41

Troubleshooting Section

i01638285 For detailed information on detection of misfire

and false misfire, refer to Testing and Adjusting,
Engine Misfires, Runs Rough RENR5908, “BTU and Precombustion Chamber
or Is Unstable Adjustments”.

SMCS Code: 1000-038; 1901-038 Spark Plug

Under certain conditions, condensation forms on
Probable Causes the spark plugs after the engine is shut down. The
condensation can cause misfire.
• Cold cylinder
A spark plug may require service. Maintain the
• Spark plug spark plug according to Operation and Maintenance
Manual, SEBU7563, “Ignition System Spark Plug -
• Check valve Check/Adjust”.
• Incorrect air/fuel ratio
Check Valve
• Needle valve
Passages for the fuel to the precombustion
• Spark plug’s extension chamber’s check valve may be blocked by
contaminants in the air/fuel mixture. Make sure that
• Ignition transformer the passages are clean. Make sure that the air and
the fuel are properly filtered.
• Air/fuel pressure module
Combustion may have leaked past the check
• Gas admission valve valve’s gasket. During operation, check the
temperature of the supply tube for the needle valve.
• Precombustion chamber If the temperature of the supply tube is higher than
average, combustion is probably leaking into the
• Fuel supply lines for the precombustion chamber cylinder head. Remove the check valve and inspect
the check valve for evidence of combustion on the
• Valve lash outside of the check valve’s body.

• Cylinder head and related components
• Incorrect electrical connection or power supply
• Air inlet restriction
The check valve may be stuck. The check valve
must move freely in order to allow fuel to enter the
precombustion chamber. Clean the check valve with
a nonflammable solvent that will not leave residue.
Replace the check valve, if necessary.

• Problem with the electrohydraulic system Air/Fuel Ratio

• Driven equipment Operate the engine with a different air/fuel mixture
in order to determine if the misfiring is affected by
Recommended Repairs the air/fuel ratio. To change the air/fuel ratio, operate
the engine in the prechamber calibration mode. Use
Note: If the symptom only occurs under certain ET to change the setting of the fuel’s BTU.
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under If the rate of misfiring changes, use an emissions
the conditions. Troubleshooting the symptom under analyzer and tune the engine according to Testing
other conditions can give misleading results. and Adjusting, RENR5908, “BTU and Precombustion
Chamber Adjustments”.
Cold Cylinder
Before you can determine the cause of the cold
cylinder, use the display on the control panel in
order to locate the cold cylinder. You can view the
actual combustion burn times and the exhaust port
temperatures of the cylinders.
42
Troubleshooting Section
Needle Valve
Check the needle valves for the precombustion
chambers. If the needle valves are closed, no fuel
is supplied to the precombustion chamber. If the
needle valves are open too far, the air/fuel mixture
will be too rich for combustion. If the adjustment
of the needle valves is suspect, fully close all of
the needle valves. Open the needle valves for
four full turns. Adjust the needle valves according
to Testing and Adjusting, RENR5908, “BTU and
Precombustion Chamber Adjustments”.
Make sure that the fuel lines for the needle valves
are not clogged.
If adjustment of a needle valve does not affect
operation, the needle valve may be faulty. Replace
the needle valve.
Spark Plug Extension
Inspect the outside of the extension for oil and
moisture. Look for holes that are burned through
the extension’s insulator. Inspect the extension’s
terminals for corrosion.
Ignition Transformer
Inspect the ignition transformers for loose
connections, moisture, short circuits, and open
circuits. Inspect the primary wiring and the
secondary electrical connections. For information
on troubleshooting the ignition system, refer to
Troubleshooting, “Ignition Transformers Primary
Circuit” and Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plug”.
Gas Admission Valve
Check the gas admission valve lash. Refer to
Testing and Adjusting, RENR5908, “Engine Timing
Procedures”.
Precombustion Chamber
Inspect the precombustion chamber. For instructions
on removal and installation, refer to Disassembly
and Assembly, SENR5535, “Prechamber Check
Valve - Remove and Install”.
The precombustion chamber’s gasket and/or the
ignition body’s seals may have allowed coolant to
enter the precombustion chamber. Inspect the spark
plug and the precombustion chamber for evidence
of coolant and residue of liquid crystalline material.
If the gasket and/or the seals have leaked, clean
the sealing surfaces and install a new gasket and
seals. Also check for coolant leaks at the bottom of
the cylinder head.
Remove the combustion sensor and use a
borescope to view the hole for the spark plug in the
precombustion chamber. For a two-piece ignition
body / precombustion chamber, the locating pins
may be broken. This would allow the precombustion
chamber to move and the hole for the spark plug
could be misaligned. If this is the case, remove the
ignition body and the precombustion chamber in
order to make the necessary repairs.
Fuel Supply Lines for the Precombustion
Chamber
Inspect the fuel supply lines and the passages
between the needle valve and the check valve.
Look for signs of debris and carbon buildup. Make
sure that the lines and passages are clean.
Multiple problems with a check valve for a particular
cylinder can be caused by fuel supply lines and
passages that are dirty.
Valve Lash
Check the valve lash. Refer to Testing and Adjusting,
RENR5908, “Engine Timing Procedures”.
Cylinder Head and Related Components
Measure the cylinder compression. Refer to
Operation and Maintenance Manual, SEBU7563,
“Cylinder Pressure - Measure/Record”.
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear
to the valves, cylinder head gasket, etc. Inspect
the condition of the camshafts. If a camshaft is
replaced, new valve lifters must be installed.
Electrical Connection or Power Supply
There may be an intermittent interruption of power.
Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect
the battery connections and the ground.
Inspect the wiring from the battery to the ECM.
Inspect the wires and the power relay. Check
the power and ground connections. Refer to
Troubleshooting, “Electrical Power Supply”.
Air Inlet Restriction
The maximum allowable air inlet restriction is
3.75 kPa (15 inches of H2O). If the indication is
higher than the maximum permissible restriction,
clean the filter element or install a new filter element.
Check the restriction again. If the restriction remains
too high, inspect the air inlet piping for obstructions.
 43
Troubleshooting Section

Electrohydraulic System
Make sure that the hydraulic oil is not contaminated.

Make sure that the electrohydraulic actuators are

operating properly. During operation at a load that
is less than 50 percent, observe the operation of the
air choke actuator. During operation at a load that is
greater than 50 percent, observe the operation of
the wastegate actuator.

The governor gain may require adjustment. Refer

to Systems Operation/Testing and Adjusting,
RENR5908, “Governor Adjustment Procedure”.

If a solenoid for an actuator is suspect, switch the

solenoid for another solenoid that is known to be
good. Obtain a new solenoid, if necessary.

Make sure that the linkage moves freely. If any rod

ends are worn, replace the rod ends.

If an actuator is suspect, inspect the actuator

according to Operation and Maintenance Manual,
SEBU7563, “Electrohydraulic Actuator - Inspect”.

Driven Equipment
Make sure that the load is not excessive. Reduce
the load. If necessary, disengage the driven
equipment and test the engine.

Variation of the load can cause instability. Make sure

that the signal for the engine speed is not corrupted.