- Asphalt Paver:
- AP-1000 (S/N: 1HD1-UP)
- AP-1050 (S/N: 1JG1-UP)
- BG-245B (S/N: 3XL1-UP)
- AP-1050 (S/N: 1JG1-UP)
- Backhoe Loader:
- 446 (S/N: 6XF1-UP)
- 446B (S/N: 5BL1-UP)
- Combine:
- Lexion 450 (S/N: 6JK1-UP)
- Marine Engine:
- 3116 (S/N: 1SK1-UP)
- Excavator:
- 205B (S/N: 5ZF1-UP)
- 211B (S/N: 6XG1-UP)
- 213B (S/N: 1EJ1-UP)
- 214B (S/N: 4CF1-UP; 9MF1-UP)
- 215D (S/N: 9TF1-UP)
- 224B (S/N: 7WF1-UP)
- 312B (S/N: 9NW1-UP)
- 320B (S/N: 5BR1-UP)
- 325L (S/N: 2JK1-UP)
- E110B (S/N: 8MF1-UP; 4FJ1-UP)
- E120B (S/N: 6JF1-UP; 4XK1-UP)
- E180 (S/N: 1RF1-UP)
- E200B (S/N: 6KF1-UP; 6KG1-UP)
- E240B (S/N: 8SF1-UP; 9PF1-UP; 6MG1-UP)
- E240C (S/N: 2RL1-UP)
- EL180 (S/N: 4EF1-UP)
- EL200B (S/N: 7DF1-UP)
- EL240B (S/N: 5WG1-UP)
- EL240C (S/N: 9PK1-UP)
- M315 (S/N: 7ML1-UP)
- 211B (S/N: 6XG1-UP)
- Integrated Toolcarrier:
- IT12F (S/N: 1KF1-UP)
- IT14B (S/N: 3NJ1-UP)
- IT14F (S/N: 4EL1-UP)
- IT18B (S/N: 4ZD1-UP)
- IT14B (S/N: 3NJ1-UP)
- Off-Highway Truck/Tractor:
- 776B (S/N: 6JC1-UP)
- 777B (S/N: 4YC1-UP)
- 785 (S/N: 8GB1-UP)
- 789 (S/N: 9ZC1-UP)
- 793 (S/N: 3SJ1-UP)
- 777B (S/N: 4YC1-UP)
- Paving Compactor:
- CB-434 (S/N: 3TF1-UP)
- CP-563 (S/N: 1YJ1-UP)
- CS-533 (S/N: 3BL1-UP; 4HL1-UP)
- CS-533C (S/N: 2XN1-UP)
- CS-563 (S/N: 8XF1-UP; 7GG1-UP)
- CS-583 (S/N: 1EL1-UP)
- CP-563 (S/N: 1YJ1-UP)
- Track-Type Loader:
- 963B (S/N: 9BL1-UP)
- Track-Type Tractor:
- D11N (S/N: 74Z1-UP)
- D6M (S/N: 4GS1-UP)
- D9R (S/N: 7TL1-UP)
- D6M (S/N: 4GS1-UP)
- Wheel Loader:
- 910F (S/N: 1SF1-UP; 1YK1-UP)
- 924F (S/N: 6MN1-UP)
- 928F (S/N: 2XL1-UP)
- 950 Series II (S/N: 4DJ1-UP)
- 950F (S/N: 7ZF1-UP; 6YG1-UP)
- 966F (S/N: 7HL1-UP)
- 924F (S/N: 6MN1-UP)
- Generater Set Engine:
- 3116 (S/N: 1NJ1-UP)
- Industrial Engine:
- 3116 (S/N: 4PG1-UP)
- On-Highway Engine:
- 3116 (S/N: 9GK1-UP)
- Engine:
- 3116 (S/N: 2SG1-UP; 2WG1-UP; 4KG1-UP; 2BK1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information. This Special Instruction provides troubleshooting procedures for engines that have Mechanical Unit Injectors (MUI) that are having the following issues.
- Misfire
- Low Power
- Hard Starting
Note: The following Special Instruction covers misfires, low power, and hard starting symptoms. This document is not intended to serve as an all-inclusive Troubleshooting Guide, but rather as a supplement to the current Service Manual.
Instructions
- Use the Customer Interview on the next page as a guide to determine the Customer's Complaint. Determine the symptoms present and the conditions at which the symptoms occur. Encourage the customer to be specific.
- Investigate and inquire about recent repairs to the engine. A previous repair could be related to the current problem.
- Verify the Customer's Complaint. If possible, repeat the conditions that are causing the problem.
