Hard starting 2400H - lift pump failing?

[oldnslo]

Starting update: I was reading articles on different injector cleaners options and ran across multiple posts on filling fuel filter with sea foam both to help prime and clean system. So Sunday I removed filter bowl and filled with sea foam. Started right up zero sputtering, minimal smoke. Ran it for around 2 hours anywhere from idle to full throttle, heavy load to little load tilling my garden and doing winter to summer implement shuttle.

Monday tried stating again it sputtered less but still missed on one cylinder for a few seconds.

Is the sea foam more volatile than diesel fuel so would be less prone to missing if injector is not spraying properly?

Heading into spring planting season so might be a couple weeks before get back to looking at this.

 

[K5lwq]

I think you are on the right track. I suspect an issue with number 2 injector. The sea foam probably did help and may do better with another treatment.

 

[oldnslo]

Got rained out doing field work so took time to replace factory filter with a Parker/Raycor and saw little to bo change in how it starts after sitting for a period of time. Tried electric lift pump with new filter and again no noticeable change.

Tried cracking fitting on each injector while sitting at approx 1200 RPM and was very noticeable change in sound with each line so to me confirms firing on cylinders once running.

Going to run a tank or two of treated fuel through it and then make decision do I pull and swap injectors to see if problem follows injector. If not then I have more diagnosing to do…

 

[YanmarFever]

This might sound to simple, but have you drained the fuel tank and put in fresh diesel along with a new fuel filter.
Maybe you have contaminated fuel or water in the fuel tank.
I always look at the simple fixes first, and it sounds like you have a fuel or air leaking problem.

 

[oldnslo]

This might sound to simple, but have you drained the fuel tank and put in fresh diesel along with a new fuel filter.
Maybe you have contaminated fuel or water in the fuel tank.
I always look at the simple fixes first, and it sounds like you have a fuel or air leaking problem.

Yes, I have totally replaced original filter since was concern about the pressed in fittings leaking.

 

[YanmarFever]

Did you drain the tank first, THEN change the fuel filter?
If not, the bad fuel (if its bad) also contaminated the new filter.... which wont let the fuel get past it enough to let it run smooth.
Sea foam is thinner than diesel fuel, so it will most likely make it run smooth until it runs out.

 

[oldnslo]

trying to remove injectors today and cannot get them out. Instructions say hold injector body while turning jam nut. I have tried this and the nut will not turn. I have applied penetration oil and still no luck. Have applied what I believe is borderline excessive force and just don't want to damage something by getting to strong armed.

any suggestions?

 

[K5lwq]

I am not sure but it looks as if the whole thing will unscrew as a unit. I don’t see that nut jamming anything.

 

[oldnslo]

K5
You are correct the whole assembly unscrews. Either I misread instructions or Korean to English translation was misleading.

All 3 injectors are pulled now to test them.

 

[oldnslo]

I connected two of the injectors to injector pump lines and had them spraying into a container. Neither injector had what I would call a good mist spray pattern so took all three injectors to a local Diesel injector pump repair house. They took all three back on there injector tester and agreed that at normal flow rates the pattern was bad so they hit them with high flow to see if could flush them. All three then had good mist pattern so brough them home and installed them. First start as expected was rough from air. Let run for awhile last night and tried again this morning. Started much better so will see how it does for the next few days.

 

[K5lwq]

I connected two of the injectors to injector pump lines and had them spraying into a container. Neither injector had what I would call a good mist spray pattern so took all three injectors to a local Diesel injector pump repair house. They took all three back on there injector tester and agreed that at normal flow rates the pattern was bad so they hit them with high flow to see if could flush them. All three then had good mist pattern so brough them home and installed them. First start as expected was rough from air. Let run for awhile last night and tried again this morning. Started much better so will see how it does for the next few days.

Excellent news! Look forward to seeing if that solved the issue!

 

[oldnslo]

Well it has been a couple months and rough start, poor idle, excessive smoke came back far worse that previous so broke down and ordered a set of new injectors that I installed Sunday. Was pleasantly surprised when there was a note with the new injectors stating the fluid used to test them can cause the injectors to stick so run them for a few minutes. On first start it idled fine but had a fuel leak so shut it down to repair the return line leak. On restart it smoked like a chimney and ran a little rough so backed it out of the shop and reved up to around 1500 RPM's till temp gauge started to move and then went to full throttle and back to idle a couple of times and they cleaned right up and ran smooth. Hooked up the 5 foot rotary cutter - brush hog and cut some road ditch weeds - grass that was 4 - 5 ft tall and purposefully drove fast enough to keep it grunting. Didn't smoke, had full power so very happy. Restarted Monday night with no glow plugs and fired right up in 85 degree ambient conditions.

Old injectors looked nasty with carbon build on nose on injectors and black soot on tip. Concerned on why so much carbon after 2 months since was rarely left at idle and most of time 1500 - 1800 RPM moving storm damage trees with loader or full throttle on chipper.

Will try and remember to post an update in a month or two.

 

[Slowpoke Slim]

Didn't Branson do a recall on the 2400 a couple years before the merger? Wasn't it about changing out the injectors on that engine? If I recall it was emissions related, or they installed the wrong injectors, or something. Heck I may have the wrong model in mind...

 

[oldnslo]

Yes their was a recall on the 2400 a few years ago. The explanation I received from my dealer was that the 2400 was producing more power than listed 24 HP with original injectors so put it into a different emissions class and at that time was mentioned about injectors failing or being carboned up.

I am trying to find a parts diagram for this injector that shows how the poppet tip should be shaped so can compare with my old injector to see if the wore some. I took one apart and with naked eye can see no evidence of water damage but tip feels like has lip on it. Looking for a good magnifying lens to study is closer since would like to try and determine what caused this failure.

 

[JeffinNB]

Hey oldnslo. Nice to see you got the starting smoking issue sorted out. My 2016 2400h has smoked a little on start up since I bought it this spring. It now smokes a lot and does sound like it's missing. Do you have the part number for the injectors you got from the dealer? Was it HT17020100A3?

 

[oldnslo]

Jeff
I will send you a PM