letters "M" stamped on the magneto gear and camshaft gear. See the topic, TIMING GEARS."

Sorry, Cat didn't see fit to add a pic and I can't find the one I took. .maybe someone else will have one.

The pipe plug referred to is a 3/4" pipe plug with a square head fairly low on the front of the intake manifold where the mag mounts. It can be a little hard to find if the engine is fairly dirty/greasy but it's there. Once you get the marks lined up and it still doesn't fire, swap the plug wires.