3126 Industrial Engine 9ZR00001-UP(SEBP2557 - 32) - Documentation Page 1 of 4

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Product: INDUSTRIAL ENGINE

Model: 3126 INDUSTRIAL ENGINE 9ZR
Configuration: 3126 Industrial Engine 9ZR00001-UP

Troubleshooting
3114, 3116 and 3126 Engines
Media Number -SENR6502-06 Publication Date -01/07/2010 Date Updated -28/07/2010

i01132208

Air in Fuel
SMCS - 1250-035

This procedure checks for air in the fuel. This procedure also assists in finding the source of the air.

1. Examine the fuel system for leaks. Ensure that the fuel line fittings are properly tightened.
Check the fuel level in the fuel tank. Air can enter the fuel system on the suction side between
the fuel transfer pump and the fuel tank.

2. Install a 2P-8278 Fuel Flow Tube (Sight Gauge) in the fuel return line. When possible, install
the sight gauge in a straight section of the fuel line that is at least 304.8 mm (12 inches) long.
Do not install the sight gauge near the following devices that create turbulence:

Elbows

Pressure relief valves

Check valves

Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If the engine
starts, check for air in the fuel at varying engine speeds. When possible, operate the engine
under a load and look for air in the fuel.

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3126 Industrial Engine 9ZR00001-UP(SEBP2557 - 32) - Documentation Page 2 of 4

Illustration 1 g00578151

2P-8278 Fuel Flow Tube (Sight Gauge)

(1) A steady stream of small bubbles with a diameter of approximately 0.1588 cm (0.0625 inch) is an acceptable
amount of air in the fuel.

(2) Bubbles with a diameter of approximately 0.635 cm (0.25 inch) are also acceptable if there is two seconds to
three seconds intervals between bubbles.

(3) Excessive air bubbles in the fuel are not acceptable.

3. If excessive air is seen in the sight tube in the fuel return line, install a second sight tube at the
inlet to the fuel transfer pump. If a second sight tube is not available, move the sight tube from
the fuel return line and install the sight tube at the inlet to the fuel transfer pump. Observe the
fuel flow during engine cranking. Look for air bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds. When possible, operate the engine under a load and
look for air in the fuel.

If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system
after the fuel transfer pump. Proceed to Step 5.

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3126 Industrial Engine 9ZR00001-UP(SEBP2557 - 32) - Documentation Page 3 of 4

To avoid personal injury, always wear eye and face protection when
using pressurized air.

NOTICE

To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the
fuel tank.

4. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found. Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For information about checking the fuel pressure,
see Testing and Adjusting, "Fuel System Pressure - Test".

5. Proceed to Step 6 if an infrared thermometer or an exhaust temperature pyrometer is not

available. Start the following procedure with a cold engine. Take all measurements within the
first five minutes of operation. The temperatures of the exhaust manifold ports should be within
20 C (68 F). An exhaust port that has a low temperature may have an injector that is leaking
air.

a. Start the engine and operate the engine at low idle.

b. Measure the temperature at the center of the number one exhaust manifold port and at the
center of the number six exhaust manifold port. Compare the two temperatures.

c. Measure the temperature of the number two exhaust manifold port and the number five
exhaust manifold port. Compare the two temperatures.

d. Measure the temperature of the number three exhaust manifold port and the number four
exhaust manifold port. Compare the two temperatures.

Note: Injectors that are downstream from a leaking injector may measure cold but not
leaking air.

6. Remove the valve cover and operate the engine at low idle rpm.

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3126 Industrial Engine 9ZR00001-UP(SEBP2557 - 32) - Documentation Page 4 of 4

Illustration 2 g00598910

(1) Fuel injector rack

(2) Fuel-on position

7. Check each cylinder sequentially from the number six cylinder to the number one cylinder. Use
a screwdriver to move each fuel injector rack (1) to the fuel-on position. Watch the sight tube in
the fuel return line. An increase in the amount of air in the fuel indicates that the injector is
leaking air. Also note the amount of increase in fuel injector rack that is required to cause a
cylinder to knock. An injector that is leaking air will require the fuel rack to be advanced more
toward the fuel-on position. If the source of air can be isolated to a particular injector, remove
the injector. Ream the injector sleeve if the seat area for the injector is pitted. Replace the
injector sleeve, if necessary. Reinstall the injector. Ensure that the injector is properly seated.
Refer to Tool Operating Manual, NEHS0738, "Using the Injector Seating Tool " and Tool
Operating Manual, NEHS0610, "Using the 128-8822 Tool Group on 3114, 3116, and 3126
Engines with Mechanical Unit Injectors (MUI)". Also, refer to Video Tape, LEVN4032,
"Troubleshooting Guide for the 3100 Family of Diesel Engines" and Video Tape, LEVN4732,
"Injector Seating Procedure". After the injector is reinstalled, check for air in the fuel.

8. If the source of air can not be isolated to a particular cylinder, remove each injector. Ream all
injector sleeves or replace all injector sleeves. Replace an injector only if the injector cone is
damaged. A burned O-ring or a missing O-ring on the end of the injector does not indicate a
faulty seal. The O-ring should not be replaced.

Copyright 1993 - 2012 Caterpillar Inc. Sat Jul 7 04:52:40 UTC+0700 2012
All Rights Reserved.
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