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How?? burned through piston within hour of startup...

Delmer

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In Post #11 u say>it has a plug & play power booster on the pump.. What the hell is THAT.??

Power "chip", converter box to boost the pump, etc. He says it was turned off, but that was my first question also.

Otherwise, what could have changed to burn up new pistons in short order? I don't think piston oil jets would have done it without significant load. Did the head get set on the injectors to damage some of them? How would it go that many hours and then burn up the new pistons without something changing.
 

jrgreene1968

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I’ve seen stuck injectors and dirty injectors do this, they tend to not spray, but just dump raw fuel, but the times I’ve seen it, there was considerable smoke, even at idle. Other than that, timing would be my next thought, which has also been mentioned already. Any scarring on the piston skirts?
 

Truck Shop

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Notice the fire ring on head gasket at each cylinder, should be shiny with that many hours on it. No seal.
 

RZucker

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Notice the fire ring on head gasket at each cylinder, should be shiny with that many hours on it. No seal.
Yeah, OP stated "pushing coolant out" something is amiss here. If the pump wasn't pulled I highly doubt injectors would be the culprit either.
I saw a 3406A do that once in a 14 mile test drive... the guy that assembled the engine used the wrong plug in the flywheel housing for a timing pin hole (the big plug for Allison flex plate bolts) the pistons looked just like these.
I'm not sure but that plug got him about 45 degrees BTDC. He said the pyro was reading low. :eek: and when I went into it, the front Jake was on the rear... "FRONT" in big cast letters
 
Last edited:

jrgreene1968

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I couldn’t see the piston pic to good on my phone.. looked at it on the iPad, I agree, I don’t see coolant doing that. Looks to me like a ton of fuel dumped in, or wayyyyyyy out of time
 

Truck Shop

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Well those pistons are partially broken from coolant, you notice it worked over the shallow side. Those pistons fractured and the pieces beat the crap out of the top.
When pistons burn its normally pin point near the center, those have sharp edges where they broke. Coolant doesn't compress worth a sh!t.
 

Tenwheeler

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Just sharing thoughts and some experience.
Decided to skip that and just say it was hot in the chambers. Damage to multiple cylinders. Could it have had an air lock in the cooling system? Could it have been out of time?
It has a programmer to increase HP. The dealer or manufacturer would not warranty that. Why should you?
Yes the injectors should have been checked or the customer have been given the option. That puts you in a bit of a pickle now.
Go have the injectors tested before you commit to any warranty. Just put them off a bit and get it done. Then make your decision. I fixed something like that once that I should not have. Found out latter after that guy did everybody he could and filled bankruptcy.
 

RZucker

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Well those pistons are partially broken from coolant, you notice it worked over the shallow side. Those pistons fractured and the pieces beat the crap out of the top.
When pistons burn its normally pin point near the center, those have sharp edges where they broke. Coolant doesn't compress worth a sh!t.
I rebuilt a 3406B that had been cranked up and the pistons had that same look, but it had run several hundred thousand miles.
 

wrwtexan

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Not sure yet. It is a 'Diesel Performance' module. Injectors are going to my local shop soon as I get them out.
 

John C.

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I started a job years ago where my trial period consisting of helping install a D9G engine that someone else rebuilt. They said they ran it in on a dyno but the thing wouldn't start. The guy used ether to get it going and it sat and idled for a bit and then started making noise. The fella kept running it trying to figure out what was going wrong when the heavy knocking started. I made him shut it down as this was a Friday afternoon told him to go home. We were in Black Diamond, Washington and he lived in Eugene, Oregon. I told him when he left to figure on pulling heads first thing on Monday. Come Monday at noon we had the rear head off and the pistons looked just like those. I told him the only thing that can do that is timing. I looked in the book and found the D353 timed at the back of the engine on the flywheel and it wasn't hard to do it wrong. The guy pulled the flywheel and sure enough it was off a bunch. He reset the timing proper this time and was going to put the head back on when I stopped him. We nearly came to blows when I told him that engine was coming back out for new liners and pistons at the least. One of the owners heard us from down at the main office and came up half expecting blood, guts and a police call. Anyway he sent the guy home and I got to pull the engine by myself. I'm not saying your engine was timed wrong. It just looks like the same kind of damage.
 

wrwtexan

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Top of head has hose back to fill tank to bleed air.

Well those pistons are partially broken from coolant, you notice it worked over the shallow side. Those pistons fractured and the pieces beat the crap out of the top.
When pistons burn its normally pin point near the center, those have sharp edges where they broke. Coolant doesn't compress worth a sh!t.

The burn through looked like a plasma torch had blown through it and was right where a spray jet was shooting. The piston is structurally intact and underside is shiny new. The spray pattern is uniform on all pistons and the machining rings in the fire bowl of #4 are perfect.

Again, this engine had LESS than an hour run time since startup. I coppercoated the gasket and used all new torque to yield bolts (60 ft/lbs, then 90 90 90 degrees) on a cabinet cleaned block.

As we had to grind the crank and check block for funny bearing wear, the pump did come off but not the adjustable drive hub and the gear is keyed to the shaft. I went by a detailed video on this engine for using the timing pin behind drive gear with crank and cam aligned for #1. One thing dawned on me tonight is the cam gear had spalling on the teeth and when replaced, I was told to use a pen marked tooth or valley on the new gear as it had 2 timing marks on it instead of the one on old (I'll have to refresh details with owner in morning). My dealings have mostly been with Roosa's, CAV's and Model 100 Bosch's which a FEW degrees off they either won't start of run like sh!t. This animal may have some wiggle room on static timing that bit me. I wonder now could Trinity have screwed up on the new gear marks??

Sleeves have some shallow vertical line scuffing.
Injectors were removed before head came off as they are in the way of a line of head bolts.
I couldn't get a good pic to upload but one valve in #3 hole(will have to verify I or E) was heat blued around half of it.
 

wrwtexan

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Little things keep coming to mind. He complained of and I could hear it also, a consistent chirp towards the front of engine. Maybe like gas burner knocking from spark advance?
After some heat in engine, upon killing and restarting, there was a slow rollover spinup then start like advanced gasser timing which I attributed to the batteries and a new tight engine.
After starting it ran fine though, good power curve, little smoke...
 

Tenwheeler

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I guess I'm old and don't know my a$$ from a hole in the ground anymore.
Ha Mister! Don't know if you are talking to me but I was the next post after yours.
I mean no disrespect and was just sharing my experience and understanding. Started on some of these forums looking for information and help. This sight and its people have been great! Do not really understand how what you are saying works? Would they not be also mentioning lose of coolant? Well likely did not look at that I suppose. Would it not smoke very badly?
 
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