- Based on the symptoms and previous engine repairs, find the cause for the complaint using the Misfire, Low Power, and Hard Starting flowcharts. Consider the probable causes in the order they are listed. Avoid pre-conceived ideas.
- For Fuel System causes, find the corresponding Fuel System Tests in the back of this manual and follow the Tests step by step. When a test procedure is completed but the problem is not solved, move on to the next test on the flowchart.
Note: For Fuel Injector Timing and Synchronization Procedures, refer to the engine's Service Manual.
Customer Interview
Misfire Complaints (Rough Running, Missing, Skipping, Fuel Knock, Hunt, Surge, and Flutter)
1. Is Misfire present? (check all that apply):     | |
_____     | Under Load?     |
_____     | With No Load (Free Running)?     |
_____     | At Low Idle?     |
_____     | At High Idle?     |
_____     | Only when the engine is warm?     |
Description of Problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
2. List any recent repairs or modifications that could affect the current problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
3. Has the Misfire problem:     | |
_____     | Developed Gradually?     |
_____     | Developed Suddenly?     |
_____     | Been present since purchase?     |
Low Power (Slow Response, Poor Accelecration, Won't Pull Load, Track Stall, and Bucket Stall)
1. Is Low Power experienced:     | |
_____     | Under Load?     |
_____     | Only During Acceleration or Load Change (Poor Response)?     |
Description of Problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
2. Is too much exhaust smoke seen in addition to Low Power?     | |
_____     | Yes     |
If Yes     | ________Black Smoke? ________ White Smoke?     |
_____     | No     |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
3. List any recent repairs or modifications that could affect the current problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
4. Has the Low Power problem:     | |
_____     | Developed Gradually?     |
_____     | Developed Suddenly?     |
_____     | Been Present since Purchase?     |
Hard to Start or will not Start
1. Is the engine Hard to Start (Check all that apply):     | |
_____     | After a hot shutdown (30 minutes or less)?     |
_____     | After an extended shutdown (30 minutes or more)?     |
_____     | All the time?     |
_____     | Only in cold ambient temperatures?     |
Description of Problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
2. List any recent repairs or modifications that could affect the current problem:     | |
_______________________________________________________________________     | |
_______________________________________________________________________     | |
3. Has the Hard Starting problem:     | |
_____     | Developed Gradually?     |
_____     | Developed Suddenly?     |
_____     | Been Present since Purchase?     |
Misfire (Rough Running, Missing, Skipping, Fuel Knock, Hunt, Surge, Flutter)
Illustration 1 | g01411815 |
Flowchart for Misfire (Rough Running, Missing, Skipping, Fuel Knock, Hunt, Surge, Flutter) |
Low Power (Slow Response, Poor Accelecration, Won't Pull Load, Track Stall, and Bucket Stall)
Illustration 2 | g01455800 |
Illustration 1 - Flowchart for Low Power (Slow Response, Poor Accelecration, Won't Pull Load, Track Stall, and Bucket Stall) |
Illustration 3 | g01455802 |
Illustration 2 - Flowchart for Low Power (Slow Response, Poor Accelecration, Won't Pull Load, Track Stall, and Bucket Stall) |
Hard to Start or Will Not Start
Illustration 4 | g01411879 |
Flowchart for Hard to Start or Will Not Start |
Fuel System Diagnostic Tests
The following tests are diagnostic tests that are used to isolate the issue with either a misfiring injector, a low power engine, or a hard starting engine.
A. Fuel Linkage Binding Test
B. Fuel Injector Preliminary Test
C. Fuel Injector Misfire Test
D. Governor Instability Test
E. Fuel Quality Test
F. Air in Fuel Test
G. Fuel Injector Cranking Test
H. Fuel Shutoff Solenoid Test
I. Fuel Ratio Control (FRC) Setting Test
J. Governor Servo Retaining Ring Test
K. Fuel Transfer Pump Test
L. Fuel Ratio Control (FRC) Diaphragm Leak Test
Fuel Linkage Binding Test (Test A)
Note: Do not run the engine during this test.
Note: The fuel linkage binding test checks for binding in the governor, injector rack, and the control linkage.
Illustration 5 | g01422811 |
(1) Paddle |
Illustration 6 | g01411905 |
(2) Injector Rack |
Note: Refer to Illustration 6 for the location of the injector rack on the fuel injector.
Illustration 7 | g01411915 |
(3) Mounting brackets for the fuel injectors |
Note: Refer to Illustration 7 for the location of the mounting brackets for the fuel injectors.
