Hi, Have a truck in the shop Cascadia with DD S60 with DPF. Truck is choking when pressing accelerator and black smoke coming out ( rpms jump from 100 to 600 ). Once released gas pedal everything is working. History: Did overhaul and put old head ( per customer ). After 2 months head failed and valve broke. Changed liner and piston on cylinder #1 and #4. Changed injector on cylinder #1. And cylinder head. Issue started after this happened then: Changed ecm, injector #1, injector harness, turbo ( old actuator ) calibrated and passed, oil filter, fuel filter changed, checked timing twice, check valve adjustment... I notice when I turn off injector on cylinder #1 everything is working fine. The time I turn on the injector on cylinder #1 RPM starts jumping 100-600 rpm up and down, smokes black and acts like wants to turn itself off. Also - no codes active.
Amazingrepairman, Did ever you solve the problem?? Could you swap injector #1 with #3 for example? Then does problem move to cylinder three or stay at cylinder one when you do the cylinder cut out? I don't have practical experience with Series 60 injectors so this is just theoretical. Last month did install six re-manufactured injectors on DD15 and discovered you need to write the injector codes down that are right near the four electrical terminals at top of injector (hidden by the plastic caps that protect the terminals during shipping) , not the codes below the reman part number further down on injector body.
