SOP for K19 ENGINES INITIAL HUNTING/ OVERSPEED/ HARD STARTING

Sr No Complaint Type Checkpoints Photos Remarks

Open the fuel tank cover plate and check whether the
Not Starting/ Hard suction tube is dipped in fuel, and having a 45 degrees
1 Fuel Tank Suction Tube
Starting cut to it. Ensure the pipe is having free space below
fuel entry, not touched to the fuel tank bottom.

Check the arrangement of pipe. In case of welding,

Not Starting/ Hard confirm if there is any air entry from confirm there is not any hole or puncturs in the
2
Starting/ Hunting welding/ brazing in suction tube welding/ brazing portion from where air can enter in
the system.

Remove the tube and fill the fuel, and check for any
Not Starting/ Hard remove tube and inspect threaded area leackages of fuel from the tube body/ threads. Differs
3
Starting/ Hunting for any crack or pinholes in threads. from OEM to OEM, and applicable only for threaded
type suction tube fitted on fuel tank.

Usually elbow comes with male side fitting and female

Not Starting/ Hard Check the fuel hoses for proper male to fitting hose. Air entry can be observed if both the
4
Starting/ Hunting female fitting. connections are done with male to male/ female to
female fitting.

Fitment in wrong direction results in fuel restriction.

Causing poor fuel supply and resulting not starting/
Not Starting/ Hard Check the NRV fitted wrt arrow mark.
5 not starting.
Starting/ Hunting Inlet to outlet.
(attached photo for Modified NRV, but Arrow marks to
be aligned for all NRV)

Fill the diesel and check whether diesel coming from

Check the fuel tank NRV location and
Not Starting/ Hard opposite side of the arrow.
6 correct operation. Whether NRV is leaking
Starting/ Hunting (attached photo is of Modified NRV, but leackage
or nor.
need to check for all NRVs)
 In case K19 engine with fuel tank below the engine,
modified NRV is introduced which need to be replaced
Check whether fuel tank to fuel filter
along with fuel tube on the fuel tank. (Existing NRV P
Not Starting/ Hard hoses getting empty after stop gap. If
7 no 4958277)
Starting/ Hunting getting empty, then install a modified NRV
in bottom fuel tank option.
If there is already a NRV installed and still facing the
same issue, need to go for the modified NRV.

Check and confirm the Check, Valve

Not Starting/ Hard orientation fitted in engine after fuel Check Valve- 3874153 (High Pressure Line NRV)
8
Starting/ Hunting pump (High Pressure) and Return Line Check Valve- 3874152 (Return Line NRV)
before fuel return block.

fuel filters to PT pump hose getting empty after

keeping long idle, then an additional NRV can be
Not Starting/ Hard
9 Check fuel filter to fuel pump hose. placed in fuel filter outlet. (Part No 4958277)(Remove
Starting/ Hunting
the tank NRV spring which may cause fuel restriction
in suction side)

Not Starting/ Hard Check the PT Pump cooling kit elbow for
Check Valve part number for ¾” gear pump is 4913272
10 Starting/ Hunting/ any leaks. If leaking then replace the same
which comprises Check Valve 3033740 + Orifice
Overspeed with correct part number
3045005

LHS: Cooling Kit elbow with Orifice If after all the checkpoints are verified, and still facing
Not Starting/ Hard RFH: Cooling Kit elbow without orifice the issue, then remove the orifice using allen key. In
Remove cooling kit elbow and check the
11 Starting/ Hunting/ some cases orifice can result in additional restriction in
orifice.
Overspeed fuel return line.
(This is an optional checkpoints, not mandatory)
 Not Starting/ Hard
Check the PT Pump fuel inlet elbow O ring An O ring is provided in PT pump suction elbow,
12 Starting/ Hunting/
for any damages or mutilitation. replace in case any slight mutilitation observed.
Overspeed

Remove the shut off valve (There is a O ring in bottom

i.e inlet side of shut off valve). Fill the diesel at outlet
Not Stopping/ Hunting/ Check fuel shutoff valve leaking fuel if it is
13 of FSOV and check whether fuel is coming from inlet
Overspeed in not energized condition
side of the FSOV. If coming then the FSOV assembly
must be replaced.

Check the actuator coil resistance on PT Pump, should

Not Starting/ Hard be between 07 to 09 Ohms. If not within limit,
Check the Actuator resistance fitted on PT
14 Starting/ Hunting/ replacement recommended. Operation can be
pump
Overspeed checked by giving external supply as per system
voltage.

Not Starting/ Hard Check the actuator internal condition for

15 Starting/ Hunting/ any bend lever causing deviation in fuel
Overspeed flow

Check the resistane of fuel shut off valve with 8mm

Not Starting/ Hard Check the fuel shut off valve for proper
nut pin to body where paint isn't available. To
16 Starting/ Hunting/ operation - check resistance by isolating
replaced if not under limit. Operation can be checked
Overspeed the wires
by giving external supply as per system voltage

Insert breakout cable and check the supply coming to

Not Starting/ Hard Check the supply voltage coming to the actuator from AUX 104 module while cranking.
17
Starting actuator during cranking state. Should have 20-22 VDC during cranking (In healthy
battery condition)
 check the coil resistance of MPU should be 1.3-1.5 k-
Ohms.If not within limit, replace.
Not Starting/ Hard Check the MPU resistance fitted on
Internal termination resistance on AUX105 and PCC
18 Starting/ Hunting/ flywheel housing and check for any burr
Baseboard - 24 Kilo-Ohms +/- 0.3 Kilo Ohm
Overspeed on tip of MPU.
for PCC1302 - Check on J11-9 and J11-10 on PCC
for PCC3300 - Check on J11-9 and J11-10 on AUX 105

Check the output voltage of MPU while

In cranking condition if MPU output voltage is less
Not Starting/ Hard cranking. Should e minimum 1.5 VAC. If
than 1.5 VAC, replace the MPU.
19 Starting/ Hunting/ not then same can be achieved by
MPU part number With PCC 3300 - 4085824
Overspeed adjusting the MPU close and away from
MPU Part Number With PCC 1302 - 3875360
flywheel teeth.

