0301912 JOHNSON COTTER PIN

Troubleshooting
To troubleshoot engine problems make reference to Troubleshooting, 3408C & 3412C Industrial Engines, SENR6582.Fuel System
Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system. Many times work is done on the fuel system when the problem is really with some other part of the engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust. Smoke that comes from the exhaust can be caused by a defective fuel injector, but it can also be caused by one or more of the reasons that follow:a. Not enough air for good combustion.b. An overload at high altitude.c. Oil leakage into combustion chamber.d. Not enough compression.e. Fuel injection timing incorrect.Fuel System Inspection
A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance.1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a defective bend. Verify that the fuel return line has not collapsed in the sections subject to heat.3. Install a new fuel filter. Clean the primary fuel filter.4. To remove air from the fuel system, use the procedure that follows: a. Use the priming pump to remove air from the low pressure side of the fuel system.b. Loosen one-half turn the fuel injection line nuts at each adapter in the valve cover base. Move throttle lever to Low Idle position. Use the starting motor to turn the engine until fuel without air flows from the loose connections. Tighten the nuts. Because of the check assemblies in the injection pump outlets the priming pump will not give enough pressure to remove air from the fuel injection lines.5. Inspect the fuel bypass valve to see that there is no restriction to good operation.Fuel Transfer Pump
With the engine operating at full load speed, the fuel transfer pump receives fuel from the primary fuel filter. Fuel then moves through the ECM and the secondary fuel filters to the fuel injection pump.To check the fuel transfer pump pressure, disconnect the fuel line (from the filter) at the fuel injection pump housing inlet. Install a tee at the inlet and connect the fuel line to the tee. Connect a pressure indicator to the tee and start the engine. Fuel is delivered to the fuel pump housing at approximately 414 kPa (60 psi) at full load speed.If the fuel pressure is not up to specifications, stop the engine. Make a replacement of the primary and secondary fuel filters and check to make sure the fuel lines and hoses are not plugged or damaged.Start the engine and again check the fuel pressure. If the fuel pressure is not at specifications, a repair or replacement of the fuel transfer pump is needed.Checking Engine Cylinders Separately
An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the injection pump and injection valve for that cylinder.Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an indication of the condition of a fuel injection valve. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of an injection valve with a defect. Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by an injection valve with a defect.The most common defects found with the fuel injection valves are:1. Carbon on tip of the fuel injection nozzle or in the fuel injection nozzle orifice.2. Steel wire brushing of fuel injection nozzle tip.3. Orifice wear.4. Dirty fuel injection nozzle screen.Testing Fuel Injection Nozzles
Testing of the fuel injection nozzles must be done off the engine. Perform the following tests using the 5P4150 Nozzle Testing Group to determine if nozzle performance is acceptable:Valve Opening Pressure TestFlush The NozzleTip Leakage TestOrifice Restriction TestBleed Screw Leakage TestMake reference to Special Instruction, SEHS7292, for operation of the 5P4150 Nozzle Testing Group.Removal And Installation Of Fuel Injection Pumps
Removal Of Injection Pump
Put Rack At Zero Position
(1) Plug. (2) Governor control shaft.1. Remove plug (1) from the timing pin hole on the fuel injection pump housing.2. Install 4C9581 Rack Zero Pin with the flat end down in the hole that the plug was removed from.3. Remove rack solenoid (BTM) and use the 4C9583 Fuel Pump Indicator to hold the rack against the rack zero pin.4. Disconnect the fuel lines from the injection pumps.5. Use the 8T5287 Wrench and 6V7050 Compressor Group to loosen the bushing that holds the fuel injection pump in the housing.6. Install the 8S2244 Extractor on the threads of the injection pump. Pull the pump straight out of the bore.When injection pumps and spacers are removed from the injection pump housing, keep the parts for each pump together so they can be installed back in their original location.Be careful when injection pumps are disassembled. Do not damage the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part is worn, install a complete new