Illustration 8 | g01455803 |
Illustration 1 - Flowchart for Fuel Linkage Binding Test (Test A) |
Illustration 9 | g01455806 |
Illustration 2 - Flowchart for Fuel Linkage Binding Test (Test A) |
Fuel Injector Preliminary Test (Test B)
Note: The Fuel Injector Preliminary Test is a visual inspection of the fuel injectors and the rocker arm assembly.
Illustration 10 | g01412186 |
(1) Follower (2) Thrust Plate |
Note: Refer to Illustration 10 for the location of the follower and the thrust plate.
Illustration 11 | g01412043 |
Flowchart for the Fuel Injector Preliminary Test (Test B) |
Fuel Injector Misfire Test (Test C)
Note: The fuel injector misfire test assists in identifying a cylinder with a misfiring injector.
Illustration 12 | g01412188 |
Illustration 12 shows the direction the rack moves when the fuel injector is receiving fuel.
Illustration 13 | g01412058 |
Flowchart for the Fuel Injector Misfire Test (Test C) |
Governor Instability Test (Test D)
Note: The governor instability test checks for the misfires due to governor instability.
Illustration 14 | g01422813 |
(1) Dashpot orifice |
Illustration 15 | g01422815 |
(2) Bumper Spring Adjustment Screw |
Illustration 16 | g01422817 |
(3) Low Idle shims |
Illustration 17 | g01422820 |
Paddle assembly with the bias spring |
Illustration 18 | g01455808 |
Illustration 1 - Flowchart for the Governor Instability Test (Test D) |
Illustration 19 | g01455809 |
Illustration 2 - Flowchart for the Governor Instability Test (Test D) |
Fuel Quality Test (Test E)
Note: The Fuel Quality Test check for fuel quality problems. For more information, refer to Applied Failure Analysis, SEBD0717, "Diesel Fuels and Your Engine".
Illustration 20 | g01412094 |
Flowchart for the Fuel Quality Test (Test E) |
Air in Fuel Test (Test F)
Note: The air in fuel test is to check for air in the fuel. This test is also for correcting the air in fuel issue.
Illustration 21 | g01412188 |
Illustration 21 shows the direction the rack moves when the fuel injector is receiving fuel.
Illustration 22 | g01455811 |
Illustration 1 - Flowchart for the Air in Fuel Test (Test F) |
Illustration 23 | g01455812 |
Illustration 2 - Flowchart for the Air in Fuel Test (Test F) |
Fuel Injector Cranking Test (Test G)
Note: The fuel injector cranking test checks for worn out injectors by measuring the cranking rack.
Illustration 24 | g01412134 |
(3) The rack control (4) The number one fuel injector |
Note: Refer to Illustration 24 for the location of the rack control and the location of the number one injector.
Illustration 25 | g01412115 |
Flowchart for the Fuel Injector Cranking Test (Test G) |
Fuel Shutoff Solenoid Test (Test H)
Note: The fuel shutoff solenoid test determines if the fuel shutoff solenoid and wiring harness are operating properly.
Illustration 26 | g01412143 |
Flowchart for the Fuel Shutoff Solenoid Test (Test H) |
Fuel Ratio Control (FRC) Setting Test (Test I)
Note: The FRC setting test checks the FRC setting.
Illustration 27 | g01412145 |
Flowchart for the Fuel Ratio Control (FRC) Setting Test (Test I) |
Governor Servo Retaining Ring Test (Test J)
Note: Do not run the engine during this test.
Note: The governor servo retaining ring test checks for faulty internal parts of the governor.
Illustration 28 | g01422811 |
(1) Paddle |
Illustration 29 | g01422821 |
(2) Clevis pin |
Illustration 30 | g01412147 |
Flowchart for the Governor Servo Retaining Ring Test (Test J) |
Fuel Transfer Pump Test (Test K)
Note: The fuel transfer pump test is a visual inspection of the fuel transfer pump components.
Illustration 31 | g01412150 |
(1) Screen (2) Inlet check valve (3) Spring (4) Bolt (5) Piston (6) Outlet check valve (7) Freeze plug (8) Piston check valve (9) Passage (10) Tappet Assembly (11) Cam |
Note: Refer to Illustration 31 for the location of the components for the fuel transfer pump.
Illustration 32 | g01412149 |
Flowchart for the Fuel Transfer Pump Test (Test K) |
Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
Note: The FRC diaphragm leak test checks for a leaking FRC diaphragm.
Illustration 33 | g01412154 |
Flowchart for the Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L) |