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Testing Cat 3116 injectors

BKubu

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I have a 1998 M1078 with a Cat 3116. I think I have an injector that is bad. The truck smokes a bit (for about 15-20 seconds) from unburnt diesel fuel, but only when it is cold. Someone told me that I might have a bad injector. I have called around to quite a few diesel shops that specialize in injector work, but no one can test these injectors because they are mechanical. Any ideas of how to get them tested? Does anyone know of a company that could test them if I sent the injectors to them?
 

Ronmar

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Yea because these are both injector pump and injector, it takes a pretty special rig to hold and feed fuel, as well as manipulate the rack, compress the mechanism repeatedly and monitor output pattern and volume… if you find a place it will probably be overseas(south America, Europe or Asia…

This may also simply be a adjustment/synchronization issue. Pay close attention to injector height/timing when you adjust the valves. when you get it back together measure individual exhaust temps(IR thermometer as close to the top of each ex manifold port as possible) looking for temp differences.
 

GeneralDisorder

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Agreed. 15-20 seconds is nothing. My 2008 C7 will roll coal under load when cold. The 370 HP map might have a little to do with it, but yeah - when REALLY cold they will smoke on startup.

Remember these are non-emissions engines so there's no DPF, and on your 3116 there's no catalytic converter, etc. You WILL see exhaust.
 

BKubu

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I understand about diesels smoking in cold weather. I've had all kinds of trucks with many different diesel engines. This is NOT typical diesel smoke in cold weather. While it only smokes for 15-20 seconds, the cloud of smoke is quite impressive afterwards. The truck runs very well overall, but I'm interested in getting rid of this condition if it is possible without just replacing all of the injectors. I appreciate all of the responses.

By the way, the "someone" who told me that it could be a bad injector is on this list and is a very reputable member who knows his stuff. He knows more than most and much more than I do.
 

KN6KXR

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When I worked on ships we called this type of injector a "unit injector" because it has the jerk pump and nozzle holder all in one unit. We had test stands that were bought or built by the crew and fixed in place near the machine at a station or in the shop dedicated for service. Most folks don't have this kind of bandwidth in their home shop. As far as I get at home is rebuilding multifuel injectors but those are stupid easy and the tools are cheap.

I suggest you talk to some commercial bus and/or RV folks. A couple years ago I had to swap the injectors on a Detroit 12V-71 powering a generator. Those guys were the only guys that knew what I had and even had refurbed units to sell me at a decent price. They knew what they were talking about as well when I asked for the measurements to set the racks they had the numbers for me straight away.

When you find the folks that can help please post it up. I own one of these I might need the info some day.
 

aw113sgte

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When I worked on ships we called this type of injector a "unit injector" because it has the jerk pump and nozzle holder all in one unit. We had test stands that were bought or built by the crew and fixed in place near the machine at a station or in the shop dedicated for service. Most folks don't have this kind of bandwidth in their home shop. As far as I get at home is rebuilding multifuel injectors but those are stupid easy and the tools are cheap.

I suggest you talk to some commercial bus and/or RV folks. A couple years ago I had to swap the injectors on a Detroit 12V-71 powering a generator. Those guys were the only guys that knew what I had and even had refurbed units to sell me at a decent price. They knew what they were talking about as well when I asked for the measurements to set the racks they had the numbers for me straight away.

When you find the folks that can help please post it up. I own one of these I might need the info some day.
C12 uses what's called "unit injectors" and are cam driven. Do you know if those work the same way? C12s do have an electrical plug though
 

BKubu

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Gaithersburg, MD
When I worked on ships we called this type of injector a "unit injector" because it has the jerk pump and nozzle holder all in one unit. We had test stands that were bought or built by the crew and fixed in place near the machine at a station or in the shop dedicated for service. Most folks don't have this kind of bandwidth in their home shop. As far as I get at home is rebuilding multifuel injectors but those are stupid easy and the tools are cheap.

I suggest you talk to some commercial bus and/or RV folks. A couple years ago I had to swap the injectors on a Detroit 12V-71 powering a generator. Those guys were the only guys that knew what I had and even had refurbed units to sell me at a decent price. They knew what they were talking about as well when I asked for the measurements to set the racks they had the numbers for me straight away.

When you find the folks that can help please post it up. I own one of these I might need the info some day.
This is very helpful. If I find anything out that would help others, I'll be sure to post about it.
 

KN6KXR

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Well.... those are very fancy machines! When I did this work I was the machine.

Nice to see the injector out I hadn't taken mine out yet (no reason). Yeah we called those unit injectors. The nozzle, pintle, spring and pump are all in one "unit". You have to set the rack up just right when swapping them. There are special tools but if you have finer machine tools (calipers, micrometers) they can fit or you can make the jig you need. Those machines in the videos are like the machine in the TM for the multifuel. Only big shops doing this all day have them. Then there's the rest of us....

For field service we would take them out, decarbonize the end with a specific cleaner and soft brush, then check them in the tester for a spray pattern and leakdown test. You were the actuator: large lever on a pivot and your arm pulling it. If it failed the leakdown or spray pattern out it came and a new nozzle/pintle would go in then back on the tester. Those components are way too fine for any type of field service they get swapped for new. Once they passed (spray pattern, leak down) you inserted a volumetric cylinder under them, set the rack with another jig, started pumping away. So many pumps was so many cc's of fuel at such and such a rack setting. Failing this was tearing it down again and installing a new jerk pump (matched piston and sleeve). There were variations on this. Some bench setups had small fuel pumps to mimic the engine driven pump supply pressure. All the rebuild stations were as compact as they could be. There's no space for those big test machines in ship engine rooms. You carry as much spare as you can afford to (or the company will allow) but to a large extent you have to be fairly self sufficient. The above it's how I was taught and what I did.

I don't see any reason one can't do this at home BUT you're going to have to be a bit more dedicated than a multifuel (basically a simple tractor). Not as complicated as the new high pressure PWM (pulse width modulated) though. When those came along the small shops got left in the dust. Much more expensive test equipment and no work around. Could it be done? Sure. Just an exponential amount of more dedication in both time and money....

I'd be interested in the specs on these. Pressures, volumes, etc... May tackle it someday. Maybe.... so many projects and I'm not even retired yet....
 
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