F8538 Force SPRING PIN

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Certain 3406E and C-15 Engines have experienced problems in the field for a rough low idle. The rough low idle is happening after the engine has had an OPT overhaul which included a set of remanufactured injectors or after the engine has had a complete set of remanufactured injectors installed. The rough low idle usually occurs at the 700 to 1000 Revolution Per Minute (RPM) range and when the engine is at the proper operating temperature. The fuel injector part numbers associated with the rough low idle are 10R-2780 Fuel Injector Gp , 10R-2781 Fuel Injector Gp , 10R-0957 Fuel Injector Gp , 10R-0958 Fuel Injector Gp , 10R-8501 Fuel Injector Gp , and 10R-8502 Fuel Injector Gp .Solutions
Verify the following before any work is performed to solve the rough low idle issue.
Verify that the engine has the correct injector part numbers installed for the current engine rating.
Verify that the overhead adjustments are correct.
Make sure that the engine has the latest flash file installed along with the correct FLS/FTS and trim codes installed.
Check the timing calibration and the sensor.
Check the low-pressure fuel system for the correct pressure and for any restrictions.
Verify that low-pressure fuel system has been updated to include high-pressure spring kit. Refer to Truck Engine News, SEBD6821.
Check for air in the fuel both in and out of the head.
Make sure that the wastegate is operating properly.
Check the wiring harness and connectors for intermittent opens or shorts.
Run and upload the automated cylinder cutout tests.
Run a manual cylinder cutout test at the rough low idle RPM.Note: Improvements to rough idle have been generated when fuel pressure is increased to approximately 85 psi at low idle and 95 psi at high idle. Rough idle improvements have been generated when using an updated transfer pump and spring kit.Note: For S/N:5EK1-80006 ensure that the fuel lines allow fuel to flow into the front of the cylinder head and out the rear of the cylinder head. Ensure that the software is correct and updated.Note: Use the following logic when running the manual cutout test. The fuel rates with no injectors cutout should be compared with the fuel rates for each cylinder that is cutout. This method is looking for a weak or a strong injector.
Illustration 1 g02720506
(1) Injector Trim Code (2) Injector serial numberNote: If any of the above suggestions did not solve the rough low idle, then work through your Caterpillar Dealer Technical Communicator to submit this information to the DSN (Dealer Solution Network) for information necessary to complete any repairs. Be sure to supply the following information to your Dealer TC:
Fuel injector part numbers
The serial numbers and the trim codes from the fuel injectors currently in the engine. Serial numbers appear on the side of the solenoid next to the part number. Refer to Illustration 1.
The miles on the fuel injectors
The Manual cylinder cutout test data
The fuel transfer pump part number
The type of fuel pressure regulator valve that is inserted in the fuel manifold
The serial numbers of the fuel injectors that are available at the dealership that could be used for fuel injector replacement.Note: The reman service engineers will review the factory test data of the fuel injectors currently in the engine and fuel injectors available at the dealership. Based on this factory test data, the reman service engineer will make recommendations to replace certain fuel injectors in the engine.
Replace any fuel injectors that were recommended by the Reman Service Engineer. Run the cylinder cutout tests again and provide this information to your Dealer TC.Note: If nothing above resolved the rough low idle then proceed to Step 1.
Continue to work with the reman service engineers through the DSN system.
The reman service engineers will review the cylinder cutout test data. If needed, the reman service engineer will request changing other injectors.
The reman service engineer may request checking the injector bores in the cylinder head. Start by removing all the fuel injectors. Apply layout bluing to all the fuel injectors. Insert the fuel injectors into the cylinder head. Remove the fuel injectors and examine bluing on the injectors to insure the injectors are seating into the cylinder head properly. The fuel injectors should be sealing 360° on the cylinder head. If the fuel injectors do not make 360° contact, then replace the cylinder head. Also install new reman injectors when replacing the cylinder head.
If the preceding steps do not resolve the rough idle, the reman service engineer may recommend replacing the reman injectors with new equivalent injectors.Note: A reman 6 Sigma team is analyzing the test data and is working to resolve the rough idle complaints.