1. if MPU is creating spike in running condition need to

replace the MPU.
2. If there is no spike. But output not within 18-25
VAC, same can be acheived by adjusting MPU
Check the output voltage of MPU with
3. If voltage measured on MPU and AUX 105/PCC not
Hard Starting/ Hunting/ multimeter when the engine is in running
20 matching, harness need be checked.
Overspeed condition. And confirm if there is a spike
(In case PCC1302 - MPU can be disabled from
of voltage while running.
governing menu)

PCC 1302 - J11-9 and J11-10 On Baseboard

PCC 3300 - J11-9 and J11-10 On AUX 105

1. Check for any leakages in oil lines of the STC hoses.

Hunting/ Smoke in off/on Check for any leackages or loose
21 2. Check for any loose or cut connections in the STC
load connections in STC circuit.
wiring circuit.

Give direct Battery B+ve supply to STC solenoid and

check for operation of the STC solenoid. If there is no
Hunting/ Excessive smoke or hunting after external supply, then need to
22 Check the solenoid for proper operation
smoke check the electrical connection, if still same issue,
need to check further mechanical components of
ESTC.

Check the Fuel pressure switch on below condition.

1.When started and engine is below 18% of load/ fuel
pressure below 21 Psig the switch will be close.
Hunting/ Excessive Check the Operation of the Fuel pressure 3. Above 18% load condition/ fuel pressure more than
23
smoke switch. 21 psig - THe switch will be open.

If not within limit, replace the fuel presusre switch.

(New Part Number - 5462276 - SWITCH,PRESSURE)
 Hunting/ Excessive Check the coil resistance of the E-STC Check the resistance of the E-STC valve solenoid coil,
24
smoke Solenoid after isolating the harness. should be within 30 (+/-2) Ohms

if there is momentarily supply drop at ESTC Solenoid,

Hunting/ Excessive Check for any intermittent supply drop at
25 an additional relay can be added in the circuit as
smoke STC solenoid coil.
shown in adjacent diagram

Remove the outlet line of STC valve and check the

outlet supply going to injectors, if no supply or less
Hunting/ Excessive Check the outlet flow of oil from E-STC flow of oil, check the internal components of the STC
26
smoke valve to injectors. valve.
even supply disconnected condition, there will be some
oil like may seem like leakage, which is normal.

Hunting/ Excessive Check the internal components for any Open the E-STC valve assembly, and check the internal
27
smoke rust. components for any burr/ marking or abnormality.
ANNEXURE 1 - KTAA 19 FUEL FLOW AND BLOCK DIAGRAM
ANNEXURE 2 - KTAA 19 PCC SETTINGS FOR HUNTING/OVERSPEED/ HARD STARTING
Post confirming there is no issue on mechanical side, issue can be arrested after adjusting some parameters in PCC 1302 and PCC 3300 as well.
For both Controllers PCC version need to updated with latest revision. For PCC 1302 - 3.16v and For PCC 3300 - 3.400v
Post Updating to latest versions, all the parameters will be availabe to edit. For both the controller, parameters are the same as below table.

Description Default Modified

Initial Crank Fueling Command 25 50%
Initial Crank Fueling Period 2 1sec
Crank Fueling Ramp Rate 25 25%
Maximum Crank Fueling 100 50
Crank Exit Fueling Command 100 40%
Governor Enable Speed 1100 800
Governor Ramp Time 0.25 10sec
MPU Operating Voltage - 18-25 VAC
1. ACCESS THE SETTING FOR PCC 1302

A. THROUGH INPOWER Adjustments >> Governor >> Startup

B. THROUGH HMI 220 Go to Setup >> OEM >> Engine

 2. ACCESS THE SETTING FOR PCC 3300

A. THROUGH INPOWER Initial Crank Fueling Command

Initial Crank Fueling Period

Setup >> OEM Setup >> OEM Engine Setup >>
Crank Fueling Ramp Rate HMECM >> Cranking
Maximum Crank Fueling
Crank Exit Fueling Command
Governor Enable Speed
Setup >> OEM Setup >> OEM Engine Setup >>
Governor Ramp Time
HMECM >> Governor Gains >> Rated Setup
B. THROUGH HMI 320 Initial Crank Fueling Command
Initial Crank Fueling Period
Crank Fueling Ramp Rate OEM Engine Setup >> Screen 4 Out of 8
Maximum Crank Fueling
Crank Exit Fueling Command
Governor Enable Speed
Governor Ramp Time OEM Engine Setup >> Screen 1 Out of 8
ANNEXURE 3 - KTAA 19 FLOW DIAGRAM FOR GOVERNING SYSTEM