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Dan, Technician
Category: Construction and Road Equipment
Satisfied Customers: 4291
Experience:  17+ yrs. shop and field experience with all major brands of heavy equipment and trucks - 1995 WyoTech graduate.
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2006 john deere ct-322 has a surging issue under full power,

Customer Question

2006 john deere ct-322 has a surging issue under full power, has new injectors that brought the engine power back but i still have a surging. fuel filters and oil have all been changed, new air filters, its not over heating, and it has a little black smoke at start up but goes away, fuel pressure is at a constant 10 psi when the surging happens skid steere has 2206 hours.
does not surge if you back the throttle off and all hydraulics work fine.
Submitted: 6 months ago.
Category: Construction and Road Equipment
Expert:  Dan replied 6 months ago.
Hi Matt, My name is***** will be glad to help. If there are no fuel leaks sucking in air or restrictions in the fuel supply then the likely problem is in the governor causing your surging problem. What is the serial number of your machine and the complete engine information from the engine tag?
Customer: replied 6 months ago.
tq322ta122666 is the machine id 4024tt002 engine id
Expert:  Dan replied 6 months ago.
thanks for the info. Also, it is possible that one of the individual pumps has a problem. These individual pumps have to be timed and shimmed to synchronize them properly. This requires special tooling to do if the pumps are removed. Let me know
Customer: replied 6 months ago.
do you have the procedure to check the injector pump
Expert:  Dan replied 6 months ago.
Is it misfiring at all? If it is running smooth but surging your problem will be likely the governor in the front timing cover. With the valve cover off you will see the control rack that connects the individual injection pumps. Look for a worn or loose control rack on the injector fuel metering arm allowing play that would cause surging and also watch the control rack with the engine running at idle to see if the governor is making the control rod that connects all the pumps move back and forth creating the surging. A faulty pump would cause a misfire, low power and rough running
Customer: replied 6 months ago.
it is not misfiring at all, is it safe to run the engine with the valve cover off, the valve covers is also the intake on this engine
Customer: replied 6 months ago.
and the turbo hooks up to the valve cover
Expert:  Dan replied 6 months ago.
I would not open it up outside in a dusty environment but there is no boost at an idle and you are only running it long enough to watch the fuel rack movement... all other checks are with the engine off.
Expert:  Dan replied 6 months ago.
I have the complete manual I can offer you in PDF as an additional service. I will send over the offer if you are interested just click accept and I will share the link to the manual.
Customer: replied 5 months ago.
do you have pics of the where the gov is and
Expert:  Dan replied 5 months ago.
It is inside the front timing cover. click the link below and here are the part descriptions to go with it.1622 (FUEL INJECTION PUMP)CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS1R502996Clamp5219M9766Screw5M10 X 45351M7039O-Ring18.100 X 1.600 mm4RE519890Adapter Fitting1528H1511Washer10.364" X 0.540" X 1/4"6R135106Clamp1719M7866Screw1M8 X 208R51936Sealing Washer29RE522410Aneroid Line110RE502650Fitting1CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS11RE522774Rack11234M7201Spring Pin24 X 10 mm13R515112Shim114R502760Spur Gear1(CAMSHAFT)15R516770Washer116R517240Screw11719M8425Cap Screw4M6 X 1618RE521054Engine Kit1-062231(C) (INCLUDES RE528481 AND RE528480)RE528481Weight Kit1062232-(C) (USE WITH RE528480)19RE540501Magnet Kit1(SUB FOR RE524705)CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS20RE42713Pipe Plug12119M8483Screw1M6 X 6522A4365RO-Ring123R520209Cover124R504206Plug22514M7147Nut1M82614M7273Nut1M827RE521049Governor Kit1-062231(A) (D) (SUB RE528480 AND RE528481)RE528480Governor Kit1062232-(A) (D) (USE WITH RE528481)28R520420Extension Spring1CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS29R517155Leaf Spring13014M7273Nut1M831RE507488Seal132R72653Snap Ring13334M7278Spring Pin23 X 18 mm34RE521050Throttle Kit1(B)3514M7297Nut1M536RE525797Lever137R519746Stud138R72654Snap Ring1CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS39R515303Pin Fastener14022M7179Set Screw2M6 X 354114M7272Nut2M64219M7864Screw1M8 X 1243RE521048Guide Kit144RE523413Rack145R518615Clamp546RE544814Fuel Injection Pump5SUB FOR RE515801; RE526484 OR RE530789SE502052Seal Kit5(REMAN FOR RE530789)......Seal KitAR(ORDER RE521175)(9901)CartkeyPART NO.PART NAMEQTYSERIAL NO.REMARKS..PM710XX280SealantAR(A) R517155 NOT INCLUDED IN KIT(B) THROTTLE LEVER (C) FLYWEIGHT(D) GOVERNOR LEVER
Expert:  Dan replied 5 months ago.
You will see cover 32 at the top front left of the front cover. the governor linkage is in there. There are also flyweights for the governor in #18 which bolts to the gear. I do not recommend working on this fuel system without the manual as one wrong adjustment and the engine will overspeed and could run away causing extensive damage. I offered the complete manual in PDF to be shared in file sharing. Did you not get the offer?
Customer: replied 5 months ago.
the spring feels good, cutoff switch engage good every thing seems to move good and is not in a bind, only thing that seems to be a little goofy is part 36 moves freely is it supposed too?
Expert:  Dan replied 5 months ago.
This engine is used for multiple applications such as generators, etc so they set up the throttle controls differently depending on application. #11 is the control rack I was referring too as being worn allowing the injectors to be loose and surge. Air can also cause it.... You need to remove the valve cover to check if there is a lot of play in the rack. JD uses a special white silicone for a valve cover gasket on those engines
Customer: replied 5 months ago.
the control rack is tight what are the chances of it being a bad drive pump as it only happens when it is moving, the skid steer can idle and run at a high idle all day long but when you go to move it at full idle is when it surges, could it be the hydraulics?
Expert:  Dan replied 5 months ago.
If the fuel pressure if with a gauge installed remains constant then yes a varying load on the engine can cause a surge.
Expert:  Dan replied 5 months ago.
Hi, Did you get this resolved?

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